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Editorial
Solid State of Fluids
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o a quirky question on doubting the relevance of ‘almost dedicating’ an edition on seemingly smooth operating metalworking fluids, our answer is precisely that!! ‘Smooth Operations’ is what it ensures and hence, the attention. Another reason is the all important factor, ‘cost’—which has become the anthem of survival.
Traditionally, metalworking fluids have been widely used in machining operations to increase cooling and lubricity, and, as a result, enhance the tool life, reduce process variability, etc. In short, assist and ensure smooth operations. However, over the last decade, it has become apparent that fluid-related decisions have all too frequently been based upon industrial folklore rather than knowledge-based quantitative evidence. But lately, there has been a change in this thought process…a change which could be attributed to the fact that costs associated with fluid use often constitutes between 7% and 17% of total production costs, as compared to 4% for tooling costs. Fluid-related expenses include the cost of installing a fluid supply system, fluid purchase and system maintenance, and discarded fluid (waste) treatment. Fluid-related costs are large because high production manufacturing plants frequently utilise several cutting fluid reservoirs—each containing thousands of gallons of cutting fluid. Often, an entire reservoir is flushed to clean the system when quality issues arise. Certainly, reducing the amount of fluid employed can result in significant cost and waste savings.
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
Given the critical role it plays in smooth operations as well as cost optimisation, this monsoon, MMT is all drenched with key stats and facts about the demand that the metalworking fluids industry can expect, going forward. According to a report, the metalworking fluids market in North America, Asia and Europe is projected to grow at about 3% per annum, from 2.1 million metric tonne in 2010, to nearly 2.5 million tonne by 2015. Asia is the fastest growing market with 5% annual growth from 2010 to 2015. Over those five years, the projection says that the North American metalworking fluids market will grow at 2% and Europe’s by 1%, annually. The report focussed on North America (the US, Canada and Mexico), Asia and Europe, whose estimated metalworking fluid consumption totalled 2.1 million tonne, valued at $6.9 billion, in 2010. Since 2007, Asia’s metalworking fluid demand grew 3.3% annually, while Europe’s slipped 1.8% and North Americas’ fell 7.8%, per year. With so much happening in this segment, the metalworking fluids industry has responded to the market demands by offering newer and wider variety of cutting fluids. Many new coolants have been developed to meet the needs of new materials, new cutting tools, and new coatings on cutting tools. All this, while keeping the goal of machining operations intact, which is to improve productivity and reduce costs. And this is accomplished by machining at the highest practical speed, while maintaining practical tool life, reducing scrap, and producing parts with the desired surface quality. In short, the key lies in proper selection and use of cutting fluids to achieve all of these goals. Here’s to slick operations and flowing solutions!
Past President, IMTMA & MD, RAS Transformation Technologies
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
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Contents Insights & Outlook Industry Snapshot ............................................................... 96 Construction Equipment Machining ................................. 98 Machining Solutions .......................................................... 100 Compact Rebar Shop .......................................................... 104 Manufacturing Modules .................................................... 106
Special Focus Metalworking Fluids
49
Insights & Outlook Construction Equipment
95
Geography Watch Chennai ............................................................................. 32
SMEs@Glance Growth Enablers .................................................................. 38
Facility Visit Hittco Tools Ltd ................................................................... 88
Special Focus
Energy Management
Industry Snapshot ............................................................... 50
Using Energy Efficiently Can Boost Profitability............... 108
MWF Projection ................................................................ 52
Event Report
Advances in MWFs ........................................................... 54 Occupational Hazards ........................................................ 56 Mist Control ....................................................................... 64
ACMEE-2012 .................................................................... 116
Event Preview AMTEX 2012 .................................................................... 118
In Conversation With
6C—Metalworking Fluid Management ............................ 66 Cutting Fluid Costs............................................................ 68 Terrence Miranda MD, HAAS Automation India Pvt Ltd .... 42
One Q Many Views ........................................................... 70 Biodegradable Fluids .......................................................... 76 Maintenance & Filtration ................................................. 78
Turn to Page 122 for Latest TENDER Updates
MWF Additives ................................................................. 82
Regular Sections
Tips & Tricks ..................................................................... 86
Editorial ...................................................................... 13 Sarathi Sutras .............................................................. 19 News, Views & Analysis .............................................. 20 Technology & Innovation ............................................ 40 Event List .................................................................. 120 Products .................................................................... 124 List of Products .........................................................170 List of Advertisers .....................................................178
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NEXT EDITION HIGHLIGHTS Special Focus: Rapid Prototyping Insights & Outlook: Railway & Equipment Machining
Cover illustration: Hemant Lambe
July 2012 - MODERN MACHINE TOOLS
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Printed by Mohan Gajria and published by Lakshmi Narasimhan on behalf of Infomedia 18 Ltd. Executive Editor: Archana Tiwari-Nayudu Printed at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Infomedia 18 Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai - 400 028. MODERN MACHINE TOOLS is registered with the Registrar of Newspapers of India under No. MAHENG / 2008 / 24347. Infomedia 18 Ltd does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition.
July 2012 - MODERN MACHINE TOOLS
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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
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develop in stages, from initiation to quantity expansion to hat do Stuttgart in Germany, Shanghai in China, quality improvement to eruption. Each stage involves the Bilbao in Spain, Osaka in Japan and Taichung incorporation of key developmental elements as shown in in Taiwan, all have in common? Each one is the figure. In order to achieve, by 2020, a 67% market share an industry paradigm, clusters that have been meticulously for domestic manufacturers, a rise in exports to 20% and a fostered and developed by nations that have led the world in ranking within the top 10 machine tool producers globally, the manufacture of machine tools. These clusters have evolved every element of a machine tool ecosystem must be developed as global hubs, concentrating in a cohesive geographical space, in Bengaluru, Pune, Rajkot and Ludhiana. The integration the resources, institutions, knowledge, and capital required to of large players in the industry with the hordes of smaller build the “mother machines that build all other machines”. manufacturers and ancillaries must be supported by visionary These concentrations symbolise a key, but often ignored, government policies, investment in setting up of bridging ‘sutra’ of this mother industry, the development of a machine institutions such as machine tool eco-system encompassing the The Machine Tool Eco-system tool parks, common facility entire value chain. centres, business and market Industrial clusters are a must for development support, and manufacturing in any developing Part Suppliers technology institutes. Looking nation, doubly so for a vertically Components Jobwork at the Indian machine tool ecointegrated and technology-driven Manufacturers Companies system, R&D development and industry like machine tools. In (Vendors) innovation seem to be elements a global market, clusters offer where Indian manufacturers competitive advantages conducive have particularly fallen behind, to growth, such as flexibility, Financial Consultants Institutions in terms of initiative, access efficient logistics, information Machine Tool and investment. Clusters exchange, and reduced transaction Manufacturers like Taichung have proved costs. To illustrate these how heavy investment in advantages, Taiwan, the small Skill IT Support R&D goes a long way in island nation that incredibly Development Service ensuring the sustainability and ranks 6th in production and 4th in & Training Providers Institutes competitiveness of a machine tool exports, globally, has 72% of its industry. Besides strengthening machine tool industry focussed in R&D + Trade Academic CMTI and widening its Taichung! Over 490 enterprises Association Institutions presence, manufacturers need to are clustered within a city that in a indigenously develop high-class few decades of planning and rapid products, and academia should be deeply entwined progress, has rightfully earned the tag, the world’s with the industry, right from training to cutting-edge first ‘Machine Tool Village’. innovation. Such clusters are, essentially, little ecosystems that bring together all the elements necessary for On the whole, it is pertinent that the machine tool the development of a sustainable machine tool sector is perceived, not in isolation, but intrinsically industry. In India, where 50% of the industry’s nurtured in an ecosystem. For Indian industry cluster, output comes from clusters in the south, Bengaluru the sutra is to muster strength to usher in an era of a is the best example of an evolved eco-system, ‘New Deal’, the need for which is greater now than albeit leaps and bounds behind Taichung. Industrial clusters ever before. July 2012 - MODERN MACHINE TOOLS
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News, Views & Analysis
Freudenberg Expands Operations in Mysore and Pune
Hypertherm Introduces Powermax105
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H
ven amidst e c o n o m i c uncertainties in India, Freudenberg Group, a family-owned German company, expanded its reach in the Indian market through a new plant at Mysore. ChemTrend Chemicals Co Pvt Ltd and Klüber Lubrication India Pvt Dr Jörg Matthias Grossmann (centre), Regional Representative, Freudenberg Group, India, along with other Freudenberg officials, addresses the press on Ltd, headquartered the Group’s major Indian investments. at Mysore, will manufacture specialty lubricants, release agents and maintenance crisis in other parts of the world, we products. By 2016, Freudenberg expects showed 20% growth in India,” said Dr to invest around Rs 130 crore in the Jörg Matthias Grossmann, Regional new production plant, which is spread Representative, Freudenberg India, and across 40,000 m2. The two companies Executive VP & CFO, Freudenberg Chemical Specialties. supply to a wide range of customers Apart from this, the Group, under including the automotive, energy and the brand, EagleBurgmann Pvt Ltd, is wind energy sectors. expanding its R&D centre at Pune. It “India is not just a low-cost will be a fully automated, computerised production centre for us. Almost 60% of state-of-the-art test centre for testing its GDP comprises local consumption seals for refineries, petrochemicals and compared to only 40% in China. We chemical plants. The facility will become are here to serve the local market and functional by the end of 2012. not to export. When we were facing
ypertherm, a manufacturer of advanced cutting products, launched Powermax105 in Asia at the 17th Beijing Essen Welding & Cutting Fair, 2012. Powermax105 is a new 105-A air plasma system used for hand-held and automated cutting and gouging. The system is designed to comfortably cut metals into 32-mm thick pieces and sever metals by up to 50 mm. The new system delivers faster cut speed, improved cut quality and industry-leading consumable life for better performance at a lower operating cost.
Rittal bags innovation award
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ittal India has won the best innovation award for Liquid Cooling Package (LCP). Rittal RimatriX5 solves the problem of climate control for high heat losses per rack with LCP. Extremely high heat loads are dissipated from the rack via the LCP air/ water heat exchanger. The system also allows temperature-neutral expansion of the data centre with pay as you grow concept, in terms of scalability and modularity.
FANUC Opens New State-of-the-art Facility in Pune
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he Indian subsidiary of leading control system and robot manufacturer, FANUC Corporation, recently inaugurated its new technology centre at Pune. The one-ofits-kind facility saw a grand opening in the presence of dignitaries from leading companies in the machine tool & allied industries, apart from dealers, customers and the dynamic team of FANUC India Pvt Ltd. The event was graced by Sonali Kulkarni, President & CEO, FANUC India Pvt Ltd; Kazuhisa Otsuka, Executive VP, FANUC India Pvt Ltd; Katsuo Kohari, Manager, FA Overseas Sales Joint Department Sales Division, 20
MODERN MACHINE TOOLS - July 2012
FANUC’s Pune Centre
Will be used as a new training centre Will help in providing total engineering solutions Will be treated as a live technical centre Will help to serve Pithampur, Rajkot and Mumbai regions, apart from Pune.
FANUC Corporation; and Nirmal Bhogilal, Chairman & MD, Batliboi Ltd. The facility has been designed in such a way that no electricity is required for lighting during day time, thereby
saving valuable energy. To make it more environment friendly, the facility does not use glass that prevent heat generation inside the building, thus reducing the energy consumption. With the opening of this new technology centre, the machine tool major has reinforced its commitment to the customers in the Indian market. It is being equipped with training & seminar rooms and solution gallery that are designed with specific focus on customer requirements during pre- and post-sales. Currently, FANUC India has its Head Office at Bengaluru and branch offices at Pune and Delhi, along with a strong sales and service network spread across the country.
MMT July-2012
Ad Name: BigDaishow Pg No. 21
MMT July-2012
Ad Name: Precihole Pg No. 22
MMT July-2012
Ad Name:Mitutoyo Pg No. 23
MMT July-2012
Ad Name: Fullton Pg No. 24
News, Views & Analysis Timken Chennai Wins ‘Foundation of Quality Excellence’ Award
IMTMA Seminar Calendar: July 2012 Date
Topic
Venue
July 11, 2012 Seminar on Idle Time Reduction in Metal Technology Centre, Cutting through Quick Changeover Techniques BIEC, Bengaluru July 11, 2012 Seminar on Welding Technology in Auto Industry July 12–13, Workshop on Process Capability—The Quality 2012 Route to Sustained Growth in Manufacturing July 13, 2012 Seminar on Servo Technology for Industrial Motion Control
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imken has awarded ‘2011 Foundation of Quality Excellence’ Award to its bearing plant at Chennai, India, during its Asian Quality Conference in May 2012. The awards are presented each year in recognition of top quality performance amongst its more than 50 plants around the world, and the Chennai plant is one of the two Asian plants recognised. The facility produces single- and double-row case-carburised tapered roller bearings, including cups, cones and assemblies, of 8 inches and above outside diameter.
Pune Technology Centre, BIEC, Bengaluru SKF College Campus, SKF India Ltd, Chinchwad, Pune Technology Centre, BIEC, Bengaluru
July 17–18, 2012
Training Programme on New Product Development on CNC Turning Centres
July, 17–18, 2012
Seminar on New Manufacturing Strategies Pune using Multi-Tasking and 5-axis CNC Machines
July 20, 2012 Seminar on Lasers in Metalworking
Technology Centre, BIEC, Bengaluru
July 20–21, 2012 July 23–24, 2012
Workshop on Measurement Systems Analysis
Gurgaon
Seminar on Heat Treatment Process in Metalworking
Technology Centre, BIEC, Bengaluru
July 24, 2012 Seminar on Design of Hydraulics, Pneumatics Coolant and Lubrication System
Gurgaon
July 24–25, 2012
Workshop on Workholding and Fixturing Techniques for Productivity Improvement on CNC Machines July 25, 2012 Seminar on Right Selection of Linear Motion Guideways, Ball Screws & Servo Drives for Industrial Machinery
SKF College Campus, SKF India Ltd, Chinchwad, Pune Gurgaon
July 27, 2012 Workshop on Calibration of CNC Machine Tools
SKF College Campus, SKF India Ltd, Chinchwad, Pune
CAPA, VIC to Promote Aerospace City in Bengaluru
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entre for Asia Pacific Aviation (CAPA) India and Vittal Innovation City (VIC) will co-promote CAPA-VIC Aerospace City in Bengaluru. The aerospace park will be one of the industry clusters at VIC and will spread over an area of 750 acre. VIC is India’s first green technology & IPR safety zone focussing on aerospace, defence & electronics. CAPA, the region’s leading specialist advisory, research & knowledge practice, will bring together international aerospace operators and manufacturers.
Nicolás Correa Received Orders of the Order of €5.5 million at the BIEMH
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icolás Correa—the Spanish company—received orders worth multi-million pounds during the 27th edition of BIEMH (May 28–June 02, 2012, Bibao, Spain): One order was from Italy for a gantry milling machine, with a mobile sleeper, with X–Y–Z–W runs of 11,800 × 6,800 × 1,500 and 1,650, respectively, for a total value of €2 million. It will be used to machine large components for the nuclear sector. 26
MODERN MACHINE TOOLS - July 2012
The company provides milling solutions for:
Equipment manufacturing Die and large mould manufacturing Monolithic elements for the aerospace, railway, and energy, including turbines, wind milss and general mechanical sectors
Another order, worth €1.5 million, was from Chinese client Beyang Hanfen for FPV-W 75 gantry milling machine, with a mobile sleeper, with X–Y–Z–W runs of 7,500 × 4800 × 1,500, and 1,650, respectively. German client Zeisier bought a mobile column floor-type machine from the Axia family for €675,000. The company also sold fixed bench machines in the UK and France to clients CMS Cepcor and Robatel, respectively, for a total sum of €650,000.
Leaders’ Views
Impact of Economic Slowdown on Machine Tools Industry
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ven as the Indian economy is rendered rudderless, with political leadership unable to rise to the occasion, we are happy to note that our industry is full of optimism, despite a weakened rupee, high interest rates and rising costs. All our customers are geared to achieve 30% growth in 2012–13 amidst these major external handicaps. - Sonali Kulkarni, President & CEO, FANUC India Pvt Ltd
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he Indian machine tool industry has no option but to grow exponentially over the next decade. Robust consumer-driven demand will accelerate progress in India like never before, as it rises to become a powerful contributor to the international supply chain. The current economic situation is probably not as exciting as we would like it to be; however, it should hardly be interpreted as a situation that merits a critical or desperate attitude. If we were to modestly forecast an average growth of 7.5% in GDP over the next 5 years, we can arithmetically translate that, at the minimum, to a healthy 15% growth per year in the machine tool industry. - Satish Sadasivan, MD, SCHUNK Intec India Pvt Ltd
T
he Indian machine tool industry is facing stiff competition from all over the world. We, therefore, have to constantly innovate in terms of technology and processes as well as value engineering. The missing links in the Indian industry are in the areas of machine reliability and faster delivery. To achieve this, we need to create a strong vendor base. However, this aspect of the industry is not very strong. We still do not have reliable suppliers of auxiliary systems and critical machine components. The industry needs to concentrate on strengthening the vendor base. - Mohini Kelkar, MD, Grind Master Machines Pvt Ltd
T
he current economic situation that the country is facing has definitely resulted in a slowdown in capital investment. This does not augur well for the machine tool industry. Coupled with this, the rising petroleum costs and the high inflation rate have resulted in the overall slowdown of the manufacturing industry. Consequently, our customers are deferring investments. We have to definitely look at the ways in which the input costs can be reduced in areas such as the cost of the raw materials, labour, etc. In addition to this, the government also has to look into the cost of imports in the import duty. - N Gopinath, VP – Marketing, MMC Hardmetal India Pvt Ltd
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News, Views & Analysis
JCB launches New 3DX Backhoe Loader in India
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launch of this CB India, Advantages of 3DX all new JCB the country’s Backhoe Loader 3DX Backhoe largest manufacturer Will result in 20% lower fuel Loader. The consumption in excavation benefits that of construction Will create 20% more cabin t h i s new equipment space generationhas launched Has twin ram steering e q u i p m e n t ‘The All New facility for easy steering provides to its 3DX’ Backhoe Has been provided with customers are Loader. With new brake linkage to ease immense. It the launch the braking effort ensures 20% of this new Has been fixed with new lower fuel equipment, the bonnet for easy maintenance consumption company aims Offers the best return on in excavation, to strengthen investment. which will its share of the result in fuel backhoe loader savings worth `2.25 lakhs market in India. per year at current diesel Speaking about the launch, prices. It is the best engine in Vipin Sondhi, MD & CEO, the construction and the JCB India, said “We are equipment industry.” extremely delighted with the
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MODERN MACHINE TOOLS - July 2012
Component Firms Cut Output as Automakers Trim Production
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ith the demand slump in the automotive industry, component manufacturers are also trimming down their output to prevent inventory pile up. The automakers this year have seen a steep reduction in demand pattern, which led to downsizing the production. As vehicle sales dwindle due to high interest rates and petrol prices, many automobile manufacturers in India have planned to shut down their plants temporarily to reduce inventories. This has directly affected the component manufacturers
across the country. As per Auto Component Manufacturers Association (ACMA) reports, the components industry saw a turnover of around $40 billion in 2010–11 and is estimated to touch $66.3 billion in 2015–16. India’s exports from the sector stood at about $5.2 billion in 2010–11, expected to reach $12.3 billion 2015–16. Car sales in India grew at the slowest pace in seven months during May with just 2.78% rise as high interest rates, which are hovering around 11-13%, and petrol prices hit the market.
GEOGRAPHY WATCH Chennai
Chennai’s automotive industry is moving forward at full throttle, and with this, the city encompasses in itself a cauldron of business opportunities for the machine tool builders of India. Debarati Basu throws light on the various lucrative options that Chennai offers...
T
he huge conglomerate of automobile manufacturing industry based in and around Chennai has created a thriving industrial ecosystem for business to pour in. From the very inception of the automotive industry in the country, Tamil Nadu has been providing the right environment to optimise on the emerging opportunities. Starting from Ford Motors, which ventured here in 1995, to Hyundai, BMW, Mitsubishi, Nissan and the leading Indian companies such as Ashok Leyland, TVS Group and M&M, almost all major automakers have made Chennai their home. Chennai hosts around 35% of India’s auto ancillary units, and has thus rightly gained the sobriquet ‘Detroit of Asia’.
Building Business However, even with one of the biggest auto clusters in place, Chennai could never promote its own machine tools setup. It either imports or outsources most of its machine tool requirements from various Indian cities. It procures its machine tool requirements mainly from Bengaluru and Coimbatore, which have established their manufacturing base for machine tool requirements. Syed Amjed, Sr VP - Global Marketing, Bharat Fritz Werner Ltd, explains, “Though we agree that Chennai is an auto hub, Bengaluru’s business is divided into categories like automotive, aerospace & general engineering.” 32
MODERN MACHINE TOOLS - July 2012
A setup for manufacturing machine tools would need established requirements for castings apart from suppliers and sub-suppliers. For Chennai’s auto industry, importing machine tools or outsourcing its requirements from other Indian cities is more feasible than putting in the investment for manufacturing the same in Chennai. Rama Bhatathi, Head Sales, South, Hyundai WIA Pvt Ltd, says, “Over the last 20–30 years when Chennai was strengthening its automotive industry, Bengaluru was simultaneously building up its machine tools segment. And now, both these cities have their own matured market with established players. Today, any global machine tool builder entering the Indian industry would look at Bengaluru just like any global auto company will come to Chennai. This is the ecology that has been traditionally been created.” This has given rise to an opportunity for the Indian machine tool builders to extract business opportunities from this auto cluster. “Metal forming and metal cutting form almost 60% of the total manufacturing process of automotive industry. Hence, the machine tools industry has a huge role to play. Bengaluru alone provides 55–65% of the total national domestic consumption followed by other Indian machine tool clusters including Ludhiana, Rajkot and Coimbatore,” says TK Ramesh, CEO, Micromatic Machine Tools Pvt Ltd.
Machine tools industry is a manpower-intensive industry that requires volumes to justify the investment. While the national requirement for machines is around 15,000–20,000 machines per annum, Chennai’s requirement is roughly around 2,000–3,000 machines per annum. While Chennai has some key machine tool builders providing for the auto industry’s requirements, it can also explore this segment of manufacturing as well. “As the auto industry grows, the machine and tool industry will also see a rise, even though it may not be as huge an industry as the automotive. The state does have a few machining companies and although they are not large in number, they certainly produce quality machine tools,” says Dilip Kumbhat, CEO, K-Lite Industries, and Chairman, Chennai Auto Ancillary Industrial Infrastructure Upgradation Co.
Paving the Way India today has positioned itself as one of the fastest growing auto markets in the world. According to a CII Survey, the Indian automotive industry is expected to grow at the rate of about 13% per annum over the next decade to reach a size of around $165–175 billion by 2022. At the rate at which the automotive cluster is gearing up for the global race, the machine tool industry definitely has a lot to draw from Chennai. debarati.basu@infomedia18.in
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SMEs@GLANCE Growth Enablers
Aiding small companies manufacture bigger wonders At a time when the industry is on a full swing towards development, SMEs need to be strengthened to ensure consistent growth. However, while the big industries are growing even bigger, SMEs in India still have to fight for better benefits to explore its opportunities. Here is an insight into what SMEs really need. Debarati Basu reports…
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he Small and Medium Enterprises (SMEs) play a vital role in the growth of Indian economy. They contribute over 45% of industrial output, 40% of exports, employ 60 million people, and more importantly, have the potential to create 1.3 million jobs every year. The contribution of the SMEs towards the GDP in 2011-12 was around 17% and studies predict that it is likely to increase 22% by 2012-13. According to a study, liberalisation and deregulation in the industry would also contribute to the sector’s growth. The sector, which has grown at the rate of 35% in the last two years, is likely to register 40% growth in the next five years. However, with all the growth projections, the Indian SMEs are still grappling for support from government and bigger companies alike.
Challenges Encountered With the potential that the Indian SMEs possess, the segment can grow manifold if given appropriate support from all quarters. The growth of this segment would result in the overall growth in the production of the Indian industry as well, and thereby the Indian economy. However, the odds that SMEs have to face have outweighed their growth. This segment of the industry is still grappling to own a share of benefits from India’s growth 38
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story. Here is a wish list of the Indian SMEs and what they actually want: Availing easy finances: It goes without saying that finance is a major constraint that SMEs face. The non-availability of credit facilities and exorbitantly high interest rates are some key issues that all levels of the industry have to grapple with. However, these issues come down heavily, especially on SMEs. Therefore, they need a quicker and hassle-free procedure to avail finances. Government aid: A helping attitude of the Central Government and state governments is the first requirement of SMEs. Support to undertake R&D: SMEs are the fountainhead of innovations as they are the closest to the ground realities of manufacturing. But, in a desperate measure to cut down cost to make profits, howsoever marginal, the first thing that is usually struck off from the list of expansion plans is the investment in research and development. Despite every effort, most SMEs today have become offloading units for mass production. “Being an SME makes you a puppet at the hands of the Original Equipment Manufacturers (OEMs). SMEs are usually trapped in the cycle of scope, quality and schedule and one of them is compromised in the entire process. Although it
involves a lot of investment, every SME should try to design its own products and create a brand for themselves in the market,” feels D Ramamoorthy, Director, Applied Engineering & Technologies Pvt Ltd. Knowing the global requirements: The world is growing at a rapid pace and there is a dire need for SMEs to keep themselves abreast with the recent developments. The small scale industries need to have a clear understanding of what the global customers need to manufacture products that match the international specifications. For this, the industry needs to have a proper channel of communication between the OEMs and the entire gamut of SMEs.
Looking Ahead Gone are the days when SMEs were synonymous with low-quality manufacturing at less cost of production. Today, they are trusted upon by OEMs to produce quality-testified components as per the standards of international market. Various state governments have started taking note of the potential that SMEs hold and numerous industry associations are also now coming forward to help this segment. However, SMEs still await a synergised effort towards strengthening the backbone of Indian machine tool industry. debarati.basu@infomedia18.in
TECHNOLOGY & INNOVATION
Scissor Kinematics provides flexible machining strategies
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igh feed rates call for powerful drive systems and weights that are as low as possible. On the other hand, a high level of accuracy requires a high level of rigidity, which also leads to large cross sections, and hence, to large volumes and weights where designs to cope with force distribution are concerned. Past reaction to the different processing requirements relating to rough and finishing machining was to develop modular sub-assemblies. These sub-assemblies were then combined to adapt the machining level in the best possible way. This meant that a number of machines or process units
were necessary for complete machining of the tool. The concept of scissor dynamics links the dynamics of a parallel structure with the broad operational range
encompassed by scissor kinematics. In contrast to other solutions, the dynamic gain was deliberately set as the limiting parameter because the traversing movements of the serial axes are accelerated within the range of the required compensatory movements. Through dynamic-oriented utilisation of axial redundancy, it is possible to achieve optimum adaptation of the machine characteristics to the relevant stage in the process. At the same time, a considerable expansion of the process scale is achieved because new machining strategies are made possible by the means of these improved and controllable machine characteristics.
