Modern Machine Tools - March 2011 by Infomedia18

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Editorial

The sign of things to come

he writing is on the wall and the latest IMTEX & Tooltech certainly reflected some of the mega trends with significant bearings on the metalworking sector. To begin with, fastchanging industry demand and shrinking product lifecycles are hastening the need to have machine tools with higher flexibility. Also, going by the rising competitiveness of key user industries, there is ample scope for more sophisticated machine tools that can yield increased performance, flexibility and productivity. Moreover, thanks to growing eco-sensibility as well as focus of investment and research on new technologies, there is a surge in preference towards machine tools, which produce less waste and are less dependent on coolants (and other fluids) that have environmental and health implications. In brief, the overall focus was on technologies to enable users in achieving higher productivity, better tool-life and cost-effective solutions. Also, it was apparent that the priority aspect in selecting machine tool was not only its pricing, but also the machining technology employed and cost-per-component thereof. So, how do all these factors shape the contours of metalworking in India and what can be the derived strategies to succeed in this sector? The time has come for both the private Editor Manas R Bastia Senior Features Writer Hema D Yadav

Features Writer KTP Radhika Jinoy (Delhi)

Correspondent Rachita Jha Anwesh Koley (Delhi)

Editorial Trainee Nishant Kashyap

Copy Desk Meghanadan Sudhakaran

Assistant Art Director Varuna Naik

Products Desk Sudheer Vathiyath

Photographer Neha Mithbawkar, Joshua Navalkar

Chief Photographer Mexy Xavier Sr. Designer Hemant Lambe Production Pravin Koyande, Dnyaneshwar Goythale, Vikas Bobhate, Ravikumar Potdar, Ravi Salian, Sanjay Shelar, Lovey Fernandes, Pukha Dhawan, Varsha Nawathe, Akshata Rane, Abhay Borkar Branding & Marketing Jagruti Shah, Ganesh Mahale CEO - Publishing Sandeep Khosla Associate Vice President Sudhanva Jategaonkar

and public sectors to work in synergy to achieve the goal of India’s self-sufficiency, considering the needs of the country as well as future prospects. The ‘Report’ highlights some of the key facets of IMTEX 2011 and Tooltech 2011. On a specific note, dies & moulds segment in India has been clocking a growth rate of nearly 15 per cent per annum. At the same time, there is a call for reducing or eliminating the need of manual polishing and thus improve on quality, cut production costs & lead times. Some of the prominent trends witnessed in this domain include enhancements in engineering simulation and the evolving role of design optimisation. Turn to the ‘Sector Watch’ for further details on some of the latest trends and analysis in dies & moulds. Not to be left behind, turning centres are seeing continuous advancements of multitasking machines with integration of 5-axis and turning technology in a unified turn-mill solution. Take a look at the ‘Industry Update’ for more on turning centres.

Manas R Bastia Editor manas@infomedia18.in

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Editorial Advisory Board M Lokeswara Rao President, IMTMA & MD, Lokesh Machines Ltd Vikram Sirur Vice President, IMTMA & Executive Vice Chairman, Miven Machine Tools Ltd N K Dhand Past President, IMTMA & CMD, Micromatic Grinding Technologies Ltd R Srinivasan 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

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March 2011 - MODERN MACHINE TOOLS

Contents Sector Watch

Regular Sections

Indian dies and moulds: Stepping up the game .......................................... 68

Editorial...................................... 29 National News ........................... 32 World News ............................... 44 Tech Updates............................. 60 Events ...................................... 138 Book Shelf ............................... 150 Product Update ...................... 152 International Products ............ 184 Product Index.......................... 192 Advertisers’ List ...................... 202

Industry Update Turning centre: Powered by new-age tools and technology.......... 74

Practical Insights Indian machine tools: Diversifying technology to maximise gains .............. 83

Facility Visit Premier Ltd: Pioneering innovative excellence ................................. 93

Design Corner 3D design: Moulding the future ......................................................... 98

Manufacturing Excellence CNC machines:

Leaders Speak M S Arora, MD, Birla Precision Technologies Ltd ..................... 88

Notching up speed ..................................................... 103

Case Study Precision engineering: Crucial investment for subcontractors ...................... 108

Expert Zone ERP solutions: A boon to project-based companies ......................... 113

Factory Fundamentals

Highlights of Next Issue: Sector Watch: Sheetmetal Working Industry Update: Robotics in Machine Tools Cover photo courtesy: Awanti Polymoulds Pvt Ltd

MODERN MACHINE TOOLS - March 2011

CAM features facilitate five-axis ‘Hog-outs’ .... 118 Details on page 141-142, 159-160

Milling, turning machine line supports versatility ..... 124 CAM system simplifies swiss-type lathe programming ............................................................ 130

National News HAAS opens 100 per cent Indian subsidiary

Europe. “This will provide our existing distributor set up with a localised, comprehensive spare parts inventory (to augment the inventory already available at our six local HAAS Factory Outlets [HFOs], thereby eliminating the need for our distributors to order parts from the US), factory level technical service,

applications & training support and spares rebuild capability,” Roth said. Sharing his views on some of the key challenges facing the machine tool industry worldwide, Haas observed, “Getting brand recognition, prompt customer support, product innovation as per the changing demand and right pricing are some of the focus areas.” Currently, there are more than 4,000 HAAS machines functioning in India in leading engineering companies from diverse sectors such as precision aerospace, medical, mould making, auto components, oil & gas, precision general engineering, etc. Further, the company has six HFOs located in Ahmedabad, Bengaluru, Chennai, Coimbatore, Manesar and Pune, which are locally owned & operated by its two distributors CNCSSIPL and MANAV. It plans to add six more HFOs in India over the next few years.

LOSMA SpA launches new subsidiary in India

Schaublin inaugurates a new office

C & B machinery travels to Indian shores

The Italian company opened its subsidiary in India to strengthen its presence in the world market. This subsidiary was opened in Pune, particularly to meet the demand from local market for eco-compatibility and health protection in the workplace. Giancarlo Losma, Chairman, LOSMA SpA said, “This is the fourth

Located at Secunderabad, (Hyderabad), Schaublin Machines (India) opened its new office in the country. The company has also established a full-fledged service centre with highly skilled and qualified engineers at Bengaluru since K Shanker 2006. A part of the Schaublin Machines SA (Switzerland), in the last 10 years the company has developed 15 new types of machines featuring high-precision, reliability, flexibility and longevity. Heading the proceeding was K Shanker, General Manager-Sales & Service, Schaublin Machines (India). The company started with marketing conventional lathe machines, spare parts & accessories and subsequently started the sale of Schaublin’s CNC products in India.

C & B Machinery has been awarded an order by Allison Transmission to build a ‘flexible’ double disc grinding cell for its Indian facility in Chennai – Allison Transmission India Pvt Ltd. The cell is designed to grind the faces of transmission pinion gears for Allison’s 1000 and 2000 series transmissions. Double disc grinders remove equal material from both faces simultaneously. This particular machine will be arranged to grind four various pinion configurations with the capability to grind 11 more already being produced at the plant (on grinders previously provided by C & B). This grinding cycle, developed by C & B engineers also allows 100 per cent gauge feedback on every component ground. Size control is tightened resulting in higher statistical capability.

HAAS Automation Inc has inaugurated its 100 per cent Indian subsidiary - Haas Automation India Pvt Ltd in Mahape, Navi Mumbai. The grand opening ceremony was attended by representatives of leading engineering companies, associates from the machine tool & allied industries as well as the entire team of HAAS Automation India and its local distributors. Present on the occasion were Gene Haas, Founder President, and John Roth, Director of Customer Service, HAAS Automation Inc, USA; and other dignitaries included S M Nayak, General Manager (Engineering Services), Godrej & Boyce Mfg Co Ltd, and Terrence Miranda, Managing Director, HAAS Automation India Pvt Ltd. The new subsidiary is aimed at providing the same superior level

Giancarlo Losma (second from left) at the press conference

international location, in addition to the subsidiaries in USA, Germany and UK. With the opening of LOSMA India Pvt Ltd, we will able to provide local support to our customers and supply highly customised solutions based on market requirements.”

MODERN MACHINE TOOLS - March 2011

of technical support (in service, applications, training and parts) to its customers in India, similar to what is experienced by customers in the US and

(L-R): John Roth, Gene Haas and Terrence Miranda

National News DHI in favour of ` 1,000-crore technology upgradation The Department of Heavy Industry (DHI) has asked the Finance Ministry to create a corpus to fund technology upgradation of the auto components industry to make it globally competitive. “We are asking for ` 1,000-crore technology fund creation for the entire next (five year) plan. The fund can be a revolving kind of fund. People can take out, repay it, refurbish and new participants will take it,” a DHI official said.

The DHI, in its pre-Budget recommendations, has sought the amount under Technology Upgradation Scheme (TUFS), wherein companies can avail 5 per cent subsidy on loans for upgrading technology from the government. Currently, only the textile sector is provided these benefits under the Upgradation Scheme (TUFS). The DHI feels that technology fund creation is required to make auto components sector, especially the SMEs, more competitive, as they are lagging behind their global peers. Besides, the Department has also urged the Finance Ministry to continue stimulus measures such as continuation of the same rate of excise duty.

HAL on the fast track for modernisation The defence major Hindustan Aeronautics Ltd (HAL) has recently announced a ` 20,000 crore plan for modernising its plants and hinted at the possibility of the company going public and being listed on stock market. D Shivamurthi, Director

MODERN MACHINE TOOLS - March 2011

– Finance, HAL said, “The company plans to spend ` 20,000 crore for modernising its facilities over the next 10 years, which would be funded through internal accruals.” The Bengaluru-headquartered company already has reserves of ` 9,000 crore and proposed to add ` 1,500 crore every year. According to company officials, HAL has 19 production divisions and 10 R&D centres across the country. Shivamurti said that the company plans to design, develop and manufacture 1,500 helicopters over the next 10 years. The company has ` one lakh crore worth orders to be delivered over the next 10 years.

Government keen to boost engineering exports The Central Government has set an ambitious target of $ 120 billion engineering exports by 2015 and emphasised on the need to align policies in that direction. At the EcoProducts International Fair 2011 and International Engineering Trade Fair, the Commerce and Industry Minister, Anand Sharma, said, “The country’s engineering e x p o r t s have already reached $ 40 billion and is expected to touch $ 50 billion by the end of the current Anand Sharma financial year. We have remained mindful of the fact that we need to align government policies with the ambitious target of tripling India’s engineering exports of $ 120 billion by 2015.”

According to industry experts, the demand for engineering goods is increasing in the US and other markets such as Middle East. However, the demand is still fragile in Europe. “If we look at the overall scenario of engineering exports, we are one of the fastest growing exports in the world at nearly 30 per cent, well above the global average of 13 per cent,” he added. Out of India’s total engineering exports worth $ 32.5 billion in 2009-10, the US and EU accounted for about 65 per cent of the shipments. To reduce dependence on traditional markets like the US and Europe, exporters are exploring new destinations in regions like SouthEast Asia and Latin America.

L&T eyeing greener pastures To tap the vast opportunities offered by the defence electronics market, engineering giant Larsen & Toubro and Cassidian, a Division of Europe’s leading aerospace and defence group EADS have formed a Joint Venture (JV). The JV will be active in the defence electronics market and aims to cover manufacturing, design, engineering, distribution and marketing in the fields of electronic

warfare, radars, avionics and mobile systems such as bridges for military applications. The name for the venture has been submitted to the authorities for approval. Talegoan will be the location for the JV where L&T has set up the facility on 30 acre land and about $ 20 million will be invested in the first phase. Also, a strategic electronic centre will be established in Bengaluru.

National News BFW in expansion mode with CAPEX of ` 350 crore The Bengaluru-based Bharat Fritz Werner Ltd (BFW) has aggressive expansion plans, which include setting up of a new facility in Hosur, restructuring of its aerospace business and intentions of international mergers & acquisitions. The company has earmarked ` 33 crore towards setting up a new plant for manufacturing machine tool spindles in Hosurand. It has also reserved ` 115 crore to acquire new machinery and add shop floors to accommodate new lines of products to be churned out from the manufacturing facility in Bengaluru, while ` 45 crore has been set aside for restructuring its aerospace business.

(L - R): Shailesh Sheth, Director; S N Mishra, Vice Chairman & President; and N N Upadhyay, Director

It plans to pump ` 350 crore in the next five years towards vertical and horizontal growth. The company is eying a turnover of ` 330 crore in the financial year ending March 31, 2011, a 65 per cent jump from the previous year. According to BFW, the ` 3,000 crore machine tool industry in India is slated for rapid growth, with demand expected to reach ` 55,000 crore by the year 2020. In sync with the trend, the company plans to log turnovers of ` 850 crore and ` 1,300 crore in the years 2013 and 2016 respectively. The company is considering several options for merger and acquisition with international players as well.

WIDIA relaunched at megaevent IMTEX 2011 IMTEX 2011, India’s largest manufacturing technology event,

MODERN MACHINE TOOLS - March 2011

was the location chosen by WIDIA to debut its latest products and services for India. “This is a significant milestone for us, as it marks a major ‘relaunch’ of WIDIA in India in line with launch events held around the world since we announced the formation of the WIDIA Products Group last year. It also marks the completion of our brand migration

efforts with the move of MetCut™ and Metal Removal™ brands under the WIDIA umbrella,” said Bernie McConnell, Vice President, WIDIA Products Groups & Services. With the consolidation of many separate metalworking brands including Circle™, Rubig™, Manchester™, Clapp-DiCo™, GTD™, and Hanita™ under the WIDIA umbrella, the powerful product portfolio now has the full range of metal cutting tooling and wear solutions. The WIDIA Victory platform, which showcased at IMTEX 2011 included new extensions to the bestin-class WIDIA M1200™ mini series face-milling cutters and inserts, new TN series turning grades specifically engineered for steel and cast-iron applications, and the new TOP DRILL M1™ modular drilling system.

Premier Ltd eyeing buyouts in Europe Engineering and automobile company Premier Ltd is looking at both organic and inorganic routes to grow its engineering division business. “We have drawn up an investment plan involving a capital expenditure of ` 150 crore for the next three years to expand the

capacities of our machine tool unit as well as to set up a greenfield manufacturing facility somewhere in and around Pune to cater to the growing demand for our smaller machines in the domestic market,” said Maitreya Doshi, Chairman and Managing Director, Premier Ltd. The company is also looking at the merger and acquisition route in Europe to expand inorganically. The company is presently evaluating machine tool firms available for acquisition in the range of $ 30-50 million. “We are actively evaluating a few companies in Germany and Italy. We wish to complete the acquisition in the next

one year,” Doshi further added. The greenfield expansion and overseas acquisition will be funded from the company’s internal accruals. The company plans to widen its machine tool product portfolio by focussing on smaller machines priced in the range of ` 15 lakh to ` 25 lakh to increase its sales volumes. The company’s heavy engineering business division manufactures components for the wind energy sector, railways and automobile applications. It supplies components like cylinder blocks to Tata Motors, under chassis components to metro coaches made by BEML; carriers, rotor hubs and starter rings and towers to wind mills among others. With the expansion of product portfolio, the company aims to increase its turnover of the engineering division from ` 250 crore in 2010-11 to ` 700 crore in the next three years.

National News Danfoss makes effort for a greener world The company recently launched its innovative Micro Channel Heat Exchanger (MCHE) in India. The ground-breaking product has always been used in the automobile space and Danfoss recently advanced this technology and is the first to bring it to India for residential and commercial use. This innovative product replaces

has been used for automotive air conditioning, its success and prowess have been proven time and again. Given our expertise in the field, we deemed it necessary to advance the technology and enhance its working to fit both residential and commercial air conditioning systems. We are expecting MCHE to be standardised in the coming year. The product is customised according to the requirement of the customer which will help manufacturers design their systems to be energy efficient and environmentally friendly,” said A Rajesh Premchandran, Vice President - Refrigeration & Air Conditioning, Danfoss India.

ElectroMech enters into a strategic alliance the traditional heat exchanger in refrigeration and air-conditioning units and is 100 per cent aluminium constructed thereby allowing for increased energy efficiency of 10 per cent. It also saves energy by 10 to 50 per cent. On the occasion, Chief Guest Dr Ajay Mathur, Director General, Bureau of Energy Efficiency (BEE) said, “I congratulate Danfoss in bringing the MCHE to India. Efficiency is paramount today. For us in the Bureau, it is a matter of great satisfaction, as the copany has showcased various components and we are seeing innovation in all of them. We hope that these innovations may provide the kind of environment that is needed in order to be cost effective and make a transition to more energy efficient air-conditioners.” The heat exchangers that are used currently in air-conditioning systems are only equipped to meet present star labelling requirements. With MCHE, the efficiency of air conditioning systems can be improved and benchmarked against the highest standards and labelling requirements of the future. “Although, Micro Channel as a technology

MODERN MACHINE TOOLS - March 2011

Pune-based ElectroMech, India’s largest industrial crane manufacturer and customised material handling solutions provider has entered into

The gantries which can lift loads between 13 tonne to 450 tonne can be successfully adapted across multiple industries including pre-fabricated concrete, steel, modular buildings and wind power generation equipment. “The Indian MHE industry is maturing fast and specialist lifting concepts are never far behind. Our customers have been asking for more dynamic and cost effective hoisting solutions that demand technical innovations and this is obviously a big step in that direction,” quipped Tushar Mehendale, Managing Director, ElectroMech. Speaking on the alliance Neil Calder, Regional Sales Manager, Shuttlelift stated, “We are proud to have partnered with ElectroMech which has always aimed to be a total solutions provider; setting the standards for service, efficiency along with productivity.”