Precision turn milling machine makes dry machining more efficient
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otential for cost saving in crankshaft manufacture and for enhancing the quality of machining is offered by the use of a high-precision dry machining process instead of the previously used machining process of grinding. Consider, for instance, crankshaft manufacture. Here, the precision turn milling technology has the potential to replace the grinding process. Grinding process, as a machining process, requires the use of cooling lubricants for geometrically indeterminate cutting. The trend towards machining using geometrically-determined
cuts and the subsequent achievement of levels of precision of less than IT4 as well as form deviations smaller than 4 micrometers (previously achievable exclusively by grinding) holds out the
Thermo cell simulates workshop conditions for machine analysis
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o research thermal characteristics, a rigid temperature management is necessary to simulate various operating conditions. One aim is to determine the correlation between temperature change and heat-dependent shifts for the machine sub-assemblies, which, to a major extent, determine the working accuracy. Based on the knowledge acquired relating to the heat sources and the flow of heat, design measures can be derived to reduce thermal deformations/shifts. 40
MODERN MACHINE TOOLS - July 2012
A further possibility is the correction of the thermal shifts by direct/indirect compensatory action. External thermal influences are simulated by means of conditioning the surrounding air and
promise of enormous potential for cost saving, resulting not only from the use of dry machining, but also from shortening the process chain. The preconditions for economic and process-reliable dry machining of the component have been created by the development of this new type of precision turn milling machine, associated integrated studies of the Work-Piece-Tool-Process-Machine system, and new approaches to development in respect of process, tool & coating and/or lubricating principals.
base plate temperature for the thermo cell to supplement conditions in practice. Experimental tests may be carried out during machine downtime, at idle with the programme cycle and while machining, in order to determine thermal loads that have a disruptive effect on the operational accuracy of the machine tool. Over and above this, vertical or horizontal temperature layers may be generated, which may be used to render thermoneurological zones on the machine tool identifiable by means of which workshop conditions can be simulated. Courtesy: Fraunhofer Institute for Machine Tool and Forming Technology IWT
IN CONVERSATION WITH Terrence Miranda
The machine tool companies in India are facing serious challenges… …and depreciation of the rupee and the situation in Europe is making overall business conditions uncertain. The industry wants the government to take certain policies and decisions much faster,” says Terrence Miranda, MD, HAAS Automation India Pvt Ltd, a leading CNC machine manufacturer, as he shares current trends and challenges that the industry is facing with Nishant Kashyap. Excerpts…
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Terrence Miranda Q How has the machine tool industry
responded to the increasing demand from customers for high speed and better productivity? In recent years, machining tasks have become more complex. This means that the machine technology has to become more complex to provide cutting-edge machining. The demand for quicker and better productivity has naturally gone up. Customers now want to increase their productivity dramatically. At the same time, they do not want to compromise with the cost. Hence, to be in the business, machine tool builders have to manufacture products that are cost effective as well as provide value for money. The increasing demand for better productivity, efficiency and speed would mean that we would need faster machine tools that can efficiently deal with complex machining. On the other hand, from the user industry’s perspective, faster machining of components would require highly specific tools tailored to the machining process to maximise process speed. At the same time, for higher productivity, the product needs to be handled properly for setting up the tools. Naturally, all these additions to handle complex machining will increase the cost. Hence, the industry is continuously going through a cost– quality tussle.
Q What are the current market
trends? Currently, I see three major trends in the industry. First is the extensive use of automation. Loading/unloading of parts with the help of robots, automatic pallet systems or bar feeding systems is a clear trend that is being seen in India. In this ever-growing world, it is not just enough to have CNC machine tools; customers want to automate the entire process. This would reduce dependence on manual operation and also increase productivity. The second trend is the growing demand for 5-axis machining centres. As the accuracy standards are going up, the necessity to machine a part in a single setup (i.e., 4–5-axis machining) is also growing. This trend is seen in every machine shop, big and small players alike. Companies
UP CLOSE
&personal
Which personality inspires you and why? If I was asked to name one person who inspires me, I would say John Roth who is the present Director of Production at HAAS. He has been my mentor and guide since I started working for HAAS as a dealer and then as the Country Manager for HAAS India. What do you consider as a turning point in your career? The challenges that we faced in the difficult years from 1998 to 2002 to bring the HAAS name to India were the turning point for me. I truly believe in the adage that adversity can very often bring out the best in people.
multi-tasking machines that are affordable for the mass market. I believe that multitasking is a trend for the future.
Q What are the emerging sectors for
machine tool builders? The construction equipment industry is one of the fastest growing sectors and it is definitely creating a lot of demand for machine tools. One more sector to look for is that of the aerospace industry, which is growing at a fast pace in India. Apart from these, medical, defence, telecommunication, and other such industries are also generating demand for machine tools. The automobile and auto component industries remain the biggest customers of machine tools. I believe that in the next two years, these industries will provide an impetus to machine tool builders and will demand the latest generation of CNC machine tools.
Q What are your projections for the are forced to adopt 5-axis machining. The immediate cost of adopting a 5-axis machine may be high, but in the longer term, it will ensure increase in productivity and reduced costs in manufacturing. Currently, many cost-effective 5-axis machines are available that can perform almost all 5-axis operations other than very high-end processes. Transitioning from 3-axis CNC machine to 4- and 5-axis machines was not as easy as it is now. The third trend is the use of multi-tasking machines. Multi-tasking machines combine various processes, such as milling and turning, in a single machine. These machines are growing in importance as customers look to reduce part handling and increase machine versatility. Manufacturers are now trying to combine more processes in a single machine. Adopting multi-tasking machines would improve productivity of the machine and work space, as there will be one machine for all these operations instead of 2–3 different machines for each operation. However, the challenge that machine tool builders face today is the way it has increased the complexity in manufacturing operations. Many machine tool builders are focussing on developing
industry? In 2011–12, the sales in the metal forming and metal cutting industry of India were around $2.5 billion. In the market in which we compete (where we deal with machining centres and vertical, horizontal & turning centres), we estimate that a little over 14,000 machines—both local and imported—were sold in India in 2011–12, of which our market share would be around 5%. The year 2012–13 has started on a slow note due to the Eurozone crisis and high inflation. So I think this financial year will also see a similar number of CNC machines being sold. We do expect to see stronger growth in the 3rd and 4th quarters of 2012–13. In this situation, the major challenge for us is to increase our market share.
Q How is the adoption rate of CNC
machines in India? The machine tool industry in India has shown a double-digit growth rate over the last several years and this trend should continue. As large and small companies in a diverse range of industries move from conventional to CNC machines to upgrade their productivity and meet their own customer or product requirements, July 2012 - MODERN MACHINE TOOLS
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Terrence Miranda the demand for CNC machine tools will continue to go up.
Q Where does India stand in terms of R&D activities
in the machine tool industry? R&D in the Indian machine tool industry is in its nascent stage. But, there are many Indian machine tool builders who are introducing indigenous products that are suitable for both the domestic and global markets. However, the industry has not seen many path-breaking technologies yet. The Indian industry has a lot of opportunities for growth. Many Indian machine tool builders are now showing the potential to develop products that are unique and patented worldwide. But in terms of technology, they have a long way to go. Products from Japan, Germany and the US are technologically highly advanced as compared to the products that are made in India.
Q What are the challenges you see in the industry today? The machine tool companies in India are facing challenges similar to what other industries are facing. The depreciation of rupee against all major currencies like dollar, pound and yen is a major challenge. The situation in Europe is making overall business conditions uncertain. The industry wants the government to take certain policies and decisions much faster. The current situation is not making India’s condition any better as it is affecting the market sentiment and it is definitely not helping capital investment. The machine tool industry is a capital-intensive industry and anything that hurts capital investment will hurt the machine tool industry. India’s poor infrastructure is also a big cause of concern, even though the country is making rapid progress. While power and infrastructure represent huge opportunity areas, they are also a bottleneck. As demand for better infrastructure increases, it will call for a lot of machine tools. Whether it is power generation or infrastructure, the equipment used in these industries would require CNC machines for their manufacture. Thus, we have both potential and opportunity in these sectors, but the machine tool industry needs to gear up to meet these requirements. Another challenge for us is to build value in the product. Companies that can combine the need for higher productivity and cost effectiveness will be successful.
Q What are your strategies to deal with the current
situation? We are neither a low-cost machine tool manufacturer nor do we make high-end or highly specific CNC machines. Our focus will be on enhancing the value proposition for our customers. When you combine productivity and efficiency with cost, it becomes a value proposition. Any discounting on these is a very short-term strategy, and it is not HAAS’ philosophy. We are instead trying to focus on providing value for money. We have been very successful with this in the past. In future also, our focus will be on adding value to the product and satisfaction of our customers. nishant.kashyap@infomedia18.in
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MMT July-2012 Ad Name:Ganesh Pg No. 45
MMT July-2012 Ad Name: Tungaloy Pg No.46
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SPECIAL FOCUS METALWORKING FLUIDS 50 52 54 56 64 66 68 70 76 78 82 86
Industry Snapshot
Lubricating Industry Potential
MWF Projection
Demand Drenched: 2.5 Million Tonne Annual Global Consumption 2015
Advances in MWFs
Innovation & Efficiency, in Every Drop
Occupational Hazards
Making Fluids Health-Friendly
Mist Control
Techniques for Healthy Manufacturing
6C—Metalworking Fluid Management
Spraying Edge to Manufacturing
Cutting Fluid Costs
The Changing Costs of Coolants
One Q Many Views
Is Cryogenic Cooling an Emerging Alternative to MWFs?
Biodegradable Fluids
Vegetable Oils Turn MWFs Green
Maintenance & Filtration
The Faultless Fluids
MWF Additives
The Key to Cost Effectiveness
Tips & Tricks
The Right MWF
July 2012 - MODERN MACHINE TOOLS
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SPECIAL FOCUS Industry Snapshot
Lubricating Industry potential Global Industry Analysts (GIA), in a recent report, forecasts that the global market for functional fluids will reach $19.7 billion by the year 2017. With such a growth in demand, the opportunities in the market will be driven by innovations that meet the changing regulatory requirements and standards. Over the last year, the lubricating industry has seen burgeoning growth and expansion and promises greater potential for the future. Debarati Basu brings to the fore some of the latest happenings in this industry.
Fuchs opens a lubricant laboratory and technical centre in Australia Using Australia’s position as a leading lubricant industry development hub, Fuchs Lubricants opened a world-class Regional Lubricant Laboratory and Technical Center. The new laboratory will be part of the global research and development as well as develop new products for the market. It will also be responsible for providing technical support to the region. This is a step towards more research and development and to set national standards for lubricant product development in Australia.
Hyundai Oilbank, Shell in a joint venture ( JV)
Blaser Swisslube’s MWFs make titanium machining easy
Hyundai Oilbank, a South Korean company, entered into the lubricant base oil business by establishing a JV with Shell Petroleum Co. With plans to start production in the latter half of 2014, the JV, named Hyundai and Shell Base Oil Co, will break ground in October this year for this new venture.
Blaser Swisslube’s expertise in creating vegetable oil-based MWFs led to a breakthrough in the machining of titanium, particularly in aerospace applications, where stable and safe working environments are of paramount importance.
Wrapping Up Greenbriar Equity Group acquire PetroChoice
With the increase in the machining complexities, the role of MWFs will Greenbriar Equity Group LLC—a become more important US-based company—acquired PetroChoice, to ensure flawless a leading, value-added distributor of machining processes. petroleum lubricant solutions. Greenbriar Apache Oil with Houghton However, with the everacquired the company from KRG Capital to distribute eco-friendly increasing competition in Partners. Headquartered in Riddlesburg, metalworking fluids (MWFs) this field, new products Pennsylvania, PetroChoice is the largest Apache Oil, a Minneapolis-based need to stand out in distributor of consumable commercial, company, has partnered with Houghton terms of technology and industrial, and passenger vehicle lubricants International—a world leader in highperformance. According to in the Mid-Atlantic and Upper Midwest tech, metalworking, hydraulic fluids a GIA report, biofluids are regions of the US, providing its customers and fluid management services—to expected to be seen as a with total fluid management for their distribute Houghton’s premier line of key area of expansion and lubricant needs. environment-friendly MWFs to the demand. Innovation in customers. lubricants and greases are required to match developments in the equipment and machinery Quaker becomes leading die casting lubricant provider in the US industry. In future, while the With the acquisition of GW Smith & Sons, Inc—a leading manufacturer and developing markets will drive supplier of die cast lubricants—Quaker Chemical Corporation became the leading the lubricanting industry, the die casting lubricant provider in the US. The acquired business has net sales industry will itself be volatile of approximately $14 million. GW Smith’s proprietary formulations of die cast to the demand trends of the lubricants, metalworking lubricants and machining fluids are sold through direct machining industry. sales, distributors and agents in the US and international markets. GW Smith now operates as a standalone subsidiary of Quaker. debarati.basu@infomedia18.in
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SPECIAL FOCUS MWF Projection
Little over a decade into the 21st century and consumption in the global Metalworking Fluids (MWFs) industry already finds itself driven by burgeoning automotive and transportation sectors. Moreover, the meteoric rise of Asian manufacturing and intraregional trade forecast a bustling 5% CAGR for the continent in MWF consumption leading up to 2015. By then, with over $6,500 million in value, the global MWF industry will see over 2.5 million tonne of lubricants flood the market. Tarun Tampi & Nishant Kashyap track the numbers, drop by drop‌
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he impact of the recent global economic recession reverberated in markets across the world, in industries linked, directly or indirectly, to the epicentre of the collapse. The MWFs industry, an integral part of manufacturing, inevitably shuddered from these reverberations, particularly in North American and European markets. Yet, the drop in demand was momentary, although growth in Europe reduced to 1.8% CAGR post 2007, since major regional markets, like in Asia, picked up through the recession, growing at 3.3% CAGR.
Demand Driver: Asia & the Machine Tool Sector Asia, especially China, has by far the biggest and fastest growing machine tool industry globally. In the near future, 52
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Number Crunching
Global CAGR through 2015: 3% Global expected consumption by 2015: 2.5 million metric tonne Removal fluids constitute 50% of total MWFs in use. Forming fluids, protecting fluids and treating fluids make up the rest in that order Two-third of total supply comes from 25 major suppliers
Asia-Pacific Region Growth rate (through 20102015): 5% (China fastest) Expected consumption in Asia by 2015: over one million metric tonne Largest clients/market sector: Transportation, followed by machinery Current total consumption: 891,330 tonne Current value: $3,160 million
India is moving towards becoming one of the top five consumers of machine tools. As a direct result, MWFs are expected to witness a surge in demand in the Asian markets. With huge manufacturing hubs established in Asia, the demand for machine tools is bound to rise, resulting in a surge in MWF consumption. Supplementing this, modern machines and processing equipment function at higher speeds and temperatures, demanding better performance, safety and easy disposal for MWFs, all at lower costs and volumes. The largest markets that drove this growth were Japan, India, China and Korea, which undoubtedly indicates that the future of the MWF industry has shifted to Asia. But as economies rebounded, major manufacturing economies in Europe and North America began recovering, buoyed by growth in the transportation equipment and automotive
MWF Projection sectors. As of today, the global functional fluids market is set to reach $18 billion, with 2.5 million metric tonne of MWFs to be consumed annually by 2015.
India If we consider India alone, the country has several greenfield steel projects underway, aggressive automobile and aerospace sectors are expanding rapidly, numerous global companies are entering its markets, and capacity expansion projects alongside heavy infrastructure development are underway. As a sideeffect of this progress, the consumption and application of MWFs and associated technologies has been rising. Dr AK Singh, Scientist Emeritus, Specialty Product, IIP Dehradun, estimates, “In India, consumption amounted to nearly 115,830 metric tonne in 2010. Of this, straight oil and soluble oils are the major types of MWFs used.” This growth is in spite of rising crude oil prices, heavy import dependencies and the emerging shift from petroleumbased lubricants to biodegradable vegetable oil-based lubricants. As the manufacturing industry leans towards the adoption of ‘green’ solutions on their shop floors, the global demand for ‘green’ fluids is expected to grow by more than 30%, along with substantial growth in the overall MWF demand. M Krishna, MD, Master Fluid Solutions (India) Pvt Ltd draws a line through current consumption and the demand projection, “300,000 drums is a rough estimate of annual usage of MWFs in India. Overall, consumption is dominated by water-miscible MWFs,
Highlights from the Kline Report on MWFs Global Series 2010 Market Analysis and Opportunities The MWF market in North America, Asia and Europe is projected to grow at about 3% per year, from 2.1 million metric tonne in 2010, to nearly 2.5 million tonne in 2015. Asia is the fastest growing market with 5% annual growth from 2010 to 2015. Over these five years, the projection says that the North American MWF market will grow at 2% and that of Europe’s by 1%, annually. The report focussed on North America (United States, Canada and Mexico), Asia and Europe, whose estimated MWF consumption totalled 2.1 million tonne, valued at $6.9 billion, in 2010. Since 2007, Asia’s MWF demand, annually, grew 3.3%, while Europe’s slipped 1.8% and North Americas fell 7.8% per year.
North America North America’s MWF market amounted to 613,000 tonne in 2010. The United States accounted for 83% of total consumption, Canada for 11% and Mexico 6%. The North American MWF market had the top 10 suppliers accounting for just 55% of the market. Those were Houghton (12%); Quaker Chemical (10%); Henkel (7%); Fuchs (6%); BP Castrol Industrial (5%); ExxonMobil, Milacron and Metalworking Lubricants (each at 4%); Chemtool (2%); and Master Chem (1%).
Asia Asia’s MWF market amounted to 891,000 tonne in 2010. In 2010, China accounted for 43% of MWF consumption in Asia, Japan, 24 %, India, 13% and Korea, 10%. Other important Asian markets include Thailand, Vietnam and Indonesia.
Europe MWF consumption in Europe – including Western, Central and Eastern Europe and Russia – totalled 601,000 tonne in 2010, falling around 1.8% per year from 2007 to 2010. The European MWF market weathered the storm largely because of Germany (21% of the region’s consumption in 2010) and Russia (23%).
Automotive Manufacturing Global automobile production increased from 71.7 million in 2007 to 75.2 million in 2010. amounting to about 70%, while neat oil contributed about 30%. Within water-miscible MWFs, soluble oils and emulsion-based oils account for about 70% of it, with the balance taken
Consumption
ASIA
EUROPE (including Russia)
NORTH AMERICA
Volume (tonne) Current (2010): Projection (2015)
891,330 over 1 million
601,100 640,110
612,900 680,500
Approx Market Value (Million USD) Current (2010): Projection (2015)
3,160 over ~3,900
1,550 1,650
1,850 2,043
up by the rising use of synthetic and semi-synthetic MWFs. In the next five years, consumption volume could grow at a CAGR of 15%. With growing demand and rapid changes in machine tool requirements, there will be a shift in the percentage of MWF usage, especially for water-miscible MWFs. Additionally, the semi-synthetic and synthetic-based MWFs will increase to at least 50% of the total volume of water-miscible MWF.” All these factors will provide great opportunities for MWF manufacturers and distributors in India, to double their sales and stepup production. tarun.tampi@infomedia18.in nishant.kashyap@infomedia18.in
July 2012 - MODERN MACHINE TOOLS
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SPECIAL FOCUS Advances in MWFs
The global decline in fluid sales in the past few years and the ever-widening web of environmental and safety regulations have led the industry to rethink the manufacturing and applicability of Metalworking Fluids (MWFs). Further, the costs of MWFs have increased to constitute almost 17% of a manufacturer’s overall costs, leading to an increase in the number of out-of-the-box innovations and specialised lubrication techniques. Tarun Tampi reports on the various emerging solutions in the MWF industry to improve tool life, reduce wear & costs, and minimise shopfloor and environmental mishaps. New Test Method to Detect Microbes in MWFs Bacteria, fungi and other microbial contaminants are a perpetual problem as far as implementing MWFs is concerned. Apart from health risks to those working with such fluids, microbes degrade the quality of the fluid, reduce its components in its composition, increase tool wear as well as corrosion, and can lead to the formation of biofilms, thus plugging filters. Conventional dipslide tests to detect microbial contamination take too long and can, at best, detect only 0.01–1% of microbes in the MWF. They are also limited to samples tested in laboratories, which may not provide the most accurate measurement. Hence, a new method that tests MWFs for microbial contamination has been developed. This method can be conducted within minutes, accurately and on-site. The test
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works by measuring the concentration of Adenosine Triphosphate (ATP), the main energy-carrying molecule in all living things. However, before the ATP is extracted and measured, the MWF sample is filtered through a 10-micron filter to isolate bacteria from fungi, and then through a 0.7-micron filter to isolate the ATP from the organic chemicals that may be dissolved in the sample. The concentration of ATP directly relates to the level of microbial contamination in soluble oils and synthetic & semisynthetic fluids.
Boron Nanotechnologybased Lubricant Additive Conventional solid lubricants are being revisited as the proliferation of nanotechnology has led to research looking to use nano-sized particles as lubricant additives. One such material is boric
acid whose particles, sized between 50 & 100 nanometers, have been found to reduce the coefficient of friction to between 0.02 & 0.1, nearly two-thirds, for lubricants used on ceramic or metallic surfaces. They are also easier to disperse in mineral oil-based stocks than larger micron-sized particles and are compatible with most additives used in making lubricants. Nano boric acid, however, is susceptible to agglomeration when exposed to water, although the technology is being improved to remedy this as well. Potassium borate nanoparticles used in an ester matrix as an additive result in better lubrication, anti-wear and extreme pressure performance. The dispersion of potassium borate nanoparticles in the ester does not agglomerate in the presence of water and is not adversely affected by other contaminants. It remains stable for
Advances in MWFs three to four years and results in a coefficient of friction as low as 0.037. Not only is the boron nanoparticle containing lubricant additive better in terms of replacing anti-wear and extreme pressure additive packages, it also exhibits some corrosion resistance, thus allowing the concentration of corrosion inhibitors to be reduced in the lubricant mixture. The colour, viscosity and tolerance to water are better and no unpleasant odours are detected. Seen as a replacement for chlorinated paraffin additives, it can be used at one-third the treat rate. A key application for this nanoparticle containing boron additive is in lithium greases, where it has brought significant improvements in the treat rate.
To Get More from Less… Over the last 20 years, the disadvantages of metal-cutting fluids and machining lubricants have begun to weigh heavily against the advantages. Reduced friction, wear and corrosion were convincing positives until MWFs were shown to pose serious risks to health and environment. With permissible exposure limits increasing in their severity, along with the everwidening web of regulations, standards and management practices, MWFs are beginning to lose their lustre. At the same time, in order to stay competitive, manufacturers are looking to reduce costs, of which MWFs form a growing chunk, while simultaneously improving productivity. “From the machining perspective, the MWF sector is at a nascent stage, but growing at a rapid pace, moving priorities from the ‘Need for Cost’ state to ‘Need for Performance’ state. The Indian industries growing globally, feel the need for better productivity, better process control beyond machine parameters, better machine maintenance and more advanced machine tools. All these broaden the spotlight on innovating and extract better performance from MWFs,” says M Krishna, MD, Master Fluid Solutions (India) Pvt Ltd.
…by Dry Machining This has led to the increasing prevalence of various machining processes that are run ‘dry’, without using MWFs. Although the heat generated and questionable surface finish were concerns in dry machining, improved tool coatings with impressive thermal properties, like TiAlN, are making dry machining more feasible. Milling and boring processes are inherently more suited to dry machining, whereas drilling, tapping and other closed-face operations are still difficult to perform dry due to chip removal issues. Material has also been an issue for this technique since several high-end alloys and materials, like titanium, could only be machined in the presence of cutting fluids due to the quantity and temperature of the heat generated. However, materials that react with water, like magnesium, can only be machined dry. Considering all this, the use of dry machining is becoming increasingly suitable if carefully customised to the machining process, the workpiece material and the tool.
…or Minimum Quantity Lubrication (MQL) Given that dry machining still has some notable limitations, near-dry machining or microlubrication is a far more attractive solution. If minimal quantities of oilbased or vegetable oil-based coolant are used, at flow rates around 50–500 ml/h, and applied directly at specific points between the tool and workpiece, then huge savings in fluid, machining time and costs can be made. Also known as MQL, the aim is to maintain a thin film of oil that will lubricate the cutting surface, sometimes one drop at a time, applied externally or through the spindle and holes in the tool. For high-speed carbide tools, MQL has been found to be the most efficient method for lubrication in terms of wear, tool life and accuracy. The costs related to cutting fluids are frequently higher than those related to cutting tools. One study found that Ford had reduced its costs by 13% when MQL was implemented. The cutting
performance using MQL is far better than when conventional flood-cutting fluid supply is used since it reduces the cutting temperature, improves chip–tool interaction, reduces wear and damage to the tool, and improves dimensional accuracy in machining. Moreover, most MQL lubricants are biodegradable, thereby making the technique environment friendly. Globally, several companies, particularly in Europe, retrofit MQL systems to existing machining centres. HAAS Automation also offers a Minimum Oil Machining (MOM) as an option for its machining centres.
Neat Oils, Emulsions & the Environment Milky fluids are a factory feature of the past. Synthetic esters have long replaced mineral oils and consequently increased sump life. The same fluid can now be used for over three years while extending tool life and reducing corrosion. Tramp oil issues have been largely dealt with as modern day emulsions do not pick up tramp oil, while still maintaining performance and reliability. Further, environment and regulatory measures have led to the development of advanced emulsions, far less prone to mist formation. Neat oils are still most suitable for a variety of low-speed applications, having become lighter in colour, less prone to smoke, odour and mist, and are inherently much easier to recycle. “Keeping environmental concerns, improved performance, consistent structure and characteristics in view, there is a need to develop alternative lubricants and emulsifier components for soluble oils, which are biodegradable and less toxic. Particularly those developed from renewable sources, like vegetable oil, show equivalent performance properties to mineral oil-based or synthetic lubricant-based soluble oils. Biodegradable MWFs will solve the disposal problem as well,” says Dr AK Singh, Scientist Emeritus, Specialty Product, IIP Dehradun. tarun.tampi@infomedia18.in
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SPECIAL FOCUS Occupational Hazards
Making Fluids
HealthFriendly While metalworking fluids are one of the significant ingredients of smooth machining, they are also a source of various health ailments on the shop floor. Debarati Basu brings out the measures to curb health hazards‌
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eduction of heat, friction and removal of metal pieces during machining operations are the key roles of Metalworking Fluids (MWFs). They can be complex mixtures of oils, emulsifiers, anti-weld agents, and other additives. However, the fluid gets compounded with the contamination of substances from the manufacturing process, such as tramp oils and hydraulic fluids. Water-based MWFs support microbial growth, which introduces biological contaminants and their related biological byproducts, such as endotoxins, in the fluids. A worker is constantly exposed to the fluids by breathing aerosols generated during the machining process, or through skin contact with them while handling the tools and equipment.
Health Ailments Exposure to MWFs causes a range of ailments, some of which are as follows: Respiratory disorders: Hypersensitivity pneumonitis, chronic bronchitis and impaired lung function are some major respiratory ailments caused by MWFs. Work-related asthma is another most prevalent occupational disorder. Waterbased MWFs are excellent sources of bacteria and fungi, which cause respiratory problems in the exposed workers. A proper MWF system management programme needs to be maintained on shop floors which should include fluid monitoring, record keeping and maintenance, proper mist control including close-capture ventilation, 56
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machine enclosures and training employees on the hazards and proper use of MWFs. Dermatological disorder: A direct skin contact with MWFs causes allergic and irritant dermatitis. Folliculitis, oil acne, keratoses and other allergic reactions are some other dermatological disorders. Most shop floors need to incorporate the following preventive measures: Use of safe, less irritating and nonallergenic additives or MWF Process modification and isolation to limit the dispersal of MWFs Work practice and administrative controls to assure the proper MWF Cancer: Studies show that some MWFs increase the risk of larynx, rectum, pancreatic, skin, scrotum and bladder cancers.
Measures to be Taken According to the National Institute for Occupational Safety and Health, exposures to MWF aerosols should be limited to 0.4 milligram per cubic metre of air (thoracic particulate mass) or 0.5 milligram per cubic metre of air (total particulate mass), as a time-weighted average concentration up to 10 hours per day during a 40-hour workweek. Some important measures that need to be taken are as follows: Fluid selection: The MWFs selected should be non-irritating and nonsensitising. Petroleum-containing MWFs should be evaluated for potential carcinogenicity. Water-miscible MWFs should be checked for safe-use guidelines. To minimise nitrosamine formation, nitrate-containing materials
should not be added to MWFs containing ethanolamines. Fluid use and application: Mist generation should be minimised. Most machines today are incorporated with the necessary mist controllers to minimise mist dispension during the process. Fluid maintenance: An MWF management plan that includes maintenance of the fluid chemistry, fluid filtration and delivery systems should be developed. MWFs should be maintained at low temperatures to slow down the growth of microorganisms, reduces water loss and change in viscosity, and reduce fire-hazard risks in the case of straight oils.
Alternative Fluids Given the various issues related to the use of MWFs, most manufacturers are accepting Minimum Quantity Lubrication (MQL) as an option. MQL is an environmentally viable technology that helps in reducing manufacturing costs. It is the process of applying a small amount of a quality lubricant directly into the cutting tool workpiece interface and is effective in a wide variety of metal cutting processes, including sawing, turning, milling, drilling and tapping. According to one study, the use of MQL led to a 13% decrease in overall costs. It also led to better cutting tool life, a significant fluid reduction, reduced costs of coolant handling, decreased maintenance and an increase in machine uptime. Most Indian manufacturers too are focussing on the benefits of MQL in manufacturing technology. debarati.basu@infomedia18.in
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SPECIAL FOCUS Mist Control
Techniques for HEALTHY MANUFACTURING Metalworking Fluids (MWFs) can cause adverse health effects through skin contact with contaminated materials, spray or mist and through inhaling MWF mist or aerosol. Workers engaged in the manufacture of automobiles, farm equipment, aircraft, heavy machinery and other hardware are exposed to the harmful effects of machining fluids. This has forced companies to adopt various mist-control programmes at their shop floors. Here, Nishant Kashyap discusses the different methods that are used to control and prevent the formation of mist.
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etalworking fluids are used to cool, lubricate and remove metal chips from tools & metal parts during grinding, cutting and boring operations. Straight oils, water-based oils, synthetic and semi-synthetic fluids are the most commonly used MWFs. Except for the straight oils, all other MWFs are mixed with water before use. However, using MWFs in the technological process of metalworking often generates aerosols by atomisation, and this mist stream represents a significant hazard to the workers and the environment. 64
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MWFs are complex mixtures and some of their ingredients can be toxic. Without adequate precaution, bacteria and fungi can start growing in these mixtures, especially if the fluid has been used for a long time. Heavy metals can also build up and become highly concentrated over time.
Health Risks and Preventive Techniques MWFs can cause adverse health effects through skin contact with contaminated materials, spray or mist and through inhaling MWF mist or aerosol. The severity of health problems caused by
MWFs depends on a variety of factors such as the type of fluid, the degree and type of contamination, and the level and duration of the exposure. Failure to control MWFs has long been associated with work-related health problems, such as work-related asthma, bronchitis, irritation of the respiratory tract and other breathing difficulties. It can also cause extrinsic allergic alveolitis following repeated exposure, which can result in severe breathing difficulties in recurrent episodes. Exposure may also cause irritation to the eyes, nose and throat. Many companies are making
Mist Control efforts to create greater awareness about the problems as part of their employee-safety programmes and are actively targeting respiratory diseases caused by inhaling MWF mists, including bronchitis and asthma. To achieve this end, many techniques have been successfully implemented in the industry. Some of the preventive techniques are as follows: Use splash guards, where provided, to control splashing and misting Minimise the production of mist and vapours by controlling the volume and rate of delivery of the fluid to the cutting edge of the tool Use enclosures or ventilation to remove or control any mist or vapour produced Allow a time delay before opening the doors of machine enclosures to ensure that all mist and vapours have been removed by ventilation Do not use compressed air to remove excess MWFs from the machined parts, plant or equipment. However, mist- and vapour-control programmes have not been properly implemented in the small job shops; they still lag far behind in applying the required safety norms.
Mist-control Programme Various factors are responsible for the formation of MWF mist in the atmosphere of different manufacturing industries. Some such factors are high-speed dynamic forces involved in machining operations, the chemical composition of fresh fluids and contaminants that enter fluids from extrinsic machinery sources. The latter considerations are important in the design of devices for efficient removal of mist from the workplace. M Krishna, MD, Master Fluid Solutions (India) Pvt Ltd, says, “In water-miscible cutting fluids, the root cause of smoke and mist on the shop floors is the high tramp oil content in the coolant. Companies need to ensure that the tramp oil level in the coolant is maintained properly. This can be done by reducing the tramp oil contamination as much as possible in
the lubrication system leakages. Regular cleaning of the MWF is also a good measure to ensure that the coolant is always cleaned. Our coolant recycling equipment can help ensure that the coolants in the machines are always as good as new coolants.” The role of tramp oil in the formation of MWF mists in the atmosphere of machining operations is significant for all types of fluids. Therefore, an effective mist-control programme should include maintenance measures to reduce the amount of fluid leakage from machinery. Also, prudent housekeeping, adequate ventilation and mist enclosures can work together to provide a comprehensive system of mistreduction practices. Proper utilisation of chemicals and creating awareness among the workers are some other mist-control programmes.
Current Trends With greater emphasis on the reduction of carbon footprints, several manufacturers are experimenting with vegetable oilbased coolants in their day-to-day activities, as mineral oil and synthetic alkanes are not appropriate to be used as the base oil for environment-friendly cutting fluid. This is because they have poor biodegradability, and as a result, they remain in the environment for a long time causing pollution. Vegetable oils and synthetic esters, on the other
How to Prevent Mist Generation
Minimise the fluid delivery pressure Match the fluid to the application Use MWF formulations with low-oil concentrations Avoid contamination with tramp oils Minimise the fluid flow rate Cover the fluid reservoirs and return systems wherever possible Maintain control of the fluid chemistry.
hand, possess good biodegradability and are thus safe. Pratap Marathe, MD, Pratap Tex-Chem Pvt Ltd, says, “Selection of base oils and additives to ensure environmental aspects is a very important factor, since it has become absolutely necessary to take care of our nature and deteriorating environment. Therefore, we have to be constantly in touch with the developments happening in this field. For instance, the industry is gradually implementing the usage of esters and naphthenic base oils instead of gum rosin and conventional base oils, respectively, as they are easily disposable and less harmful. The latest advancement is the usage of synthetic esters instead of mineral base oils to save the reducing crude oil stocks. Thus, we can divert these stocks towards making fuel for vehicles, planes, etc., and buy time till we find an alternate solution. Moreover, synthetic esters have a single boiling point unlike mineral oils that have variable boiling points, and therefore, while machining at elevated temperatures, they yield excellent lubricity with less coolant evaporation.”
Looking Ahead It is in the interest of industries to provide a healthy environment to their workers. In this regard, numerous improvements have been made in MWF products, engineering controls, anti-misting technologies and industrial hygiene procedures to reduce workplace mists. It is noteworthy that many of these advancements have been achieved as a result of cooperative efforts between MWF manufacturers and the end users. As the science of MWF mist generation is better understood, the industry can expect more improvements in mistreduction technologies. At the same time, we cannot employ similar methods to control MWF mists and mineral oils, as they are clearly different materials and any considerations to pose limits on them in a similar manner is neither scientifically sound nor in the interest of workers’ health. nishant.kashyap@infomedia18.in
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SPECIAL FOCUS 6C—Metalworking Fluid Management
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f we perform a root cause analysis for bad odour, skin irritation, tool life, corrosion, residue, paint peeling off, foam, etc., from amongst the most probable causes, such as concentration, pH, water quality, tramp oil, filtration, etc., we will find that there is a high interaction among these variables. This makes it difficult to pinpoint the root cause. Hence, many times, a solution to a specific problem in one company may not yield the same result in another company. In such scenarios, one of the best proven and the most economic methodologies in problem solving is to have good preventive measures through systematic approach to ‘Periodic Fluid Management’ that will address all the probable root causes within its operational limits.
6C Concept
The significance of Metalworking Fluids (MWF) is widely recognised, but very often treated only as a support function that is necessary, but not important. The average MWF cost in any industry lies approximately between 10% and 20% of the total production cost. Any lapse in fluid management, starting from the selection of right fluid, will result in failure in terms of quality issues and will also deteriorate the machine tool. To manage this important contributor, the industry must possess a robust management system.
The coolant management concept, described here as ‘6C’, is a fundamental and systematically choreographed process for effectively managing Metalworking Fluids (MWFs) and holding the variables within their operational limits, so that productivity and performance could be increased in all forms of RECYCLING metalworking applications. We start with the assumption that the right coolant has been selected for the application. This is because the coolant selection process is ‘application– CLEANING manufacturer’ dependent. As the SCHEDULE process variables are relatively large and highly interactive, the same coolant may not be necessarily suitable for the same application across different industry segments, or CLEANLINESS sometimes, even within the same (SUMP) industry at different locations. Hence, coolant selection must be done in conjunction with the
manufacturer. However, the 6C-MWF management concept presented here is generic and application–manufacturer independent. With these facts, let us now move to individual ‘Cs’. 1C
Circulation
The method of mixing for circulation forms an important process in the coolant management cycle. ‘Premixed coolant’ addition is generally the best way to add new coolant in the machine. This ensures homogeneity in the fluid. Premix is done either through automatic mixers or is mixed manually. While handling emulsion products by hand, one must ensure to add coolant OIL (Oil In Last) in the agitated water to set the fluid emulsion. This fluid emulsion has small oil droplets suspended in water phase that penetrate the point of cut better and reduce carry off of the fluid system. (Adding water to the coolant oil will form reverse emulsion or thick emulsion and is not what we want to achieve!) Thus, the 1st C of the ‘6C’ concept emphasises the importance of having good mixing and circulation CIRCULATION process, which form the basis for realising effective coolant value. It is generally recommended to use an automated mixer, which could be a low-end venturi type or high-end CONTROLS proportional pump, for good mixing and circulation.
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CONTAMINANT
2C
Controls
This ‘C’ is also the dashboard of the Coolant Management System (CMS). Therefore, most of the coolant manufacturers or service providers claiming to provide coolant management service focus only on this segment
6C—Metalworking Fluid Management of the 6C concept. The ‘Control’ section is critical to ensure that the machine tool sump is monitored for coolant level, coolant concentration and coolant pH. As water constitutes anywhere between 85% to 95% of the end coolant, the water quality parameters need to be monitored at least weekly or with an increased frequency, depending on the water source being used. This ‘C’ is only the beginning of CMS, but, for many, it is also the end of CMS. It is up to the end user or the customer to impress with their CMS providers to look and move beyond this ‘Control C’ to complete the coolant management cycle. 3C
Contaminant
The most common reason for many MWF failures is contamination, or rather the ‘unattended contamination’. The two major contaminants are tramp oil and metal chips & fine particles. In a machine tool, it is rather economical to have some system to remove or reduce contaminants than preventing the contamination itself. The coolant dynamics in the machine should first be properly understood before selecting appropriate automatic tramp oil removal and metal chips removal systems. It is suggested that the end user, in conjunction with the coolant manufacturer, should decide the most suitable methodology for automatic contaminant control and have the system installed. 4C
Cleanliness (Sump)
The cleanliness requirement of the sump is the most important factor but is the least attended to, as the machine will have to be taken down for a considerable time for cleaning the sump. Moreover, designers of machine tools often overlook the necessity for a good accessible sump design for cleaning. In many cases, the sump is a ‘design filler’ and takes all sorts of geometry that cannot be accessed by humans. Moreover, cleaning is undertaken only
when the machine is down, thereby not giving enough time for justifiable cleaning action. For effective cleaning within the available cleaning time, it is recommended to use such sump cleaners that could completely empty the sump, clean particulate matter to, say, 50 micron (commonly used filter size), and charge back again into the tank either manually or automatically. In this way, the automation system will be much more effective and the complete cycle for a 1,000-litre sump cleaning will be anywhere between 20 and 30 minutes. On the other hand, the manual method would normally need more than 4–5 hours. In this way, cleanliness could well be achieved with good returns on investment. 5C
Cleaning Schedule
Along with good cleaning, a sustained cleaning schedule that ensures cleanliness of the sump on a continual basis is also essential. This scheduling could be a part of Preventive Maintenance (PM) or Conditional Monitoring (CM) schedules. The adherence to the schedule should be driven from topdown, otherwise this will become just a cleaning activity. Thus, ‘cleanliness’ is an activity and ‘cleaning schedule’ is a commitment. This could be implemented through TPM. 6C
Recycling
Recycling is a well-planned and executed activity on a continual basis for enhancing the performance of a coolant by increasing its useful life, which, in turn, enhances the machine-cutting performance, finally contributing to greener initiatives by reducing the disposal of coolants. All these, of course, give better returns to shareholders. We need to understand that recycling does not transform old coolant into a new one; it merely reconditions the used coolant by removing solid particles, contaminants and tramp oil through recycling and
adding the necessary additives to control the microbes. Thus, we need to understand that the coolant that has lost its efficacy cannot be brought back to life through recycling. Another myth about recycling is that the coolant’s life becomes infinite by continuous recycling. This is not the case; a coolant has a designed life expectancy and it has to be disposed of at the end of its life. The recycling will only ensure that we get the designed life expectancy of the coolant. ‘Recycling’ is not ‘reclaiming’ of coolants. Therefore, a well-planned and scheduled management programme is necessary for recycling.
Wrapping Up Most of the organisations execute 2nd C—‘Controls’, wherein a chart is displayed by the service provider in terms of three or four controllable factors and updated daily. This is done religiously and rigorously without failure, as any slippage on this ‘C’ will directly affect the production. The other Cs do not directly affect the production, but do affect productivity and performance, and as a result, the profit. Hence, a true CMS must focus on all the 6Cs. It is necessary that any (new) business concept or philosophy should be a set of simple principles/activities put together in a choreographed sequence of processes to address the 3Ps of business—business productivity, business performance and business profitability. The ‘6C’ MWF management addresses all the 3Ps of business, both directly and indirectly. In terms of production, availability, performance and quality are considerably improved, thereby improving overall equipment effectiveness. In other words, 6C is an important component of TPM activity, contributing to increased business sustenance. M Krishna, MD, Master Fluid Solutions (India) Pvt Ltd. He has over 27 years of progressive business experience. He is also a ‘Six Sigma’ and ‘Lean’ exponent with over 12 years of hands on implementation and training expertise.
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SPECIAL FOCUS Cutting Fluid Costs
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he costs of Metalworking Fluids (MWFs) have risen over the last few decades, and today, account for 10–18% of the total production costs. This has become increasingly significant given that fluid sales declined in 2009, the variety of fluids available in the market has decreased, and costs of raw materials have increased along with purchasing costs for MWFs. Moreover, stricter environment and health regulations have also placed a huge burden on MWF manufacturers and users. Worldwide, over 2 billion litre of MWFs are being used annually, and this is after taking into account only the concentrate volumes (excluding the volumes used after dilution that could be 10 times more).
Understanding the Costs The costs involved in MWFs go far beyond just the purchasing costs.
Purchasing costs vary depending on the price and supply of base oil, additives and emulsions, and these costs have been rising due to continuous increase in the cost of crude oil and fluctuations in the global economy. Yet for end users, MWFs have a far bigger financial effect, apart from the cost of purchasing, in their Total Cost of
Ownership (TCO). This TCO involves hidden costs and performance leverage. The hidden costs can be attributed to fluid management (from procurement to implementation), shop floor maintenance, performance monitoring, waste treatment and disposal. Performance leverage costs arise from the efforts used to ensure optimal functionality from MWFs, process quality, tool life, scrapping, reworking and rejecting parts. Syed Md Samim, Marketing Manager, Quaker Chemical India Ltd, explains, “There are many components in considering overall fluid usage costs. As MWF demands change and costs increase, it is imperative for plants to implement a fluid management programme. In today’s competitive markets, customers must continuously seek improvement in their processes to raise productivity, lower costs, maximise efficiency and generate more income. You want partners to help deliver all of these”. “We have repeatedly demonstrated the fulfilment of these objectives. Day in and day out, everywhere in the world,
Leonardo da Vinci was the first to use lubricants and lay down the importance of tribiology. Its importance has grown steadily over the centuries. With over 2 billion litre of lubricants being used worldwide annually, the need and consumption of metalworking fluids (MWFs) have been firmly established. However, the downside is that the costs of lubricants have risen exponentially. Tarun Tampi and Nishant Kashyap look at how effective fluid management, customer collaboration and innovations in MWF technology can help in halting the rise in cost. 68
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Cutting Fluid Costs we provide high-quality products, which we incorporate into a unique offer of teamwork, service, application knowhow and ongoing support. The result is superior value for the customer, expressed in lowered total cost, a combination of chemical products, services and technical expertise that help establish sustainability, improve performance & achieve a safe work environment,” Samim adds.
Coolant Cost Vs Total Cost Per Component
costs include waste treatment, machine downtime, maintenance cost, labour cost and investment cost. Premium quality coolants and proper coolant management practices mean that the coolant will perform better, will be cleaner and its useful life will be longer. A cleaner coolant will directly benefit as it will have better lubricity, lesser carry-off, better corrosion protection and better dimensional accuracy & repeatability. Other benefits that contribute to increased profitability arise from lesser consumption, lesser disposal costs and improved machine performance. Availability, performance and quality will improve to get the user
In the recent years, there has been a paradigm shift from coolant cost to total cost per component and productivity with MWFs, which is Cutting Tools 4% significantly high and more relevant in today’s 14% competitive market. 7% Manufacturers value and 10% acknowledge high-cutting performance as the most essential aspect of a 40% Other Cost coolant. The industry is focussing increasingly on 22% being more efficient in every way. The cleaner 7% an MWF delivered to Coolant 8-16% the cutting zone is, the greater the machining A break-up and distribution of coolant costs in manufacturing. performance and the lower the cost per part a better overall equipment effectiveness will be. (OEE), and thus better capital and The main focus area for industry capacity utilisation.” has been to work on high cutting performance with the help of better lubricity in coolants and cutting oils. Enhancing Performance It has been noticed that cutting-tool A company needs to have an efficient cost is high as compared to the coolant lubrication programme in place to cost on all CNC machines, and hence, get maximum productivity from its focus on maximising tool performances machines. A well-lubricated machine has increased. The net saving effect constitutes an integral part of such a can be higher as compared only to programme. Without administering the the oil cost. Therefore, the focus for proper amount of lubricant at correct continuous development in the coolant intervals, a machine can experience industry will remain performance. serious performance failures, resulting According to M Krishna, MD, Master in costly remedies. A centralised Fluid Solutions (India) Pvt Ltd, lubrication system is a common tool “There are direct and indirect costs used in the industry to distribute a involved in using MWFs. The direct precise amount of lubricant to specific costs include coolant cost, tool cost locations at a particular time by using and rejection cost; while the indirect programmable timers, lubricant
pumps and lubricant injectors. Samim highlights the need to have in-house expertise for the customisation of MWFs to suit a company’s requirements. “The metalworking fluid specialist should have the knowledge to grasp the unique metalworking issues first, and then identify areas where a change in fluid could reduce the overall costs. MWF manufacturer can then custom-engineer fluids that enable the process to deliver improved efficiencies with reduction in total cost per unit, scrap/waste, operation downtime and increment in productivity and tool life,” Samim explains. A company may use the best cutters and the best coolant medium available, but if the flood coolant is not aimed precisely at the cutting edge of each tool, it results Coolant in the wastage of time and Energy money. “Metalworking fluid Personnel manufacturers need to focus on offering innovative products Equipment that are cost effective and satisfy customers’ changing needs. A collaborative approach with Disposal customers with increased focus on research and development Other and enhancing services would go a long way to give a boost to this market,” avers Samim.
Wrapping Up A host of eco-friendly solutions and productivity-driven innovations have led to the use of newer types of fluids, such as macro-emulsions, semi-synthetics, synthetics, biodegradable oils, etc., in the the manufacturing sector. With the growth of automotive, aerospace and construction sectors in developing countries, the demand for MWFs is on the rise. Thus, it becomes all the more important that end users reassess their approach towards MWF usage, i.e., they should be open to use semisynthetics, synthetics, etc., instead of MWFs and work towards extracting more with less while employing better reuse and recycling methods to optimise the material and investment. tarun.tampi@infomedia18.in nishant.kashyap@infomedia18.in
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SPECIAL FOCUS One Q Many Views
an EMERGING ALTERNATIVE to MWFs? Cryogenic cooling, the latest in coolant technology, delivers liquid nitrogen through cutting inserts at -3210 F with a flow rate of 0.1 L/min per cutting edge. It dissipates heat like never before, extends tool life and increases materialremoval rates. It provides a fresh, ‘cool’, approach to machining without liquid coolants, although like any other technology, it comes with a mixed bag of benefits and drawbacks. Tarun Tampi speaks to industry experts... Eswari Prasad, President, MAG India Cryogenic machining tests have achieved a 60% increase in speed while milling Compacted Graphite Iron (CGI) with carbide, and up to four times using Poly-Crystalline Diamond (PCD) tooling. Additionally, with Minimum Quantity Lubrication (MQL), we tripled speeds with carbide. We have focussed on higher material removal rates, while keeping tool life equal to what would be achieved with conventional wet coolants. This technology dramatically improves the lifecycle cost for cutting
difficult-to-machine materials by reducing the required number of machines and associated plant infrastructure, or possibly increasing tool life beyond anything thought possible today. It becomes even more competitive when you consider that it is a ‘green’ technology. There is no coolant mist collection, filtration, wet chips, contaminated workpieces or disposal cost, and certainly less energy consumption without all the pumps, fans and drives that go into handling coolant.
Dr AK Singh, Scientist Emeritus, Speciality Product, IIP Dehradun The limitations outweigh the benefits. First of all, obtaining liquid nitrogen is a costly affair. Then, cryogenic cooling will end up managing heat at the tool itself, instead of at the workpiece. Hence, it results in comparatively high temperatures at the
M Krishna, MD, Master Fluid Solutions Pvt Ltd, India It is an interesting concept, but like other alternative technologies (refrigeration without using a compressor), it needs to be proven, practically, apart from the cost factor. The question is if it can replace not just cutting (lubricity and cooling), but also non-cutting functions of conventional
metalworking fluids (MFWs), such as corrosion protection, viscosity, oxidative and hydrolytic stablising, etc., which go a long way in adding to the quality of a machined part. However, like any other industry, MWFs will also come out with options to handle these innovations.
surface of metal workpieces, thereby causing work hardening. Further, the problem of corrosion on new metal surfaces will not be resolved. Additionally, the issues of lubricity and chip removal will also remain unresolved.
Verdict Although cryogenic machining is not being seen as a direct substitute for liquid MWFs, it could still replace conventional coolants and lubricants as a standard in several applications. With easy retrofitting of existing machines becoming possible, the benefits of cryogenic cooling (if used along with MQL) like lower overall costs, longer tool life, fewer health & environmental risks, lower maintenance, etc., can be availed of by any manufacturer. tarun.tampi@infomedia18.in
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MMT July-2012 Ad Name: Blaser Pg No. 71
MMT July-2012 Ad Name: Object Pg No. 72
MMT Julye-2012 Ad Name:Jyoti Pg No. 73
MMT July-2012 Ad Name:Neway Pg No. 74
SPECIAL FOCUS Biodegradable Fluids
Vegetable Oils Turn Global warming, limited oil reserves, environmental & industrial safety regulations, changing priorities in corporate ethics and government policies are driving the trend towards renewable lubricant technology, biodegradable metalworking fluids (MWFs) and other biomaterials. With IIP Dehradun indigenously developing a patented vegetable oil-based fluid, Tarun Tampi takes a look at the state of biodegradable fluids and what it means for India.
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he industry has long been using mineral- and petroleum-based oils as the standard. However, petroleum-based soluble oils suffer from inherent limitations, such as high toxicity to the environment, poor biodegradability and inconsistent characteristics with change in crude oil composition. The disposal process for such oils also adds an extra financial burden to the users in the manufacturing industry. As a result, synthetic lubricants are increasingly being used as an alternative to the mineral- and petroleum-based oils. Synthetic lubricants are especially useful for use in extreme conditions of temperature, pressure and radiation. Some commonly used synthetic lubricants are polyglycols, phosphate esters, silicones, polyalpha olefins, etc. However, synthetic lubricants can also be toxic to the environment and are not readily biodegradable, with similar disadvantages to those found in petroleum sulfonates and other 76
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petroleum-based emulsifiers. “In formulating eco-friendly MWFs, the selection of the right additives and components in the proper ratio is a unique factor. Apart from the vegetable oil base, emulsifiers and additives should also be eco-friendly and low cost. To strike a balance between eco-friendliness, performance, cost, availability in concentrated form, ease of disposal and health issues, is not easy task. This biodegradable MWF is free from phosphorous, chlorine and sulphur, with neem oil acting as a natural fungicide. Emulsifiers are obtained from natural products such as oleates, sugar esters and rosin. Other biodegradable MWFs are generally based on synthetic esters, although this increases the cost of MWFs,� says Dr AK Singh, Scientist Emeritus, Specialty Product, IIP Dehradun.
Biodegradability in MWFs The biodegradability is primarily determined by measuring the loss of extractable hydrocarbon or complete
breakdown into CO2, H2O, inorganic salts and/or microbial biomass. Vegetable oils are more prone to microbial deterioration. This can be a benefit when disposing of operationally exhausted fluids, which can be biocatalytically broken down by microorganisms using bioreactors. Lubricating fluids usually have the following composition: A base oil Emulsifier (if miscible) Extreme pressure (phosphorous and sulphur compounds) Anti-wear and other additives, which include corrosion inhibitors, oil fog reducing additives, oxidation inhibitors, etc. For vegetable oil-based fluids, the base oils often used are canola, rapeseed, soybean and sunflower. They are used in, more or less, the same application areas as the conventional MWFs. They are used as metal-removal fluids, metalprotecting fluids and in conventional hydraulic oils, gear oils, way oils, spindle oils, and so on.