Volkswagen hopes to grab more market share by 2018 The German automobile major Volkswagen Group is eyeing a 20 per cent auto market share as it plans to expand its reach through dealerships

an agreement with the US-based manufacturer - Shuttlelift to extend its offerings to the construction & material handling industry. The new partnership was formally announced to customers and the crane industry at BAUMA 2011 - the international trade fair for construction machinery held in Mumbai. The company also unveiled its single-beam and mobile gantry cranes. ElectroMech will now supply various models along with adjustable heights and spans under the SL series that stand for lighter duty and limited flexibility & ISL series that stand for heavy duty and maximum flexibility.

in tier 2 and tier 3 cities across the country. Neeraj Nag, Director, Volkswagen Passenger Cars India said, “In our estimate the market size in 2018 should be around five million cars and we should be targeting to achieve 20 per cent market share from the group. For Volkswagen brand it was two per cent market share in 2010.” At present, the Volkswagen Group has three brands under its umbrella- Audi, Skoda and Volkswagen.

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National News National Instruments symposium attracts industry leaders under one roof Conducted in association with Society of Indian Aerospace Technologies & Industries (SIATI), the fourth edition of the India Defence & Aerospace Symposium (IDAS) 2011 was held at Bengaluru. Over 400 delegates participated in the various technical sessions on next-generation test and embedded systems for defence and aerospace applications.

The symposium commenced with a welcome note by Retd Air Commodore J Varkey, SIATI, amidst industry leaders like National Aerospace Laboratories, Hindustan Aeronautics Ltd, etc. The key note session was delivered by Padma Shree Dr Kota Harinarayana (Raja Ramanna Fellow, National Aerospace Laboratories, Former Programme Director & Chief Designer of LCA and Former Vice-Chancellor of University of Hyderabad). At the event, he said, “India is emerging as a technology hub for engineering services and product development for the global defence market. This has emphasised the relevance and importance of public-private partnerships.” Other highlights at the event included a unique exhibition arena that displayed live demonstrations, case studies presentations, innovative products from NI partners and technical consultation. The event also hosted various technical sessions on next generation test and design. The sessions were attended by defence personnel, engineers and researchers representing various functional groups, government authorities and multi-national companies.

MODERN MACHINE TOOLS - March 2011

A CAPEX of $ 40 million for Maini Global Aerospace The wholly-owned subsidiary of Maini Group has chalked out an investment of $ 35-40 million over the next years to scale-up infrastructure & capacity and to widen its product and service offerings. “By 2015, our target is to have a turnover of ` 215 crore and we have a detailed investment plan for this. We will invest $ 35-40 million in the next five years,” revealed Naresh Palta, CEO, Maini Global Aerospace (MGA). The investment will be funded by internal accruals. MGA, whose core strength lies in precision machining, has taken a consortium approach, in line with its aim to become a full-fledged tier-I supplier. The company is targeting segments such as aero structures, systems and small engine components. Currently, more than 90 per cent of the company’s business is

export-oriented. It recently bagged an order from Hindustan Aeronautics Ltd (HAL) to manufacture drop-tanks for fighter aircrafts. It is also working with HAL to make components for the SU-30 fighter aircraft, Dornier aircraft, intermediate jet trainers, Cheetah and Chetak helicopters.

Siemens PLM Software and VISTAGY enhance partnership A business unit of the Siemens Industry Automation Division and VISTAGY Inc has recently announced a significant upgrade and long-term extension to their partnership at the recently concluded Aero India 2011. The new agreement results in an improved ability to meet

market demand with an end-to-end composites engineering solution based on Siemens PLM Software’s NX™ software and VISTAGY’s FiberSIM®. “By creating a stronger partnership with VISTAGY, we are continuing our strategy of working with the industry’s leading solution providers to constantly improve the value we deliver to our customers,” said Joan Hirsch, Vice President – Product Design Solutions, Siemens PLM Software.

Raj Khoshoo, Vice President, Siemens PLM Software, and Dr Olivier Guillermin, DirectorProduct and Market Strategy, VISTAGY Inc

By extending their joint expertise in PLM, product development and composite engineering, Siemens PLM Software and VISTAGY are delivering an integrated offering that will enhance the ability of customers to perform the design, analysis and manufacture of composites within the PLM process. The solution combines NX, manufacturing and engineering analysis (CAD/CAM/ CAE) solutions, with FiberSIM, a software for composites engineering. “With FiberSIM, customers address the entire composites engineering process, from conception, laminate definition and ply creation through simulation, documentation and manufacturing. By combining that unique capability with the power and functional breadth of NX, we are extending the ability of both organisations to deliver the benefits of an integrated composite engineering solution to all the industries we serve,” said Steve Luby, President & CEO, VISTAGY Inc.

World News ABB delivers high output from a small footprint The company recently launched an additional model in its IRB 2600ID range of industrial robots. The robot brings Integrated Dressing (ID) technology to a larger working envelope and can reduce arc welding cycle times by up to 15 per cent. The IRB 2600ID is the first ID robot to be offered in the range and has a reach of 2 m, and payload capacity of 8 kg. The robot features a unique combination of high-payload capacity, a large working range and ID, which routes the arc welding hose package inside the robot’s upper arm and wrist.

“The current trend in industrial robotic design is for process equipment to be fully integrated with the robot,” said Per Lowgren, Product Manager, ABB Ltd. He further added, “A robot with integrated dressing increases output and cuts down operational costs. Because the movement of the hoses and cables is totally predictable, one can operate at full speed. It also simplifies and improves off-line programming, as swinging cables are not taken into account when simulating robot systems. This minimises the time required for fine-tuning programs and enables a faster start of production. The total programming time is reduced by 90 per cent.” The robot also opens new possibilities in production. With a

MODERN MACHINE TOOLS - March 2011

slimmer arm and wrist, the robot can enter narrow spaces. With its compact design, the IRB 2600ID has a very small footprint with a swing base radius of only 337 mm and a base width of only 511 mm. For arc welding, the reduced risk of interference with other robots allows high-density installations.

Somers Forge utilises shop-floor program for productivity With over 130 years of experience in heavy engineering, Somers Forge in West Midlands, UK, work in a variety of materials ranging from carbon steel to super alloys and specialised non-ferrous alloys. The company was looking for an easy-to-use, reliable CAM software package suitable for shop floor programming, and which would also be compatible with SolidWorks® software & their DEPO machine tools. With the introduction of CNC machines with NCG CAM, the company has been able to reduce jobs from 300 hour to just under 30 hour. It was also able to derive multiple benefits from the software, which allows drilling & milling on the same machine tool, and by using the 3+2 it eliminates further operations on parts. The simple-to-program software allow users to open the model and create program in minimal time.

The NCG CAM software is an easy-to-use stand-alone CAM system that integrates with existing CAD and CAM systems. It boasts of many innovative features and is suitable

for all types of forms, creating an optimised, smooth cutter motion for 3D high speed machining, while helping to extend tool life, minimising wear on the machine tool, and producing parts with excellent surface finish. Its user-friendly interface, with a typical learning curve of only one day is required to machine a live job. It is perfect for high-speed machining of moulds, dies, prototypes and precision surface machining.

Pegasus Northwest experiences bumper sales The Boeing-certified waterjet cutting shop has increased its sales figure by 57 per cent since 2007, by keeping its five jet edge waterjet cutting machines humming 20 hours a day on weekdays and 12 hours a day on weekends. The company attributes its success to AS9100 certification. Ron Palstring, General Manager, Pegasus Northwest, dedicates his company’s stunning success throughout the economic slowdown

to its decision to invest in its quality programme, “While other businesses went into bunker mode, Pegasus Northwest took the initiative to become the first AS9100-certified company in Washington and hired a full-time Sales & Marketing Manager to drum up new business. As a result, we are running at 70 per cent capacity and have even installed two additional jet-edge waterjet cutting machines to keep up with demand. The price tag for such certification was over $ 30,000, plus a lot of hard work from our quality manager and the entire staff ensured and we got it.”

World News Boeing ahead in the race with launch of SBN The Chicago-based aerospace giant began production at its new military aircraft assembly plant at St Louis Airport in Mascoutah, USA. The workers are performing assembly and sub-assembly work on the F/A-18 fighter jet, the C-17 Globemaster III air cargo plane, and its CH-47 Chinook helicopter. The company is expected to put another 20-25 employees to work at the plant in the second quarter of this year. The facility is expected to employ 75 workers by mid-2012. The state is giving Boeing $ 2.3 million

The announcement comes as Poland and Russia plan to intensify economic and scientific ties as a way of improving traditionally strained political relations. Komorowski said,

Nippon and Sumitomo Metal to form JV

Bronislaw Komorowski, President, Poland

to help cover the cost of setting up manufacturing base in America. The company has also announced that it has completed the post-launch testing and on-orbit handover of the first Light Squared satellite and Space-Based Network (SBN). The satellite system has been accepted by LightSquared and is ready to begin service.

Intrall Rus shows interest in Poland Following the deals inked by Russian President Dmitry Medvedev and his counterpart, Bronislaw Komorowski, the Russian car maker signed a letter of intent to build a research centre and small factory in northwestern Poland by 2014. The total investment will be around $ 366 million. According to a statement released by the company, the research & development centre and small factory to be built near Szczecin will co-operate with a bigger truck and SUV factory being built in Stavropol, in southern Russia.

MODERN MACHINE TOOLS - March 2011

management, instrument refresher courses and instructor preparatory courses. “The C-130 ATS programme has an unrivaled track record in delivering critical, on-time training to pilots and aircrews,” said Jim Weitzel, Vice President – Training and Engineering Services, Lockheed Martin Global Training and Logistics. Annually, nearly 12,000 students from more than 25 countries depend on the C-130 ATS for their training needs.

“As a member of both EU and NATO, Poland wants to have the best possible mutual relationship with Russia. We also want, in this way to influence the general direction of EU and NATO policies in relations with our important neighbours to the east.” The factory in Poland is to make up to 5,000 cars annually, starting from 2014.

Japan’s Nippon Steel Corporation and Sumitomo Metal Industries are planning a merger to create the world’s second-largest steelmaker in an effort to fend-off tough competition from Asian rivals and offset shrinking demand from domestic automakers. The deal will likely see Nippon Steel acquiring Sumitomo Metal. In the recent times, Japanese steelmakers have been particularly hard hit as domestic automakers such as Toyota Motor Corporation and

Lockheed Martin awarded $ 270 million training system contract The US Air Force has awarded the company a contract to provide affordable and effective academic and simulation training programme for C130 aircrews around the world. The eight-year contract includes training and instruction, site management, engineering support, and operation & maintenance for the aircrew training devices. Training is provided for all aircrew positions, cockpit resource

Nissan Motor Company have built few cars at home, while expanding in emerging markets such as India using products from local steelmakers. They also face cut-throat competition from South Korea’s Posco and Baoshan Iron & Steel Co, China’s biggest listed steelmaker. Analysts, as well as Japanese government officials and politicians have welcomed the plans for the merger, which is subject to approval from Japan’s Fair Trade Commission (FTC). The companies are planning to merge by October 2012.

Modern Machine Tools (Mar 11) IGF Front Pg49 50

Modern Machine Tools (Mar 11) IGF Back Pg51 52

World News Toyota to boost auto production in Russia The company will be joining forces with Russian automobile major Sollers to boost auto production in the country. It is also planning to tap into the ever-growing car market of Russia by utilising Sollers’ existing factory in the far eastern port city of Vladivostok four months of consecutive growth following International Manufacturing Technology Show (IMTS), ending the year on an upswing. With backlogs firming and quotation levels accelerating, we are optimistic that the industry will register strong results in 2011,” said Douglas K Woods, President, Association for Manufacturing Technology (AMT). The positive report has further strengthened the machine tool market across the globe. to produce cars. According to industry experts, the company will be producing Sport Utility Vehicles (SUVs). The Russian automaker’s Vladivostok plant will be upgraded so that it can assemble around 30,000 Toyota vehicles annually. It will be the company’s second production base in Russia. Japanese firm Mitsui & Co will also join the project in Russia.

US machine tool consumption up in 2010 With the economy reviving its lost momentum, the consumption of US manufacturing technology also witnessed a significant growth from November to December in 2010, marking a strong end to the year. The total consumption value of machine tool and related equipment from the country manufacturers rose to $ 446.76 million in December, a 40.9 per cent increase from November, and 104.8 percent above the December 2009 total, according to the latest US Manufacturing Technology Consumption (USTMTC) report. For 2010 as a whole, machine tool consumption was 85.3 per cent more than the total for 2009. “For the first time in USMTC history, we experienced

BMW X1 high on the quotient of style The recently launched c o m b i n e s agility and elegance without compromising on speed. The dynamic shape of the automobile consists of rising lateral lines, while short overhangs and a sloping rear windscreen create a sporty silhouette. At the front, the distinctively shaped bonnet and the threeeye look of the headlights make for a striking impact, while the L-shaped taillights in conjunction with the horizontal flow of lines visually broaden the rear.

model

The car is equipped with Dynamic Traction Control (DTC). The wheel slip is slightly increased, while DTC optimises propulsive power and enables a more sporting driving style. The X1 is based on BMW’s ‘Efficient Dynamics’ and features a smoothrunning 2.0 litre 4-cylinder diesel engine which delivers 177 horsepower and can travel from 0-100 km in just 8.3 seconds. The car is packed

with features, which considerably reduce emissions and improve fuel consumption, while at the same time boosts performance.

March 2011 - MODERN MACHINE TOOLS

World News Volvo launches a new version of FH 16 The company recently launched a version for heavy haulage involving gross combination weights of up to 295 tonne. The combination of massive power, agility and robust technology puts the truck ahead in its heavyweight category. “This is a solution for the heaviest and most demanding transport assignments, one of the few solutions on the market capable of handling such high-gross combination weights,” said Hayder Wokil, Product Manager – Long-Haul Segment, Volvo Trucks – Europe Division.

The new heavyweight truck is equipped with a 16-litre engine producing 600 horsepower and 2,800 Nm of torque. The engine is matched by a seven-speed automatic transmission with a torque converter, a combination that allows the truck to start off smoothly and improves its manoeuvrability at low speeds. The transmission also offers benefits on the highway. The 16-litre engine is equipped with Volvo’s VEB+ engine brake, which offers braking effect of up to 425 kW. The transmission features an integrated retarder, which on its own offers braking power of up to 450 kW. It is also available as a tractor with leaf springs on air suspension and comes in a wide range of wheel and axle combinations.

Toyota’s new factory kindles hope in the home market The company opened its first assembly plant in Japan in 18 years, despite macroeconomic pressures threatening to make the strategy impractical. The latest addition to

MODERN MACHINE TOOLS - March 2011

Toyota’s production base, which will export Yaris subcompact cars to the US and Middle East, comes as the yen rises to near-record levels against the dollar. While in the past, the company has indicated difficulty in exporting small cars from Japan profitably at current exchange rates, the company

is hopeful that the new facility will be able to compete globally. “We believe Japanese-based manufacturing still has plenty of competitiveness when it comes to exporting. However, Japan will seek to meet increased demand abroad with localised production wherever possible,” said Atsushi Niimi, Executive Vice President, Toyota Motor Corporation. The new plant features a number of cost-space and labour-saving innovations to boost productivity and competitiveness. The factory, located in a rural hamlet outside the northern Japanese city of Sendai, will produce 1,20,000 vehicles a year, including two versions of the Corolla model for sale in Japan.

engineers to easily develop, analyse, inspect and document the CNC programming and machining process. Along with proactively adding new features, CGTech developers and engineers have focussed on addressing hundreds of customerdriven enhancements. “VERICUT 7.1 builds on CGTech’s highly successful VERICUT 7.0 release, and subsequent point releases, that contained over 700 customer requests delivered throughout 2010. It contains further improvement in user interaction, simulation capabilities & analysis, cutting tool creation and CAD/CAM integration,” said Bill Hasenjaeger, Product Marketing Manager, CGTech. The latest version includes enhancements such as creating a ‘true helix’ motion type helical milling material; support for material removal for general broaching operations and simulation of back spot-facing tools. Also all popular controls are enhanced with new advanced features: Siemens 840D, Fanuc 30’s, Heidenhain, Okuma OSP, Mazak Matrix etc.

Bosch acquires CST/Berger Bosch Power Tools, a leader in power tools segment recently acquired CST/ Berger, an American manufacturer of measuring instruments. The acquisition adds to the range of survey tools like range finders, laser levelers

CGTech ships VERICUT 7.1 The company is now shipping the next major version of VERICUT CNC machine simulation and optimisation software. The VERICUT 7.1 features significant enhancements to reduce the time required for manufacturing

and line lasers available from Bosch. Martin Merchant, Head Marketing, Measuring Tools Division, Bosch Power Tools said, “The acquisition will help us to increase our product range in measuring equipment and will enhance our market share in the US.” CST/Berger specialises in designing, developing & manufacturing leveling and layout instruments & accessories.

World News EMO 2011: Solutions for manufacturing challenges EMO Hannover 2011 will be highlighting the contribution made by machine tools in our everyday life. Food, building materials, textiles, medical devices, vehicles, conveying systems, natural resources, electricity, the Internet and mobile phones – these and much more are made possible with the aid of machine tools, either directly or indirectly. Machine tools are essential for manufacturing high-quality industrial products with the least possible impact and at the lowest possible cost. At one of the largest industry forums for metalworking from September 1924, 2011, manufacturing technology vendors and solution providers from across the world will be presenting their solutions that can be an answer to the current and future challenges of the industry. Titled ‘World of Metalworking’, the event will bring together a comprehensive line of products and systems. “Machine tools contribute substantially in determining whether new products can even be made, what they will look like, and how much will they cost ?,” explained Dr Wilfried Schäfer, Executive Director, German Machine Tool Builders’ Association (VDW) – the organisation responsible for staging EMO. Many countries

Dr Wilfried Schäfer, Executive Director, German Machine Tool Builders’ Association (VDW)

MODERN MACHINE TOOLS - March 2011

have recognised the key role played by the machine tool industry and the significance of high-performance manufacturing technology for increasing and updating industrial competitiveness. VDW therefore promotes the development of its domestic machine tool industry and boost imports of cuttingedge technology from established producer countries. Competition in the international machine tool market is strong. This is also reflected in the fact that exhibitors from more than 40 countries will be taking part in EMO Hannover 2011. “However, the latest technical solutions alone are not enough today,” pointed Dr Schäfer. Technical products and services are becoming more alike. Finding a way to stand out is becoming more essential. He further added, “Machine tool suppliers are increasingly interested in showing what ‘more’ they are offering, than their competitors, in terms of machinery and related services, which can help users to meet their manufacturing challenges.” The event will present current developments in manufacturing technology, from single machines to production systems and complete manufacturing solutions. The show’s main focus is on cutting and forming machine

tools, manufacturing systems, precision tools, measurement technology, automated material flow, CA technologies, control and drive engineering and accessories. This appeals to professionals from every corner of the world. “A single visit gives them a complete overview. They meet all the important players in the industry at one time & place, and can directly compare what the relevant competitors have to offer,” added Schäfer. The focus of EMO Hannover 2011 is on sustainability and resource efficiency because machine tools are a key to reducing the environmental impact of manufacturing. This is especially important for the growing economies of Asia, South America and Eastern Europe, as well as established industrial nations. The machine tool industry is striving towards developing products and processes that allow machines to be designed, produced and operated sustainably. Reducing energy consumption by introducing new drive concepts, extending dry machining to other processes, using alternative cooling techniques and reducing emissions are at the centre of today’s concerns. Machine & process efficiency, service and sustainability will be the key topics at EMO Hannover 2011.