Biodegradable Fluids Advantages and Disadvantages Both mineral oils and vegetable oils have advantages as well as disadvantages. They are: Lubricity Mineral oils have poor lubricity as compared to vegetable oils. Moreover, they carry a slight polar charge that draws the vegetable oil molecule onto the metallic surface. This bond is strong and protects vegetable oils from being wiped off. No such charge exists for mineral oils, and therefore, they tend to adhere less tightly to a metal surface. Flash point The flash point for vegetable oils is higher, which means that fluids based on these oils are less prone to smoke formation and have a lower risk of fire. Oxidative stability Mineral oils are far more stable and less prone to oxidation than vegetable oils. As a result, vegetable oils tend to form sticky and thick polymerised residues, and can be hard to clean. Their viscosity and lubricating ability can also change. However, this disadvantage of vegetable oils has been turned to an advantage and has led to new applications as grease for guideways, trucks, machinery, and so on. Under heat, both will oxidise, but vegetable oils are more prone to oxidation. Hydrolytic stability Vegetable oils, which are composed of triglycerides, tend to break into fatty acids. These broken down components act differently from the original vegetable oil. However, mineral oils are resistant to such hydrolytic reactions. Nevertheless, innovations in biotechnology have led to the development of genetically enhanced oilseeds that are naturally stable and may eliminate such problems. These stability problems can also be overcome by using additives, like antioxidants, or by chemically modifying the vegetable oils.
Differences between Mineral Oil-based and Vegetable Oil-based Lubricants Criteria Biodegradability Renewability Pour point Misting Dermal sensitivity (depends on additives used)
Mineral Oil Based Slow to degrade No -300 F Medium Can be harmful; can cause dermatitis
Vegetable Oil Based Quick to degrade Yes 50 to 250 F Low Minimal dermal harm
Carcinogenic
Yes; can be low if solvent refined or hydro treated
Naturally low
Cost
Depleting resources and political instability leading to high prices; cost comparable today to vegetable oils
Used to be more expensive. But cultivation has increased; cost now comparable to mineral oils
Viscosity index (VI) VI measures the viscosity of the fluid. Mineral oils are fairly viscous. Yet, vegetable oils have far better viscosity, particularly at high temperatures. For example, soybean oil has VI of 223 as opposed to 90–100 for mineral oil. As machining temperatures rise, the viscosity of vegetable oils decreases far slowly than that of mineral oils. Similarly, as temperature falls, vegetable oils remain more fluid than mineral oils, resulting in quicker drainage and removal of metal chips from the workplace. The higher VI of vegetable oils ensures that they will provide more stable lubrication across a range of operating temperatures. The high viscosity also means that vegetable oils can be used as lubricants for guideways and gears in machine tools.
India and Biodegradable Fluids In India, over 50,000 kilolitre of MWFs, developed from mineral oil bases, are consumed annually. The rising costs of crude oil, costs of disposal, filtration, recycling, etc., make the switch to vegetable oil-based lubricants easier to understand. However, vegetable oils are costly, and until now, could not penetrate the Indian market. IIP Dehradun has developed a non-edible vegetable oil-based fully
biodegradable MWF, under Indian Patent No. IN244501, and transferred the technology to Ecocare Bio Lube India Pvt Ltd under product name EBL-Cut 12. It has been developed from rice bran oil to form a soluble oil concentrate. According to Dr Singh, “At present, industries in the public sector (railways, SAIL, BHEL, defence, etc.) are importing biodegradable MWFs at a very high cost from the Western manufacturers, and the private sector has no other choice, but to use low-cost petroleum-based MWFs. Indigenous manufacturing is limited to IOCL, HP and Castrol, the main producers of petroleum-based MWF. The remaining MWFs, prevalent across industries, are imported. The Government of India is trying to replace and reduce the use of mineral oils, and promote the use of vegetable oils. Biodiesel programmes have been launched. Fundamentally, biodegradable MWFs are being developed for the greater goals of saving petroleum, reducing energy consumption in metalworking and saving the environment. Improved R&D will lower the financial burden and increase work quality in the public sector, encouraging the private sector to use this innovative and ecofriendly product.� tarun.tampi@infomedia18.in
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THE FAULTLESS FLUIDS Maintenance and monitoring systems, along with strict shop floor policies and procedures, improve the health of machine operators and also reduce the impact of Metalworking Fluids (MWFs) on the environment. Moreover, it would protect companies from the risk of prosecution whenever more stringent health, safety and environment regulations are enforced. Tarun Tampi & Nishant Kashyap explain how, even in the world of MWFs, prevention is better than any cure.
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onitoring, maintenance and optimisation of MWFs are critical aspects in the implementation of coolant systems in manufacturing. The emphasis on reducing costs and addressing environmental and health concerns, while, at the same time, maintaining or increasing productivity, has increased over the last decade. Such an emphasis arises from the obvious benefits of maintaining and optimising MWF usage. The service life of fluids is extended, thereby saving on the costs for purchase and disposal. Tool life maximises and becomes consistent, ensuring quality productivity. “MWF manufacturers should use their industry knowledge and process expertise to 78
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understand specific issues related to MWFs, solve particular problems, and implement demonstrated solutions. Trained on-site teams serve as your eyes and ears, capturing data and analysing results to provide detailed reports and recommendations on how to reduce costs and improve performance. As a result, customers of machined parts and other products experience vast improvements in productivity, quality and profitability, immediately as well as in the future,� says Syed Md Samim, Marketing Manager, Quaker Chemical India Ltd. Maintenance and monitoring systems, along with strict shop floor policies and procedures, improve the health of machine operators and reduce the impact of MWFs on the
environment. Moreover, it would also protect companies from the risk of prosecution whenever more stringent health, safety and environment regulations are enforced.
Maintenance MWFs are complicated mixtures containing an array of additives in various concentrations. There are four basic MWFs used in the industry— straight oils, soluble oils (emulsifiable), synthetic oils and semi-synthetic oils. Of these, straight and soluble oils have been in usage for the longest time. However, as non-mineral oil-based fluids are being increasingly used, synthetic oils (based on water) are also being developed. Semi-synthetic oils use both mineral oils and water. The most
Courtesy: Valenite
SPECIAL FOCUS Maintenance & Filtration
Maintenance & Filtration important criteria in evaluating any of these fluids over their lifetime are performance and environmental impact. The performance, of course, depends on the application, the machining process (broaching, grinding, milling, etc.) and the metal being machined. One of the biggest problems faced in terms of performance is fluid contamination, particularly microbial contamination. The deteriorated biomass impedes fluid flow, clogs filters and reduces the ability of the fluid to dissipate heat. Further, the numerous additives deteriorate at different rates, and therefore deplete at different levels. The three major causes of failure that prevent optimal use of any MWF are biodeterioration, water quality (deioniser and reverse osmosis systems) and other contamination (metal particles, tramp oil, swarf, dirt, etc.). In order to tackle these issues, a common sense approach involves using the following three main steps in maintaining the quality of MWFs:
Monitoring the condition of the MWFs, especially their concentration
Minimising contaminants Maintaining consistently high water quality and using deionised water to lower the mineral content.
Select biocides may be used to reduce microbial growth to eliminate corrosion, odour, filter plugging and to extend fluid life.
Monitoring The most important test is to measure the concentration levels of a fluid. Although these tests need to be improved in terms of accuracy, precision, output time and reliability, there are several other tests, which if employed, provide a good enough understanding of the state of an MWF. To measure concentration, a refractometer, which measures the refractive index of a fluid, is used. Alkalinity titration measures the alkalinity of the MWF. Cationic titration measures the anionic emulsifiers. Acid split and wet chemical tests measure the 80
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oil content in a fluid by reacting it with mineral acids. A pH meter test is the basic test to check fluid maintenance as it measures the fluid pH, which should be around nine for most MWFs. Any deviation from this indicates contamination. Instrument tests like infrared analysis, X-ray fluorescence and elemental analysis provide more specific measurements of components in the fluid. Then, there are a host of tests that measure population density of microbes in a fluid.
Filtration Filtration consists of the separation of two phases using a physical barrier. In the case of MWFs, this usually involves the separation of chips. Large oil droplets can be removed by filtration, and depending on the affinity of oil for the filter media, smaller oil droplets can also be removed. There are two kinds of filtration methods that are generally used—membrane filtration, which is used for bacterial separation; and traditional filters used in MWF recycling operation. When the MWF enters the filter in the same direction as it exits, it is called ‘deadend filtration’. In contrast, membrane filtration typically operates with the MWF entrance direction perpendicular to the direction of filtration. This is called ‘cross-flow filtration’. A new MWF filtration technology can help in achieving extended tool life, improved component quality and reduced maintenance & spare parts’ costs. Fluid Maintenance Solutions Ltd has developed such a technology. In fact, it was recently chosen as the sole UK agent for its IFDR range of advanced MWF filtration solutions for machine tools and grinding systems.
Dead-end Filtration Dead-end filters can be disposable or permanent. From the standpoint of the environment, permanent filters are preferred because disposable filters present the problem of solid waste. However, to the extent that in-plant hazards and extension of MWF
life can be achieved using filtration, disposable filters can be warranted from the environmental perspective where permanent filters are ineffective or uneconomical. Dead-end filtration operations utilise gravity, pressure or vacuum as the driving force. As filters clog, the driving force required to maintain a given filtration rate increases, otherwise the filtration rate will decrease for a constant driving force. After some time, demands on driving force or declining filtration rates become unacceptable. Disposable media must be changed and permanent media be cleaned. Permanent media can be cleaned with high-pressure air or MWF.
Cross-flow Membrane Filtration Membrane filtration utilises a semipermeable barrier or a membrane capable of separating feed stream constituents according to their particle size relative to the pore sizes of the membrane. Membranes can separate MWF ingredients from bacteria, tramp oils and chips. Membrane filtration is surface filtration similar to that described for the permanent filters. However, membrane filters do not depend on a cake layer for fine separation. Instead, a porous membrane support is lined with a thin skin where surface filtration takes place. Pore sizes that have been used in MWF recycling range from 0.01 to 0.1 μm (ultrafiltration) and 0.1 to 1.5 μm (microfiltration).
Looking Ahead The industry should develop quantitative guidelines with the help of institutions like technical laboratories to determine the useful life of an MWF as well as parameters for when it should be removed, such as reduction in tool life, loss of surface finish, reduced concentration, increased contaminants, etc. This will help suppliers, maintenance workers and end users work together to optimise the use of MWFs. tarun.tampi@infomedia18.in nishant.kashyap@infomedia18.in
Photo by: Prateek Sur
SPECIAL FOCUS MWF Additives
The Key to Cost Effectiveness Metalworking Fluids (MWFs) are a key production aid in the manufacturing of any kind of metal parts. They have come a long way from being just a coolant to becoming an ingredient for cost effectiveness and productivity. Many new additives are also being developed, which help in cost reduction and are also environment friendly. Nishant Kashyap provides insights on new additives and how they affect the overall industry dynamics.
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etalworking fluids (MWFs) are used in a wide range of activities, from simple grinding and metal removal to honing and broaching. Additives are used both in water-soluble fluids and in water-free neat oil formulations. Over the years, many highly successful additives have been developed that offer formulators almost everything they require. Syed Md Samim, Marketing Manager, Quaker Chemical India Ltd, says, “MWF manufacturers need to focus on offering innovative products that are cost effective and satisfy customers’ changing needs. A collaborative approach with customers with increased focus on R&D and enhancing services would go a long way in giving boost to this market.” 82
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Additives in Minimising Waste Waste minimisation has become one of the biggest cost-cutting strategies. It is an issue that affects the choice of MWF additives when used in the metal stamping process. Additives that are stable to bacterial degradation and hard-water salts, for example, are more difficult to treat, but, at the same time, promote longer tank life of MWFs, thereby requiring less frequent disposal. Metalworking lubricants are important to the metal stamping process for cleaning, stability, lubrication and rust protection. MWFs evaluation is often assessed by the amount of waste disposal. The less waste produced, the lower the disposal costs will be for metalworking companies. The waste disposal of MWFs is
a major issue that the metalworking industry is facing. It is important to find additives that are easy to treat by most systems. This is the most important element in minimising wastes from MWFs. There are a number of lubricants, corrosion inhibitors and emulsifiers that can be evaluated for their potential waste treatability. It is important to be careful while deciding the appropriate chemicals to use when combining additives. This requires thorough research and analysis.
Going ‘Green’ Coolants are being increasingly utilised to contain the heat generated during machining. About two-third of all coolant applications involve mineral oil-based products, the rest utilise
SPECIAL FOCUS MWF Additives synthetic products, while only a few use vegetable oil-based coolants. As the manufacturing sector is adopting green norms, and as this trend will only increase in future, MWF industry will witness huge demand for vegetable oilbased coolants. M Krishna, MD, Master Fluid Solutions (India) Pvt Ltd, says, “Unfortunately, in the MWF sector, the need for conserving environment is at the ‘womb’ stage. Even some larger multinationals seems to disregard the need for better effluent treatment. When the industry across developed countries are running towards better and stringent control mechanism, India is learning to walk in these areas. However, with global players setting foot in India, the learning will become faster for the Indian players.”
The World of Additives
Choosing the Right Additives Choosing the right MWF for operations is a Herculean and time-consuming task. In order to select additives for a particular application, both the advantages and disadvantages of MWF products should be compared through reviewing product literature, supplier information and usage history. Product performance information shared by other machine shops is another means of narrowing choices. Ultimately, the best indicator of fluid performance is through the actual use. While choosing fluids, it is imperative that one should get value for money. During fluid selection, the benefits of fluids and their versatility should be weighed against its performance in each metalworking application. Because of significant improvements in fluid formulations, fluids available today are capable of handling a wide variety of machining
M Krishna, MD, Master Fluid Solutions (India) Pvt Ltd Unfortunately, in the MWF sector, the need for conserving environment is at the ‘womb’ stage.
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Boundary lubricity additives: These are used to improve the lubricity of the fluid by getting adsorbed on the surface of the metal to form a film, thereby reducing metal-to-metal contact. These additives generally have a polar group that interfaces with metal and a tail that is compatible with mineral oil or water. Extreme pressure additives: These are a special type of boundary lubricity additives that actually react with the metal surface, instead of getting adsorbed on the surface, to form a metal-salt layer or a physical barrier between the tool and the workpiece under severe metalworking conditions. They contain molecular compounds that react with metal surfaces under extreme friction conditions, producing a protective film that prevents welding and surface damage. Reserve alkalinity additives: These are used for maintaining the fluid’s corrosion by neutralising acidic contaminants and maintaining the pH in a suitable range. It can also form emulsifiers with other components to stabilise the fluid. Stabilising oil-soluble additives: These additives work in waterdilutable MWFs by reducing the interfacial tension between incompatible components by forming micelles (a submicroscopic aggregation of molecules, as a droplet in a colloidal system). These droplets can then remain suspended in the fluid. This is what happens when we wash our hands.
applications. Usually, semi-synthetic coolants or MWFs with Extreme Pressure (EP) additives are used while machining
Syed Md Samim, Marketing Manager, Quaker Chemical India Ltd MWF manufacturers need to focus on offering innovative products that are cost effective and satisfy customers’ changing needs.
hard components made of titanium and soft components like aluminium. These EP additives help in reducing friction between the tool and titanium components, and provide proper finish. It also strengthens aluminium, which is comparably soft and melts even at low temperatures. These EP additives increase the chip welding property of the coolant, thereby giving good finish and ensuring fast removal of chips from the tool that eventually increases tool life. Machine shops that earlier required several types of fluids may now find that just one or two fluid types meet their needs. Consolidating the number of fluids used on the shop floor simplifies fluid management.
Going Forward With emphasis on the reduction of carbon footprints and adoption of green process, several manufacturers are experimenting with vegetable oilbased coolants in their day-to-day activities, as mineral oil and synthetic alkanes are not appropriate to be used as the base oil for environmentfriendly cutting fluids. This is because mineral oils and synthetic alkanes are poor at biodegradability, and remain in water & soil for a long time, causing pollution, whereas vegetable oils and synthetic esters possess good biodegradability properties. Since the metalworking industry demands environment-friendly and cost-effective solutions, coolant industry constantly needs to improve its products with such additives that will reduce heat generation and biocides to control the bacterial growth and wastage, as well as increase the tool life. nishant.kashyap@infomedia18.in
TIPS & TRICKS The Right MWF
Selecting the ‘PERFECT’ Cutting Fluid Metalworking Fluids (MWFs) are crucial in the manufacturing and machining of metal products, from coins and wires to complex aerospace and medical parts. Apart from being a vital aid in producing high-quality finish, reducing tool wear and optimising machine performance, MWFs maintain a constant temperature and lubricity between the work piece and the tool, while simultaneously carrying metal chips away from the cutting area. Tarun Tampi reports...
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electing an MWF for a particular machining operation requires an understanding of the basic types of MWFs and the various compositions (additives, emulsions, etc.) they are available in. Although research is underway, there is no single MWF that can be effectively used in every manufacturing facility, in every machining process and under every condition. Some MWFs have better corrosion control, while others may lubricate better. Hence, an understanding of the benefits and applications of each type of MWF along with corresponding machining processes are provided below.
Good heat reduction, physical lubricity, clean, good rust control
Excellent lubricity, rust control, long sump life, easy to manage Expensive fill-up, excess heat generated, fire hazard, slip hazard, high mist formation
STRAIGHT OILS
SEMISYNTHETICS
May foam, affected by hard water
Machining Process Severity: Light milling, grinding (surface, double disk, rotary)
Synthetic Oil Rust inhibitors & cleaning agents only, no lubricants
Semi-synthetic Low oil content (5-10%), rust inhibitors
Severity: Moderate turning, grinding (tool room, internal, center and centreless)
Some polymeric lubricants
High oil content (20-30%)
High oil, esters & fats
Severity: Heavy drilling, sawing, tapping, reaming, gear cutting grinding (creep feed, form, thread & flute)
High level of polymeric lubricants + phosphate esters
High oil + EP lubricants
High oil + EP lubricants
Very clean, excellent heat reduction, unaffected by hard water, low foam, transparent mix
Excellent physical lubricity, less heat generated, easy to manage Heavy oil residues, affected by hard water, haze, mist and smoke formation
Soluble
SOLUBLE OILS
SYNTHETICS
Poor physical lubricity, no oily protective films
tarun.tampi@infomedia18.in
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FACILITY VISIT Hittco Tools Ltd
Creating OPPORTUNITIES in Difficult Times Sometimes, it is not the big investments but smart decisions that lead to success. From the 2008 recession to the precarious economic situation of the present time, Hittco Tools Ltd has learnt from its own experiences to widen its reach when others are going back into their shells. Debarati Basu finds out how a mid-sized company made the right moves during difficult times to strike the perfect equation of growth.
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ittco Tools Ltd—a Bengaluru-based company—started its operations way back in 1974 as a High Speed Steel (HSS) drills manufacturer, and over the next four decades, it expanded its portfolio to products like HSS taps for threading operations. In 2008, the company entered an entirely new domain of carbide tools manufacturing. “We took the decision to start the carbide tool factory when most people were wrapping up their business activities due to recession. We had a different perspective. When the market is in full swing, manufacturers are so busy executing the orders that they do not observe the market trends. We entered this segment during the deepest recession, but when the market came back to normalcy and orders started 88
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to flow, we were ready to handle it,” explains Rajib Ghosh Roy, Director Operations, Hittco Tools Ltd. This segment of Hittco’s business has grown by 80%, while the overall growth of the company between 2008 and 2012 has been over 100%. Keeping pace with the market trends, Hittco Tools has found its way to some of the major Indian manufacturers in the automotive, aerospace, railways, shipping, and medical industries, among others. Hittco now has experience and theoretical knowledge in fields such as tool material, tool geometry, production process and quality control. The company now has a panIndia presence and its shop floor is equipped with latest SPIBOMAT, NORMAC, HERTLINE, WALTER & ROLLOMATIC machines.
Business Module Apart from being one of the key suppliers to Indian companies, Hittco, over the years, has been supplying to various countries like Singapore, South Korea, Philippines, Taiwan, Thailand, Vietnam, Spain, Czech Republic, Netherlands, West Asia, Turkey, South Africa and the US. “We are now working towards making our global presence stronger and bigger. The economic conditions are confusing. And while the global economic situation is difficult to comprehend, the manufacturing is shifting to Asia,” says Roy. Hence, the company focusses on manufacturing products to meet the global demands. Roy further explains, “Through our experience in various countries and by understanding their needs and demands, we have
Hittco Tools Ltd continuously tried to bring changes in our products. The tool geometries have to change with the changing demands and we have been introducing around five to six new products every year in the market.“ Given the vast array of industries that the company caters to, the tool dimensions offered by it range from 0.4 mm to 36 mm. The company has also caught the pulse of t h e industry. Therefore, despite being a midsized organisation, it has been successful in keeping the cost of its products comparatively low. “Today, the overall cost of manufacturing has gone up right from the cost of raw materials to the wages of workers. Hence, every company wants tools that can cut faster with more precision and decrease the time of manufacturing to increase productivity,” says Roy. To be in the competition with major tool manufacturers, Hittco has been consistently reducing the overhead costs to bring down the cost of tools offered to the market. “Bengaluru has some of the major brands like Guhring, Seco, Tagutec, Kennametal, etc., which means that we have to provide tools that are at par with international quality standards to sustain ourselves in the market,” says Roy. The company, to bring down its overhead cost, works on the ‘Just In Time’ strategy, commonly called JIT. Roy elaborates, “We never increase the raw materials inventory level too high and we have the kind of product mix that sells off very quickly. This way, our finished goods inventory is kept low, which automatically keeps a check on the bank interest from shooting too
high. Our raw material-buying pattern also helps us to bring down the costs. Reducing cost is a closed loop where every entity of production has to be taken care of.”
Quality Quotient
Rajib Ghosh Roy, Director - Operations, Hittco Tools Ltd The big companies, as they make money, need to share their profits with the SMEs and MSMEs. If the country wants to grow, the backbone of the country, comprising of SMEs and MSMEs, needs to be taken care of.
Even though the cost of the tools offered has to be kept low, in order to cater to the global market, quality just cannot be negotiated. Hittco has adopted a stringent process of product inspection to reduce the rate of rejection. “Apart from the regular monitoring at every level, we have inculcated a sense of ownership in every operator where they check the products themselves and implement immediate steps of correction at the primary level of manufacturing itself. Every employee should have a sense of ownership and take decisions in a way they would take for their own company,” says Roy.
them are neck deep in loans. On the other hand, while the big companies are growing by making huge profits, the same profits are not shared with the SMEs. If the country needs to grow, the backbone of the country, comprising of SMEs and MSMEs, needs to be taken care of,” avers Roy.
Challenges Encountered
Expansion Plans
Sustaining in the market for a midsized company has never been a cakewalk. Also, the competition from big manufacturers is just enormous. Therefore, the challenges faced by Hittco are huge. “The main challenge that every SME and MSME face today is that they do not get the real price of the products they sell. Many times, when the bigger Indian players buy their supplies, the optimum price is not given. The industry needs to understand that the MSMEs do not receive any government support that they are entitled to and most of
The company already has over 150 employees at it two manufacturing units designated for HSS and carbide tools. It has had an annual turnover of `10 crore. The company also has been diversifying its portfolio and has recently entered into manufacturing tool holders. Now with the target to increase its production, the company is planning open branch offices in the USA and Singapore. “Initially, we thought of opening manufacturing units in these countries, but our idea was to make India the global manufacturer. This would be our first extension outside India and the offices will become operational by the end of this year,” informs Roy. With this expansion, the company expects a growth of around 30%. Roy positively affirms, “There is nothing like a recession. It is the fear psychosis that is making the bigger companies hold back on the investment. How would the market grow if money does not flow in the market?” The company is not just expanding its business, but is also creating a strong team that can make the brand international.
What is JIT? JIT or ‘Just in Time’ is a management philosophy, a production strategy that strives to improve a business return on investment by reducing in-process inventory and associated carrying costs. This method is also called the ‘Toyota Production System’. It originally referred to the production of goods to meet customer demand exactly, within time, without failing in quality and quantity.
debarati.basu@infomedia18.in
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INSIGHTS & OUTLOOK CONSTRUCTION EQUIPMENT 96 98
Industry Snapshot
Tracking the Growth
Construction Equipment Machining
Creating an Era of Opportunity
100 Machining Solutions
Offering Construction a Cutting Edge
104 Compact Rebar Shop
Pumping Adrenaline into Process Efficiency
106 Manufacturing Modules
Encountering Challenges in Construction
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INSIGHTS & OUTLOOK Industry Snapshot
The global construction equipment industry is experiencing robust development. While 2007 saw the growth of this industry at its peak, year 2008—09 saw a cumulative fall of 35.4%. However, it subsequently picked up, with skyrocketing momentum, and in 2011, its growth rate was approximately 26%, with the market value of roughly $190 billion. As the global construction equipment industry grows, India, too, is entering the league in a big way. Debarati Basu draws out the latest happenings in the construction equipment market from across the globe.
Tracking the
GROWTH
Caterpillar India sets up new manufacturing facility Construction and mining equipment maker, Caterpillar India, launched the company’s new backhoe loader manufacturing facility at Thiruvallur near Chennai. The new facility will strengthen the company’s presence in India and would augment the distribution channel for earth-moving machines by bringing in enhanced local production capabilities. This is the fourth manufacturing operation in India. Caterpillar manufactures construction and mining equipment, diesel and natural gas engines, industrial gas turbines and diesel-electric locomotives.
Hyundai Construction Equipment expands in Tamil Nadu Hyundai Construction Equipment India Pvt Ltd (HCEIPL), a subsidiary of Hyundai Heavy Industries, opened a 3S facility at Puddukottai in Tamil Nadu to cater to the needs of the fast-growing market in the South Indian state. It is the fifth such facility, and along with Shristi Construction Equipment—a dealer for HCEIPL—it will cover areas like Puddukottai, Tanjore, Sivagangai and Tiruvarur. The expansion will help develop and expand operations in the Indian excavator and backhoe loader business. Excavators in this region are employed mainly for blue metal quarry (black stone) and granite quarry applications.
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Isgec, Hitachi in joint venture ( JV) Isgec Heavy Engineering and Hitachi Zosen Corporation, Japan, joined hands to form Isgec Hitachi Zosen to make specialised and critical process equipment with an investment of `100 crore. Isgec Heavy Engineering is a leading global supplier of process equipment and Hitachi Zosen Corporation is a Japanese engineering giant. The JV will use one of the manufacturing facilities of Isgec located at Dahej in Gujarat. Isgec will hold 51% stake in the new venture.
Industry Snapshot
SANY Heavy Industry starts crawler crane production in India SANY Heavy Industry India, subsidiary of one of China’s fastest-growing manufacturing companies, SANY Group, started its first integrated crawler crane production line at Chakan near Pune. The plant will substitute the import of crawler cranes from China and cater to India’s growing needs. Earlier, the cranes were imported from SANY China as per customer requirements. However, looking at the constant growth of crane market and products receiving higher appreciation by Indian customers, SANY has taken this step to start the production of cranes at its manufacturing centre in India.