Tech Updates Your gateway to the latest trends and technologies worldwide

Millitronics CNC control accelerates speed

Roughing module increases material removal

Renishaw addresses manufacturing need

The company has recently introduced its new 8200 CNC control on its box way and linear way machining centres. The 8200 CNC is built on a robust realtime Linux based kernel, RTLinuxPro, which offers faster, quicker and greater

OPEN MIND CAD/CAM Technologies India has launched the new hyperMAXX® optimisation strategy for stock roughing. The high-performance roughing module is fully integrated in hyperMAXX® combined with optimal milling path. It increases material removal with minimum machining time and is fully automated. Its excellent feed rate makes fast & gentle climb

The company is highlighting a range of process control solutions that will help tackle the increasing drive towards Lean manufacturing, from new technologies for pre-process machine calibration, to online and offline post-process measurement. The new pre-process calibration tools from Renishaw include the QC20-W wireless ballbar, as well as the company’s latest advancement in fast 5-axis CMM measurement – the motorised PH20 probe head with ‘head touch’ capability. In addition to the convenience of wireless operation, the new QC20-W ballbar is the first calibration tool to allow testing in three orthogonal planes through

number of crunching capabilities. It has all user-friendly features, which Milltronics CNC controls are known for, viz, compatibility with all G&M Code programs plus macro programming, auto routines, trig help and benefits of conversational programming. The new ‘mill away’ function has been added for mid-program offset adjustment, which is especially helpful for 3D contouring operations in mould making. All electrical/ mechanical and programming manuals can be stored on the 8200 control for quick customer access. The new control has a state-of-theart user interface with wire frame and standard solid model graphic modes. The operator can select characteristics to tailor motion control performance for specific applications that demand faster speeds or smoother operations. The algorithm enables smooth application of half g acceleration, reducing cycle times in part programs with high-feed rates. Processing speed is 2,000 blocks per second. The company is offering two-year warranty on standard parts.

MODERN MACHINE TOOLS - March 2011

milling, and provides the basis for perfect cutting conditions. The new roughing module reduces wear & tear for both machine and tools. The high performance of hyperMAXX® is made possible by intelligent automated functions, which dynamically optimises both feed rate and infeed during 3D arbitrary stock roughing. It is beneficial for machining soft as well as hard materials like titanium, nickel-based alloys or stainless steel, which are hard to chip. It has two options for machining the ‘first opening’ cut, which is for full cut machining of areas that are difficult to reach. The ‘lateral cutting’ option enables opening via trochoidalstyle movements without complete cutting. It ensures maximum material removal and the fastest possible safe positioning of the tool, resulting in reduced machining time and more efficient production.

a single reference point. A single and simple hardware set up results in quick testing and the ability to produce a representative volumetric measurement of positioning accuracy. Also, the company is offering AxiSet™, a leading range of machine tool testing and calibration systems, with a new cost-effective solution for checking alignment and positioning performance of rotary axes. In only a few minutes, users of 5-axis machining centres and multi-tasking mill-turn machines will be able to identify & report on poor machine alignments and geometry that can cause extended process setting times, as well as non-conforming parts.

Ad Name: Ceratizit Pg No. 61 MMT Mar-2011 MMT Mar-2011

Ad Name: Ceratizit Pg No. 61

J P Machine Tools

MMT Mar-2011

Ad Name: JP Machine Pg No. 62

MMT Mar-2011

Tech Updates Reaming with adjustable hydraulic expansion chuck

Vardex tool increases tool life and productivity

Honing machine increases tool life

The DR reaming systems from Horn PH are setting new benchmarks in highprecision and cost-efficient reaming. The cylindrical MDR reaming insert holders is produced from either steel or hard metal with internal cooling. This sub-assembly is mounted on type DRHD adjustable hydraulic expansion chucks. It has simple concentricity adjustment of the insert in the machine or spindle, which is specially designed for holes from 11.9-35.6 mm. To achieve this, the DRHD hydraulic expansion chucks have four adjusting screws arranged offset by 90°. These screws can be tightened alternately, allowing correction of the shank’s concentricity to be determined by means of a precision measuring gauge, preferably on

The new VARDEX MilliPro from Vargus Ltd is able to avoid the traditional problem of in situ broken tools. It has high scrap rates, which is often associated with machining titanium. The new VARDEX MilliPro allowsone component to be produced after initial turning in a single setup. Designed for the creation of internal threads as small as M2x0.4, VARDEX MilliPro EL (Extra Long) features three flutes each having three teeth, and can

Sunnen’s new SV-410 automated CNC honing system delivers finest control of cylinder geometry, crosshatch and surface finish for superior ring seal, lubrication and power. The

the mounting shank of the reaming insert holder. Once the insert, which is ground to a diameter tolerance of up to ± 1 µm has been attached, it is tightened cross-wise on the face side using a torque screwdriver. The extremely rigid insert, just 4.3 mm thick, is aligned to the shank by a precision-ground, short conical clamping surface similar to the HSK. This simple and precise clamping process guarantees a consistency of concentricity of < 3 µm.

tackle applications of thread depths up to three times diameter. The overall length of the tool is much longer than the standard tool, therefore it has long access to provide much deeper holes. The MilliPro HD is equipped with TM Solid range for small threads from 2 mm (M2x0.4 - No 2-56 UN) in hard materials up to 62 HRc applications where conventional tooling typically breaks. MilliPro HD is designed with 4-6 flutes and two teeth – one tooth for roughing and the second for finishing. These features reduce the workload, and increases productivity. MilliPro HD is ideal to thread job, where taps typically break and for thread length applications two- and threetimes the diameter. These features reduce the workload and therefore increase tool life.

new automated CNC honing system provides performance builders and production rebuilders a new level of control for achieving precise cylinder geometry, surface finish and crosshatch parameters for superior ring seal, uniform lubrication, minimal leak down and highest horsepower. The new SV-410 is ideal for highnickel and CGI blocks. It allows engine builders to deliver customised results quickly, for consistent quality, high performance and long engine life. The flexibility of the system allows for in-line 4- and 6-cylinder engines, as well as all V-6/8 blocks. The automated CNC honing system utilises two-stage metal-bond diamond tooling therefore eliminating tool changes and completely finishing the bore surface with a plateaued finish. The straightness sensing capability provides a display of the bore profile during the cycle. Combined with a patented, servo stroking system, it allows the machine to auto-dwell in any part of the bore to correct straightness automatically in the shortest cycle time.

March 2011 - MODERN MACHINE TOOLS

Tech Updates Torch provides longer consumable life Hypertherm recently introduced its new Duramax Torch Technology for its Powermax1000® and Powermax1250® plasma system. The new Duramax™ torch series provides more durability and longer consumable life, while using their existing Powermax systems. It utilises new Conical Flow™ nozzle and spring electrode for longer consumable life. The Duramax retrofit torches are designed with the same Easy Torch Removal (ETR) connection as the standard Powermax1000 and Powermax1250 torches, enabling switching from the older torch to the new in just seconds. These retrofit torches utilise the same consumables as Hypertherm’s Powermax65 and Powermax85, allowing customers

with a mix of systems to simplify their consumables stock. In addition, Spring Start™ technology, a new patent-pending design, eliminates moving parts within the torch for greater reliability. The new torch series include more durability and longer consumable life, while employing their existing Powermax systems. The Duramax retrofit torches are available in either an ergonomic, 75o hand torch (HRT) or a 15-inch full-length machine torch (MRT). Similar to the standard Duramax machine torches, customers have the ability to convert the MRT into a 6-inch, short-barrelled machine torch perfect for robotic and pipe-cutting applications.

MODERN MACHINE TOOLS - March 2011

TAL manufacturing solutions launches breakthrough new products

Measuring system with exchangeable measuring surface

The company, a wholly-owned subsidiary of Tata Motors, has recently launched a new range of machines. The vertical machining centre – VM 300, V 450 RAPC, V 650 twin spindle and the 5-axes versatile production centre TAL Flexi Cut (5-X 700) are the new generation breakthrough technology machines, which mark a major milestone in the progression of the company’s world-class cost-

Blum-Novotest, a leading supplier of innovative, high-quality measuring and testing technology, has recently launched its new probe Z-Nano

effective technology offerings. The contemporary machine tools are designed to meet the most stringent standards of precision and other performance parameters. The VM 300 is most suitable for the new emerging and growing component machining industries in India. The machine is suitable for technical institutions, educational institutions, job shops, and first time CNC buyers. The TAL 5-axes Flexi Cut (5X-700) versatile production centre machine is based on the Parallel Kinematics (PKM) technology, from Exechon AB, Sweden. The machine brings versatile machining, and other production capabilities for most complex machining and various production requirements, with minimal or no setups, facilitating the production of complex components, where normally a multiple number of machines would have to be engaged in a conventional set up.

at IMTEX 2011. The compact tool measuring system is employed in CNC machining centres for automatic tool length measurement and breakage detection as well as for temperature compensation in one machine axis. The new probe is the further development of an approved system known under the identical name. It is equipped with exchangeable measuring surface, which allows worn measuring surfaces to be replaced by a new one. It has additional adjustment possibility by a spheric disk, which enables easy adjustment on the machine table. As all other tactile systems of Blum, the Z-Nano complies with protection class IP68 and functions with an optoelectronic measuring mechanism. During measuring, the trigger signal is generated by shading a miniature light barrier inside the probe. It can be mounted in vertical as well as horizontal orientations. Practically proven and optimised measuring cycles for all common control types are included in the delivery programme. Especially, for the production of large series, timeoptimised software is available, which enables fast tool breakage detection within 1-2 seconds.

Tech Updates CAMWorks increases productivity

Measurement system provides high precision

New machining technology ideal for micromachining

Geometric Ltd has launched CAMWorks® VoluMillTM, which is an optional milling toolpath engine for 2.5 and 3 axis roughing operations. It is ideal for prismatic parts and complex 3-D shapes as its algorithms result in more intelligent toolpaths to machine pockets, slots, and arbitrary shapes. CAMWorks® VoluMillTM can be used with any material and the result is increased efficiency and utilisation of machines, tools, labour and materials. VoluMill creates an ultra high efficient toolpath by exploiting the capabilities of modern machining hardware to control the material removal rate. Its unique approach to high speed material removal allows the programmer to determine the

The test and measurement system manufacturer Carl Zeiss launched CARMET II a high precision measurements system during IMTEX 2011. The new CARMET II has been optimised to ensure that the maximum measuring range is available for the specified machine dimensions. This is especially beneficial for the measurement of car bodies, car body parts and cast parts in the automotive industry, and also different workpieces

Electronica Machine Tools Ltd recently introduced a revolutionary machining technology ‘PECM-Precision Electrochemical Machining’. PECM is a similar concept like Electric Discharge

optimum material removal rate for any combination of part geometry, material, machine, and cutting tool. Material is removed in the most effective way possible. Electrodes for CAMWorks, is an optional module used to design electrodes for Electrical Discharge Machining (EDM). The comprehensive and easy to use interface, automates all aspects of the calculation and design of EDM electrodes including design, management, documentation and manufacturing.

MODERN MACHINE TOOLS - March 2011

in the power and aerospace industries. It is equipped with integrated controller which not only decreases the number of interfaces, but also simplifies installation and reduces system footprint. Optimal accessibility for easy and safe workpiece loading and unloading ensures a smooth process. The CARMET II guideway systems are protected in such a way that it practically eliminates contamination; also it can be tailored for individual need – in-the-floor or on-the-floor installation. Utilising the system as a dual-column measuring machine not only expands the measuring range, but it also reduces measuring times by more than 50 per cent. Its measuring range is from 4,000-7,000 mm. Flexibility and reliability, combined with affordability and precision, make CARMET II totally unique.

Machining (EDM) in which high current passes between an electrode and the part, through an electrolyte. However, there is no tool wear in PECM, and unlike EDM no sparks are created. It provides high speed metal removal along with no thermal or mechanical stresses being transferred to the workpiece, and mirror surface finish is possible. PECM can cut intricate contours or cavities in extremely hard steel or exotic metals such as titanium, inconel, hastelloy, kovar and carbide without any tool wear. PECM is able to machine any metal such as high-durable steel, hard alloys, cermets, nano-structured alloys, exotic metals like tungsten carbide, titanium, inconel, etc with great ease and zero electrode wear, hence as many as parts with the repeatability of ± 0.002 mm can be produced. Surface finish can be achieved up to Ra 0.001-0.1 µ. It is ideal for micromachining and can carry out machining in non-toxic and flame-proof mineral salt. The machine is equipped with ET-Eco-1 and eco-friendly automatic disposal system of wastes.

Sector Watch

Changing customer expectations and rapid model changes require a fast turnaround in the manufacturing of die & moulds. Currently, market demands require the ability to react to frequent product changes, shorter production runs, lower inventory levels and higher productivity. The die and mould industry in India has evolved with the changing times and is committed to deliver productivity within quality time.

Courtesy: Awanti Polymoulds Pvt Ltd

Hema Yadav & Nishant Kashyap

MODERN MACHINE TOOLS - March 2011

Sector Watch

o meet the challenges of market demand, a host of new technologies have evolved over the years. Apart from the conventional technologies like die sinking & wire EDMs the new generation manufacturing extensively utilises hard machining and complex profiling on multi-axis machining centres to completely finish the dies and moulds with little need for manual finishing and correction. Supporting these machining methods are new developments in design analysis, inspection techniques and complex programming systems. According to A S Agarwal, CEO, Abhijeet Dies and Tools, “Dies & moulds is an ever-evolving industry in India growing at a rate of about 15 per cent per annum. Broadly, plastic moulds and sheetmetal tooling constitute around one-third of the total demand and remaining one-third of the segment is covered by forging, casting and other types of toolings.”

The major factor in increased demand for high-precision equipment is continuously changing demands of shorter delivery linked to cost reductions expected due to shorter product life.

S C Kalyanpur,

President, TAGMA

solid carbide, mixed ceramic or Polycrystalline Cubic Boron Nitride (PCBN) With many components, the production process involves a combination of these options, and in the case of dies & moulds, it Demand drivers for dies and moulds industry

Aerospace Automobile Plastics Heavy machinery Nuclear energy Wind turbine Electrical and electronics

Tosher G Hormusjee, Managing Director, GW Precision Tools (I) Pvt Ltd, says that new technology and processes are aimed at productivity, both in the manufacturing of dies & moulds and in their design concepts. “With the increased usage of 5-axis machines, faster mould making is possible by reducing machining time. With the usage of new-generation multi-helix, variable pitch and selective tool geometry, flat end mills are fast replacing ball nose in 5-axis rough machining as this removes material with high depth of cuts. Also, new double radius geometry like GW 489, offers high stepover pitch; reducing peaks – thereby minimising stock for the finish cut,” he adds.

High-speed machining also includes time consuming hand finishing. This results in increased production costs and excessive lead times. Developing one or few tools of the same design involves a corresponding need of measuring and reverse engineering. The main criteria are quality of the dies or moulds regarding dimensional, geometrical and surface accuracy. If the quality level after machining is poor and does not meet the equipment there will be a varying need of manual finishing work. This work gives a satisfying surface accuracy, but it always has a negative impact on the dimensional and geometrical accuracy. One of the main targets for the dies & moulds industry is to reduce or eliminate the need of manual polishing and thus improve quality, shorten production costs and lead times. The development of new, more difficult-to-machine materials has underlined the necessity to find new machining solutions.

Traditional v/s automated method To reduce error & time and provide better productivity, mould making companies are bound to use 3-D CAD/CAM software systems in design and manufacturing.

Courtesy: GW Precision Tools (I) Pvt Ltd

S C Kalyanpur, President, Tool And Gauge Manufacturers Association of India (TAGMA) avers, “The major factor in increased demand for highprecision equipment is continuously changing demands of shorter delivery linked to cost reductions expected due to shorter product life.” Majority of the steel components are hardened to approximately 32-42 HRC. Currently, machining options include: Rough machining and semifinishing of the material in its soft (annealed) condition Heat treatment to achieve the final required hardness Machining of electrodes and Electrical Discharge Machining (EDM) of specific parts of the dies or moulds (specifically small radii and deep cavities with limited accessibility for metal cutting tools) Finishing and super-finishing of cylindrical/flat/cavity surfaces with appropriate cemented carbide,

Point angle

March 2011 - MODERN MACHINE TOOLS

Sector Watch

3D simulation not only eliminates errors, but also gives the manufacturer an opportunity to visualise the path and act according to fastest machining.

Tosher G Hormusjee Managing Director, GW Precision Tools (I) Pvt Ltd

Sectors like personal hygiene and medical are growing rapidly, driving demand for the industry.

A S Agarwal CEO, Abhijeet Dies and Tools

The traditional methods cannot meet the present customer requirements of quality and delivery time.” Computers have replaced drafters and drawing boards making the design easier, accurate, and faster. Hormusjee avers, “The role of software today goes hand in hand with the manufacturing industry. 3D simulation not only eliminates errors, but also gives the manufacturer an opportunity to visualise the path and act according to fastest machining. The output of dies is tremendously complemented as it reduces the trial &

One of the growing trends in the industry is the enhancements in engineering simulation and the evolving role of design optimisation. In the field of die design, precision metal stamping has gained considerable prominence in recent years. Kalyanpur is of the view, “Previous traditional methods were slow and difficult to handle the 3D profiles of the components. Moreover repetition of the same profile would differ, hence today they are obsolete, except for preliminary operation covering blank preparation and roughing operation.

$ million

9,000 7,800

8,000 7,000

6,500

6,000

5,400

5,000

4,350

4,000

3,500

3,000 2,000 1,000

Source: TAGMA

2010-11

2011-12

2012-13

2013-14

2014-15

Plastic moulds

1,283

1,578

1,957

2,387

2,937

Sheetmetal dies

970

1,183

1,455

1,761

2,113

Jigs, fixtures and gauges

321

391

481

587

704

Die casting dies

542

651

794

960

1,152

Forging dies, metal pattern and others

458

550

671

812

974

Expected growth rate - CAGR of 21.7 per cent between 2009-15 Figure 1: Future tooling demand - estimates

MODERN MACHINE TOOLS - March 2011

$ 1 = ` 45

error method and advances the scope of manufacturing and time taken for the output of a die or mould.” Tool & die makers are hardpressed to cut down on lead times and optimise the material/tool costs to compete in this demanding market. This has led to increased use of software solutions to simulate the outcome of the processes, long before the dies are built or even designed. Srinivas Kavali, Managing Director, Eqic Dies & Moulds Engineers Pvt Ltd is of the view, “Automation has changed the way companies used to work, as it has reduced the production time and manpower. New development of softwares like Pro-E, Catia and Solidworks provide better productivity, accuracy and efficiency.” Elaborating further, Agarwal adds, “Software is extensively used in the area of product design for conceptualisation and visualisation. This has opened limitless options for styling which has already taken centre stage in our life. Styling has even surpassed functionality, as more customers are choosing products based on styling features of product rather than its functionality or utility.” Software provides the full range of integrated modeling, simulation, visualisation, and communication tools that mould, tool & die manufacturers need to design for better products at fast rate and low cost. Kalyanpur describes, “Software has contributed in a big way in manufacturing dies & moulds continuously. The introduction of solid-based and feature- based machining system and tools like verifiers and simulations have improved the quality & productivity and helps in saving considerable time & efforts. The software focus is on the structural interaction of CAD & CAM information, thereby generating an integrated data and information model for the entire manufacturing process, from planning and preparation for NC machine.” As the industry evolves, the scope for

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Modern Machine Tools (Mar-11) Insert 6 Front -Pg 72

Sector Watch

Automation has changed the way companies used to work, as it has reduced the production time and manpower.

15% 13%

Srinivas Kavali, Managing Director

adopting automation is gradually rising, leading to greater adoption of automated machining.

Culture of stamping die Sheetmetal stamping dies are used to produce high precision metal components, which are identical in shape and size. Metal stamping dies are now integral part of any manufacturing industry as it provides high dimensional accuracy and stability. As the metal stamping component caters to every industry from small electric switches to large automobile and aircraft, the demand for high precision stamping component is rapidly increasing. Metal stamping dies can be used for various sheetmetal operations like, blanking, bending, shearing, piercing, forming, coining, embossing, extrusion, deep drawing, etc. Tool and die making is one of the most high precision engineering branches. It requires precision machinery and highly skilled workforce. Precision metal stamping dies need regular maintenance to ensure the quality of the components it produces. In normal cases, the maintenance works involve sharpening of cutting punches, replacing broken and damaged parts, working on dies to ensure the final stamped product meets all quality specifications of customers. With the systematic processes like preventive maintenance and consistent parts enhanced life of stamping dies can be achieved.

Global competition The technological development of emerging markets like India and China is leading international manufacturers

for setting up production base in these countries. For example, all prominent international car manufacturers are building up capacities locally and expect their suppliers to do the same. This holds true for manufacturers of dies and moulds as well. The Indian and Chinese toolmakers are one step ahead in their development - both as local suppliers or as a source for tools to be used outside India or China. In addition, more and more European toolmakers are evaluating the possibility of integrating India and China in their international strategies. “Emerging sectors driving the tooling industry are automotives, automotive ancillaries, consumer durables and packaging. In fact other sectors like personal hygiene and medical are growing rapidly too. More than 50 per cent of the tooling demand comes from automotive OEMs and ancillaries which still remains the main driving force,” says Agarwal. Although India and China are often mentioned in the same context, their market structures and strategy are different from one another. While China courts a dubious reputation in terms of quality, India has been able to retain its quality standards.

Future prospects Driven by domestic demand and the cost efficiency advantage of India, the die & mould industry in the country is expected to grow considerably and consequently generate stronger demand for advanced processing equipment, software, systems and cutting tools. According to the figures compiled by TAGMA (as shown in figure 1 & 2), the demand for tooling will increase in the coming years. Plastic moulds and sheetmetal dies

27%

36%

Plastic moulds Sheetmetal dies Jigs, fixtures and guages Dies casting dies

Source: TAGMA

Eqic Dies & Moulds Engineers Pvt Ltd

Forging dies / others Total = $ 2.95 billion

$ 1 = ` 45

Figure 2: Tooling demand - by type of tool

will lead the pack followed by jigs, fixtures, gauges, casting dies, and forging dies. Dies & moulds industry is helping enterprises in areas such as technological exchanges, economic co-operation, equipment procurement, market development, and expansion of trade. Kavali explains, “Automobile is the biggest caterer to the die and mould industry. Besides demand is rapidly increasing from aerospace, computer hardware and telecom industry. All these companies are still importing equipment from abroad. This is a challenge as well as opportunity for Indian dies and mould manufacture to deliver high quality product at low cost in future.” Despite the impact of the global financial crisis, India’s die & mould industry has maintained its growth momentum in recent time and has managed to maintain its status as one of the world’s top consumers and importer of machine tool equipment. Although, the country has become more proactive in procurement of foreign and private capital, the future market prospects of Indian mould industry still has large room for development.

March 2011 - MODERN MACHINE TOOLS

Courtesy: Jyoti CNC Automation Pvt Ltd

Industry Update

TURNING CENTRE

Powered by new-age tools and technology The demand for high performance and multi-tasking machines is compelling the machine tool builders to introduce new turning machines that are flexible, fast and accurate. Multiple tooling fits in turning centres for multi-tasking functions and capabilities to turn a wide range of job materials and complex contours with ease, efficiency and throughput. There are some of the features that have become popular in recent times. Rachita Jha

urning centres, until now meant simple turning, but with changing industry trends, it has been redefined as machines that offer more depth with a variety of application

MODERN MACHINE TOOLS - March 2011

for the manufacturing sector. Modern turning centres have moved away from a fixed machine with a particular standard design and workpiece application, to multiple functions in a single machine setup. These complete

Industry Update multiple operations in a single setup bring down per-piece cost significantly and that too with better accuracy, surface finish and minimum floor space utilisation. Thus, it is a customer-driven market in which constant development is required. The pressure is on the machine tool manufactures to deliver solutions rather than only a machine that can run faster, is more efficient and economical on energy.

High-powered machines

Tom Sangho Shin, General Manager – Overseas Sales Team, Machine Tools & FA BG, Doosan Infracore Co Ltd

On the other hand, for work requiring extreme accuracy, a Swissstyle lathe is often used. Shin elaborates, “The collet sits behind the guide bushing, and the tools sit in front of the guide bushing, 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 & forth along the Z axis.”

Demand curve Rapidly changing consumer tastes and shorter product life cycles are driving the demand for machine tools with greater flexibility. “Manufacturers need machine tools that are conducive to short changeover times for small-lot production. End-users are increasingly seeking machines capable of performing a range of functions with minimal setup times. Moreover, traditional transfer line technology is often being replaced by the technology incorporated in these flexible machines,” avers Shin.

Courtesy: Jyoti CNC Automation Pvt Ltd

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 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,” says Tom Sangho Shin, General Manager – Overseas Sales Team, Machine Tools & FA BG, Doosan Infracore Co Ltd. The part may be designed, and the tool paths programmed, the resulting file uploaded to the machine. Once it is set, the machine will continue to turn out parts under the occasional supervision of an operator.

Machine tool builders are developing new machining techniques to handle the increasing usage of alternative materials in place of traditional metal.

Turning centres have multiple functions in a single machine setup

MODERN MACHINE TOOLS - March 2011

Fast acceleration and deceleration also reduces the idle time for the machine. There is also a global demand for these machines. Elaborates Mihir Baxi, Director – Marketing, Jyoti CNC Automation Pvt Ltd, “We have seen a rise in demand for machines in turning technology segment like turn mill centres, vertical turning, compact twin chuckers with gantry robot, multitasking machines. Turn mill centres are now gaining recognition in a growing market like India, which was popular in Europe and the US. New concepts like machines inter-phased with automatic loading/unloading system such as gantry system or robots are a new choice for the industry, which enables least human interface and offers optimum results.”

Market trends The increased competitiveness of major consuming industries such as automotive and job shop is driving the demand for more sophisticated machines. End-users are investing in machine tools that offer increased performance, flexibility and productivity. “Turning centres have been, and will be the heart of any manufacturing industry, as almost all machines have parts that rotate, which are made in turning centres, making it an omnipresent manufacturing technology. Such a technology finds its presence in applications like automobile, which is one of the biggest users of these machines,” says Baxi. The computerisation of the industry is leading to rapid improvements in the existing machine tool product lines and the development of new products. Machine tool producers

Industry Update are introducing products with vastly expanded capabilities and significant improvement in precision. Moreover, increased emphasis is now on machine design to incorporate the new features and performance parameters in the most effective way. Digital drives and control enable 2-way communication over analog systems, resulting in improved resolution and slow speed control.

Turning centres have been, and will be the heart of any manufacturing industry, as almost all machines have parts that rotate, which are made in turning centres, making it an omnipresent manufacturing technology.

Mihir Baxi,

Director – Marketing, Jyoti CNC Automation Pvt Ltd

reasons, as the conventional machines operated manually became more or less unreliable.

Automation advantage The economic slowdown brought in the urgency for cost reduction and unmanned operation capabilities of machines on the shop-floor. CNC involves replacing human intervention with programmed application of CNC machines. It is similar to switching to autopilot mode to run the desired manufacturing processes. This innovation was developed for

Advantages of hard turning over grinding

Courtesy: Jyoti CNC Automation Pvt Ltd

End-users are investing in machine tools that offer increased performance and

MODERN MACHINE TOOLS - March 2011

A machine with high-dynamic stiffness Efficient work-holding devices A correctly chosen CBN grade or other tooling material types High-quality cutting edges Rigid tool mounts Appropriate machining parameters Part-piece rigidity Chip management and cooling systems

Possibilities are that conventional tools may cause instances when a worker’s efficient production in handling the machine may tire in the long run. This is when the growing demand for quantity is not met due to human factor, as fatigue may set in. It may cause failure in producing high-quality products. To remain competitive, manufacturers are now buying machines that give them world-class quality at lowest cost to company. “The main advantages of automation include reduction in human error so that quality control becomes easy & stable, and having no fluctuation. It increases the productivity by running full time. Automation system, especially robots, can work non-stop for hours and perform tasks that are beyond human capabilities of size, weight, speed, endurance,” says Narayan Kumar, General Manager, Hurco India Pvt Ltd.

As a pre-requisite to promise machine performance based on applications of high velocity and acceleration, the overall machine design must be carefully optimised to maintain part quality over extended periods of time. “Finite Element Analysis (FEA) software (to optimise casting strength to weight ratio) is now being employed by many leading machine builders to achieve the optimised frame design and create the best machine possible,” says Kumar. It has been undoubtedly the power of CNC software and automation applications that has brought in significant advancements in the turning centre efficiency and performance.

Toolings for multi-tasking The tools employed in the lathe, especially spindle, are the heart of the machine, as a point of machine performance and job finish. The selection of the right module configuration by the users allows them to run small-to-high volume production with the ability to transfer and change parts to complete the machining in one step. This significantly reduces operational expenses and cycle time. “Trends towards multi-tasking, utilising live tooling in lathes to complete parts in few setups, less time significantly increases efficiency over traditional mill and lathe machining cells, while at the same time increasing accuracy,” says Kumar. Carbide – a popularly used material – is available in a wide range of grades and coatings, and is intended to be best-matched to the application. Similarly, CBN cutting tools are available in several grades

Industry Update and likewise should be properly chosen as per the requirements. There is also a trend towards hard turning instead of grinding for hard grade steel and similar alloys. The advantages of shifting towards hard turning include low investments, micro finish, turn complex contours and execute multiple operations in a single step.

Going green

Narayan Kumar,

General Manager, Hurco India Pvt Ltd

Design optimisations in turning centres

Reduction in non-cutting time by increasing rapid traverse speeds reduce tool change time Small machines for space optimisation Concept of swarf removal system – to reduce operator intervention in production High-speed automatic component loading/unloading systems High accuracy and surface finish of machined parts Machine monitoring systems Machines enabling multitasking for minimum setups

has reduced labour requirements and increased up-time productivity & reliability of the machine. Moreover, using 400 V systems reduces current requirements,” avers Kumar.

Courtesy: Jyoti CNC Automation Pvt Ltd

Environmental concerns are factors that are now driving investment and research in new technology. “Many end-users are seeking machines that produce less waste and are less dependent on coolants and other fluids that have environmental and health ramifications. Machine tool builders are developing new machining techniques to handle the increasing usage of alternative materials in place of traditional metal,” says Shin. Among other tools, the usage of production-scheduling software offers the capability to have a lightsout production plan. In this, the machine runs largely unattended during the day. According to the job work schedules and the type of work being run, the lathe may run completely unattended at night. “The move towards ‘lights out’ machining

The move towards ‘lights out’ machining has reduced labour requirements and increased up-time productivity & reliability of the machine. Moreover, using 400 V systems reduces current requirements.

Machine tool producers are introducing products with vastly expanded capabilities and significant improvement in precision

MODERN MACHINE TOOLS - March 2011

He further adds, “Regenerative breaking systems on motors put power back into the line instead of being given off as heat through resistors; thereby conserving power. In addition, timers which power down the machine after a user definable period of time also save power.” ‘Lights out’ function is seen as providing additional turning capacity at no extra cost, and is an important factor that can help manufacturers shorten delivery schedules on certain jobs.

Future outlook The continuous advancement of multitasking machines with integration of 5-axis technology and turning technology in a unified turn-mill solution is an upcoming trend in the case of turning centres. Thus, the future outlook of turning centre is advanced design with better concept machines , which will suit applications and its interface with automation to become a reliable partner for advanced technology. “The combination of power, precision and accuracy delivers performance, which ultimately shortens cycle time and ensures optimum surface quality, accuracy and precision, along with longer tool life leading to lowering cost per component,” says Baxi. Infused with the ability to turn a wide range of job material with efficiency and throughput, these latest features have made CNC lathe popular in the recent times. In addition, arrival of powerful spindle drives have further accelerated the speed of roughening operations and fine surface finishing. These have revolutionised the role of tools in lathe machine market for turning operations.

MMT Mar-2011 Ad Name: Musumi Pg No. 81 MMT Mar-2011 Ad Name: Musumi Pg No. 81

MMT Mar-2011 Ad Name: Cosmos Pg No. 82 MMT Mar-2011 Ad Name: Cosmos Pg No. 82

Practical Insights Milling Turning

Grinding

Courtesy: Doosan Infracore Co Ltd

Process concentration/ high efficiency

Composition of element Machining speed/ upgrade the machining product

Reducing the lead time

Quick confrontation

High speed & high precision

Complex & multi-function

Big size & multi-function

INDIAN MACHINE TOOLS

Diversifying technology to maximise gains In recent years, customersâ&#x20AC;&#x2122; demands have been diverse, and relevant industry technologies are growing rapidly, requiring high precision and multi-tasking. Therefore, machine tool builders are focussing on being flexible & agile to meet diversified demands, and also in providing proper models fit for complex parts, through high speed, high efficiency, multi-axes and complex technologies. Jeongjin Kim & Tom Sangho Shin

urrently, systems are capable of machining complex forms requiring simultaneous control. These also prevent loss

in machining accuracy derived from dismounting and remounting a workpiece because once it has been mounted to the chuck, machining processes are executed

March 2011 - MODERN MACHINE TOOLS

Practical Insights without rechecking the workpiece. Eventually, multi-tasking machines make the concentration of production processes possible while it provides highly efficient machining of complex products at the same time. This leads to significant reduction in manufacturing cost and delivery time. Hence, multi-tasking machines continue to evolve and diversify further. Currently, large simultaneous 5-axis machining centres are attaracting customersâ&#x20AC;&#x2122; attention. Advanced multi-tasking machines also drive the software development.

Price-oriented machine tool

Courtesy: Doosan Infracore Co Ltd

Today, competition is fierce among machine tool manufacturers, which drives them to introduce different strategies for their products in two different markets represented by the conventional high-value machine tool market and the lowprice machine market. Low-price market is also important because of its volume.

Automatic machine light turns off: This is a smart function that can turn off the machine light automatically when no user touches the keyboard of operational panel during a specified time

MODERN MACHINE TOOLS - March 2011

Benefits of automation

The main advantages of automation are: Replacing human operators in tasks that involve hard physical or monotonous work Reducing human error so that quality control becomes easy and stable, no fluctuation occurs Replacing humans in tasks done in dangerous environments Increasing productivity by running full time Performing tasks that are beyond human capabilities of size, weight, speed & endurance Economy improvement. Automation may improve economy of enterprises, society or most of humanity. For example, when an enterprise invests in automation, its investment is recovered through technology

Conventional low-priced models based on the previous models were made with limited functions, the same machine structure with low part, or NC specifications. However, current models are revised from the reference models, which are attracting customers who want to buy affordable machines with basic functions fit for their products.