Volvo goes green with construction equipment To reduce greenhouse gas emissions, save resources, lower costs and help protect the environment, Volvo Construction Equipment (Volvo CE) is offering customers a range of revitalised components with its Volvo Reman programme. In view of environmental care and cost effectiveness, more and more people are willing to recycle, reuse and make the best use of limited resources. Volvo CE is imbibing the same in the construction industry—evidenced by the Volvo Reman programme, arguably one of the company’s most resource-friendly initiatives.
Ashok Leyland, John Deere enter into JV
Hitachi Construction expects record sales this year
Hinduja Group flagship Ashok Leyland entered the construction equipment business, along with American company John Deere, with the launch of the 435 backhoe loader. Backhoe loader was the first product to roll out the 50:50 JV. Around `200 crore was invested in the first phase of the 435 backhoe loader. The product will be sold under the ‘Leyland Deere’ branding and manufactured at a greenfield facility at Gummidipoondi, near Chennai.
Hitachi Construction Machinery Co, the world’s biggest maker of giant excavators, expects its global sales of mining equipment to reach a record this year. The company won an order from Vale SA (VALE5) to supply excavators and dump trucks for an iron ore project in Africa and has secured a contract for gold mining equipment in Turkey. Sales from mining companies may surge by a third to ¥ 200 billion ($2.5 billion) in the year to March.
Volvo Rents acquires Action Equipment Rental Volvo Rents, a worldwide provider of small to medium-sized construction equipment, announces the expansion of its operations in New Mexico with the acquisition of Action Equipment Rental, a three-location construction equipment rental company with stores in Alamogordo, Las Cruces and Silver City. With these acquisitions, Volvo Rents now has 120 outlets in North America, including four in New Mexico.
Hitachi unveils $15 million project in Zambia Taking advantage of the Multi -Facility Economic Zones of Zambian economy, Hitachi Construction Machinery Zambia Co Ltd recently announced its re-manufacturing factory project. The $15-million project is the first-ever investment in the Zambian manufacturing sector by the Japanese company. Hitachi is one of the largest manufacturers of construction, mining and earthmoving equipment in the world. The plant will have value addition activities through the provision and repair of processing equipment.
Chinese equipment maker acquires German concrete pump maker
The Future Trends
SANY, a fast-expanding Chinese construction equipment producer, in January this year, acquired German concrete pump maker, Putzmeister Holding GmbH for €525 million, making it one of the biggest purchases of a niche German business by Chinese company. SANY intends to use its German acquisition to reach new markets in the Western world, as well as to accelerate development of its own technology and design.
Looking at the global business environment in the construction equipment market, we can say that the Indian industry is well placed to enter this market with with new developments that meet the global requirements and quality standards. debarati.basu@infomedia18.in
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INSIGHTS & OUTLOOK Construction Equipment Machining
Creating an Era of
Opportunity
With the government projecting a whopping $1 trillion investment in the infrastructure sector during the 12th Plan Period (2012–17), several foreign firms are planning to enter the Indian market. This will certainly make the Indian machine tool builders more competitive and adopt international standards in their production process. Nishant Kashyap tracks the opportunities for machine tool builders in the construction equipment industry.
I
nfrastructure is an important component for industrial and overall economic development of a nation. It is considered as the yardstick to measure the investment viability of a nation. However, in India, there is a wide gap between the potential demand for infrastructure and its available supply. To minimise this gap, an investment of around
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$445 billion is required over the next five years, which will directly affect the overall business dynamics of construction equipment manufacturers. The industry will also have to grow at a Compounded Annual Growth Rate (CAGR) of 15% over the next five years to support the growing requirements of every sector of the economy.
Indian Construction Industry Considering the present industrial growth, industries working for railways, power sector, and construction machinery, among others, are doing extremely well. Companies like BHEL, L&T–MHI and Siemens are finding it difficult to cope with the orders in hand. To cater to these demands, they are investing in new technologies to reduce the machining time of the components, leading to an increase in production. According to market research firm RNCOS, the Indian construction equipment industry has been witnessing a consistent double-digit growth over the past few years. Though the economic slowdown had a moderating effect on the industry, it regained momentum in 2010, showing a stupendous growth that is expected to continue in the years to come. The earth-moving segment, in particular, has been driving the overall construction equipment industry in India, with strong demand emanating from the government-backed infrastructure projects. The segment is poised to register
a remarkable CAGR of around 21% during 2011–2015, as per estimates. According to Ramesh Chandak, MD & CEO, KEC International Ltd, “The Indian machine tool industry and automation providers have an important role to play in the infrastructure sector. They can develop solutions to achieve better quality with better safety standards. Higher accuracy and better interfaces, along with intelligence and remote diagnostics that automation processes offer today, are the trends that can help India. This must not only be restricted to large manufacturers, but must be used by medium and small units as well. Today, the availability of skilled manpower is a constraint in the construction segment and if better technologies and automation requiring lesser manpower can be developed, it would be useful.” In India, market penetration for construction equipment used to be very low. But growth in the Indian construction industry has picked up quite significantly over the past few years. This industry is estimated to be of around $12–14 billion by 2015. The rapid pace of industrial development in India is driving up demand for the use of process automation to improve manufacturing processes, especially for high value-added applications. Indian tooling firms have an important role to play in helping manufacturers achieve cost optimisation, enhanced productivity and improved product quality by introducing the latest automated solutions in the market.
Construction Equipment Machining Infrastructure: Deficit and Eleventh Plan Physical Targets Sector
Deficit
Eleventh Plan Targets
Roads/Highways
65,590 km of NH comprise only 2% of the network; carry 40% of traffic; the 12% four-laned; 50% two-laned; and 38% single-laned
Six-lane 6,500 km in Golden Quadilateral; fourlane 6,736 km NS-EW; four-lane 20,000 km; two-lane 20,000 km; 1,000 km Expressway
Ports
Inadequate berths and rail/road connectivity
New capacity: 485 m MT in major ports; 345 m MT in minor ports
Airports
Inadequate runways, aircraft-handling capacity, Modernise four metro and 35 non-metro airports; parking space and terminal buildings three greenfield in NER; seven other greenfield airports Old technology; saturated routes; slow speed 8,132 km new rail; 7,148 km gauge conversion; (freight: 22 kmph; passengers: 50 kmph); low modernise 22 stations; dedicated freight corridors payload to tare ratio (2.5)
Railways
Power
13.8% peaking deficit; 9.6% energy shortage; 40% transmission and distribution losses; absence of competition
Add 78,577 MW; access to all rural households
Source: Eleventh Five Year Plan, Government of India
Technology Trends Globalisation has forced companies to use modern manufacturing methods. Technology has increasingly altered the manufacturing process of construction equipment. While equipments are being produced at faster rates, manufacturers must continue to balance increased productivity and efficiency with quality & innovation. Some modern technologies that can boost manufacturing in the automotive industry are programmable machines & tools, industrial robots, data management, supercomputing, virtual manufacturing & complex visualisation and advanced forging techniques. G Devraj, MD, IMT Exim India (P) Ltd, says, “Some of the technologies, such as milling machine, moving column, 5-axis machine, double column and VMCs, are mostly used for construction equipment manufacturing. The size of the machines ranges from 5–10 m. But I feel that Indian machine tools companies still need to work on their technology to cater to the construction equipment industry.” Machine tools builders are constantly developing new tool geometries and technologies. Various tool geometries
are available to address the varied nature of composite materials.
Metalworking Opportunity The increasing number of infrastructure projects in the country has created huge demands for machine tool builders. The construction sector is growing by leaps and bound and so is the demand for automated machines by the Indian companies. The requirement in this segment—in terms of volume—is also increasing. As far as the competition from the other Asian countries are concerned, industry experts believe that Indian machine builders can compete with them in terms of technology and knowledge, easily manufacture costeffective products and also provide good service. “Because of infrastructure development, the demand is picking up for the construction equipment, which will also positively impact the machine tool industry. As of now, Indian companies are only able to fill 20–30% of the total infrastructure requirement. Machine tool builders have a huge opportunity in construction equipment industry,” feels Devraj. The machine tools manufacturers in India produce general purpose machinery of international standards in
terms of quality, precision and reliability. However, they lag behind in design and engineering capability. As a result, they are not able to manufacture very-highprecision CNC machines.
Future Trends As of now, Indian machine tool sector is not very demanding. However, growth in construction equipment, including small component manufacturers who are sub-suppliers to major infrastructure projects, will create huge demand for machine tools. Moreover, India is gradually becoming a manufacturing hub for all the major industries worldwide. This will also lead to an increased demand creation in the Indian machine tool sector in the near future. As a result, it becomes important that Indian manufacturers invest in sophisticated and flexible multi-purpose machines for better productivity and quality in manufacturing in order to meet stringent international standards. The Indian machine tool industry is all set to leverage this demand. Going by the statistics and recent developments, the construction equipment industry seems to be the next big focus for Indian machine tool industry. nishant.kashyap@infomedia18.in
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INSIGHTS & OUTLOOK Machining Solutions
Employing new-generation cutting-edge technologies in the construction machinery manufacturing industry will greatly improve the state of our infrastructure, which, in turn, will stimulate revenue growth. It will also generate a huge demand for machine tools and better machining techniques. Nishant Kashyap discusses some new technologies that are being used in the machining field.
W
elding Technology
The Construction equipment industry is one of the biggest customers of welding equipments. Some of the commonly used welding processes are S h i e l d e d Metal Arc Welding (SMAW), Gas Metal Arc Welding (GMAW), Flux-Cored Arc Welding (FCAW) and Gas Tungsten Arc Welding (GTAW). SMAW is the most common type of welding. It is fairly inexpensive, and can be used both on the shop floor and out in the field. GMAW has a higher welding speed than SMAW. FCAW has an even higher welding speed, along with better metal penetration. GTAW is used when a weld is very important, such as in aircraft applications. Some other features of these welding processes are discussed below: SMAW: It is defined as an arc welding process in which metals are coalesced with the help of heat produced from an electric arc. This arc is maintained between the tip of a flux-covered electrode and the surface of the base metal in the 100 MODERN MACHINE TOOLS - July 2012
joint being welded. This process is commonly referred to as ‘stick welding’. SMAW is one of the most widely used welding processes in the construction industry. The cost is low and the equipment can be portable. It can also be used in areas of limited access in all positions, and is a viable process for joining most metals and alloys. GMAW: It is used to weld all commercially important metals, including steel, aluminium, copper and stainless steel. It can be used to weld metals in any position, including flat, vertical, horizontal and overhead. It is usually connected to use direct current electrode positive (DCEP). It is an arc welding process that incorporates the automatic feeding of a continuous, consumable electrode that is shielded by an externally supplied gas. FCAW: This welding process is widely used on ferrous metals. The consumable electrode can have an interior flux or a mix of flux and metal powder and has a tubular form. The process can use DCEP or DCEN (direct current electrode negative) polarity, and is suitable for all welding positions with the correct
filler metal selection, depending on the flux composition. GTAW: It is versatile and can be used both on ferrous and non-ferrous metals and, depending on the base metal, in all welding positions. The process can be used to weld thin or thick materials with or without a filler metal.
Robotics Application Automated and semiautomated means of production have already been introduced in the construction industry, and are being widely used to manufacture excavators, bulldozers, draglines, etc. The automobile and aerospace industries are widely using Robotics systems. Robots used in the manufacture of construction goods, whether it is I-beams or insulation, are becoming more advanced and are gaining popularity. In the manufacturing sector, robots are stationary while product moves along the assembly line. Therefore, automation is easier to incorporate because each product is identical with respective tasks done over and over. However, construction robots
Machining Solutions face different demands than conventional industrial robots. These robots are mostly used for welding, cutting and material handling operations. Therefore, they have to be specialised for their respective functions. Such specialised robots have the potential to raise productivity by doing repetitive tasks efficiently. They also improve working conditions by working in areas that are hazardous for humans.
Metal-cutting Methods Due to high cost, less speed and adverse side effects of traditional metal-cutting methods, technologies such as chip-less machining processes automation, Numeric Control (NC) technique, electro discharge, waterjet, plasma cutting system and laser machining techniques have been developed. Many equipment in the construction industry have complex shapes, and therefore, techniques, such as multi-axis machining, which can be used for manufacturing complex shapes that are required. The use of computers has also increased the precision and efficiency of metal- cutting tools. Nowadays, NC controls have become more sophisticated as the concern for environment has increased in the manufacturing sector. However, new metal cutting advancements are gaining acceptance and applicability in the industry. These advances could again bring significant changes in the methods employed to cut metal.
Lathe Machines A metal lathe or metalworking lathe is a large class of lathes designed for precisely machining relatively hard materials. These rigid machine tools remove material from a rotating workpiece via the (typically linear) movements of various cutting tools, such as tool bits and drill bits. “Turning 102 MODERN MACHINE TOOLS - July 2012
machines can be classified into various categories like CNC lathes, which are now replacing the older lathes due to their ease in setting and operation. These are designed to utilise modern tooling and fully used modern processes. These processes have been widely accepted in the construction equipment industry for sheet metal cutting operation,” says Tom Sangho Shin, GM – Overseas Sales Team, Machine Tools & FA BG, Doosan Infracore Co Ltd. The part may be designed, the tool paths programmed, and the resulting file is uploaded to the machine. Once it is set, the machine will continue to turn out parts under the occasional supervision of an operator. On the other hand, for work requiring extreme accuracy, a Swiss-style lathe is often used. Shin elaborates, “The collet sits behind the guide bushing, while the tools sit in front of it, holding stationary on the Z-axis. The rigidity of the tool makes it ideal for slender workpieces. To cut lengthwise along the part, the tools will move in and the material itself will move back and forth along the Z-axis.”
Waterjet Technology In the current scenario, where saving the planet has become the most popular mantra, companies are adopting technologies that are more environment friendly. As one of the most valuable and extensive green manufacturing methods of metal-cutting process, waterjet technology is gradually gaining acceptance in the construction equipment manufacturing. This technology has proven to be a highly effective method for cutting any flat material, including stainless steel and aluminium. Waterjet tool has parameters to define minimum and maximum cutting lengths, and the simulation checks for errors such as jet cutting through multiple sections of the workpiece, cutting through fixtures when it should not, and cutting either too close or too far from the jet nozzle. It can cut large pieces of reusable scrap
material and prevent unnecessary waste that gets creative from using traditional cutting methods. It uses no chemicals, gases or harmful liquids. It is a very clean process and does not produce any by product and wastewater. Thus, waterjet technology provides a much safer working environment.
Plasma Cutting Speed, accuracy and the range of materials that plasma cutting system can cut have made it a useful technology for automobile and steel companies to utilise on a large scale. At the same time, the demand for this technology is also increasing in the construction equipment industry. Plasma arc cutting is faster and cheaper than oxyfuels, especially for cutting steel up to 2-inch thick. It also provides greater speed than laser cutting systems for thickness over 0.125 inch. The plasma cutter has many advantages: It is equipped with the latest techniques to cut metal. It prevents the warping and paint damage that occur while cutting. It is faster and cost effective than other equipment. It cuts the metal accurately. These aspects make plasma cutting one of the best options in the industry for cutting metals.
Looking Ahead As our economy is growing, it will create new challenges and opportunities for construction equipment manufacturers. Moreover, as the Indian companies are now working in a highly competitive global environment, it becomes all the more important that they employ cutting-edge technologies. Such technologies will not only help them become quality conscious and cost effective, but will also improve India’s infrastructure, thereby contributing to India’s growth story. nishant.kashyap@infomedia18.in
INSIGHTS & OUTLOOK Compact Rebar Shop
Pumping Adrenaline
Courtesy: Jaypee India Ltd
into Process Efficiency
In this era of rapid urbanisation, industrialisation and infrastructure development in the developing countries, the construction equipment industry is a rather volatile business, dependent on the fluctuations of unstable material costs and labour issues. Yet, the onus is on the industry to build faster and quicker, to squeeze phenomenal productivity from less and less. With technology, Tarun Tampi observes, this task is becoming increasingly possible. Nowhere is this more evident than in the Compact Rebar Shop, an innovative solution for rebar fabrication that pumps adrenaline into process efficiency.
E
conomic pressures and the huge opportunities lying unclaimed in developing markets have forced the construction and associated equipment industry to embrace advanced technologies and concepts more readily. Symptomatic of this shift is the gradual rise in the implementation of automated equipment for the processing and handling of rebar. The Compact Rebar Shop incorporates the latest equipment for the cutting, bending and handling of reinforcing bars, and all this, off-site.
Reassessing Rebar The common practice is to cut, bend and process rebar on-site with the use of large manpower. The process is inefficient, expensive, time consuming and results in unnecessary wastage of steel, sometimes upto 5–7% of the total volume. Improvements in productivity at 104 MODERN MACHINE TOOLS - July 2012
construction sites mean that one can build a structure in 12 months as opposed to two or three years, while simultaneously supplying multiple projects from a rebar shop. Aditya Mehta, Director, Jaypee India Ltd, points out, “Site fabrication of rebar, though effective in terms of instant modifications or last-minute changes, requires a detailed planning schedule and highly skilled fabricators. In the event of improper planning or unskilled fabricators, it can result in an increase in the wastage of steel by as much as 6%. Efficient off-site fabrication can eliminate these costs.” One of the major obstacles is the touch time involved in the transportation and handling of materials, using cranes, forklifts and other lifting equipment involving manual labour. Addressing the need to reduce the touch time and minimise the use of manual labour, Mehta explains, “With rising costs of manpower and shortages
in the supply of skilled labour at job sites, most construction companies find it difficult to get enough skilled manpower to execute large requirements in rebar fabrication, thus, the need to have more efficient equipment, which can fabricate a higher tonnage of rebar, with the use minimal manpower.”
Compact Rebar Shop: Who and How? The concept of the Compact Rebar Shop was developed by KRB Machinery, US, a company founded in 1986 that today controls 70% of the market in the US and is among the four largest manufacturers of such equipment in the world. The modular rebar shop concept is highly specific to the optimal processing of fabricated rebar with minimal touch time. KRB tied up with the pioneers of this technology in India, Jaypee India Ltd, to commission two centralised
Compact Rebar Shop
Courtesy: Jaypee India Ltd
required for the processing and handling unless an excess of modern technology steel service centres in the country. of rebar by 1/10th to 1/20th, resulting devices and controls are used. One Established in 1982, the company of the first processing equipment has led the industry in manufacturing in just three to four men operation—a implemented in the compact rebar bar-bending and cutting equipment in process whose output is virtually the shop is the AutoShakeout machine that India. Jaymac, an iconic brand in rebar same as a full fledged factory. Illustrating does the work equivalent to two men processing equipment from Jaypee its benefits, Mehta says, “Being fully in separating the required number of India Ltd, is ubiquitous in the industry, automated with no dependence on bars for processing. The cutting system wherever rebar is processed. Therefore, labour efficiency and productivity, even is optimised to ensure a cutting strategy it was only natural that the two our lowest capacity rebar processing that minimises scrap material, with companies would collaborate together equipment outputs about 0.8 tonne per in-built controllers, logging scrap and in introducing the technology in India, hour of finished product, with variations thereby bringing the best and most of approximately 0.1% from quoted efficient international-standard values, whereas in manually driven automatic equipment to the nation’s processing, the variation could be as construction industry. Reflecting high as 7–8% at minimum. Wastage on the opportunities that this tieincurred in automated rebar shops up provides to the Indian market, is approximately 2% at best, thus Mehta observers, “The concept of the productivity increase would be centralised rebar fabrication shops near about cent per cent. On site, is a budding concept across the with manual operation, the wastage country, wherein many sectors of the could go as high as 7–8% of total industry have found cost advantages production.” in the automatic method. The use of highly efficient control systems, The Market Outside in order to maintain the accuracy of Implementing the compact the final product, is very important rebar shop requires a thorough in these machines, and as a result, understanding of how the system had kept domestic manufacturers at works, what quantities and types of Aditya Mehta, Director, Jaypee India Ltd, next to the Multibay, considering the high costs of rebar are required to be processed, Form 1016M that automates the bending and shearing of developing the systems.” Therefore, and what the total cost of ownership deformed straight or coiled rebar. it was expensive and difficult to involves. Jaypee experienced this first develop such technology in a purely reducing inventory. hand while dealing with large and small indigenous fashion but that is where such clients in India for the compact rebar The bars are then fed, via walking collaborations help. “Both international shop. Mehta charts the response from bins that index the bars, into automatic collaborations and technology transfers the market, particularly in convincing double headed bending machines like the have a significant role in the growth of potential customers of the initial MagnaBend (which can cut 25–40 tonne the manufacturing sector in India. Such investment, “The whole concept came in of rebar in a single shift) or single headed collaborations give long-drawn technical India with much fanfare with many shops ones like the DuraBend. It is interesting and commercial support to the home being set up in a very short span of time. to note that so far, only one operator is industry. Also, such automated concepts No sooner did the companies realise that required to cut as much as 50 tonne of would not be practically feasible in India the cost dynamics of this shop are much rebar (depending on the size and shift) since high-end electronics, drive systems more complicated than they assumed it with parametes fed in directly, say, by and requisite software are not currently to be, which led to a slowdown in new scanning. Both the bending machines available here.” shops being set up. But the market has required only one operator, aided by matured since then, and the industry is user-friendly touch screen computer now looking at the process with a much controls that make the need for trial Inside the Shop warmer perspective.” and error bending redundant. The It all begins when rebar arrives as raw ServoForm allows for the bending of any material at the facility. It needs to As labour costs rise and automated other configurations that the other two be handled and transported from the technology becomes cheaper and machines cannot handle, like stirrups and suppliers’ flatbed truck or railcar to a easier to implement, the Compact ties. This again is completely automated, storage or inventory space. Overhead Rebar Shop is a natural solution to with electromechanical servo motors and cranes then lift the rebar, as required, increase productivity in a sustainable pneumatic cylinders. Overall, the compact onto processing machines. Till this and reliable manner. rebar shop reduces the total manpower point, the efficiency cannot be improved tarun.tampi@infomedia18.in July 2012 - MODERN MACHINE TOOLS 105
INSIGHTS & OUTLOOK Manufacturing Modules
Construction equipment as a segment faces some fundamental challenges in tool selection, use of materials, operation & maintenance and replacement of equipment components. Nishant Kashyap looks into some of the critical factors that affect the overall dynamics of construction equipment manufacturing.
S
ince the process of selection is closely associated with the factors that influence the quality of end products, selection of methods, tools and processes becomes extremely important in manufacturing any product. Some key factors that should be taken into account before opting for a specific selection process are the type and size of equipment, efficiency, working conditions, job type and operator’s experience. Many new developments have taken place in construction equipment manufacturing, such as using new materials & machines and increasing use of automated systems like robots and Product Lifecycle Management (PLM) systems, among others. Moreover, many new materials, such as alloys, coatings, etc., are being developed for use in construction equipment manufacturing. These new materials are not only corrosion free, but are also very strong.
Significance of Metals There is no simple definition for ‘metal’; any chemical element having ‘metallic properties’ is classified as a ‘metal’. Some of these metallic properties include sheen or shiny metallic appearance, good 106 MODERN MACHINE TOOLS - July 2012
electrical & thermal conductivity, the potential of being permanently deformed or shaped at room temperature and malleability & ductility. Metal is used as a structural framework for large buildings such as skyscrapers, or as an external surface covering and in manufacturing earth-moving equipment such as loaders, cranes, etc. Metals are also used for building construction equipment such as titanium, chrome, gold or silver. An example of alloy that finds extensive use in construction equipment manufacturing is steel. It is a metal alloy whose major component is iron and is the most common choice for structural building materials because of its strength, versatility, durability and economic value. Among its most popular uses today are standing seam metal roofs; it is also 100% recyclable. Earlier, A7 grade steel was used in the construction equipment industry. However, A7’s successor—A36/A36M, the standard specification for carbon structural steel—is now widely used in riveted, bolted or welded construction of bridges & buildings and for general structural purposes. As corrosion can harm steel quality, ultimately contributing to product failure, protection against rust and corrosion is critical to the life-span
of steel and its continued use in various applications and products. Therefore, steel is protected by a number of methods ranging from internal alloying to metallic coatings. Though these new materials and alloys provide efficiency and durability to the construction equipment industry, they need special attention in machining. Some of these materials with complex geometries require multi-axis machining and tools. They also need high-tech welding systems.
Machining Technologies In the construction industry, the metals used for manufacturing the parts change as per the project and geography. Often, to manufacture the same kind of product, two different categories of metals are required, which call for using different machining techniques. For instance, to cut a metal into 3-cm thin strips, depending on the type of metal, waterjet or laser cutting technique is used. New technologies are continuously being developed in the construction industry. They involve special tool materials & tool geometries and specific tool design, matching the uniqueness of operations that are indispensible for the
Manufacturing Modules future growth of the tooling industry. Methods like laser, plasma, Electrical Discharge Machining (EDM), waterjet, etc., are used as per the job specification and requirements, resulting in better productivity, speed and reduction in the cost of machining. The key to producing quality work and making wise investment in equipment is having information on the type of cutting method that would be most suitable for a particular application. While waterjet cutting is perceived as competing with laser, plasma and EDM, many shops view these processes as complementary to each other and use more than one method.
Advantages of PLM PLM system helps manage product data and integrate & automate business processes. Thus, it helps in improving efficiency, which consequently enables companies to develop more new products, shorten time to market, reduce costs, increase productivity and improve
the quality of products & procedures. As a result, all major construction equipment manufacturers have adopted the PLM solution. Vivek Marwaha, Director – Marketing, Siemens PLM Software, explains, “Three application areas of PLM have evolved—traditional design mechanical automation (CAD/CAM/ CAE), digital life-cycle management and digital manufacturing solution (this is all about simulation and manipulating processes, before putting the product for the actual manufacturing). In an ideal solution, with the use of digital manufacturing, a company should be able to simulate the entire plant/ factory they plan to set up and arrive at the most optimum architecture for their new plant/factory.” Huge demand from the customers and the need to deliver products in time have made these companies realise the importance of using the latest technology to grab maximum market share. All these factors have forced PLM solution
providers to offer affordable solutions to these companies.
Future Trends The current trend in the construction industry is to minimise the cycle time & quality variance, and achieve these objectives with optimum cost by keeping the effective cost/component as low as possible. This trend has posed challenges to metalworking and allied industries to provide better and cost-effective solutions to the construction equipment manufacturers. With the government determined to increase the contribution of the infrastructure sector to the national GDP, the sector will provide immense opportunities for the metalworking industry, PLM solution suppliers and automated (CAD/CAM) solution providers & material vendors in the form of simple trading and sourcing, setting up partnerships, wholly-owned subsidiaries, manufacturing units and in exploring technology collaborations in India. nishant.kashyap@infomedia18.in
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INSIGHTSMANAGEMENT ENERGY & OUTLOOK Energy &Magement Drives Motors The increase in energy costs has made the efficient use of kilowatts more important than ever. European firms have long known this, as energy costs are much higher in Europe than in North America. Although some retrofitting of older equipment may be helpful, newer equipment is designed and built to use less energy than machines put in service only five years ago.
and only one second between cuts means that the spindle motor has to decelerate from 8,000 rpm to zero almost instantly. As the motor decelerates or brakes, a lot of energy is released. Capturing it and returning it to the power supply is a great example of efficiency.