Environment-friendly machine tool Concerns about environmental issues are becoming more serious, and machine tools manufacturing is not an exception to this. Several manufacturers are now seeking the right way and solutions to reduce industrial wastage and save energy. The power saving function is designed to reduce the machine power consumption when it is not in use. The requirement is to reduce cutting fluid in mass production factories, because of high cost and harmfulness of coolant. Neardry cutting by utilising Minimal Quantity Lubrication (MQL) system makes it possible to machine with conventional cutting parameters without using much coolant. It reduces the amount of lubricant to nearly zero. Many advantages are realised through the usage of MQL and the reduction of cutting oil consumption. These include improvement of the plant

environment: improvements in chip recycling, reduction of electricity consumption, increased tool life, a green environment, and less machine maintenance due to contamination by coolant.

Trends and demands The computerisation of the industry is leading to rapid improvements in existing machine tool product lines and the development of new products. Machine tool producers are introducing products with vastly expanded capabilities and significant improvement in precision. The increasing competitiveness of major consuming industries like automotive and job shop are driving the demand for more sophisticated machines. End-users are investing in machine tools that offer increased performance, flexibility and productivity. Rapidly changing consumer tastes and shorter product life cycles are driving the demand for machine tools with greater flexibility. Manufacturers need machine tools that are conducive to short changeover times for small-lot production. End-users are increasingly buying machines capable of performing a range of functions with minimal setup times. Traditional transfer line technology is being replaced by the technology incorporated in these flexible machines. Major rise in demand for

Practical Insights

Courtesy: Doosan Infracore Co Ltd

front of the guide bushing, held stationary on the Z axis. To cut lengthwise along the part, the tools will move in and the material itself will move back & forth along the Z axis. This allows all work to be done on the material near the guide bushing where it is more rigid, making them ideal for working on slender workpieces, as the part is held firmly with little chance of deflection or vibration.

High-speed cutting Automatic machine sleep: If CNC operatorâ&#x20AC;&#x2122;s panel has not been used for sometime, the motors for spindle, servo axis, coolant pump and chip conveyor etc are powered off automatically. It is effective to reduce standby power

machine tools is coming from the job shop sector, which is expanding as a result of outsourcing by large manufacturers. The usage of high-speed machining technology is expected to grow steadily, as producers across the manufacturing sector face increasing pressure to improve accuracy, efficiency and productivity. Environmental concerns also are driving investment and research in new technology. Many end-users are seeking machines that produce less waste and are less dependent on coolants and other fluids that have environmental & health ramifications. Machine tool builders are developing new machining techniques to handle the increasing usage of alternative materials in place of old ones.

Turning centre A metal/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 linear movements of various cutting tools, such as tool bits and drill bits. The turning machines can be classified into various categories. First,

MODERN MACHINE TOOLS - March 2011

CNC lathes are rapidly replacing the older ones due to their ease of setting and operation. These are designed to utilise modern tooling. The part may be designed and the toolpaths programmed, the resulting file being uploaded to the machine. Once set, the machine will continue to turn out parts under the occasional supervision of an operator. For work requiring extreme accuracy (sometimes holding tolerances as small as a few tenths of a thousandth of an inch), a Swiss-style lathe is often employed. A Swiss-style lathe holds the workpiece with both collet and guide bushing. The collet sits behind the guide bushing, and the tools are placed in

CNC involves replacing human intervention with programmed application of CNC machines. It is like switching in an auto pilot mode to run the desired manufacturing processes. This innovation was developed because conventional machines that were operated manually became more or less unreliable. Possibilities are that conventional tools may face several issues such as instances when a workerâ&#x20AC;&#x2122;s efficient production in handling the machine may tire in the long run. This is when the growing demand for quantity is not met due to the human factor, as fatigue may set in. In the case of high-speed cutting, a large number of workpiece materials need to be cut, with fine, thin structure of the piece. In the current scenario of cut-throat competition, high-speed machining helps improve business responsiveness to market changes.

Jeongjin Kim is Director - R&D, Doosan Infracore Co Ltd. The company provides a comprehensive range of products, based on experience and a leading technology with rapid response services. Email: contact@doosan.com

Tom Sangho Shin is General Manager - Overseas Sales Team, Doosan Infracore Co Ltd. The companyâ&#x20AC;&#x2122;s machine tool division manufactures turning centre, machining centre, NC boring machine, double column machining centre and swiss turn EDM etc. Email: contact@doosan.com

Leaders Speak M S Arora has more than two decades of experience in the field of operations, marketing, export and management. He is the Managing Director of Birla Precision Technologies Ltd (BPTL), which comprises three companies: Birla Accucast Ltd, Birla Power Solutions Ltd and Zenith Birla (India) Ltd. Under his able leadership, the company has strategised an enviable position in the market. In a conversation with Hema D Yadav, the 47-year old B E (Mechanical) from REC, Bhopal, outlines future strategies for the company.

Product development is an integral part to innovate and upgrade to the next level of performance and productivity

MODERN MACHINE TOOLS - March 2011

Leaders Speak Q What is your take on the

current economic situation in India? The impact of slowdown on the industry in India was not as severe as in developed economies like Europe, Japan, the US, etc. The Indian economy has been on a strong growth trajectory in the last one year, mainly due to infrastructure spending by the government, boom in automotive industry, coupled with the growth of automotive component manufacturers. The increase in buying power of the consumers, especially the rapidly increasing number of Indian middleclass, is another important factor that contributed to growth in India. Hence, increase in productivity and machine tool automation have become the norm to supply more accurate & quality products at competitive rates to meet the requirement of highly aware/demanding customer.

Q What is the market

plants to upgrade technology and Tool Division (ITM) and tool-holder production capacities to service division) has been servicing Indian customers on time. Just-in-time and overseas customers for the delivery has become an important past 70 years. It has proved to be service to gain customer confidence. a partner in productivity for almost Thus, to meet this, we maintain all engineering sectors, and meets sufficient stock of raw materials the growing requirement of standard and finished goods at our plants & as well as customised tools for the branches. industry. Product development has been an integral part of the company – to innovate and upgrade Q The company has to the next level of performance and implemented Enterprise productivity. Resource Planning (ERP) on Indian Tools Manufacturers (ITM), a big scale. What have been for example, has manufactured the benefits of this? more than 10,000 different variety ERP-based working has become a of products, viz, drills, taps, reamers, part & parcel of BPTL. The Internet is milling cutters and tool bits in being utilised considerably not only various grades of HSS like M2, M35, for internal benefits such as better M42 T42, etc, which are popular for information flow & decision-making, its Dagger brand of cutting tools. but also as a marketing tool within Further, plants are also ISO 9001India and overseas. The ability to 2008 certified from TUV-RW. contact & sell one’s products across The company’s Tool-Holder the world and provide innumerable Division provides expertise in customer services with the click of a manufacturing a wide range of CNC mouse has become a reality. toolings and close dimension control products. Q What is the marketing

composition for High Strength Steel (HSS) tools, and how do you foresee the demand Q In terms of technology, what are the measures pattern? The demand for cutting tools being adopted to beat and tool holders has increased. competition? This has resulted in investments in sophisticated CNC machines, prompting a need for high-quality tool holders and compatible cutting tools. Although carbide cutting tools have been showing an increased growth rate, High Strength Steel (HSS) cutting tools have also registered a growth rate of 7-8 per cent. Market composition of HSS is still high due to the demand for reusable tooling in medium and low level industries, where major production activities are taking place in India using conventional machinery.

Q Brief us on the various

technologies and products offered by the company. BPTL (consisting of HSS Cutting

strategy adopted by the company to tap local as well as global markets? Our policy on quality says it all in a nut shell – ‘We shall strive to achieve customer’s satisfaction through continual improvements in timely delivery of quality products and services’. Dealer meets are frequently conducted to not only interact with them but also to impart hands-onknowledge at plants. Participation in exhibitions within India and in selective international markets has been one of the modes of increasing brand awareness.

The cutting tool technology has undergone various changes that match the rapid technological developments in machine tools, and to meet improved norms of productivity and quality requirements of the user segments. Different types of surface coatings and powder technology-based materials have been developed to meet the improved norms of productivity. We do routine benchmarking with the best brands, to continuously improve in process Q What are the factors areas, and upgrade state-of-theone needs to consider art technological inputs (CNC & while serving Indian and better controlled equipment). PIDinternational consumers? controlled heat treatment is a part of Indian consumers are still more this process. focussed on ‘best value for money’ Also, fresh investments have on an economical basis. However, been made in all manufacturing international consumers are more

March 2011 - MODERN MACHINE TOOLS

Leaders Speak Q Currently, China is a big

To cater to a diverse group of customers, a company needs to pay attention to industryspecific products, end-user support team, and provide online solution systems & helpline.

competitor to Indian cutting tool manufacturers. How can local manufacturers beat this competition? As per our information, Chinese drills were flowing into India in quite big volumes around two to three years back. But, this has reduced, possibly due to high cost on account of labour & steel, or due to quality issues.

inclined towards quality and delivery when there is a need to meet aspects. To cater to such a diverse delivery on time due to spurt in group of customers, a company demand are the lack of adequate needs to pay attention to industryinfrastructure, power shortages, poor Q What are your plans for specific products (tools designed logistics and the existing tax/octroi future growth in India? as per the need of particular structure. We are looking forward to strengthen applications), end-user support our technical expertise and conduct team, and provide online solution Q What is the need of the research of core markets. India systems & helpline. These help in is a hub for engineering goods/ hour for small & mediumbuilding oneâ&#x20AC;&#x2122;s brand and create an components, which will require sized companies? atmosphere for long-term business sources for uninterrupted supplies of Such companies constitute our relationship. cutting tools to meet market demand. consumer base. The first priority is In this direction BPTL has increased to tackle the lack of availability of capacities by heavily importing skilled manpower and the inability of Q What are the hurdles faced machines to meet the demand for small & medium-scale companies to by the company on the consistent quality products and justhold stock of raw material/Work-Ingrowth trajectory? in-time delivery. Progress (WIP) and finished goods. The immediate challenges, especially

MODERN MACHINE TOOLS - March 2011

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Modern Machine Tools (Mar-11) Insert 7-Pg92

Facility Visit

PREMIER LTD

Pioneering innovative excellence For over sixty years, Premier Ltd has been a pioneer of innovation in precision machine tool manufacturing. Located in Chinchwad, Pune, the company’s production facility focusses on its three core business segments – machine tools, heavy engineering and automotive. With about 0.5-1 per cent of its sales being invested towards Research and Development (R&D) in the machine tool division, the company has churned out several industry-pertinent processes in India. Nishant Kashyap

remier Ltd has been in the machine tool business for over six decades, offering comprehensive range of products to the automobile, public sectors and to almost all kinds of engineering sectors in India & across the globe. Known for its expertise and innovation, today the company receives enormous acceptance & appreciation for the quality and performance of its products across domestic & international markets. It possesses ISO 9000 certification since December 2003.

A fruitful journey Established in 1944, Premier Ltd (formerly know as the Premier Automobiles Ltd) raked in a companywide turnover of ` 172 crore in 2010. The estimated turnover for March 31, 2011, is around ` 250 crore. The projected turnover for 2012 is close to ` 500 crore. The company is on a steady growth track, garnering reputation in the engineering and automotive segments. Under its engineering segment, Premier has two functions – machine tools and heavy engineering

March 2011 - MODERN MACHINE TOOLS

Facility Visit – while the automotive segment comprises manufacturing of Light Utility Vehicles (LUV) and Sports Utility Vehicles (SUV). The stateof-the-art plant in Chinchwad is equipped with modern technology and skilled manpower. Spread over 27 acre, this plant serves as the centralised research, development and manufacturing facility for its various segments. The company’s machine tool division comprises a wide range of sophisticated CNC machine tools that include CNC gear cutting machines, machining centres, CNC vertical turning & turn mill centres and custombuilt special-purpose machines. D D Mulherkar, Vice President – Machine Tool Division, Premier Ltd, says, “This division of Premier, earlier known as Cooper Engineering, began its journey at Satara Road by manufacturing simple products like shaping and slotting machines. In 1961, we commenced operations at our Chinchwad plant, and with our expertise in machine tool manufacturing, we ventured into high-technology areas. We had two choices at that time: one to collaborate with foreign companies; the other to develop our own high-end products through R&D. We chose a combination of both, and between 1961 & 1970, we developed several new products through collaborations and on our

We will be investing more in R&D, in increasing capacity and launching new machines every year. Also, we are in talks with several global players for joint manufacturing.

D D Mulherkar,

Vice President – Machine Tool Division

own. In 1987, we became a part of the Premier Group.” The company believes in providing total solutions to achieve productivity and accuracy desired by the customer and customising its products to meet their various needs. The company has sophisticated technology centres at Chinchwad, Gurgaon & Bengaluru, and design centres at Pune & Bengaluru.

Design & technology centres Premier’s core strengths lie in its design and development capability, with a strong focus on innovation. The company’s design centre boasts of one of the most advanced R&D facilities in India. Premier’s highly sophisticated machines and experienced staff aid the company’s effort to improve productivity and efficiency. In keeping with the surging demand of the market, the company has intensified its R&D activities. “In Pune, we carry out a few developmental activities, along with improvising and customising our existing products, while major design developement takes place in Bengaluru. We have a

talented team that deals with machine tool design,” elaborates Mulherkar. These centres also function as technology centres (Pune, Bengaluru and Gurgaon), and are mainly utilised for showcasing new products and demonstrating machining operations. Training is provided to customers as well as the staff in these technology centres. Says Mulherkar, “At times, the customer wants to see the operation of a machine before purchasing it, so we carry out demonstrations of the component machining as required by customers. Also, we utilise these technology centres for sales and service activities.”

Product range Premier has a series of CNC gear cutting machines, machining centres, CNC vertical turning & turn mill centres and custom-built specialpurpose machines. The PHA, PHB and PHC series of gear hobbing machines are developed for auto component manufacturers and the engineering industry. The PTA, PTB and PTC series of vertical turning lathes are mainly designed to cater to the machining of components such as valves, pumps and wind mill/power generation components, defence and railway components. The company’s vertical and horizontal machining centres are cost-effective, suitable for tool rooms, automobile component manufacturers and the engineering industry.

Foreign collaborations

The plant is equipped with modern technology and skilled manpower

MODERN MACHINE TOOLS - March 2011

Premier has been in collaboration with global leaders since 1941 for technical proficiency, which has helped the company become the pioneer in introducing many machines in India. In the past it has technical collaborations with

Facility Visit Premier’s overseas tie-ups to promote their products in India Associate

Country

Range of product

MORARA

Italy

Heavy duty cylindrical grinding machine

IMT

Italy

Surface grinding, internal grinding, vertical grinding

Colgar

Italy

Horizontal boring and milling machines, gantry type planomillers and shearing presses

MCM

Italy

CNC heavy-duty horizontal lathe

FACFASPAR

Italy

Coil processing equipment

Rafamet

Poland

Surface wheel lathes, under floor wheel lathes

global leaders such as Hermann Pfauter Gmbh, Schiess, Hitachi Seiki Co Ltd, etc. Recently, a few other overseas companies such as MORRARA, Colgar, IMT, Rafamet have also entered into tie ups with the company to promote their products in India. “Such steps help stay abreast with technology and the global market. We are associated with MORARA from Italy, with whom we will be collaborating for a manufacturing activity in India,” says Mulherkar. “We have also entered into an agreement with Poland-based Rafamet for making certain railway-related machinery. During IMTEX 2011, we entered into a formal agreement with an Italian company, Colgar for horizontal boring machines. The initial agreement is to sell its products in India with a long-term objective of

manufacturing these as well,” avers Mulherkar. The company has recently opened an ‘International Machine Division’, which is focussed on selling foreign products in India.

Pioneer in machine tool business Owing to its expertise and foreign collaborations, Premier has constantly updated its technology. The company has to its credit the launch of several new technologies in India such as CNC gear hobbing, gear shaping, gear shaving, CNC vertical lathes, machines, machining centres, etc. At IMTEX 2011, its gear shaping machine, featuring helical path generation without helical guide, bagged the FIE Foundation Award for innovative technology.

The company’s core strengths lie in its design and development capability

MODERN MACHINE TOOLS - March 2011

States Mulherkar, “We are pioneers in several areas of manufacturing. We spearheaded CNC machine building in India. The gear shaving machine, which we displayed at IMTEX 2011, is manufactured only by us in India.” Premier attracts the best engineering talent and conducts training programmes for ITI and diploma students. It recently donated ` 2 crore to the College of Engineering, Pune, from where the company inducts promising students into its workforce. The company has also offered CNC machines to the production engineering laboratory of this college, so that students can avail practical knowledge and be ‘floor ready’ from day one after joining the company.

Expansion plans With a vision to provide the best technology solutions and to grab opportunities in India & abroad, Premier Ltd is in an expansion mode. Looking at the growth potential in the Indian market, the company is planning to continuously invest in R&D to reduce costs and improve productivity. Sharing his future outlook for the company, Mulherkar avers, “Machine tool is a sector that comprises a lot of design activities. We will be investing more in R&D, in increasing capacity and launching new machines every year. Also, we are in talks with several global players for joint manufacturing.” For 2011-12, the company’s capex in machine tools is planned at approximately ` 25 crore; and company-wide, it will be approximately ` 50-70 crore. Premier Ltd is one of the few companies that focusses on investing in technology. Most of the technology being developed is on par with international standards, which reflects in its determined commitment towards excellence in manufacturing. With the support of a modern manufacturing facility, the company is now leveraging its capability to tap emerging markets in the country and planning global expansion.

Design Corner

3D DESIGN

DFSDFSD

Moulding the future After a number of internal reviews to better understand the process bottlenecks, operator skill levels, etc, a plan was put in place to reassess the tooling requirements, train the operators on the latest software developments, and move towards fully automated 2D machining through the usage of Vero’s Compass Technology.

ased in the West Midlands, UK, MNB Moulds is a toolmaker that specialises in multi-cavity, highly accurate hardened steel tools, primarily for the automotive, medical and electrical markets. Established in 1974, MNB has a turnover of approximately £ 1.2 million and produces 50-70 moulds per year. Its list of customers includes Eaton Corporation, Honeywell, M K Electric Co and Cable Management Group, etc.

Stepping up productivity Frank Ryan, Managing Director & Owner, has always invested in

MODERN MACHINE TOOLS - March 2011

the latest machinery & CAD/CAM technology, and has implemented the VISI product suite from Vero Software since 2002. Detailing how the software is being utilised, Ryan explains, “We have been using the software extensively for 3D tool design and complex machining. However, when machining bolster plates, 2D design information was being passed to the CNC machines for MDI input. This process was labour-intensive and open to manual operator error.” He further adds, “I have visited a number of toolrooms across Europe, especially Germany, where my eyes were opened to what is possible

Design Corner waste, milk cartons are certainly in the spotlight. Britons consume 9.3 billion pints of milk every year – and only one in four plastic milk bottles are recycled. The remaining three reaches landfill, creating unnecessary waste. The JUGIT 2D plate machining automated using Compass Technology project is aimed at those concerned through the usage of specialised about the associated environmental technology. The goal was to make impact. Consumers need to buy the company more productive, one jug, then bags of milk to fill the so we invited Vero to study our unit. This concept is new in the UK, manufacturing processes to see but has been available elsewhere how it could help. We achieved for some time where milk sold in tremendous success by improving bags is already a regular choice for our quality and efficiency over the 60 per cent of consumers in Canada, years, with a particularly significant Poland, South Africa and China. The step in productivity in the last twelve JUGIT milk bags are made from months. This is in large part, down strong low-density polyethylene and to the investment we have made in use 75 per cent less packaging than automating our 2D machining and, standard plastic bottles. standardising on an integrated CAD/ CAM solution.” The company was already a happy Vero customer, but recognised that some of its manufacturing processes could be improved to maximise productivity. Not only did MNB implement the additional software, but also moved onto a network licence to provide extra flexibility within the toolroom. Ryan explains further, “Now, everyone has access to the data; the designers and machinists together can develop a clear plan as to how the tooling would best be manufactured. This includes incorporating multiple inserts into one block that can be rough-milled, hardened, ground and wire cut into individual parts – unattended.”

Saving resources The advantages of the software consolidation can be easily identified in a recent project for an environmentfriendly milk dispenser. With a firm focus on ways to reduce packaging

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Four-impression spike tool for JUGIT milk dispenser

MNB has developed tooling for a number of components including a two-impression tool for the handle, a two-impression tool for the lid, a fourimpression tool for the spout spike and an eight-impression tool for the clamping mechanism. Focussing on the four-impression spike tool, Ryan explains, “The complete tool was designed, cut and built within a 1,000-hour window. The implementation of the Compass Technology has resulted in a 20 per cent increase in our machining productivity and reduced the need for detailed tool drawings as setup sheets are generated automatically for all toolpaths. Just for this single tool, we have saved approximately 60 hour of machining time alone. If we roll out these productivity improvements throughout a typical year (10,000 machining hour), an excess of £ 60,000 per annum is expected to be saved.” The complete spike tool project can be broken down into 160 hour for design, 300 hour for CNC milling (bolster, cavities & electrodes), 250 hour for grinding, 150 hour for spark erosion, 60 hour for wire EDM and 280 hour on the bench.

A complete solution According to Ryan, moving to an entirely integrated solution had an important impact on the business as well as better synergy across personnel. “The improvements in 2D machining have also saved the cost of one of the turret mill operators who recently retired and whose work has been absorbed within the CNC milling section with the additional capacity created. Vero continually develops products that cover the design and manufacturing needs of a toolroom, and has firmly established itself as an integral part of our future,” he concludes. Courtesy: Vero Software Ltd

MMT MAR-2011 AD NAME:DIJET PG NO. 101 MMT MAR-2011 AD NAME:DIJET PG NO. 101

MMT MAR-2011 AD NAME: BHAVYA PG NO. 102 MMT MAR-2011 AD NAME: BHAVYA PG NO. 102

Manufacturing Excellence

CNC MACHINES

Notching up speed Good things come in small packages or, in the case of JK Engineering, small spaces. However, what the precision engineering subcontractor lacks in floor space, it more than makes up for in business acumen, which is why its workshop is bursting with the very latest manufacturing technology, including DMG CNC machine tools equipped with a variety of Renishaw touch probes and tool setters.

John Kenny, with specialised parts produced on DMG DMU-50 VMCs

K Engineering, located in Hertfordshire, north of London, is owned and managed by John Kenny, an apprenticed CNC machine operator with a background in aerospace and F1 engineering. The seeds for JK were planted during Kenny’s stint at Red Bull F1, in its earlier incarnation as Stewart Grand Prix. Thanks to an unplanned change in his personal circumstances Kenny took the plunge and invested a property windfall in starting his own venture.

“In time honoured tradition, I woke up one day and decided it was now or never,” he remembers. “I handed in my notice at Stewart, bought several second hand machines and went looking for business.”

Starting with less complex work With his feet planted firmly on the shopfloor, Kenny realised that he would not be doing a great deal of his work for his former employer. Not at first, that is.

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Manufacturing Excellence Once we had this, I went back to Red Bull and offered our services.” According to Kenny, many precision engineering machine shops find it difficult to cope with the unique demands of an F1 client such as Red Bull F1. “Much of the work we undertake is small batch or one-off parts and Jobs are loaded onto the DMG DMU-50 machines on small components; the kind of pallets and require multiple tool changes thing that puts off a lot of companies. We have been successful for two main reasons: First, we do whatever we must to get the job done on time and to the right quality standards. Second, just as importantly, we utilise the latest Renishaw tool setting technology to minimise set-up times and to get the maximum productivity from our machines. This is Manufacturing parts for Red Bull F1 requires JK Engineering to adopt a unique approach vital if one wants to make a profit on such lowvolume work.” In the case of the company’s two, “I did not have the equipment to 5-axis Deckel Maho DMU 50 CNC work for the likes of an F1 team. The machining centres, JK uses Renishaw technology one needs to do a good OMP40 spindle touch probes and job – 3D CAD/CAM software, 4 & fixed Renishaw NC4 non-contact 5 axis machines, etc are incredibly laser tool setters; the latter was expensive. There is little help for quickly and easily fitted to the DMG start-up firms. I had to find other, less machine by a member of Renishaw’s complex work, just to pay the bills.” UK engineering team. JK’s bread-and-butter came in the shape of dental and medical components for the likes of the Coping with multiple tool Royal National Orthopaedic Hospital; changes income that still constitutes a healthy “Jobs are often loaded on the DMU’s percentage of the company’s on small pallets and frequently require current turnover and helps to even multiple tool changes, sometimes as out the wild swings inherent with many as 30,” explains Kenny. F1 revenue. He further addes, “We employ the Renishaw OMP40s to quickly establish the part datum, then we The move into multi-axis utilise the NC4 to automatically set “We did a lot of simple, three-axis the tools and to monitor for tool work that paid the bills and enabled breakage during the program. The us to slowly replace the older consequences of a machine left machines with multi-axis equipment.

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running unmanned with a broken tool would be nothing short of disastrous. Material is ridiculously expensive, and getting more so all the time. We are using a lot of titanium and aerospace grade alloys so we do not want scrap and, given the very small quantities and tight deadlines, we cannot afford to be running a job twice.”

Upgrading every piece of machinery In the seven years since Kenny started JK Engineering, he has replaced almost every piece of machinery and software with the latest equipment. Today, it houses two state-of-theart DMU machining centres, a Haas VF-2 Super speed VMC with 4 axis and two CNC Colchester turning centres with driven tooling. To generate the CNC programs, 3D Open Mind HyperMill CAM system is available. And, to stay on top of finished part quality, a clean room inspection area is available – everything JK needs to keep its demanding F1 client happy. “Having the equipment is only part of the story. Using it effectively and efficiently is vital,” said Kenny. JK aims to keep everything running as much as possible. The Renishaw equipment allows the company to minimise unproductive set-up time, avoid costly errors and deliver a good quality product on time. “In the future, we plan to buy machines with even more tools, so set up and monitoring becomes increasingly important. It is not rocket science,” he says. He further adds, “On the contrary, the Renishaw equipment is easy to use. I know other companies that have invested in a similar combination of machine & probe technology to do similar work and they are successful, too.” Courtesy: Renishaw Plc

Case Study

PRECISION ENGINEERING

Crucial investment for subcontractors Providing high-precision engineering services to a range of demanding sectors such as aerospace, defence, medical hardware, pump & food processing industry, systems integration and automation equipment, as well as motorsport, Flexible Machining Systems (FMS) ensures its machine tools are safe with NC program verification software from CGTech. Praveen Koti

orsham-based FMS is currently a supplier to the medical, aerospace and defence sectors, which includes scheduled work released against contract requirements. The company recently received AS9100 approval and is intending to expand its customer base within these sectors. Although commercial engineering jobs are undertaken by the company, it is predominantly

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equipped to machine highprecision parts. A significant capital equipment investments have been made during the past five years, in updating machining centres and turning capacity together with inspection. Majority of the milled components produced by the company are programmed offline. This high-precision job is supported by a robust IT infrastructure running market-leading software such as Vericut from CGTech.

Case Study CGTech modelled all machines for FMS, providing a virtual representation of every machining centre. As some of the 3-axis vertical machining centres can be fitted with a fourth axis rotary unit, these have also been modelled to cover every production scenario.

A perfect model

Vericut protects multi-axis machine tools from potential collisions

Ensuring the right codes Peter Smith, Technical Support Manager, FMS, explains on the three distinct but entwined software steps of the company, “We are utilising SolidWorks CAD and OpenMind as our CAM system to create NC cutting tool paths. These files are transferred to Vericut where we verify the CNC code for the part before performing the machining operation.” Where 3D models are issued, FMS imports the customer data in STEP format. If the company is issued with 2D drawings, it always builds a 3D model to work from. The model is passed seamlessly into the CAM system and the NC code is transferred to Vericut. “This ensures that we have set up the part correctly in the CAM system, and that we will machine it correctly. We complete a virtual reality machining operation through Vericut, and if there are any mistakes in the program, the software will find those, and highlight what exactly is wrong. It will tell us if we have taken too much material off or if further material needs to be removed,” avers Smith.

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The company builds the manufacturing process from the CAD system and gathers all data needed in the software. Every cutter and toolholder employed by the company is held in a database with around 4,000 combined variations. These can be selected in the CAM system and the tooling data is transferred into Vericut. All datum points are also taken across and issued as part of the machine setup procedure. FMS has been utilising solid modelling for over 10 years and Vericut for around five years. As the components produced by FMS have become more complicated, the need to prove that the job is right when it leaves the CAM office has evolved. “With jobs becoming more complex, we need Vericut to prove that we have done it right, because one can miss bits and the software will pick it up every time. In fact, the software is so well thought of that one of our aerospace customers insists that all their parts go through Vericut, and they will monitor and audit us on this requirement,” states Smith. Machining complex parts was the reason for a recent investment in a Mazak Variaxis 5-axis machining centre. Smith elaborates, “The multi axis machine can perform five-sided machining operations. And, sometimes we can finish a part in a single setup using special fixturing and snap tags. We installed

the CAM system to support the 5-axis machine tool, and had to have the post processor written for the machine. To prove the post processor, we run it through Vericut, and if an error was identified, it could be corrected – using Vericut allows one to see exactly what is happening. This worked well because all problems with the post were found straightaway. Vericut ironed out all of the issues within the post processor.” One of Peter Smith’s responsibilities is making the company more efficient by getting the most out of machine tools. As far as he is concerned, multiaxis machines are the way ahead, machining parts in few setups and operations. He further confirms, “If one is using multi-axis machining techniques, Vericut is crucial. It minimises the risk of having a collision. It is much easier to correct it virtually in the CAM system than face the problems associated with an actual collision.”

Changing the course No milling programs are manually edited at FMS and any changes are made in the CAM system and reprocessed by Vericut to confirm the changes are correct in the machine. “We are eliminating as many errors as possible upfront. It is much more efficient for a business to run a verification process, and Vericut is the best one available. The CAM system offers verification but it does not check the G code of the actual program. Vericut is driven by the actual NC program so every motion is a response to the driving code and the software will act exactly as the machine will, which makes a huge difference,” concludes Smith.

Praveen Koti is Country Head, CGTech India. The company specialises in Numerical Control (NC/CNC) simulation, verification, optimisation, and analysis software technology for manufacturing. Email: info.india@cgtech.com

Modern Machine Tools (Mar-11) Insert 8 - Front-Pg 111

Modern Machine Tools (Mar-11) Insert 8 Back-Pg112

Expert Zone

Production

Sales

WORK

Sales

Production

PLAN

Suppliers

Accounts

Enterprise

Accounts

Purchasing

Suppliers

Purchasing Warehousing

Warehousing

Courtesy: Sescoi India Solutions Pvt Ltd

Customer

ERP SOLUTIONS

A boon to projectbased companies Enterprise Resource Planning (ERP) integrates diverse data and processes of a business into a unified system or process. The system is a natural evolution of Material Requirement Planning (MRP) systems, and Manufacturing Resource Planning (MRP2) systems, which have a major focus on supplies and materials required for the manufacturing process. Vageesh Muthya

epending on the business, there can be many different ERP processes to integrate, for example: estimating, resource management, accounting, inventory management, cash flow, cost analysis, invoicing, order entry, job tracking, etc.

Estimating and quoting For most small to medium-sized project based manufacturers, business begins with quoting or estimating a particular job. This is often an area where significant ‘opportunity costs’ exist. Often, the most experienced people are the ones who make the quotation. For example, in a

mould shop, an experienced mouldmanufacturer may be responsible or have input for making all quotations. Traditionally, several quotations are made before one materialises into an order, with the experienced mould-maker involved in all steps. Every minute that an experienced manager or employee spends making a quotation, is one less minute spent on production. This is an opportunity cost the business does not have to accept: if this process could be streamlined and simplified, managers and employees could spend more time directly on activities that support the bottom line.

March 2011 - MODERN MACHINE TOOLS 113

Expert Zone One way to streamline the process is to utilise a software module for making the quotation and estimation. Another important way to streamline this process is to have historical data readily available. Often, one quote will be similar to a previous one or job. Utilising historical data as a template, particularly data from previous profitable jobs, can not only streamline the quoting process but also ensure that the quotation is set at the right level. This captured data can be utilised even further and placed with calculations into spreadsheets to accurately calculate costs and hours for a particular job.

data about the model to make the quotation as accurate as possible, and to do that an integrated CAD data ‘analyser’ is vital. For instance, using the volume of the part, and applying a specific density, the weight of the final part can be determined. From knowing the volume of the part, and the stock block size, the amount of material to be removed can be identified. Distinguishing varying thickness can help determine how to fixture parts. Knowing the smallest radii on the part will help determine tool sizes for manufacturing, and so on.

Streamline and track paperwork Analysing data

Courtesy: Sescoi India Solutions Pvt Ltd

Manufacturing departments and job shops start the estimating process by first analysing the part that has to be manufactured. In some cases, this may involve loading the geometric CAD data. Being able to load standard file formats such as IGES and STEP is important, yet it may also be necessary to load popular native CAD system files such as Unigraphics or Catia. Many people often confuse a CAD Viewer with a CAD Analyser. The two are not the same. It is important that the person doing the quoting be able to gather

Once a quotation is accepted, a company will usually receive a purchase order. The ERP system should have an automated way of converting the quote into an order. Keeping track of all paperwork associated with a job right from the start can save countless hours later trying to find missing documentation. Raw materials and other necessary components can be ordered from the quote turned job order. Having a document manager within the ERP system will give users the ability to quickly find all files associated with a particular job and quote – be they files of the original CAD data, purchase

orders, invoices, shipping labels or emails and sign-offs associated with the job. Additionally, tiresome paperwork processes can be streamlined and automated. All job-related invoices, shipping labels, confirmations and other necessary documents can be automatically generated, printed or e-mailed.

Integrated job tracking and scheduling Often the small-scale business owner is also the manager, scheduler and salesperson. This person may spend a significant part of his or her morning’s work checking the status of each job. Add in interruptions, and it may not be until mid morning or lunch when decisions are made and actions taken, by which time these are based on hours’ old data. Having a real-time display of job and task status, at any time of day, allows the manager to make adjustments to keep processes moving smoothly. Naturally, the status can be checked any time during the day but also, if a night shift is in effect, it can be checked from a computer at home. Spending a few minutes using simple scheduler software can get any job on track from the start. By setting a preferred finish date, and scheduling backwards with simple drag and drop functions, managers will be able to create information that can easily be shared with the employees. This can keep downtime, while people wait for their next job, to a minimum. Utilising job tracking functions to compare real status to what was forecast in the initial quote or job, managers can know at a glance what is on track and what is not in terms of costs; both for time spent and for purchased materials. The manager can see at a glance whether the company is making money on a job, or starting to lose money.

Working with subcontractors Job summary

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Often a company will have to send certain work to a subcontractor or third

Expert Zone party. Tracking and managing portions of the job that are subcontracted are just as important as tracking internal jobs. Will the subcontracted elements be delivered on time? What has the particular subcontractor’s track record been so far? Will the company’s own jobs be ready at the same time as the subcontracted jobs?

Working with legacy data Many companies utilise simple office products such as Microsoft Word® and Microsoft Excel® in the beginning. Often, a lot of useful data is contained within those spreadsheets. This data may include costs for processes, profit margins, rates for machine operations, etc. It does not make sense to force a small business to re-enter all data into a new job management software package. Proficient and easy-to-use job management software will allow users to utilise the data from existing spreadsheets. This data can be used to get a user productive with their new management software faster. Similarly, companies may already have print templates in Microsoft Word®, prior to installing an ERP. If the ERP is capable of using those pre-existing templates to print, this will save a lot of time during the configuration phase.

Communicating with other systems Sharing the status of a job in progress with the customer is often part of the service process. It may be necessary to output job status into a file format usable by the customer, without giving away proprietary and special customer data. The file format to share information may be a simple Microsoft Office® product like Microsoft Excel® or something a little more detailed like Microsoft Project®. In either case, the small business should be able to share job status with their customer, without giving away company confidential information.