USING ENERGY EFFICIENTLY Can Boost ProďŹ tability
M
otors, drives, controls and machine design improvements can save operating cost, thereby reducing overhead costs. Some of these advancements are reviewed below.
Electric Feedback in All Drives Power source regeneration uses the concept that motors act as generators whenever they decelerate, which is about as often as they accelerate. Turret indexing motors on Index and Traub machines, for example, are also used to drive rotating tools, and therefore, decelerate frequently. With modern machine tools, it is possible to recover power from both the axis and spindle motors. 108 MODERN MACHINE TOOLS - July 2012
Regenerative drives on advanced machines convert the motion energy of all braking operations on spindles and axis drives directly into electrical energy and feed it back to the supply network. This reduces energy consumption on a sustainable basis and reduces the heat emission in the proximity of the machine. Drives capable of power source regeneration can redirect it and return it to the power supply through intelligent power modules. The result, it has been estimated, is that power-source regeneration can cut net energy use by as much as 40%. Power source regeneration yields the best returns for applications with high speeds and frequent changes in acceleration. Multi-tasking machines with multiple tool changes in a cycle
Use of Synchronous Motors Properly sized motors and drives also add savings. Alternating current (AC) motors feature a rotor spinning with coils passing magnets at the same rate as the AC and resulting magnetic field that drives it, avoiding energy-wasting slip under most operating conditions. They operate synchronously with line frequency. An induction motor, on the other hand, slips in order to produce torque. Synchronous motors are a highly efficient means of converting AC energy to work. They are typically used in positioning machine axes where high precision and constant speed are required. Most European builders are prepared to provide power consumption details because of the required energy tags (CE) mandated in Europe.
Reduce Energy Also, there are clever mechanical designs are also appearing, which reduce the weight of the axis components in the machine tool, thus requiring less
Drives & Motors energy to move them. The turret slides of an Index automatic lathe move in the ‘X’ and ‘Z’ directions on a single slide, plate-type slide system. This system, unique to Index, permits rapids as much as 60 m/min and accelerations as much as 1 G while maintaining rigidity. Using this plate-type guideway for the turret slides also means that turrets glide directly on the machine bed, resulting in high stiffness and dampening, longer tool life and better surface finish while reducing energy consumption.
Saving through Shorter Cycle Times As machines use energy when they are switched on and even more while they are cutting, the two most cost-effective options for reducing consumption are to optimise machine usage and minimise run time. An idle machine can use several hundred watts simply at rest. Properly sized motors and servos relative to the mechanical weight and structure of the machine can also save energy, potentially reducing peakpower requirements. Plus, they respond quicker, and therefore, can help reduce cycle times. Compared with a less welldesigned machine system, it has been estimated that a machine designed with this type of efficiency in mind can save 1 to 2 kW an hour per machine, per shift.
time elapses following an unplanned production interruption (standby mode).
Centrally Controlled Machine Cooling System Older Direct Current (DC) motors and some large Variable Frequency Drives (VFDs) include resistors on top of the control cabinet to dissipate the heat directly into the shop. Smaller VFDs, however, include bleeder resistors inside the drive housing, which means the heat is retained inside the cabinet. In these cases, a larger air conditioner is installed on the cabinet to protect the electronics inside. But this arrangement results in an energy efficiency loss, plus the electricity to cool the cabinet and/or the shop costs money. The cooling concept from Index Corp cools the spindles, hydraulics and control cabinet constantly and the captured heat can be fed to another useful application via a ‘water interface,’ for example, for service water heating or as process heat for other manufacturing steps. The cold water interface provides the ability to dissipate heat in a climateneutral manner if the machine waste heat stored in the cooling medium cannot otherwise be used. The cooling unit can, with the aid of the water
Reduced Consumption If a machine has some scheduled stops during the shift or at the end of an unmanned job, the controller should be able to turn off affected parts of the machine—as any PC does. Turning off motors, such as those running fans, pumps and chip conveyors, can save a lot of energy, and while the spindle is not turning, it may also be powered down. Adjusting the cycle of the chip conveyor can contribute to meaningful energy savings, particularly when combined with turning it off completely at the end of production. The automatic shutdown function of machines today automatically shuts down all high energy consuming units after a user-defined 110 MODERN MACHINE TOOLS - July 2012
interface, be used outside the shop as well as centrally across several machines. This offers considerable potential energy savings for shop cooling/climate control, and/or increased efficiency, as a result of centralised heat disposal.
Targeted Heat Dissipation All high-loss heat sources of advanced machines can be cooled directly with different cooling media via multiple fluid circuits. In addition to the cooling circuits for the main spindle, counter spindle and milling spindles, the hydraulic system and control cabinet also have a separate cooling circuit. The lost heat energy is absorbed directly in the fluid and conducted from the machine to a central location.
Offline Simulation Techniques Programme simulation offers a major opportunity to optimise a machine’s operation, and therefore, reduce wasteful, energy-using motion even before the machine’s power switch is turned on. Machining programmes can be created, checked and optimised on a PC before they are loaded into the control with 3D simulation. Optimised cycles permit field-oriented applications, tested and reliable operation, maximum flexibility, shortest possible machining times and optimum machine usage. As machines become more complicated, simulation becomes more helpful in saving setup time—potentially 50% to 75%—because users do not have to tool and run the machine to complete a setup. Machine time is very expensive and if users can save 50% on setup time, they can get that much more production out of a 24-hour day, avoiding machine idle time and maximising productive time.
Wrapping Up
In addition to more energy-efficient electronics, such as axis drive and spindle motors, mechanical designs using less mass are being incorporated to reduce energy requirements for motion without sacrificing rigidity.
Cost savings are where you find them, and these are only some of the ways that machine builders are responding to the demand for more energy-efficient machine tools. The quest is on, and it’s delivering tangible results. Courtesy: MMS Magazine
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MMT July-2012 Ad Name: Gudel Pg No.114
REPORT ACMEE-2012
Broadening the Scope of Opportunities Tamil Nadu, over the years, has developed the perfect ecology for manufacturing, metalworking and automotive industries. But is that enough? With the exponential growth of the global industry, coupled with rising demands and challenges, the state has to go beyond the conventional to prove itself as an enviable investment destination. Promising to be a platform to upgrade, build technology awareness and foster business prospects, ACMEE-2012 opened its doors for investment to pour in. MMT reports…
T
he year 2012 has been an excellent one for Tamil Nadu in striking the best investment deals. Yet the amount of investment trickling in is just the beginning of what the state has to offer. The 10th edition of the biennial international machine tools exhibition, ACMEE-2012, is being held at just the right time. Organised by Ambattur Industrial Estate Manufacturers Association (AIEMA), the event is the ideal tool for Chennai to advertise its potential to the world. ACMEE-2012, was inaugurated on June 14, 2012, at Chennai Trade Centre amidst the august presence of Thiru MC Sampath, Hon’ble Minister of Rural Industries and Nutritious Noon Meal. Dr Niranjan Mardi, Principal Secretary, MSME Department, presided over the event. Other luminaries who graced the inauguration ceremony included Thiru Hans Raj Varma, CMD, TANSIDCO; P Sriram, Chairman, CIT; Satish Sadasivan, MD, Schunk India; John Donlon, Executive VP, HURCO; Brijesh Agarwal, COO, Indiamart.com; P Ramdas, MD, ACE; 116 MODERN MACHINE TOOLS - July 2012
RSS Satish Babu, Chairman ATC; and K Ayyappan, President, AIEMA, among others. Commenting on the importance of ACMEE at the inaugural ceremony, MV Robert, Chairman, ACMEE, said, “The Government of Tamil Nadu recently announced its Vision 2023, which focusses on two main strategic initiatives for upgradation of manufacturing technology and MSME development. ACMEE is working towards this.” Talking about the extensive growth in the Ambattur Industrial Estate, Sampath elaborated that Ambattur, Thiru MC Sampath, Minister of Rural Industries and Nutritious Noon Meal Exhibitions like ACMEE will strengthen the rapid progress and industrialisation in the state and help usher in economic development, not only for the people of Tamil Nadu, but the whole country as well. Trade shows like these also help in extending the benefits of the local industry to various overseas participants.
being one of the oldest industrial estates in the small and medium sectors, offers direct and indirect employment to nearly 2,80,000 people. It has a turnover of nearly `8,000 crore. He added, “AIEMA has been established to champion the cause of the small and medium sectors, to help voice their grievances and other difficulties in their business operations to the government, and collaborate with the state & central government agencies to provide suitable solutions.” ACMEE-2012 saw heavy participation from overseas delegates, as well as from companies from all over India. Visitors to ACMEE-2012 witnessed a variety of technologies including abrasives, automotive component parts & supplies, bearings, CAD/CAM solutions, power tools, and low-cost automation solutions, among others.
Expanding Global Reach The exhibition has grown exponentially through each of its 10 editions so far. This edition had over 430 exhibitors (both national and international) who participated in the exhibition. A host of
ACMEE-2012 countries participated in the exhibition, with special pavilions for companies from Taiwan and South Korea. In-Ho Shin, President, Korea Machine Tool Manufacturers’ Association (KOMMA), expressed, “We had earlier taken part in the expo held in Bengaluru and realised that Chennai too is a potential market. This is the first time we are here with seven Korean companies.” He added, “India is the 7th largest consumer in the world and is one of the fastest growing industry. Being a major automotive hub of the country, Chennai
Exhibitors’ Views AV Srinivasan, CEO, Meiban Engineering Technologies Pvt Ltd This was the first time that we exhibited in ACMEE. This exhibition is a way for us to increase our exposure and reach in Chennai. We are the only company exhibiting fully-automated products. Since we displayed our machines and demonstrated the process, the visitors could touch, feel and know the machines better.
Satyanarayanan A, GM - Regional Sales, UCAM Pvt Ltd
Thiru MC Sampath, Hon’ble Minister of Rural Industries and Nutritious Noon Meal, Government of Tamil Nadu, inaugurates ACMEE-2012 by lighting the traditional lamp in the presence of eminent dignitaries.
has a huge potential for machine tool builders. All these make it important for Korean companies to showcase their expertise in India.”
Dr Niranjan Mardi, Principal Secretary, MSME Department I congratulate ACMEE-2012 for the overwhelming response that it has received. As a part of the recently released Vision 2023 document for Tamil Nadu, the initiatives taken by government include the allotment of `50 crore for the development of district industrial centres in 32 districts, implementation of common facilitation centres for 20 industrial clusters and programme to encourage first-generation entrepreneurs. The Department acts as a catalyst for the development of the medium-scale industries.
Thiru Hans Raj Varma, CMD, Tamilnadu Small Industries Development Corporation Ltd (TANSIDCO) We have been working towards the promotion and development of the MSME industry in Tamil Nadu. We have taken up skill-development initiatives, best technology and management practices for which we are seeking proactive partnership from the industries. We will be further working towards making the MSME industry proactive. Further to this, I complement ACMEE for taking up this initiative of encouraging business in the state.
We have been regularly participating in ACMEE and have been in association with this show since its 2005 edition. ACMEE is more of a platform to propagate our brand and create awareness about our products among the visitors. We have had a good response and many of the visitors have also shown serious business interest in our products.
Visitors’ Views KS Srinivasan, GM - Marketing, Star Circlips & Engineering Ltd The quality of the exhibition has significantly gone up both in the number of participants and the quality of exhibits. My main purpose is to understand the new trends in the market & promote parts & components of my company to the exhibitors here.
S Raghuram, Director - Operations, Oliver Valves India Pvt Ltd The range of exhibits this year is wonderful and I could meet many companies of my interest. I am into valves manufacturing and this exhibition has broadened my knowledge in this segment. The wide range of companies also gives opportunities to strike good deals.
Thiru MC Sampath, Hon’ble Minister of Rural Industries and Nutritious Noon Meal, Government of Tamil Nadu, witnesses a live demonstration at the FANUC stall after the inauguration.
Taiwan participated with more than 13 machine and tool companies in the exhibition. Henry Chen, Chief Executive, Evergreat Yota Machine Co Ltd, who participated in this event for the first time, said, “I was mainly looking for dealers in India and have already met some potential clients. Next time, we would come with bigger stalls and more machinery to display at the event.” Other countries present at the expo included Austria, Australia, Brazil, China, France, Germany, Italy, Malaysia, Norway, Russia, Singapore, Spain, Switzerland, Thailand, Turkey, the UAE, the USA and the UK. Photos by Prateek Sur
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EVENT PREVIEW AMTEX 2012
A Gateway to Exciting Opportunities Triune Exhibitors Pvt Ltd, India’s leading organiser of industrial exhibitions, is all set to host the 8th Indiamart AMTEX 2012 at Pragati Maidan, New Delhi, India, from July 27–30, 2012. The exhibition will offer a superlative stage for showcasing the latest in machine tools, be it product service or newage applications. It facilitates interaction between manufacturers, suppliers and users of the growing Indian market on one platform. Nishant Kashyap reports…
T
he Asian Machine Tools Exhibition (AMTEX) has grown by 300% since its inception 12 years ago, and has now become one of the largest shows of machine tools, machineries and manufacturing technologies in Asia. It is working towards creating a platform where all relevant sectors and technologies could interact. It offers the exhibitors an opportunity to present brand new approaches to enhance productivity by optimising the production process. Here, the key industrial sectors can display their individual strengths, and, at the same time, engage in interdisciplinary knowledge transfer.
Exhibitors’ Profile
Lathes & CNCs Machining centres Electric Discharge Machines Hydraulic, mechanical & pneumatic presses Shearing and bending machines Metal-forming machine tools Drilling and boring machines Milling and grinding machines Gear-cutting and finishing machines Assembling systems & industrial robots Sawing and cutting machines Measuring and testing instruments
An International Event The 8th Indiamart AMTEX 2012, as in the past editions, will provide its visitors with technological solutions to enhance their competitiveness. A large proportion of visitors from the metalworking, automobile, aerospace, industrial automation and general engineering industries are expected to visit the exhibition in search of innovative solutions. It will present the 118 MODERN MACHINE TOOLS - July 2012
(This list is only illustrative and features only a limited number of profiles.)
visitors a unique cross section of key metalworking technologies. The grand event would witness representation from 16 countries including Germany, Italy, Switzerland, Czechoslovakia, the US, Sweden, Belgium, Spain, Israel, Turkey, Japan,
China, Korea, Malaysia, Sri Lanka and Singapore. Exclusive Chinese, Taiwanese and Korean pavilions will be the principal attraction.
Opportunities Galore AMTEX 2012 will be a splendid spectacle of the latest advances in machine tools and manufacturing solutions. More than 1,600 exhibitors, sprawled in Hall Nos. 2A, 8, 10, 11, 12 and 15, will be participating in the event and will put their efficiency and innovative power to test before eager national and international visitors. Terrence Miranda, MD, HAAS India Pvt Ltd, says, “AMTEX promises to be a key exhibition for us this year, which is why we opted to be one of its sponsors. The events in Europe, currency fluctuations and global economic uncertainty are all combining to create tough trading conditions, especially for importers like HAAS. However, irrespective of where a smallto mid-sized machine shop is based, they all share the need for reliable, high-productivity, well-supported and affordable machine tools.” nishant.kashyap@infomedia18.in
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
AMTEX 2012 AMTEX (Asian Machine Tools Exhibition) has constantly strengthened its position as one of the largest shows of machine tools, machineries and manufacturing technologies in Asia. The event will showcase the latest advances in machine tools and manufacturing solutions; July 27-30, 2012; Pragati Maidan, New Delhi. For details, contact: Triune Exhibitors Pvt Ltd 25, 3rd Floor, 8th Main Road Vasanthnagar, Bangalore 560 052 Tel: +91 80 4330 7474 Fax: +91 80 2235 2772 Email: info@triuneexhibitors.com Web: www.triuneexhibitors.com
Tel: 28505138/ 28514673
India Manufacturing Show 2012 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. 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
Automation 2012 The event will showcase the power of collaboration between solution providers, ie, 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 For details, contact: IED Communications Ltd, 243, Shiv Shakti Industrial Estate, Marol, Andheri Kurla Road, Opp Mittal Estate, Andheri (E) Mumbai 400059
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CeMAT India 2012 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. 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
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 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: 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
Event List - International
MTA VIETNAM 2012 The 10th exhibition will serve as a platform to network with pioneers from machine tools, precision engineering and metalworking technology sector; July 3–6, 2012; Saigon Exhibition & Convention Centre, Ho Chi Minh City, Vietnam. For details, contact: Singapore Exhibition Services Pte Ltd 1 Jalan Kilang Timor 09-02 Pacific Tech Centre Singapore 159303 Tel: +65 6233 6638, Fax: +65 6233 6633 Email: mta@sesallworld.com Web: www.mtavietnam.com
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.
Tel: +49/69/27 40 03-0 Email: asiamold@demat.com Web: www.asiamold.de
Tel: +44 0 1727 814400 Fax: +44 0 1727 814401 Email: press@mackbrooks.co.uk Web: www.euroblech.com
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; Guangzhou Poly World Trade Center, 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
JIMTOF 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
July 2012 - MODERN MACHINE TOOLS 121
Tenders
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Org: Organisation’s name, TRN: Tendersinfo Ref No, Desc: Description, DSLD: Doc Sale Last Date, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type.
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122 MODERN MACHINE TOOLS - July 2012
Products - National This section gives information about the national and international products available in the market
CNC swiss machine This CNC lathe features heavily ribbed cast-iron construction to dampen cutting vibration for enhanced productivity, superior surface finish and improved tool life. A 10-HP Mitsubishi spindle motor drives the powerful 6,000-RPM spindle. Both the main and sub spindle use 32mm Traub A-32 collets for easy part transfer and complete “done-in-one” machining efficiency, including all radial, end-working, and Y-axis live tooling work on both the front and backside of the part. It weighs over 7800 pounds, making it the heaviest machine in its class. Ganesh Machinery, Inc New Delhi Tel: 818-3499166 Mob: +91-9810133968 Email: info@ganeshmachinery.com Website: www.ganeshmachinery.com
pair of heavy duty taper roller bearings in the front and by a pair of ball bearings in the other end. Bearings are lubricated for life with molybdenum sulfide grease. The rotary movement ranges from 2 to 20 rpm in a step-less range through vector VFD. The spindle is made of EN-24, hardened and ground. The box type ram and the ram housing are made of high grade CI. Shenoy Engineering Pvt Ltd Bengaluru - Karnataka Tel: +91-080-28361767 Email: shenoyengg@gmail.com Website: www.spm-india.com
Radial drilling machine This machine is used for radial drilling. It has 16 steps of spindle speed & feed which brings about economic & highefficiency cutting. All mechanical & electrical controls are centralized on headstock. Clamping for assemblies & speed change of spindles is done by hydraulic power. Maximum drilling diameter is 50 and range of spindle speeds lie between 25-2000 r/min. Macht Exim LLP.
Solid state relays These solid state relays features 5mm wide pluggable/PCB mountable single-in-line AC and DC output SSRs, single channel DRS series sockets for CN series SSRs, and DIN rail mounted CN series SSR/socket assemblies. These relays meet industry standard pin out configurations for both solid state and electromechanical relays and are designed for plugging into Crydom DRSCN series sockets or soldering into printed circuit boards. The marker strips for the sockets are also offered to allow easy circuit function identification for each socket. CST Sensors India Pvt Ltd Bengaluru - Karnataka Tel: +91-080-41132204 Email: india@cstsensors.com Website: www.cstsensors.com
Flange facer The electro-mechanical flange facer is offered for ID clamping or OD clamps or face clamping, depending upon the job requirement. The flange facer consists of a rotary drive unit, horizontal arm, electrical control panel & operator’s console. Powered quill mechanism is optionally offered for depth of cut setting and for boring operations. The spindle (rotary drive shaft) is supported by a
124 MODERN MACHINE TOOLS - July 2012
Ahmedabad - Gujarat Tel: +91-79-40087600 Mob: 9925700006 Email: sales@machtexim.com Website: www.machtexim.com
Peening machine The machine consists of robustly built and sturdy blast cabinet having servo driven rotary turn table. A six-axis robot with controller unit with teach pendant is stationed inside the cabinet having arm provided with sand blasting hose pipe with boron carbide long nozzle for peening application. The media recovery system consists of vacuum recovery unit with double chamber pressure blaster for continuous shot peening operation. Online spiral separator is provided for removing broken shots, hollow shots & shot with sharp edge. The cartridge type dust collector is provided for ventilating blast cabinet. The movement of robotic arm is pre-
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Products - National programmed as per job requirement for peening application. The quantity of shots to air ratio is precisely monitored by magna valve provided at the outlet of bottom chamber. Surface Finishing Equipment Co Jodhpur - Rajasthan Tel: +91-0291-2740128,+91-291-5120021 Email: sfec@sify.com Website: www.sfecindia.net
Junction boxes The output junction box has transmission range up to 50 to 60 meters for indoor application and 1.2 km for outdoor application. Its working band of frequency is 2.4 GHz. It accepts 24 V DC as a supply voltage. It has a very wide application in the field of machine to machine communication. It accepts M12 socket connection of sensor / input. Katlax Enterprises Pvt Ltd Gandhinagar - Gujarat Tel: +91-2764-286784 Mob: 09724506614 Email: info@katlax.com Website: www.katlax.com
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Products - National Digital readout It can be used to replace many models of competitive digital readout displays. It accepts 5v quadrature encoder feedback (TTL) and is compatible with many models of Acu-Rite, Anilam, Mitutoyo, Fagor linear encoders as well as several others. Adapter cables are available for many models. Topaz Digital is available in 2 and 3 axis variants and is also available for Mill and Lathe applications. They are available in two versions, SA100 and SA100-R, where SA100-R is the rotary version of the SA100. CST Sensors India Pvt Ltd Bengaluru - Karnataka Tel: +91-080-41132204 Email: india@cstsensors.com Website: www.cstsensors.com
CNC Lathe This twin spindle CNC lathe is equipped with 2 Strong headstock and spindles assembled with angular contact bearings for more powerful cutting. Spindle speed is 3003000 RPM. Spindles can be either mounted with Colet system or pneumatic or hydraulic type. Two main motors provided for more speed range to complete various turning and machining, even powerful cross drilling or milling head can be provided for turn milling option. Machines can be provided with either single CNC system or Double CNC system. This machine will be very useful for manufacturing auto parts, textile parts and motor parts. Arrow Machine Tools Chennai - Tamil Nadu Tel: 044-2658 2694,09840236534 Email: info@arrowmachinetools.com Website: www.arrowmachinetool.com`
Treated fresh air units The DRI TFA is manufactured in accordance with the best technology in casing manufacturing. It offers all the prerequisites for creating a ventilation system with the lowest running costs possible to suit retail application with the added advantage of Energy Recovery which cuts down the aircon costs. The FlexAir Treated Fresh Air Units with Eco-Fresh Molecular Sieve Coated Heat Wheel inside provides a complete solution for IAQ and Energy Saving in a single unit, with the option to add modules for cooling, heating, humidification, high efficiency filtration, mixing, sound
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Products - National attenuation, etc. The FlexAir Series TFA from DRI is designed in accordance with European Standard for leakage Class B. All functions like coils, heat exchangers etc. are optimized to give lowest possible pressure drop in proportion to highest possible efficiency resulting in very low LCC. Deep folded bag filters with big filter areas and good sealing. The good tightness ensures clean air supply to the room is of high quality. Desiccant Rotors International Pvt Ltd Gurgaon - Haryana Tel: 91-0124-4188888 Email: drigurgaon@pahwa.com Website: www.drirotors.com
affordable media blasting to clean, peen, deburr, or finish parts. The larger enclosure (50” x 39” x 43” tall) accepts powered turntables. The suction blast cabinet come with a unique pilot actuated air logic system to maximise airflow to the blast gun. Prism Surface Coatings (P) Ltd Bengaluru - Karnataka Tel: +91-8110-417999,09844400285 Email: sales@prismsurface.com Website: www.prismsurface.com Website: www.prismsurface.com
Heavy- duty lathe machine This extra h e a v y duty lathe machine VEH is offered with height of centre up to 1066 mm, length of bed ranging up to 12000 mm, between centres up to 11000 mm, main spindle hollow ranging 150 mm and main spindle nose is A2-12 type. Dynamically balanced spindle enable the spindle run at vibration free motion. The spindle carries the 10 T job weight. The norton gear box is able to cut the any of metric, modules and pitch. The bed is made from graded cast iron. Also offered are face plate, carrier plate, steady rest, follow rest, motorised coolant pump with tank and fittings, rear tool post, quick change tool post. The machine is maintenance free and is easy to use. Vinit Engineering Works Rajkot - Gujarat Tel: 0281-2311734 ,09879022052 Email: vinit@balajilathe.com Website: www.balajilathe.com
Abrasive blasting machines These air-powered blasting machines are used to clean, deburr, shot peen and to remove coatings. The 4,500 litre capacity unit supports four blasters and is widely used for long duration of blasting in ship building industry and on site structures and large fabrications. The BNP 220 pressure blast cabinets deliver efficient,
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Products - National HMC Machine Horizontal machine center machine H630B incorporates the optimum machine structure design and the latest technology with versatile features to suit different applications from heavy duty die mold application to feather weight aluminum auto component without bottleneck; H630B extended its strength for flexible manufacturing needs with programmed six pallets changer with the user friendly software that enhances scheduling efficiency, reduces non cutting time and boosting high productivity. The integrated built-in-high precision spindle is powered by 30 KW for zero vibration cutting, the entire axis are equipped with high performance digital servo to match the speed with very little power. S&T Engineers Pvt Ltd Coimbatore - Tamil Nadu Tel: +91-0422-2590810, Mob: 9489079060 Email: advt@stengineers.com Website: www.stengineers.com
Software This EPLAN software keeps users flexible in the process and the new update macros function makes sure that all data is updated to the most current state, either individually or automatically. Partial circuits can been inserted and can be updated effortlessly. Macro master data changes can easily be adopted into currently active specific projects. These high-quality templates gives consistent quality in the project and a standardised engineering process. The check run messages highlighted in message management can be synchronised with the opened navigators. The user can apply check routines specifically to newly entered corrections during a project edit. Rittal India Pvt Ltd Bengaluru - Karnataka Tel: +91-080-41515497 Email: info.eplan@rittal-india.com Website: www.eplan.in
Corrosion protection The ECP (Enhanced Corrosion Protection) has been established which can provide an improved rust resistance over 120 hours in salt spray atmosphere. It has a zinc coating with black passivation for valve component parts in steel and cast iron, black opaque anodizing for aluminium caps, electronic boxes and protection and natural gloss light grey anodizing for aluminium name plates. It also provides black plastic encapsulation (Rynite) for other coils and for coil’s nut rings ATOS SPA Bengaluru - Karnataka Tel: +91-80-23613840 Email: manish@atosindia.in, Website: www.atos.com
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MMT July-2012 Ad Name: Samkrish Pg No. 131
MMT July-2012
Ad Name:Cotec Pg No. 132
MMT July-2012 Ad Name: Hyundai Pg No.133
MMT July-2012 Ad Name: Universal Pg No. 134
Products - National Machine oil Specialized “Electrical Discharge Machining” (EDM) Oil is highly refined mineral oil with low viscosity which is free from aromatics and unsaturated hydrocarbons especially applicable for “Spark Erosion Metal Working Operations”. It is colourless and odourless, making it operator-friendly. This oil, which is neutral and pure, can substantially reduce the chance of effects on skin of the operators. Its lower viscosity improves flushing and fast particle settling and both of these contribute to faster machining rates and fine surface finishes. Also low aromatic content eliminates smoking during machining and higher flash point ensures safety of the environment. It has exceptional long service life due to stability towards thermal oxidation. It is used in as Dielectric fluid in finish-cut electrical discharge (spark erosion) machining operations. It is also used in manufacture of electronics, extrusions, air-craft components, hardware, tools, fasteners, silver-ware, cutlery, valves and regulators etc. Eastern Petroleum Pvt Ltd Mumbai - Maharashtra Tel: 022-2529 9990,09821531709 Email: office@easternpetroleum.in Website: www.easternpetroleum.in
July 2012 - MODERN MACHINE TOOLS 137
Products - National Lathe chuck
BP Bharti, Managing Director, Rightvision (India) Private Limited
I am glad to share with the readers that advertisements in SEARCH have fetched us a contract of â‚Ź3 million from the Indian markets. I really would like to thank them for the support and my best wishes to them.