Include accounting or utilise third-party software? Although, there are many advantages

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in implementing a job management or ERP system early on, the reality is that there are many companies that have not. However, these companies have usually purchased and are already employing an off-the-shelf accounting system. Many complex ERP systems have accounting as a built-in function and module. Other systems may function in conjunction with third-party or off-the-shelf accounting packages. Many of these third-party accounting packages include an API, an application programming interface, to allow ERP and job management systems bi-directional communication with their system.

Room to grow for mid-sized manufacturers Is the ERP system chosen for the small to mid-sized business suitable for the larger enterprise? Is the underlying database structure powerful enough to handle a large number of customers and suppliers? These are important considerations when selecting an ERP system. When starting out, a company may simply use quoting, job tracking and analysing functions. As the company grows, it may want to add products like bar code readers or touch-screens for automatically entering and tracking time data. Perhaps eventually, it would like to add modules for inventory management, quality management or cash flow forecasting.

Choosing an ERP or job management system When choosing a programme on which to base their business management processes, the following are just some of the criteria a company should consider: Security: How secure is the database, and how can a company limit access

to certain data to different employees? The software should include controls for limiting functions and data by the user. Maintenance: What is required for maintaining and providing back-up to the database? The simpler maintenance is – more time people can spend on core company work. Ease of use: Any employee should be able to be trained on the basic functions in a short amount of time. Company behind the software: Does the software developer understand the market? How long has it been in business? Modules: Are the necessary functions available, either in the core product or in modules? However, the most important aspect to consider is whether the system can grow as the company grows. It would be expensive and time consuming to replace one system with another just because the original was unable to grow at the same pace as the company.

Conclusion ERP systems are not just for large businesses. Utilising ERP or job management systems can bring benefits to small and midsized companies. Real costs and opportunity costs increase the longer a company postpones implementing a job management solution. Choosing a small system that can grow as the business grows can make practical sense. This involves looking at systems with easy-to-use interfaces and a modular structure. In all cases, companies with projectbased activity must employ an ERP solution specifically designed for this purpose.

Vageesh Muthya is ERP Business Head, Sescoi India Solutions Pvt Ltd. The company specialises in the development of advanced easy-to-use Computer Aided Manufacturing (CAM) software and Computer Aided Design (CAD) software, as well as manufacturing ERP, job shop software and job costing software for custom manufacturers. Email: india@sescoi.com

Factory Fundamentals It has been our persistent effort to provide incremental value to our readers with ‘cuttingedge’ information. As a part of this endeavour, we have this feature - ‘From Modern Machine Shop’, in an exclusive arrangement with the premier metalworking and machine tool publication in North America. Modern Machine Shop (MMS), published by Gardner Publications, US, offers exceptionally high editorial features and circulation standards that have become a hallmark of its operating philosophy and worldwide reputation. We strongly believe that the information provided in this feature will keep our readers updated about the latest global developments in business strategies & technological innovations, the quintessential ingredients for competitive manufacturing.

CAM features facilitate ﬁve-axis ‘Hog-outs’ A point of pride for MAC Machine is its ability to take on projects others would not touch. Recently, capabilities within Mastercam CAM software enabled the company to overcome challenges with a difficult aerospace component and, more significantly, to bring in new, similar work.

In addition to winning Matsuura’s 2008 International Five-Axis Machining Competition, developing a process for this complex aerospace part enabled MAC Machine to take on similar components that help customers avoid the expense of replacing or repairing aging casting tools

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t will not be long before Randy Barbe, Lead Programmer, MAC Machine, gets the latest release of his CAM software. His dealer will call him a couple of weeks before it comes out to give him a heads-up on some of the features that will be most useful for his shop, MAC Machine. Once the upgrade comes in, he will spend some time with it almost every day, working through the examples and applying the most promising tool paths to existing jobs, until he has a good idea of how it will be able to help him. Management at MAC Machine encourages Barbe to spend time exploring the advanced capabilities of the shop’s software and equipment because of the sophisticated nature of its business. The company specialises in advanced machining, primarily for surgical implant systems, medical diagnostic equipment and military & commercial aircraft components & assemblies. The ability to take on

projects that others might not consider is a source of pride for the shop, and the difference that new CAM software features and capabilities can make in this endeavour is far from trivial.

The winner takes it all Such was the case in 2008, when Barbe first got his hands on Mastercam X4 (developed by Tolland, Connecticutbased CNC Software) just in time for the software to help him solve a difficult aerospace part manufacturing issue. More significantly, the new software capabilities Barbe mastered to machine that part would come in handy later on similar components, which have since become a new specialty for the shop. Characterised by deep, thin-walled, sculptured cavities, the complex part would have to be machined from a single billet of aluminium. To do so, the shop would need a way to securely hold the thin walls and accurately control the long, slender

Factory Fundamentals

The part was machined on a five-axis Matsuura MAM72-63V with a program created in Mastercam X4 and verified using CAMplete TruePath software

tools needed to reach deep inside the cavities. With help from CNC Software and Matsuura dealer Methods Machine Tools (Sudbury, Massachusetts), Barbe developed a precision CNC machining process using a five-axis Matsuura MAM72-63V multi-pallet system. High-stock-removal tool paths were applied to the CAD model in Mastercam and later imported into CAMPlete TruePath software to verify and optimise the process before machining. The customer was pleased with the result, as was Matsuura, which named the shop the winner of its 2008 International Five-Axis Machining Competition. That project was the first in a line of similar components the shop would produce, a breed of parts Barbe refers to as ‘Hog outs’. These complex components are typically cast because of their inherent machining difficulties, but casting tooling often breaks or wears out before they are ready to be retired. That leaves the manufacturer with the prospect of continually repairing aging tools or purchasing new ones at a cost that might not be recovered for many years.

The ‘path’ ahead

Both award-winning aerospace parts shown here and other ‘Hog-outs’ are characterised by deep cavities that can cause tool clearance issues

MAC Machine offers its customers the cost-saving alternative of hogging out the parts from full billets of material. In fact, a number of customers are now having the shop develop machining processes for parts produced using old casting tools long before those tools go bad. This is a win-win scenario – the customer does not have to worry about fronting money for tooling used for parts entering sunset territory, and the shop does not have to worry about casting deliveries. Moreover, the customer can make design modifications to parts without worrying about rebuilding the tooling. The key to profitably producing such parts is the usage of tool paths that can remove large amounts of stock quickly. Barbe says the shop’s first ‘Hog out’, the award-winning part, would have been difficult to machine without Mastercam’s five-axis tool paths. “The timing worked out well because that is when CAMplete came out with their version 4, and Mastercam included advanced multi-axis tool paths in its new release. If it were not for those tool paths, I would have had a real struggle with that part. The whole algorithm is useful,” he recalls. He further adds, “If the tool path does not initially perform the way he wants it to, he can work in solids to clean up, change surface blending or otherwise manipulate features so that the CAM software can generate a cleaner tool path.”

Improved results

Mastercam’s Dynamic Milling tool paths include a microlift feature that retracts the tool a small, user-defined distance rather than fully retracting from the pocket. This minimises air cutting and keeps the tool engaged with the part for as much of the machining routine as possible

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Barbe also cites a number of other CAM software features as helpful in the high-stock-removal machining required for ‘hog outs’: Microlifts: Included in Mastercam’s 2D Dynamic Milling tool path, which is used for pocketing, the microlift feature retracts the tool by a small, user-defined distance (perhaps 0.01 or 0.02 inch) instead of fully retracting from the pocket when the program calls for a move. This minimises air cutting and improves productivity by keeping the tool engaged with the workpiece as often as possible during machining.

Monitoring for climb milling: The software monitors and adjusts tool engagement to avoid excessive stress on the cutter,

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Factory Fundamentals

particularly when it arrives at a corner. Reduced engagement prevents slamming into corners and damaging the tool or workpiece or dislodging the part from the fixture. This is particularly effective for climb cutting, in which tool rotates in the same direction as it feeds. Fixture design: Barbe uses the software’s CAD module to design fixtures that both hold the part securely and present it at the unusual approach angles required to minimise steps during multiaxis machining. Simulation: Barbe can visualise parts, fixtures and tool paths within the same CAM programming environment. The software’s Verify feature provides a colour-coded representation of how much material has been removed at a given stage of manufacturing. He saves this as an

STL file so that he can use it again without regenerating it. “We save the STL files and manipulate them for the next operations,” he explains. “By the time we are done, we have a visual model of a completed part. We use these files to find gouges, nicks and inapppopriate toolpath overlays.” Backplot is another frequently used simulation feature. This provides Barbe with a computer animation of all tool movements and a close approximation of actual machining time. These capabilities have improved results on the shop floor, Barbe says, citing faster setups, faster cycle times and fewer tool breakages and machine crashes. “We have been relying on it so much that we brought in a second programmer, and now we need a third,” he notes. Although he has not yet seen another part as complex as the

After the program is completed in Mastercam X4, it flows into Camplete Truepath Software for verification and high precision optimisation prior to being posted

original, award-winning ‘hog-out’, Barbe says he could produce another such component in about half the time. Regardless, the new software capabilities he mastered for that part have saved the company a great deal of money by increasing productivity on other, similar projects. In the end, the time spent learning was well-invested.

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Factory Fundamentals

Milling, turning machine line supports versatility Ziaja Machining Corporation relies almost exclusively on Milltronics machines for its milling and turning operations. The machines’ easy-to-use, conversational control, reliability and capacity for tight tolerances help support the versatility the shop needs to stay competitive.

uring the past 30 years, George Ziaja has become well-known in the Milwaukee area for his ability to solve tough process improvement problems. That personal reputation has also become a hallmark of his shop, Ziaja Machining Corporation (ZMC). The shop touts a track record of not only producing quality parts, but also aiding customers in revamping product designs to improve productivity and cut costs.

Troubleshooting methods With few repeat jobs, Ziaja and his employees get plenty of chances to

The Milltronics RH12 rigid-head bed mill proves out a part for a sausage making machine

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exercise their penchant for problem solving. While this keeps the shop busy, pursuing such a wide variety of work also presents challenges. Flexibility is key to maintaining a competitive edge, and for that, the shop relies in large part on its fleet of Milltronics turning and milling machines and their conversational controls. Based in Plymouth, Wisconsin, ZMC is a hybrid – a mix of lowvolume production machining and dies & tools manufacturing. The shop specialises in stainless steel and plastics. Components for the food industry, especially sausageand cheese-making enterprises, constitute approximately 60 per cent of its business. The rest consists of a smattering of components for machines in other industries, including laser cutters, printing machines and machines used to produce such paper products as diapers and toilet-paper. Ziaja, the company’s founder, has worked in the industry since he was 16 years old. After completing his apprenticeship at the machine shop where he spent the early part of his career, he learned to work in almost every position and to operate every piece of equipment. He eventually moved into a supervisory role and went on to become General Manager/ Sales. As that shop’s focus shifted to large, commercial accounts, he saw an opportunity to launch his own company to target smaller businesses

Factory Fundamentals – accounts that would be inclined to form a partnership and grow together. Since 1995, ZMC has done just that, and the majority of its new business comes from customer referrals.

All in a day’s work

Equipped with an indexing tombstone, ZMC’s Milltronics HM20 horizontal machining center is a timesaver for a wide variety of jobs

A closer look at the indexing tombstone in ZMC’s Milltronics HM20 HMC

Here, an operator machines stainless steel sausauge stuffers on the Milltronics ML18/40 combination lathe. The shop recently added a second ML18 equipped with an automatic turret to improve production on high-volume turning work

In a single day on ZMC’s shop floor, one might see machine guides for laser cutter components being machined; steel tables being fabricated and welded for a food processing customer; plastic bearing sleeves being processed on a cylindrical grinder; sausage stuffing horns being turned on a lathe; angle plates for a diaper-making machine being milled and drilled on an HMC; and foodgrade plastic paddles for the cheese industry being refurbished. To take on such a variety of jobs, the shop’s 28 employees employ a full range of grinders, presses, saws, hobs and welders. The bulk of the milling and turning work falls to 14 machines from Milltronics (Waconia, Minnesota), a supplier on which ZMC has relied almost exclusively for the past 13 years. A prime reason for that commitment is the easy-to-use, conversational programming included in these machines’ CNCs. At ZMC, programming from the shop floor is more practical than using a CAM system, which would be both costly and insufficient for supporting the versatility necessary to keep up with its variety of work, Ziaja says. “With the volume of parts we turn out every day, I would need two or three dedicated programmers,” he explains. “Some jobs take maybe 15 minute or a half hour, and these controls are so easy to program that we could have two or three of those done before a CAM programmer could get even one job out to the floor. For those jobs that do repeat, we can store the programs offline and reuse them when we need to.”

Faster, the better

This MC20 is ZMCs first Milltronics machine. Known as ‘The Beast’, the machine still plays a role in the shop’s operations despite being in service for more than a decade

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Through a menu-based question-and-answer format, the CNC prompts the operator for job information and automatically creates the program at the machine from the entered data. The usage of Auto Routines enables operators to program without knowledge of G or M codes, while a ‘Trig Help’ feature eliminates the need for shop floor calculations. The interface is designed to minimise keystrokes to avoid potential typos and missed operations. Also, programs can be edited and multiple tasks can be accomplished from a single screen. “One does not have to go through a lot of different menus; it is all right there in front on one screen,” Ziaja says.

Factory Fundamentals He further adds, “With other conversational controls I have utilised, sometimes one has to go to a page ahead or a page back, so the Milltronics control is much easier.” He adds that another benefit of standardising on Milltronics is that all controls employ the same basic interface, which eases the training of new hires. “I can send practically any operator to any of the machines. The lathe operations are a little different from the HMCs and VMCs, but it is basically the same control, so it does not take too long to train anyone.” The control’s verification features also come in handy, Ziaja says. In addition to a graphical representation of the tool proceeding along the programmed paths, which helps the shop ensure accuracy and avoid collisions or other problems, verification is especially useful for estimating the time it will take to perform any given job. “I was out of town recently, and on my way back, I called my son and said ‘put this print in there and see how long it will take for this part to run,’” he recalls. He further adds, “He called me back in about five minutes with an answer.”

A supporting hand Intuitive programming could go only so far if the machine itself were not sufficiently accurate, but that is not a problem at ZMC. The shop routinely machines parts to tolerances as tight as ±0.0002 inch. In addition, Ziaja says the machines are reliable enough for him to expect almost 100-per cent productivity from each model. “They are well-built, and unscheduled downtime is insignificant,” he notes. He further claims, “In fact, we still have our original MC20, which dates back to 1997. We call it ‘The Beast,’ and it can still be a workhorse.” The most recent additions to the shop’s Milltronics family include an RH33 and an RW18, both VMCs, as well as an ML18 combination lathe. These machines were incorporated after the shop purchased another nearby company. The timing was fortuitous, as the shop has recently begun to take on more large, fabricated parts that need to be milled and drilled as well as high-volume turning work (ie, 100 to 200-piece runs). The RH33 VMC has been invaluable for large work, Ziaja says. With X-, Y- and Z-axis travels of 78 × 33 × 28 inch, the machine is the biggest on the floor. It enables the shop to machine longer parts in one setup, rather than shifting them within the work envelope or moving them to a different machine. Likewise, the ML18’s automatic turret – an option the shop’s other ML18 lacks – improves productivity for the new turning jobs. The next time the shop seeks to expand its range of machines and capabilities, it will likely turn again to Milltronics, Ziaja says. “The machines are priced reasonably, reliable and easy to program,” he adds.

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Factory Fundamentals

CAM system simpliﬁes Swisstype lathe programming To reduce setup times, Biomet Sports Medicine medical device manufacturer replaced its conventional CNC turning and milling machines with Swiss-type lathes. However, taking full advantage of these complex machines’ capabilities required another investment – Esprit CAM software from DP technology.

olving one problem sometimes leads to another unexpected challenges. Medical device manufacturer Biomet Sports Medicine experienced this domino effect firsthand when it moved operations from conventional CNC milling and turning centres to Swiss-type lathes. While the switch eliminated the need for multiple setups on multiple machines, programming difficulties prohibited the company from taking full advantage of its capabilities. That is, until Biomet invested in Esprit CAM software from DP Technology (Camarillo, California). The new CAM system has eased programming to the point where the company has reduced cycle times on most parts by at least 50 per cent. “Esprit makes it easy to move

The components shown here are part of Biomet’s CurvTek system, which is designed to cut tunnels into bone for suture attachment

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operations from one spindle to the other and evaluate the resulting machine performance. Also, the ability to visualize machining operations helps avoid crashes and gives us ideas for improving the process,” says David Fransden, Machine Shop Lead, Biomet Sports Medicine.