The Rota-S plus lathe chuck has an optimized wedge bar drive system and an improved lubricant system ensure consistently high clamping forces from the new lathe chuck. Since higher speeds and cutting speeds are possible, users can apply more efficient cutting materials, which shorten the manufacturing time. An optimized drive allows fast, comfortable, and repeat accurate jaw changes. This lathe chuck is fully compatible, and already existing base jaws can be used in it. Its unique three-fold jaw safety device prevents operating errors. It has located an indicator pin at the chuck circumference, which displays the individual clamping status. Protection sleeve system and expansion arbor are categorized as additional equipments. Schunk Intec India Pvt Ltd Bengaluru - Karnataka Tel: +91-080-40538999
Mob: 09741211766 Email: info@in.schunk.com Website: www.in.schunk.com
Auto tool setters These TM26 auto tool setters are direct acting type, specially designed for CNC machining centres with IP67 Protection. Basically it is used for length detection of tools such as drills,
138 MODERN MACHINE TOOLS - July 2012
Products - National end mills, and cutters mounted on machining centres, drilling machines, milling machines, and boring machines. It can detect tool wear while accommodating the thermal expansion of the machine for the compensation. The operating speed is 100~200 mm/min, parallelism of contact is 0.01 / 12 mm, stroke is 5 mm & contact rating is DC24V 20mA(max). Metrol Corporation India Bengaluru - Karnataka Tel: +91-080-42105031 Email: sales@metrolindia.com Website: http://www.metrol.co.jp/en/
lightweight Lathe chuck Compared with conventional power chucks, the weight of the ROTA NCL in steel version is reduced by 35%, in aluminum by 54%, and in carbon by 62%. Only the steel chuck is in series production. The patent pending double cylinder version of the base jaws ensures that the forces are optimally distributed on the chuck body. For fully maintaining clamping force, rigidity, and precision, every
140 MODERN MACHINE TOOLS - July 2012
Products - National component which is in the direct flux of force are made of extremely resistant hardened steel. The chuck bodies themselves are completely made of steel, aluminum or CFK. Schunk Intec India Pvt Ltd Bengaluru - Karnataka Tel: +91-080-40538999 Mob: 09741211766 Email: info@in.schunk.com Website: www.in.schunk.com
AC drives The Vacon 20 series incorporates a builtin programmable logic controller(PLC) functionality which conforms to the IEC61131-3 standard. In addition, the functionality can be extended via optional modules, including field bus cards and tools for easy parameter copying from one unit to another. Efficient volume manufacturing is possible as they are fast to install and easy to set up. Also, the products can be modified and tailored to the needs of the customer. Vacon Drives & Controls Pvt Ltd Chennai - Tamil Nadu Tel: +91-044-24490024 Email: vacon.india@vacon.com Website: www.vacon.com
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Back artwork
Front artwork
Products - National Buffing & polishing machine This machine is used for mirror finishing of stainless steel, aluminum pots & pans, pressure cookers, water filter, mixer jars & hollowware in general. The job to be polished is held by specially developed vacuum chucking system. The machine is operated pneumatically and controlled by relay logic (optional PLC). Automatic buff wear compensation ensures consistent finish and high productivity. The buffing can be done by unskilled operator. Grind Master Machines Pvt Ltd Aurangabad - Maharashtra Tel: +91-240-2376262 Email: sales@grindmaster.co.in Website: www.grindmaster.co.in
Surface grinding machine The surface grinding machine ranges are 150 x 450 to 1600 x 6000mm with various types of machines. The main spindle is cartridge type which ensures the spindle run out with in 2Îź and completely sealed and lubricated for high durability and accuracy. The base is one piece design and having good rigidity, the movement and durable accuracy, the hydraulic pumps are vane pumps and having the high precision direction control valves
July 2012 - MODERN MACHINE TOOLS 145
Products - National and cross feed driven by ball screw with higher cost can obtain a grinding effect of more smooth and high precision and maintain longer life. S&T Engineers Pvt Ltd Coimbatore - Tamil Nadu Tel: +91-0422-2590810,+91-0422-2593487 Mob: 9489079060 Email: advt@stengineers.com Website: www.stengineers.com
Hydrogen gas detection system This hydrogen gas detection system is used for detection of hydrogen gas. It uses a 3-status technology which displays in terms of low/medium/high concentration. It has selectable slide switch for audio & visual built-in solid state buzzer. The system has the facility to function five gas detectors with independent alarm latching facility, potential free N.O/N.C contact, and recorder output. The system is equipped with 4-wire technology and maturity timer. Subtronics (India) Pvt Ltd Mumbai - Maharashtra Tel: 022-2422 4461 Email: service@subtronicsindia.com Website: www.subtronicsindia.com
Ashok Kumar Gupta, Chairman, Crane-Bel Hydraulics
We are pleased to share with the readers that SEARCH has helped us to reach out to our customers with the new launch of the high performance product range of EATON VICKERS. We have been able to achieve it through advertisements and product profiles, which have been continuously published in this excellent magazine having a good reach in the industry, especially in the widely spread industrial areas such as Uttar Pradesh and Uttarakhand. We have been able to promote the exclusive range of EATON VICKERS Hydraulic products in our target sectors of whole U P and Uttarakhand to our entire satisfaction and able to increase our turnover to a big extent.
146 MODERN MACHINE TOOLS - July 2012
Products - National Breath analyser with printer It detects alcohol in the breath and gives an audio-visual indication. It has 3-status technology which includes bright graphic display, easy & quick testing, reading latching, non-volatile memory, password protected critical menu settings, subject sample blow indicator, print readings with data & time, user selectable multiple number of prints for evidential record documentation etc. The instrument is housed in a robust plastic enclosure.
are available in 1 HP & 2 HP, 2800 RPM,200 diam. & 25 mm width whereas Direct Drive Polishers are available in 2 HP & 3 HP, 2800 RPM, 300 diam. & 50mm. Prem Brothers New Delhi Tel: 011 28117456, 28117464, 45595068 Email: powermaster59@gmail.com, Website: www.powermaster-india.com
Subtronics (India) Pvt Ltd Mumbai - Maharashtra Tel: 022-2422 4461 Email: service@subtronicsindia.com Website: www.subtronicsindia.com
Honing machine This ML-2000 power stroked honing machine has twice the power and more speed than older style honing machines. It has fast & easy setup. Complete setup is handled from the front of the machine without raising a cover. It has unique roll-out coolant cart for easy maintenance and coolant changeover. It can be used with sunnen’s turbo hone multi-stone mandrels for fast stock removal. It is built to be durable with a rigid machine base constructed of reinforced structural steel and cast iron. It offers lifetime application service with every machine purchase. The diameter range depends on manual stroking, power stroking & automatic sizing. It has a stroke length of 6 to 170 mm. Omira Marketing Pvt. Ltd. Mumbai - Maharashtra Tel: +91-22-26400791, 91-22-26165032 Email: sales@omira.co.in Website: www.omira.co.in
Grinding / Polishing Machines These Direct Drive Tool Post Grinding / Polishing Machines are specially designed for use on lathes, shapers, and planer machine etc. for operations like cylindrical external grinding, face / radius / surface grinding. It has a heavy duty direct drive head complete with motor, bearing loaded spindle, sturdy guard & mounting plate. Direct Drive Grinders
July 2012 - MODERN MACHINE TOOLS 149
Products - National Conical nozzle torch These conical nozzle torches of duramax are available for five more plasma cutting systems: Powermax600, Powermax800, Powermax900, MAX42, and MAX43. Duramax series of torches, provide more reliable arc starting. They also enable consumables to last up to six times longer. Hypertherm (India) Thermal Cutting Pvt Ltd Chennai - Tamil Nadu Tel: +91-044-28345361 Email: htIndia.info@hypertherm.com, Website: www.hypertherm.com
Bandsaw machines The bandsaw machines use linear motion (LM) guides and bearings instead of conventional hard chrome plated columns and bushes for sliding of cutting arm. With the use of LM guides the up-down movements of cutting arm is very smooth leading to productivity. The steel enclosure is provided to prevent coolant from splashing and spillage. ITL Industries Ltd Indore - Madhya Pradesh Tel: +91-0731-3044400 Email: itlindia@sancharnet.in, Website: www.itl.co.in
Pankaj Dhingra, Properiter Prem Brothers
Advertisement of our products in Modern Machine Tools (MMT) has increased our exposure to prospective customers, helping us enhance our reach to clients all over India. The quality and presentation of the magazine is appealing at the first look, inducing readers and subscribers to go through its informative articles and product advertisements. A truly modern magazine having useful articles on the latest innovations and technologies.
150 MODERN MACHINE TOOLS - July 2012
Products - National Variable speed polishing machines These machines are specially designed for flexible operation of polishing by varying R.P.M on the same machine. Different finish can be obtained using the same buff at different R.P.M. It is a robust design double ended machine 7.5 KW of 10 HP, has a variable RPM stepless of 5003500 max. It has dust covers with dust collector electro-magnetic brake for instant stopping. Prem Brothers New Delhi – 110 064 Tel : 011 28117456, 28117464, 45595068 Email: powermaster59@gmail.com, Website: www.powermaster-india.com
Panel Air Conditioner Panel Air Conditioners are used to dissipate heat generated by AC/DC drives, Electrical/Electronic components inside a control panel. In industries environment is hot and to avoid entry of dust, dirt and moisture inside the panel use of ambient air is refrained and a closed loop air conditioner is used to maintain desired temperature. Reliance Engineering Company Coimbatore - Tamil Nadu Tel: 91-0422-6538340, Mob: 09244420143 Email: rechiran@hotmail.com Website: www.relianceengineeringcompany.com
152 MODERN MACHINE TOOLS - July 2012
MMT July-2012 Ad Name: Certazit Pg No. 153
MMT July-2012 Ad Name: Macpower Pg No. 154
MMT July-2012
Ad Name: Austin Pg No. 155
MMT July-2012
Ad Name: EngExpo Pg No. 156
Products - National Energy recovery ventilator They are capable of recovering upto 80% of sensible and latent energy from the stale exhaust air and transferring it to the fresh outside air. The heart of the ERV is the EcoFresh desiccant coated energy recovery wheel, which slowly rotates between its two sections. The stale air is passed through the wheel, and exhausted to the atmosphere. The wheel absorbs sensible and latent energy from the conditioned air, which is used to pre-condition the incoming fresh air in the other section, during the second half of its rotation cycle. The rotating wheel transfers the sensible and latent energy between the counter flowing exhaust and supply air and in the process preconditions (cool/ heat/ dehumidify/ humidify) the fresh air. Desiccant Rotors International Pvt Ltd Gurgaon - Haryana Tel: 91-0124-4188888 Email: drigurgaon@pahwa.com Website: www.drirotors.com
Power cutters The Nile pneumatic Nipper can cut metallic wires, aluminium cables, piano wires, gold, steel wires up to diam. 6 mm, Copper up to diam. 7 mm, Soft plastic up to diam. 13 mm, and hard plastics up to diam. 4.5 mm. Just by changing the blades, several
July 2012 - MODERN MACHINE TOOLS 157
Products - National manufacturing applications are possible with same types of tools. They are of light weight & have long life. Arhan Technologies Pvt Ltd Pune - Maharashtra Tel: +91-20-65603200 Email: mahesh@arhan.co.in Website: www.arhan.co.in
Circlips The circlips are used for restraining axial movement of components of shafts and where there are space restrictions. They are also applicable in small mechanism. They are manufactured from suitable high carbon steel, such as C80 of IS: 1570-19621 or EN42J. They are hardened and tempered. They are also available in SS-304 materials of construction. R K Engineering Company Mumbai - Maharashtra Tel: +91-022-22671141 Email: rkeng@vsnl.net Website: www.rkengineeringco.com
158 MODERN MACHINE TOOLS - July 2012
Products - National Mini Jewel Foot Switch It has a 3 Terminal Micro Switch, 1 Common Change Over to NO/NC & Foot Switch is Powder Coated in Black Structure Coating. These are available in current range of 10A/250VAC, 15A/250VAC & 10A/500VAC. Dimension is 95X70X25 & Weight is 300gms. Two core 2 meter wires provided with the Switch free. Precision switchgear industries Mumbai - Maharashtra Tel.: 02522 – 645770, Mobile: 09225100895. Email: precifoot@yahoo.com, Website: www.footswitch.co.in
Induction cap sealer The water cooled Fluxosealer AFX3000 is a heavy duty induction cap sealer for high speed sealing and special applications. Bottles with neck diameters ranging from 10mm to 150mm can be sealed with ease. Standard features include no foil detection system which consists of sensors to detect induction seal inside the cap, easy line relocation & plug & play system. Enclosure is of MS Powder coated/SS304. Arshad Electronics Pvt Ltd Mumbai - Maharashtra Tel: +91-022-24451709 Email: amoolji@arshadelectronics.com, Website: www.arshadelectronics.in
July 2012 - MODERN MACHINE TOOLS 161
Products - National VLT drives The D-Frame VLTŽ drives are among the smallest in its class and designed to support any automation application. Its back-channel cooling concept keeps electronics safely within optimal operation temperatures, the advantage being the system installation and operating costs are reduced dramatically. For robust protection, all drives come with coated printed circuit boards. Using a ducted back-channel, air is allowed to pass over the unit’s heat sink with minimal air passing through the electronics area. Danfoss Industries Pvt Ltd Chennai - Tamil Nadu Tel.: 044-5550 1555 Fax: 044-5500 1444 Email: danfoss.india@danfoss.com Website: www.danfoss.com
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
162 MODERN MACHINE TOOLS - July 2012
Products - International Cable and hose carrier It was developed specifically for use in environments with heavy contamination from chips and dirt. The allround closed structure effectively prevents the intrusion of foreign bodies into the cable space, and allows for reliable protection right up to the connection area. The covers can be opened and removed easily on the inside or outside to load the cable carriers. The interior can be modularly partitioned with various divider solutions for even cable distribution. The optimised geometry and a triple encapsulated stroke system allow it to span extensive unsupported sections. The integrated gliding surfaces make the cable carrier the ideal solution for long travel lengths. Integrated noise damping ensures that the cable carrier is running silently and with low vibration at all times. Kabelschlepp India Pvt Ltd (Subsidary of Kabelschlepp GmbH) Bengaluru - Karnataka Tel: 080-4115 8997 Email: gm@kabelschlepp.in Website: www.kabelschlepp.com
Robodrill It is a small machining center with spindle taper size No. 30 for milling, boring, drilling and tapping. This machine is characterized by Nano CNC system, HRV control, AI contour control which
164 MODERN MACHINE TOOLS - July 2012
implements high-speed, high-precision machining by reading 200 blocks in advance for acceleration/deceleration control. It has a synchronous builtin servo motor installed. The number of blocks to be read in advance can be increased, thereby enabling up to 1,000 blocks to be read in advance for acceleration/deceleration control. This enables high-speed, high precision machining without feedrate variations even for a program consisting of super-minute line segments. Additional 1-axis control can be added to enable simultaneous contour control of up to 4 axes. Spindle is directly coupled with its motor. Least maintenance due to grease sealed bearings. The high speed and high precision ball bearing is used for the high-speed spindle. GE Fanuc Automation Europe SA Germany Tel: +49-352-7279 79213 Email: ingo.kaiser@gefanuceur.ge.com Website: www.fanucrobotics.com
CNC graphite machining center This closed bridge type-high speed CNC Graphite Machining Center has patent design on its structure, as its super structural rigidity is combined with advanced technologies. It has a 30000 RPM high speed spindle, resulting in high quality graphite electrode performance. The Graphite Dust Suction & Filtration
Products - International System (GDSFS) results up to 99% dust disposal efficiency. The Dry Type GDSFS is implied here. It has high efficiency dust-collecting equipment & incorporates zero wear-out draught fan function. Hsiu Fong Machinery Co Ltd Taichung City - Taiwan Tel: 886-4-22792121 Email: sales@surefirst.com.tw Website: www.surefirst.com
Steel bars These bars are processed with center-less grinding & hard chrome plating after cold drawn. The bar is abrasion-proof & corrosion-proof. These are hard chrome coated where thickness is minimum 20 microns. Standard length of mass product is 3000 mm-6000 mm. Fu-Long Metal Industrial Co., Ltd. Taoyuan Hsien - Taiwan Telephone: 886-3-4852858; Fax: 886-3-4787597 Website: www.flweb.com.tw
Laser cutting system The Sirius automationready flying optics laser cutting system is used for fast, efficient sheet metal processing. This system is designed to provide efficient processing of parts at optimal speeds and accelerations to suit the part geometry, offering reliable cutting performance at an affordable price-performance ratio. It is optimised with additional features and automation capabilities and provides quick and precise positioning and consistently accurate laser processing. The combination of a dynamic machine with an excellent laser beam quality allows high-speed laser cutting. LVD Company NV Gullegem - Belgium Tel: +32-56-430511 Email: marketing@lvd.be Website: www.lvdgroup.com
Vertical machining centre The model VM-2 vertical machining centre is designed for mould industries. It is a high-performance machine with a 30” x 20” x 20” work cube, 36” x 18” table, 12000 rpm inline direct-drive spindle and high-speed control with full look-ahead. High-precision linear guides on all axes further increase
July 2012 - MODERN MACHINE TOOLS 165
Products - International rigidity and stiffness, while providing a low coefficient of friction and long-term reliability. High-speed brushless servos, combined with fine-pitch ball screws and high-resolution digital encoders, ensure ultra-precise positioning and extreme repeatability. Haas Automation, Inc California - USA Tel: +1-805-2781800 Email: sales@mtscnc.com Website: www.haascnc.com
Boring heads A wide range of rough and finish boring heads producing diameters from 8 mm up to 500 mm plus all different couplings and accessories are offered. There are 3 basic boring heads, viz, micro boring heads fitting indexable boring bars with carbide insert pockets; finish boring heads; and rough boring heads with a synchronised adjustment. All the boring heads are radially adjustable for boring different diameters. The first two models feature a micrometer adjustment with 0.002 mm increments. Pinzbohr Boring System Barcelona - Spain Tel: +34-93-5720873 Email: pinzbohr@pinzbohr.com Website: www.pinzbohr.com
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Products - International Robocut This machine has high-performance CNC coupled with digital servo technology. It has a high-rigidity casting and a thermal insulation structure. It is incorporated with Twin-servo wire tension control, advanced AWF2 enabling safe unmanned operation, customised Fanuc PC FAPT Cut programming software & Servo water level control for stable cutting. It comes with a 15-inch LCD touch panel & an USB I/O. For high precision, it has an upgraded AI pulse controls 2 & finish cutting generator. GE Fanuc Automation Europe SA Germany Tel: +49-352-7279 79213 Email: ingo.kaiser@gefanuceur.ge.com
NC servo slide The major material used here is FC30 casting, which is for long life usage. Position accuracy could achievable in ?m grade. It is controlled by C5 ball screw and it could have less friction but raise efficiency to keep in stable precision with fully support. RH series is u Specifications are: Width: 200,250,300mm; length: 400,640,520,760,1000mm. Hann Kuen Machinery & Hardware Co Ltd Taiwan Tel: +886-4-2486 0602 Email: hann.kuen@msa.hinet.net
Milling heads units The gears and axis are all made from SCM415, and have heat-treatment and precise girded to JIS 1 level. Most of components are lubricated by auto-pump and auto-injection. High Precision, low noise and vibration free, each model has different speed for machining and some models also could be used for drilling. These milling heads most equipped on Plano milling machine for vertical and horizontal milling or the retrofit work shop. Para Mill Precision Machinery Co Ltd Taichung City - Taiwan Tel: 886-4-26800678 Email: para-mill@umail.hinet.net Website: www.paramill.com
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
168 MODERN MACHINE TOOLS - July 2012
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
Abrasive belt grinder .................................. 166
CAD/CAM software ........................................16
CNC machines ..............................6, 73, 111,154
Abrasive blast cleaning ....................................152
CAM followers ...............................................158
CNC machining center...............................14, 73
AC gear motor ..................................................22
Carbide ............................................................130
CNC milling machine ......................................45
AC servo motor ................................................22
Carbide endmill tool ............................... 137, BC
CNC multi-tasking centre ................................10
Acoustic rooms................................................152
Carbide rods ....................................................153
CNC oxy fuel cutting machine.......................132
Adaptor ...........................................................130
Carbide tools .....................................91, 130, 159
CNC plasma cutting machines .......................132
Advance cutting materials .................................25
Centre drill ......................................................130
CNC precision lathe .........................................36
Aerosol multispray ............................................63
Centreless grinding machine............125, 179,138
CNC small machining center ...........................14
Air gun ............................................................134
Ceramic ...........................................................181
CNC tool holders ...........................................171
Air pollution control .......................................152
Cermets ...........................................................181
CNC tools .................................................. 51,130
Airline fluid .......................................................63
Chain.................................................................12
CNC turning center............................11, 73, 154
Aluminum extrusion .......................................142
Chain oil ...........................................................63
CNC turn-mill centre .......................................10
AMTEX 2012 ................................................148
Chillers ............................................................168
CNC vertical machining center ...........10,73, 154
Angle encoders ...............................................BIC
Chrome bars/ shafts ........................................145
CNC vertical turning lathe ...............................10
Assembly & high temperature grease ...............63
Chuck ..............................................................130
CO2 laser marker series ..................................157
Automation .........................................37, 51, 132
Clamping tool ......................................... 137, BC
Coating machines............................................132
Automation products ......................................123
Cleaners ...........................................................143
Coating plants .................................................132
Bags bailing press ...................................... 151
Close frame hydraulic press ............................151
Coating systems ..............................................132
Ball bearing ...............................................81, 155
CMM ..............................................................177
Collets ........................................................ 94,130
Bar feeder ..........................................................33
CNC......................................................5, 73, 154
Collets chuck .....................................36, 130, 171
Bars .................................................................145
CNC controller .................................................37
Column hydraulic press ..................................151
Bearing ......................................................12, 155
CNC cutting machines ...................................132
Compressor oil ..................................................63
Belt grinder .....................................................163
CNC cylindrical external grinding machine ...179
Connector....................................................12, 41
Bench grinder cum polisher ............................166
CNC double column machining centre............10
Control cabinet .................................................41
Bench grinding machine .................................163
CNC engraving machines ...............................145
Control panel ....................................................41
Boring................................................................60
CNC equipment ...............................................31
Control system ..................................................41
Boring and milling machines ............................74
CNC external grinding machine ....................179
Controlling machine tool ...............................BIC
Boring bars ........................................................35
CNC horizontal borer.......................................83
Conventional precision lathe.............................58
Boring mill ......................................................142
CNC horizontal boring & milling machine .....10
Conveyor lubricators ........................................87
Buffing powder .................................................35
CNC horizontal machining centre ...................10
Coolant..............................................................71
Building automation .......................................132
CNC horizontal turning centre ........................10
Coolant pump .................................................166
Cabinet ..................................................... 112
CNC internal grinding machine.....................179
Coro mill .......................................................FGF
Cable carrier ......................................................12
CNC laser cutting machine ............................132
Coro thread ...................................................FGF
Cable conduits...................................................29
CNC lathe................................ 11, 45, 58, 74, 83
Corrosion preventive .......................................143
Cable connector ................................................12
CNC machine tool .........................................133
Countersink ................................................FIC, 8
170 MODERN MACHINE TOOLS - July 2012
List of Products Sl. No Product
Pg No
Sl. No Product
Pg No
Sl. No Product
Pg No
Coupling regulator ..........................................134
Disc couplings ...................................................93
Factory automation .................................... 132
Crush blade .................................................46, 47
Drawing & forming compound ......................143
Ferrous casting ................................................142
Customised tooling solution .............................94
Drill chuck arbor .............................................130
Fiber laser marker ...........................................157
Cutting fluids ..................................................143
Drill mill .........................................................130
Flexible shaft grinder ......................................166
Cutting machines ............................................132
Drilling machine .............................................103
Floor automation.............................................114
Cutting oil ...................................................35, 71
Drilling tool .............. FIC,8, 39, 91,113, 137,BC
Forged components .........................................142
Cutting tool........................39, 46, 47,91,113,153
Drive technology ............................................BIC
Form measurement ...........................................23
Cutting tools carbide metal working tool .......181
Dust collectors.................................................163
Freewheel-one-way-clutches ...........................158
Cylindrical grinding machine..................... 30,125
EDM sinker machines ............................... 145
Fuel injection system .......................................94
Dampers ......................................................93
Element shrink disc ........................................158
Fuel injection system parts................................94
Desktop printer .................................................72
End mills .........................................................130
Gantry automation..................................... 114
Diamond cutting & processing systems .........139
Exhaust brake system parts ...............................94
Gantry machining center ................................142
Diamond tool .............................................8, FIC
Exhibition- AMTEX 2013.............................128
Gap frame press ..............................................152
Didactic equipment for training .......................41
Exhibition-Engineering Expo.........................156
Gauges.............................................................147
Die coater ....................................................46, 47
Exhibitions ......................................................101
Gear box ............................................................90
Diode end pumped laser marker.....................157
Expandable mono block-reamers ......................59
Gear milling solution .......................................79
Diode side pumped laser marker ....................157
Exposed linear encoders .................................BIC
Gold purity (xrf) systems ................................139
July 2012 - MODERN MACHINE TOOLS 171
List of Products Sl. No Product
Pg No
Sl. No Product
Pg No
Sl. No Product
Pg No
Gomet bearings .................................................81
Hydraulic cylinder ...........................................162
Linear rods ......................................................145
Grease................................................................63
Hydraulic cylindrical grinding machine ..125, 179
Lm shafts ........................................................145
Grinding machine ..............30, 115, 125, 179,163
Hydraulic machine ............................................33
Load break switches ..........................................29
Grinding tool for hard material ......................115
Hydraulic press........................................151, 152
Locking elements ..............................................93
Grinding wheels ................................................35
Hydraulic shearing machine............................152
Lubes .................................................................71
Grooving & parting tools ...............................153
Hydraulic valve housing ....................................94
Machine & tools lubricators.........................87
Guide rods.......................................................145
Hypercad ...........................................................16
Machine measurement ...................................BIC
Gun drill.................................................... FIC, 8
Imaging & vision systems .......................... 132
Machine taps .....................................................35
Handling system module ..............................41
IMTMA - AMTTF .......................................160
Machine tools....................................................51
Handy probe ...................................................159
IMTMA - Finishing School Summit ............136
Machined castings .............................................94
Handy scan......................................................159
Indexable cutting tools ......................................35
Machined components ....................................142
Hard chrome plating bars ...............................145
Inductive proximity switches.............................29
Machining & grinding fluid ...........................143
Heat exchanger machines ...............................103
Industrial robots ..............................................169
Machining centre ..............................................83
Heavy duty cycling duical bearing ....................81
Integrated shot blasting rooms .......................152
Magnescale technology ...................................131
Heavy duty lathe machine ................................30
Internal grinding machine...............................125
Magnetic modular encoders ...........................BIC
Helical gear box ................................................90
Iron & steel parts ........................................46, 47
Material handling ............................................127
High performance spindles ..............................61
Jewellery polisher ....................................... 166
Material testing .................................................23
High power ups system...................................167
Keyless transmission element ..................... 158
Measured value acquisition and display .........BIC
High precision machining services ...................94
Lamp pumped laser marker ........................ 157
Measurement equipment...................................23
High precision tool holders ..............................21
Large part drilling machines ...........................103
Medium duty lathe machine .............................30
High precision wire cut EDM machine .........145
Laser cutting machine .....................................157
Metal bellow couplings .....................................93
High speed drill tap centres ..............................83
Laser cutting system........................................139
Metal cutting tool .............................................57
High speed machining center ...........................73
Laser engraving machine ................................157
Metal scrape baling press ................................151
HMC ..............................................................103
Laser exhibition...............................................101
Metal spray booths ..........................................152
Hold back ........................................................158
Laser marking - engraving system ..................139
Metrascan ........................................................159
Holders ..............................................................35
Laser marking machine ...................................157
Metrology equipment........................................23
Hole making .....................................................25
Laser medical ..................................................139
Metrology instrument & solutions .................177
Hole making tools.......................................46, 47
Laser micro machining ...................................139
Micron drills................................................46, 47
Horizontal CNC machines .............................154
Laser robotic welding......................................139
Milling....................................... 25, 39, 113, BIC
Horizontal hydraulic press ..............................151
Laser shaping ..................................................115
Milling centres ....................................................5
Horizontal machining center ...........5,73, 83, 154
Laser welding system ............................... 139,157
Milling cutter .....................................FIC, 8, 153
Horizontal spindle rotary table surface grinder179
Lathe ...................................................................5
Milling grade.................................................FGF
Hose ................................................................134
Lathe machine...................................................30
Milling machine ........................................45, 103
Hydraulic & gear oil .........................................63
LED ..................................................................29
Milling tool ............................. 46,47,91, 137, BC
Hydraulic accessories.......................................134
Length gauges ................................................BIC
Mobile cylinder hydraulic press ......................151
Hydraulic centerless grinding..........................125
Lens mould .................................................46, 47
Modular tooling system .............................FIC, 8
Hydraulic chucks ...............................................94
Light duty lathe machine..................................30
Mold components .......................................46, 47
172 MODERN MACHINE TOOLS - July 2012
List of Products Sl. No Product
Pg No
Sl. No Product
Pg No
Sl. No Product
Pg No
Motor ................................................................90
Process automation and control equipment......41
Solid carbide reamer with ic .............................57
Motor protection circuit breaker.......................29
Product assemblies ..........................................142
Solid carbide special drill ..................................57
Multi function turret .........................................33
Programmable logic controllers.......................123
Solid carbide special mill ..................................57
Multi functional tools .....................................153
Pull stud ..........................................................130
Solid carbide special reamer ..............................57
Needle roller bearings ..................................81
Push buttons .....................................................29
Solid mono block reamers.................................59
Oil coolers ................................................. 168
PVC flexible braided hose ..............................134
Solid rotating tools ............................................35
Optical measurement ........................................23
Rack .......................................................... 112
Solid state laser cutter .....................................157
Paint booths .............................................. 152
Reamer ...............................................FIC, 8, 130
Special boring bars ............................................59
Panel coolers ...................................................168
Rear cylinder hydraulic press brake ................152
Special fine boring tools....................................59
PCB drills....................................................46, 47
Robotic automation.........................................114
Special induction hardening machine .............109
PCD & carbide reamers ...................................59
Roller bearing ..................................................155
Special line boring tools ....................................59
PCD & CBN tool ..........................................181
Rolling oils ......................................................143
Special reamer ...................................................59
Pedestal grinder ...............................................166
Rotary ..................................................................5
Special tools.....................................................130
Pedistar buffer .................................................166
Rotary encoders ..............................................BIC
Speciality oils.....................................................35
Peening............................................................152
Rotary switches .................................................29
Spindle nose tooling........................................153
Photonic exhibition .........................................101
Rust preventing ...............................................143
Standard fine boring tools.................................59
Pillar type hydraulic press ...............................151
Safety protection devices ..............................29
Standard induction hardening machine ..........109
Pilot lights .........................................................29
Screw machine ..................................................45
Straightening machines ...................................138
Piston bars .......................................................145
Sealed linear encoders ....................................BIC
Super precision bearings ...................................81
Planning machine............................................138
Servo-drives .....................................................123
Surface grinding machine ...........................30, 83
Plano-millers ...................................................138
Servo-insert couplings .......................................93
Surface preparation solutions ..........................152
Plant lubrication systems...................................87
Shafts ...............................................................145
Tapping systems ........................................ 171
PLC operated hydraulic press .........................151
Shearing machine ............................................152
Taps.......................................................8,FIC, 34
Plugs and sockets ..............................................29
Sheet metal working machinery........................48
Tensioner nut ..................................................158
Pneumatic accessories......................................134
Shrink fit adaptors ............................................94
Thread mill .......................................................79
Pneumatic tools ...............................................134
Shrink fit technology ........................................35
Thread mill cutters............................................35
Polishing machines .........................................163
Side lock adaptor.............................................130
Thread milling cutters & taps holders..............34
Post processor....................................................16
Single limit switches .........................................29
Threading tool ................................... 59, 137,BC
Power press .....................................................152
Sinking EDM .................................................181
Thrush ball bearings .........................................81
Power sources ..................................................109
Slant / flat bed ..................................................83
Tool holders ......................................................94
Precision measuring instruments ....................147
Sleeve bearings ..................................................81
Tool holding systems ........................................35
Precision steel ..................................................115
Small size ball bearings .....................................81
Tooling system ..................................25, 137, BC
Precision switches single & multiple ................29
Solar cell scribing system ................................139
Tools ...............................................................130
Precision universal cylindrical machine...........125
Solid carbide drill ........................................57, 59
Touch probes .................................................BIC
Press brake machine ........................................152
Solid carbide drill with ic..................................57
Track rollers ....................................................158
Pressure sensor for wet packaging application ..135
Solid carbide mill ..............................................57
Trade show......................................................101
Printing system .................................................72
Solid carbide reamer..........................................57
Transparent gel .................................................63
July 2012 - MODERN MACHINE TOOLS 175
List of Products Product
Pg No
Product
Pg No
Product
Pg No
Travelling column milling machines.................60
Chuck ..............................................................166
Manufacturing equipment...............................158
Tubing accessory ...............................................41
Circular cold saw.............................................162
Measurement systems .....................................129
Turbo charger parts...........................................94
CNC angular cylindrical grinding machines ....27
Measuring gauge .............................................129
Turned components ........................................142
CNC cylindrical roll grinder ...........................150
Measuring machine .........................................129
Turning ..................................... 25, 39, 113, BIC
CNC lathes .....................................................141
Measuring tools ...............................................129
Turning holders ..............................................153
CNC plunge/angular cylindrical grinder ........150
Metal circular pipe / bar stock end chamfering
Turning tool ................................46, 47, 137, BC
CNC rotary tables ...........................................146
machine ...........................................................162
Twist drills ......................................................130
Coordinate measuring machine ......................129
Metal forming .................................................158
Copper anode ..................................................161
Mold changing systems...................................149
Cutting tools ...................................................165
Natural/polycrystalline/single crystal
Cylindrical .........................................................44
diamond dies ............................................. 157
Diamond grinding wheels for LCD glasses . 157
NC cylindrical grinder ....................................150
Diamond scribers for sapphires.......................157
Nickel silver wire.............................................161
Diamond tools for semiconductors .................157
Permanent magnetic chuck ........................ 166
Diamond tools for silica tile industry .............157
Phosphor bronze wire .....................................161
EDM wire ................................................. 161
Precision cutting wheels ..................................157
Electro magnetic chuck ...................................166
Press brake ......................................................158
End mills .........................................................165
Quick die change system ............................ 149
EUROBLECH 2012........................................85
Quick mold change system .............................149
Fine-pole permanent magnetic chuck ......... 166
Rolling machine ........................................ 140
For precision grinding wheels .........................157
Rotary permanent magnetic chuck .................166
Free cutting brass rod & wire .........................161
Sawing machines........................................ 140
Fully automatic circular sawing machine ........162
Saws.................................................................140
Ultra high pressure apparatus ................. 46, 47 Vacuum /pneumatic recovery and conveying system ....................................... 152 Vacuum chuck ...................................................33 Valve ..........................................................41, 134 Valve terminal ...................................................41 Vehicle lubricators .............................................87 Ventilation.......................................................152 Vertical and horizontal machining centres .......74 Vertical machining center ...................................5 Vertical machining centres-single / double column ...................................................83 Vertical turning lathe ......................................142 Vertical turret lathe ...........................................24 Wear parts ................................................. 153
Fully automatic tungsten carbide
Shafts ...............................................................140
Wear resistant tools ....................................46, 47
sawing machine ...............................................162
Shear series ......................................................158
Wire cut EDM ...............................................181
Grinding machine ........................................44
Shearing machines ..........................................158
High-speed centerless grinding machines .....27
Sheet metal working technology exhibition......85
INTERNATIONAL
Horizontal band ..............................................140
Silicon bronze wire..........................................161
Associations.................................................18
Horizontal machinery center ..........................107
Special form cutting tools .................................62
Brass wire .................................................. 161
Hydraulic angle lock vise ................................137
Spindles ...........................................................125
Carbide ball end mills ..................................62
Hydraulic automatic type aluminum copper...162
Standard (powerful) magnetic base .................166
Carbide drills .....................................................62
Hydraulic automatic type metal sawing machine ..162
Standard (powerful) permanent magnetic chuck .. 166
Carbide end mills ..............................................62
Hydraulic machinery .......................................158
Thread ...................................................... 140
Carbide reamers ................................................62
Hydraulic press................................................158
Traditional cylindrical grinder ........................150
Carbide spotting drills.......................................62
Hydraulic press brakes ....................................158
Twin-spindle compound grinding machines ....27
Cast iron cutting .............................................119
Hydraulic punch presses .................................158
Universal .....................................................44
Centerless ..........................................................44
Internal grinding machines .................... 27, 44
Universal cylindrical grinder ...........................150
Centerless grinding machines ...........................27
Lathes-automatic ....................................... 141
Universal cylindrical grinding machines ...........27
Centralized lubrication systems.......................126
Magnetic block unit ................................... 166
Vertical machinery center ........................... 107
COC - Cover on Cover FGF - Front Gate Fold FIC - Front Inside Cover BIC - Back Inside Cover BGF - Back Gate Fold BC - Back Cover
176 MODERN MACHINE TOOLS - July 2012
List of Advertisers Advertiser’s Name & Contact Details Accut Machinery Co. Ltd. T: +86-411-84804589 E: info@accutmachinetools.com W: www.accutmachinetools.com
Pg No 142
ACE Micromatic Group T: +91-80-22186700 E: customercare@acemicromatic.com W: www.acedesigners.co.in
11
Atul Machine Tools T: +91-281-2360227 E: info@atulmachine.com W: www.atulmachine.com
30
Austin Engineering Company Ltd E: sales@aecbearings.com W: www.aec-bearings.com Autotech Machine Tools Sales & Services T: +91-20-25690044 E: autocnc@vsnl.com W: www.autotechcnc.com Baker Gauges India Ltd T: +91-20-66093800 E: bakerbmi@bakergauges.com W: www.bakergauges.com
155
6
147
Advertiser’s Name & Contact Details
Pg No
Advertiser’s Name & Contact Details
Pg No
Creaform India T: +91-11-65022218 E: india@creaform3d.com W: www.creaform3d.com
159
Fong Ho Machinery Industry Co., Ltd. T: +886-4-2406-6769 E: fongho@ms26.hinet.net W: www.fongho.com.tw
162
Dees Hydraulic Industrial Co. Ltd. T: +886-2-2601-8661 E: sales@spc.com.tw W: www.spc.com.tw
158
Forwell Precision Machinery Co., Ltd. T: +886-4-8345-1960 E: forwell@forwell.com W: www.forwell.com
149
Doosan Infracore India Pvt Ltd T: +91-80-42660122 E: sandesh.kumar@doosan.com W: www.doosaninfracore.com
10 Freeze Tech Equipments Pvt Ltd T: +91-44-42152387 E: info@freezetechequip.com W: www.freezetechequip.com
168
Dowel Machinery Pvt Ltd T: +91-281-2362465 E: dowel@thedowel.com W: www.thedowel.com Durga Bearing Pvt Ltd T: +91-22-6876073 E: inquiry@durgabearings.com W: www.durgabearings.com
151
81
EFD Induction Limited T: +91-80-7820404 E: sales@efdgroup.net. W: www.efd-induction.com
109
127
Big Daishowa Seiki Co. Ltd T: +81-729-828277 W: www.big-daishowa.com
21
Electromech Material Handling Sys P T: +91-20-66542222 E: getcranes@emech.in W: www.emech.in
94
Emuge India Pvt Ltd T: +91-20-39310000 E: marketing@emugeindia.com W: www.emugeindia.com
34
Birla Precision Technologies Ltd T: +91-22-67933000 E: itmth@idiantool.com W: www.indiantool.com
156
Blaser Swisslube India Pvt. Ltd. T: +91-124-4994000 E: india@blaser.com W: www.blaser.com
71
Engineering Expo T: +91-9819552270 E: engexpo@infomedia18.in W: www.engg-expo.com
48
Cenlub Industries Ltd T: +91-129-4113701 E: cenlub@cenlub.in W: www.cenlub.in
87
Ermaksan Sheet Metal Working Machinery T: +90-224-2947500 E: emre.ozkaya@ermaksan.com.tr W: www.ermaksan.com.tr
Ceratizit India Pvt Ltd T: +91-33-24947146 E: info@ceratizitindia.co.in W: www.ceratizit.com
153
Champkraft Machine Tools T: +91-2752-241881 E: champ1@sancharnet.in W: www.solcogrinder.com
179
Changhua Chen Ying Oil Machine Co., Ltd. 126 T: +886-4-2639-3751 E: doris@chenying.com.tw W: www.chenying.com.tw Coatec India T: +91-172-5063436 E: info@coatecindia.com W: www.coatecindia.com
178 MODERN MACHINE TOOLS - July 2012
132
Fullton Machinery Co Ltd T: +86-411-82767678 E: fullton@fulltontech.com W: www.fulltontech.com
24
G W Precision Tools India Pvt Ltd T: +91-80-40431252 E: info@gwindia.in W: www.gwindia.in
57
Ganesh Techmachinery Pvt Ltd T: +91-11-41612203 E: rajesh@ganeshmachinery.com W: www.ganeshmachinery.com
45
Ganro Industrial Corp. T: +886-4-2537-6266 E: sdp@ganro.com.tw W: www.ganro.com.tw
146
Greenleaf Corp E: info@wexper.com W: http://www.wexper.com
119
GSK Cnc Equipment Co. Ltd T: +91-9886835186 E: gskwang@hotmail.com W: www.gsk.com.cn
31
ESA Eppinger Gmbh T: +91-9900588559 E: tramaiah@eppinger.de W: www.eppinger.de
161
Guang Dar Mangnet Industrial Ltd. T: +886-4-2436-0757 E: guangdar@ms32.hinet.net W: www.guangdar.com
166
164
Gudel India Pvt Ltd T: +91-20-25459531 E: info@in.gudel.com W: www.gudel.com
114
Essor International Inc W: www.essor.com.tw
FIC
Euroblech 2012 W: www.euroblech.com
85
Everising Machine Co. T: +886-4-2359-3178 E: evrs@everising.com.tw W: www.everising.com
140
Guhring India Private Limited T: +91-80-40322500 E: info@guhring.in W: www.guhring.in Haas Automation India Pvt Ltd T: +91-22-61392800 E: indiasales@haascnc.com W: www.haascnc.com
5
41
Heattrans Equipments Pvt. Ltd. T: +91-79-25840105 E: info@heattrans.com W: www.heattrans.com
142
Festo Controls Ltd T: +91-80-22894100 E: info_in@festo.com W: www.festo.com Finechrome Shafts Pvt Ltd T: +91-22-29204209 E: finechromespl@yahoo.co.uk
145
List of Advertisers Advertiser’s Name & Contact Details
Pg No
Heidenhain Optics & Electronics (I) T: +91-44-30234000 E: info@heidenhain.in W: www.heidenhain.in
BIC
Advertiser’s Name & Contact Details
Neway Cnc Equipment (Suzhou)Co., Ltd T: +(281)276-7100 E: newaycnc@gmail.com W: http://www.newaycnc.com
74
140
Nicolas Correa S.A. T: +91-20-25654891 E: u.medha@correaanayak.es W: www.correanayak.es
60
Kim Union Industrial Co., Ltd. T: +886-4-2533-1131 E: kimunion@kimunion.com W: www.threadrolling.com.tw
Hyundai Wia India Pvt. Ltd T: +91-9940653703 E: mvhari@gmail.com W: www.hyundai-wia.com
133
Komet Precision Tool India Pvt Ltd T: +91-80-280780000 E: info.in@kometgroup.com
IFM Electronics India Pvt Ltd T: +91-2312672770 E: info@ifm-electronic.in W: www.ifm-electronic.in
135
Indian Machine Tool Mfgr’S Association T: +91-80-66246600 E: info@imtex.in W: www.imtex.in
128
Indian Machine Tool Mfgr’s Association T: +91-80-22731625 E: director@amttf.in W: www.amttf.in
160
Indian Machine Tool Mfgr’s Association T: +91-80-66246600 E: augustin@imtma.in W: www.imtma.in
136
Korloy India Tooling Pvt. Ltd. T: +91-124-4930080 E: sales.kip@korloy.com W: www.korloy.com Larsen & Toubro Limited T: +91-22-67051093 E: sm.haridas@larsentoubro.com W: www.larsentoubro.com
59
113
91
Objet Ap Ltd T: +852-2174-0111 E: info@objet.com W: www.objet.com
72
171
Optical Gaging (S) Pte Ltd. T: +65-6741-8880 E: kelly@smartscope.com.sg W: www.smartscope.com.sg
129
Lico Machinery Co., Ltd. T: +886-4-2563-0950 E: sales@licomachinery.com W: www.licomachinery.com
141
P R Sales Corporation Pvt Ltd T: +91-20-25437591 E: info@prsales.in W: www.prsales.in
33
Macpower Cnc Machines Pvt Ltd T: +91-2827-287930 E: sales@macpowercnc.com W: www.macpowercnc.com
154
Palmary Machinery Co., Ltd. T: +886-4-2492-9799 E: Roger@grinding.com.tw W: www.grinding.com.tw
44
157
Paragon Machinery Co., Ltd. T: +886-4-2539-5678 E: info@paragoncnc.com W: www.paragoncnc.com
27
150
14
Jin Year Precision Co., Ltd. T: +886-4-2523-2817 E: liu0930@ms58.hinet.net W: www.jinyear.com.tw
137
Metrol Corporation India Branch Off T: +91-80-42105031 E: sales@metrolindia.com W: www.toolsensor.com Mitutoyo South Asia Pvt Ltd T: +91-11-26372090 E: delhi@mitutoyoindia.com W: www.mitutoyoindia.com
23
180 MODERN MACHINE TOOLS - July 2012
158
Lexis Tooling Systems T: +91-422-3052110 E: sales@iexisindia.com W: www.lexisindia.com
Jainnher Machine Co.,Ltd. T: +886-4-2358-5299 E: saledep@jainnher.com.tw W: www.jainnher.com.tw
137
Nmtg Mechtrans Techniques Pvt Ltd. T: +91-79-22821527 E: nmtg@nmtgindia.com W: www.nmtgindia.com
Openmind Cadcam Technologies (I) Pvt Ltd 16 T: +91-80-30504647 E: Info.India@openmind-tech.com W: www.openmind-tech.com
Mehta Cad Cam Systems Pvt Ltd T: +91-79-26840551 E: sales@mehtaindia.com W: www.mehtaindia.com
Kabel Schlepp India Pvt. Ltd., T: +91-80-27839111 E: sales@taegutec-india.com W: www.taegutec-india.com
177
123
83
73
Nikon India Pvt Ltd T: +91-124-4688 500 E: nind.Inst@nikonoa.net W: www.nikon-instruments.jp/eng/
Larsen & Toubro Ltd T: +1800-2335858 E: cic@lntebg.com W: www.larsentoubro.com
Isgec Heavy Engineering Ltd T: +91-120-3301001 E: trading@isgec.com W: www.isgec.com
Jyoti Cnc Automation Pvt. Ltd. T: +91-2827-287081 E: info@jyoti.co.in W: www.jyoti.co.in
Pg No
107
165
12
Advertiser’s Name & Contact Details
Kao Fong Machinery Co. Ltd. T: +886-4-2566-2116 E: phoebes@kafo.com.tw W: www.kafo.com.tw
HG Technology Co., Ltd. T: +886-4-7362-725 E: hg.tech@msa.hinet.net W: www.hgt.com.tw
Igus India Pvt Ltd T: +91-80-39127800 E: info@igus.in W: www.igus.in
Pg No
MMI India Pvt Ltd T: +91-9811090046 E: bhupender.singh@mmi-india.in W: www.photonicsindia.net
101
Montfort Shanghai Co Ltd T: +86(0)21/52136600 E: g.zhang@montfortshanghai.com
75
Pitroda Utility Industries T: +91-2752-243795 E: response@pitrodautilityindia.com W: www.pitrodautilityindia.com
125
Pramet Tools India Pvt Ltd T: +91-124-4703825 E: pramet.info.in@pramet.com W: www.pramet.com
39
Precihole Machine Tools Pvt Ltd T: +886-3-329-9968 E: pshtech@gmail.com W: www.peei.com.tw
22
Precimac Solutions T: +91-20-32538701 E: akektar@precimac.com W: www.precimac.com
61
List of Advertisers Pg No
Advertiser’s Name & Contact Details
Prem Brothers T: +91-11-28117456 E: powermaster59@gmail.com W: www.powermaster-india.com
163
Sandvik Coromant India T: +91-20-27104800 E: rupali.kavi@sandvik.com W: www.sandvik.coromant.com/in
Quaker Chemical India Ltd T: +91-33-22822181 E: sales@quakerchemindia.com W: www.quakerchem.com
143
Seco Tools India Pvt Ltd T: +91-2137- 667300 E: seco.india@secotools.com W: www.secotools.com/in
Quattro Engineering India Limited T: +91-80-25585439 E: bangalore@quattroengg.com W: www.quattroengg.com
Pg No
Advertiser’s Name & Contact Details
FGF
Tungaloy India Pvt Ltd T: +91-22-61248888 E: info@tungaloyindia.com W: www.tungaloy.co.jp.in
25
167
134
37
Universal Corporation T: +91-22-23422238 E: samson7@vsnl.com W: www.samson-grp.com
152
Vargus Limited T: +91-9730028248 E: vishal@vargusindia.com W: www.vargus.com
79
Synco Industries Ltd T: +91-9214407024 E: saleem@synco.co.in W: www.synco.co.in
166
Taegutec India Ltd T: +91-80-27839111 E: sales@taegutec-india.com W: www.taegutec-india.com
BC
Vijay Machine Tools Pvt Ltd T: +91-22-24950886 E: elmaco@elmacovijay.com W: www.elmacovijay.com
181
Taiwan Diamond Industrial Co., Ltd. T: +886-3-363-6971 E: Lai@taiwandiamond.com W: www.taiwandiamond.com
157
Wexper India Ltd T: +91-124-2210020 E: rajan.vaid@wexper.com W: www.wexper.com Yaskawa Robotics India Ltd T: +91-124-4758534 E: sales@motoman.co.in W: www.motoman.com
169
Quickmill Inc. T: +705-745-2961 E: info@quickmill.com W: www.quickmill.com
103
Shuter Enterprises India Pvt. Ltd. T: +91-44-32407116 E: 32407116@shuter.in W: www.shuter.in
112
R S Electro Alloys Pvt Ltd T: +91-11-25280488 E: info@rselectro.com W: www.rselectro.com
145
138
Ringfeder Power Transmission India Pvt. Ltd 93 T: +91-44-26791411 E: sales.india@ringfeder.com W: www.ringfeder.com
Siemens Ltd E: lvsgr-mktg.india@siemens.com W: www.siemens.com/industry
Taiwan Machine Tool & Accessory Builders’ Association 18 T: +886-4-2350-7586 E: tmba@tmba.org.tw W: www.tmba.org.tw
Robin Precision Products Pvt Ltd. T: +91-2827-287631 E: info@bloodtools.com W: www.bloodtools.com
130
Rotomotive Powerdrives India Ltd. T: +91-2692-230430 E: info@rotomotive.com W: www.rotomotive.com
90
Royal Precision Tools Corporation T: +886-4-2338-2068 E: oliver@royal-spindles.com.tw W: www.royal-spindles.com.tw
125
Sahajanand Laser Technology Ltd T: +91-79-23287461 E: mktg@SLTL.com W: www.sahajanandlaser.com
139
Samkrish T: +91-44-23612310 E: info@samkrish.com W: www.samkrish.com
131
Trigon Tooling Solutions Pvt. Ltd. T: +91-124-2370250 E: info@trigontools.com W: www.trigontools.com
Samkrish Machine Tools T: +91-44-23612310 E: info@samkrishmachinetools.com W: www.samkrishmachinetools.com
111
Triune Exhibitors Pvt Ltd. T: ‘+91-80-43307474 E: info@triuneexhibitors.com W: www.amtex2012.com
Takamatsu Machinery Co Ltd T: +81-76-2741403 E: h.nakagawa@takamaz.co.jp W: www.takamaz.co.jp
36
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29
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Zen Wu Zheng Sun Tool Co., Ltd. T: +886-7-352-5743 E: first@jsk-tools.com.tw W: www.jsk-tools.com.tw
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Looking For A Specific Product? pe
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FGF - Front Gate Fold FIC - Front Inside Cover BIC - Back Inside Cover
182 MODERN MACHINE TOOLS - July 2012
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46, 47
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Product Name
and send it to 51818
eg. MMT EDM and send it to 51818 BGF - Back Gate Fold BC - Back Cover
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MODERN MACHINE TOOLS
Reg No: MH / MR / WEST / 235 / 2012 – 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
July 2012
184