Three setups at one time Biomet Sports Medicine, a subsidiary of Biomet Inc offers more than 3,000 products for the $ 1.2 billion worldwide arthroscopy market. The company mainly focusses on technique-specific devices for Anterior Cruciate Ligament (ACL) reconstruction and arthroscopic shoulder repairs. Products include rotator cuff and labral repair implants, which are available in a range of designs, materials, sizes and suture configurations. The company also offers a range of instruments for placing and securing sutures. Manufacturing operations for these devices are located in Ontario, California, where Fransden works. Capital equipment is manufactured at another facility in Redding, California, and the company is headquartered in Warsaw, Indiana. Fransden cites the manufacturing process for a typical suturing device as an example of why the company endeavoured to implement Swisstypes. This particular part once required three setups on a machining centre as well as wire EDM operations

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The company says Esprit’s simulation capabilities are especially useful for getting a clear picture of operations on its CurvTek components and other small parts

Combined with Esprit CAM software, the company’s Citizen E216 Swiss-type lathes have significantly reduced setup and cycle times compared to the conventional CNC machining equipment they replaced

With Esprit, Biomet developed a new process for producing its Harpoon suture anchors. These parts previously required three machining centre setups and profile cutting on a wire EDM. Now, they are produced in a single setup on a Citizen E216 Swisstype lathe

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to cut the profile. Moreover, finishing required deburring by hand. Now, the part is produced in a single setup via milling interpolation on a Swiss-type’s C axis, a process that eliminates the need for hand deburring. As a result, the company has saved $ 40,000 per year. “We can now produce the entire part in less time than it previously took only to wireEDM the profile,” Fransden says. However, the very attributes that make Swiss-types advantageous created programming difficulties when the machines were first installed. Consider the new process for the aforementioned suturing device. After drilling a face and contouring the profile, the machine employs a corner-rounding end mill to break the edge. It then transfers the part to the sub-spindle to machine the back side. While this process is more efficient, it is also more complex. In fact, with multiple milled and turned faces, a typical part produced at Biomet might require writing three CNC programs to control as many as nine machine axes. These programs are linked together through sync codes, wait codes and queuing commands, which co-ordinate the motion of the machine’s multiple axes and enable operations to run together or independently. Programmers were utilised to manually writing G code for turning and milling machines, but this method constrained the company’s ability to take advantage of the Swisstypes’ benefits. That is because the new machines offer more options for how to machine a part, and the way programs co-ordinate different operations has a major impact on cycle time. After identifying a method – which involves considerations ranging from determining whether to hold a part in the guide bushing or subspindle

to evaluating the merits of thread milling versus single-point threading tools – programmers must determine how the cycle will flow. This also involves careful consideration of a number of factors. Explains Fransden, “Should the main spindle and sub-spindle work simultaneously? Should we perform turning and drilling on the main spindle and a secondary operation on the sub-spindle at the same time? These decisions are important because if one spindle finishes first, it sits idle waiting for the other one to catch up. By employing manual programming, we could only guess at which method would be more efficient.”

All in one package With Esprit CAM software, the company has the tools it needs to make intelligent decisions and get the most out of the Swisstypes, he says. Framsdem saus that with just a few mouse clicks, they can reorder operations, move them from one spindle to another and sync them so they start at the same time. He cites a new process he developed for a suture anchor as an example of these benefits. With a sharp point at one end and a small diameter at the other, the part requires turning, grooving and back turning, as well as milling interpolation for the eyelet oval pocket where the suture attaches. Although the previous process produced quality parts, setups were long and difficult and tool life suffered, Fransden says. In the new process, the pointed end of the part is machined first. The narrow point prohibited the sub-spindle from gripping the component at this end, so he equipped it with a basket to catch the suture anchor after cut-off from the barstock. This approach usually leaves a nub on the back side of the part where the cut-off

Factory Fundamentals Add-on features Considering the inherent complexity of Swiss-type operations, the software’s simulation features are especially useful for machining with confidence, Fransden says. In fact, the ability to simulate the cycle is key to successful programming of some parts. One example is a cam-driven bone-drilling bit made of 465 stainless steel that measures 0.078 inch With two spindles and a number of tool stations, the company’s Swiss-types can perform both turning and milling operations in diameter and 0.112-inch to produce parts in one setup. However, these capabilities long. By the time Fransden also make programming the machines more complex than took over the project, traditional CNC equipment one programmer had struggled for three months to program the part manually using G operation occurs, but he avoided that code. With Esprit, Fransden was able problem by employing a live faceto go from a solid model to a good milling tool to cut almost all the way part in only a couple of days. through, and then using a parting tool to separate the component. As “The part and the tools are small, so a result, cycle time dropped from six it was difficult to visualise what was going minutes to one. on,” he explains. “A little turned shoulder

136 MODERN MACHINE TOOLS - March 2011

past the cutting edge is particularly troublesome. If a lead-in or lead-out is a thousandth of an inch or two off, the tool will gouge that shoulder. I tried different lead-in and lead-out angles and zoomed in on the simulation to make sure there was enough clearance.” Another time-saving feature is the Esprit NX reader, an add-on that reads files from Siemens PLM’s NX CAD software without the need to convert them. Drawings are simply stored on the network and pulled up when needed. Programmers also take advantage of the ability to save tool information in the software’s tool library, from which it can be dropped easily into future programs. In the future, the company plans to invest in Esprit’s knowledgebase, which automatically applies saved machining operations to features. “Multifunction machines provide the potential for substantial productivity improvements, but they require substantially more complex programs. Esprit helps us take full advantage of these machines’ capabilities,” Fransden concludes.

Events - National

CHENNAI

AHMEDABAD

PUNE

INDORE

Tamil Nadu Mar 11-13, 2011

Gujarat Oct 14-17, 2011

Maharastra Nov 18-21, 2011

Madhya Pradesh Jan 6-9, 2012

Chennai Trade Centre

Gujarat University Exhibition Hall

Auto Cluster Exhibition Centre

Poddar Plaza, Nr Gandhi Hall

Indiaâ&#x20AC;&#x2122;s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumactics, Process Machinery & Equipment, Automation Instrumentation, Packaging For details Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022 3003 4651 Fax: 022 3003 4499 â&#x20AC;˘ Email: engexpo@infomedia18.in

DIEMOULD India 2011 International exhibition for industries including dies & moulds, press tools and machine tools; April 7-10, 2011; at Chennai Trade Centre, Chennai For details contact: Tool & Gauge Manufacturers Association of India (TAGMA) A-33, NandJyot Industrial Estate Safed Pool, A K Road, Mumbai Tel: 022 2852 6876, 2850 8976 Fax: 022 2850 3273 Email: mumbai@tagmaindia.org Web: www.tagmaindia.org

BLECH India 2011 The event will be focussing on industrial technology, sheetmetal working, handling, cutting, forming, automation and robotics; April 14-17, 2011; at Bombay Exhibition Centre, Mumbai For details contact: Inter Ads - Brooks Exhibitions (India) Pvt Ltd Plot No 859, Phase-V, Udyog Vihar Gurgaon, Haryana Tel: 0124 475 1600 Fax: 0124 475 1601 Email: blech.india@iabex.com Web: www.blechindia.com/english

AutomationExpo 2011 The event will highlight automation in industrial process, factory & building, systems and solutions;

138 MODERN MACHINE TOOLS - March 2011

April 21-23, 2011; Chennai Trade Centre, Chennai For details contact: Intel Trade Fairs & Expositions Pvt Ltd 113, New Sonal Link Industrial Estate Link Road, Malad (W), Mumbai Tel: 022 28803977 Fax: 022 28819008 Email: intelexpo@vsnl.net Web: www.intelexpo.com

InterMachinery India The 5 th edition of InterMachinery India will be showcasing machinery & equipment, which will be attended by a large number of international exhibitors; June 9-11, 2011; at Bombay Exhibition Centre, Mumbai For details contact: Worldex India Exhibition & Promotion Pvt Ltd, 309, Parvati Premises Sun Mill Complex, Lower Parel, Mumbai Tel: 022 4037 6700 Fax: 022 2496 2297 Email: info@worldexindia.com Web: www.intermachineryindia.com

Plot No. F/11 & F/12, Camlin Fine, WICEL, Andheri (E), Mumbai Tel: 022 3201 9137 Fax: 022 2832 4404 Email: sales@focussedevents.com Web: www.focussedevents.com

MetEx India 2011 International exhibition on metal, metallurgical technologies, equipment and service; September 22-24, 2011; Bangalore International Exhibition Centre, Bengaluru For details contact: Koelnmesse YA Tradefair Pvt Ltd B 501/502, KEMP Plaza, Mind Space,Chincholi Bunder, Malad (W), Mumbai Tel: 022 42107804 Fax: 022 40034433 Email: n.seth@koelnmesse-india.com Web: www.metex-india.com

IA India International trade fair for process & production, automation and industrial building automation; December 6-9, 2011; Bangalore International Exhibition Centre, Bengaluru For details contact: Hannover Milano Fairs India Pvt Ltd B-303, Dynasty Business Park Andheri- Kurla Road, Chakala Andhrei East Tel: 022 40050681 Fax: 022 40050683 Email: info@hmf-india.com Web: www.ia-india.com

CeMAT India Internation trade fair for material handling and logistics; December 6-9, 2011; Bangalore International Exhibition Centre, Bengaluru

Automotive Engineering Show International exhibition on technologies for automotive manufacturing; June 10-12, 2011, at Chennai Trade Centre, Chennai For details contact: Focussed Event Management Pvt Ltd

For details contact: Hannover Milano Fairs India Pvt Ltd B-303, Andhrei (E), Mumbai Tel: 022 40050681 Email: info@hmf-india.com Web: www.cemat-india.com

Events - International BLECH Russia

PMTS 2011

SHEETMETAL ASIA 2011

The event, an ideal platform for decision makers and business partners within the sheetmetal industry in Russia, will focus on sheetmetal machinery, tools and service; March 15-17, 2011; at Pavilion 7 of Lenexpo Vasilievsky Island, St Petersburg, Russia

An international event on precision machined parts manufacturing; April 1921, 2011; Ohio, USA

The 15th international exhibition will showcase the latest developments in sheetmetal fabrication technology and machinery; May 12-15, 2011; at Bangkok International Trade Exhibition and Convention Centre (BITEC), Thailand

For details contact: Mack Brooks Exhibitions Romeland House Romeland Hill St Albans, UK Tel: +44 1727 814 400 Fax: +44 1727 814 501 Email: info@blechrussia.com Web: www.blechrussia.com

MTA2011 The event will focus on the technology and quality required to machine parts and components in metals and composites; March 23-26, 2011; at Singapore Expo, Singapore For details contact: Singapore Exhibition Services Pte Ltd 1 Jalan Kilang Timor 09-02 Pacific Tech Centre Singapore Tel: +65 6233 6638 Fax: +65 6233 6633 Email: mta@sesallworld.com Web: www.mta-asia.com

MATERIALS HANDLING 2011 International event on material handling equipment; March 30-31, 2011; Birmingham, UK For details contact: easyFairs UK Ltd 3rd Floor, Regal House 70 London Road Twickenham, UK Tel: +44 (0) 20 86 22 44 11 Fax: +44 (0) 20 86 22 4412 Email: uk@easyfairs.com Web: www.easyfairs.com

140 MODERN MACHINE TOOLS - March 2011

For details contact: Gardner Management Services 6915 Valley Avenue Cincinnati, Ohio, USA Tel: +1 800 950 8020 Fax: +1 513 527 8801 Email: allison@gardnerweb.com Web: www.pmts.com

JAPAN METAL STAMPING TECHNOLOGY EXHIBITION 2011 The exhibition will highlight the latest technologies in metal stamping, press forming machines, forging press machines and accessories & tools for forming machines; April 20-23, 2011; at Tokyo Big Sight, Japan For details contact: Japan Metal Stamping Association Shiba-koen 3-5-8 Kikai Shinko Kaikan 212 Minato-ku, Tokyo, Japan Phone: 3 3433 3730 Fax: 03 3433 7505 Email: jmsa@nikkin.or.jp Web: www.nikkin.or.jp

For details contact: UBM Asia (Thailand) Co Ltd 503/23 KSl Tower, Sri Ayuthaya Road Thanon Phayathai, Rajathewee Bangkok, Thailand Tel: +6600 2642 06911 Fax: +660 2642 6919-20 Email: info@sheetmetal-asia.com Web: www.sheetmetal-asia.com

Blechexpo International trade fair for sheetmetal processing, June 06-09, 2011, Stuttgart, Germany For details contact: P E Schall GmbH & Co KG Messeunternehmen Gustav-Werner-StraĂ&#x;e 6 D-72636 Frickenhausen Tel: +49 7025 92060 Fax: +49 7025 9206620 Email: info@schall-messen.de Web: www.blechexpo-messe.de

Chongqing Lijia International Machine Tool Exhibition The 12th west Chinaâ&#x20AC;&#x2122;s leading international exhibition will showcase the latest development and technology in the industry; May, 11-14, 2011; Chongqing, China For details contact: Chongqing Nanping Development Road, International Business Building, No. 31, Cole 28-5 Chongqing, China Tel: +86 23 86376088/311 Fax: +86 23 86376323, 86308310 Email: chinawmte@gmail.co Web: www.cwmte.com.cn

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

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DFSDFSD

The seed and spark of development With the machine tool industry back on the growth path and experiencing chock-a-block order books, IMTEX 2011 & Tooltech 2011 were brimming with enthusiasm and positive demand. Moving at full speed, visitors from various manufacturing domains across the country thronged the event in droves. Hema Yadav

he buzz surrounding IMTEX 2011 & Tooltech 2011 was amply justified. The events, hallmark of the best in the machine tool industry, not only catered to the expectations but also raised the bar quite high. The euphoria at Bangalore International

144 MODERN MACHINE TOOLS - March 2011

Exhibition Centre (BIEC) was palpable and contagious as one of the mostawaited events of the year IMTEX 2011 opened its door for the connoisseurs of the metalworking domain.

Inaugural ceremony IMTEX

2011

showcased

ews i V rs’

Report

ito

ib Exh exhaustive range of innovations and technological refinements in the complete product segment of metal cutting machine tools. Along with IMTEX 2011, the Indian Machine Tool Manufaturers’ Association (IMTMA) also held a concurrent fair, Tooltech 2011. The inaugural ceremony was attended by industry stalwarts. Welcoming the august gathering M Lokeswara Rao, President, IMTMA, said, “IMTEX is not just a trade fair, but an opportunity to reinforce relations and form collaborative partnerships. The current edition is unique because for the first time in India, digital factories with Enterprise Resource Planning (ERP) packages are introduced in the machine tool industry. Also, machine manufacturers are replicating ideal shop-floor conditions in the exhibition for consumers to experience the machines in working condition.” Chief Guest for the occasion Arun Maira, Member, Planning Commisson, Government of India emphasised on the need for effective partnership between policy makers and the industry, “The time has come for the Indian machine tool industry. Think long, broad and clearly. Many stakeholders have to be taken along for the implementation of this objective. The private and public sectors together can achieve the goal, looking at the future prospects and needs of the country. The goals can be achieved through execution of seven key thrusts.” The seven points to achieve desired growth level as mentioned by him: Overcoming the deficiency of infrastructure by clustering Planned urbanisation and managing industry growth Better governance and simplification of procedures Developing skilled workforce, fairness in employment and creating a sensitive and flexible work environment Learning and assimilation of technology

There were more quality-conscious visitors whose enthusiasm was visible, indicating future growth opportunities. To meet the growing market demand, we were showcasing our latest technologies/products, which generated good interest. This proved to be an ideal platform to meet our existing customers, potential customers and competitors, at the same place.

L Krishnan,

Managing Director, Taegutec India Pvt Ltd

The industry is passionate about this event. Managing directors and important decision-makers of OEMs visited us. Since IMTEX is a launch pad for new products, we displayed our latest technologies. Some of the latest machines came with capabilities such as better speed, feeds, spindles, compact size and more electronics, which are suited to customer needs. As a platform, the event helped us match customer demands with the right technologies.

Ranjit A Bhide,

President & Country Head, Makino India Pvt Ltd

IMTEX 2011 was at par with international events, and we received good response for our business. The participation of international companies highlights its importance, and we expect the event to grow bigger in the coming years. We have been participating in IMTEX since 1996, and have witnessed a shift from conventional machinery to CNC machinery.

Sunil M Haridas,

Head - Projects & Technical Services,

Larsen & Toubro Ltd

The customers today have an intention of buying the latest technologies, and are also looking at next-generation requirements. As an enabling platform, the event has helped us showcase our latest products, viz, the electrical drives. We have been able to create awareness about our capability to offer a combination of electrical and pneumatic drives for slow movements. For companies, IMTEX is as a good platform for meeting existing customers and potential buyers.

S M Dangi,

Marketing Manager, Festo Controls Pvt Ltd

The market is buoyant. The discussions we had at the event point towards this. Customer demands have also changed, as they are seeking quicker solutions with better productivity and reduced cycle time. We showcased some of our latest technologies focussed on market demands. These are the latest generation controls, software solutions and a combination of machine automation with the usage of robotic technology.

T K Ramesh,

CEO, Micromatic Machine Tools Pvt Ltd

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Report Signing of MoU between IMTMA and Electropneumatics & Hydraulics IMTMA and Electropneumatics & Hydraulics (India) Pvt Ltd signed an MoU to establish ‘Metal Forming Technology Training Centre’ at Pune. The memorandum was signed between V Anbu, Executive Dirtector, IMTMA, and A Rasquinha, Chairman & MD, Electropneumatics & Hydraulics (India) Pvt Ltd. Rasquinha is donating 1.5 acre of land for this purpose. The Centre will be named ‘RASQUINHA - IMTMA Metal Forming Technology Training Centre’ and will impart training in sheetmetal and other metal forming technologies to Diploma and Degree holders to upgrade their knowledge and hone their practical skills to meet the need of industries engaged in metal forming activities. The Centre will comprise shop-floor, classroom and administrative office, and will have machinery & equipment worth ` 1 crore.

Investing in technology Updating the role of governance in public sector enterprise The ceremony concluded with the signing of an Mou between IMTMA and Electropneumatics & Hydraulics for a training centre.

Technologies for today and tomorrow The event proved to be a mine of technological innovation and advancement. Prominent was the live demonstration ‘Digital Factory’ organised at the Technology Centre, by creating a replica of factory engaged in batch production with all departmental functions – marketing, design, planning, purchase, CAD/ CAM, CNC machining, QA, assembly and stores, digitally connected through ERP. During the demonstration, participants could walk through various departments and visualise the data flow across the organisation, including scheduling and online monitoring of resources, tracking of projects, vendor management, customer communication, etc, right from preparing quotation to dispatch of finished goods. Project-based industries such as machine tool builders, tool rooms and job shops attended the demo to realise the potential benefits of ‘Digital Factory’. The exhibition witnessed the latest machines/products/technologies, with companies showing live

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demonstrations. Some of the recent technologies/solutions were the 5-axis machines, usage of new coolant techniques, increased utilisation of high-level automation and employment of robotic arms by the machine tool industry. The leading industry players also showcased their latest CNC control systems and software for the industry. With growing concerns regarding the environment, many companies featured their ‘green technology,’ the energy efficient solutions. Tooltech 2011 focussed on tools that utilised new materials for metal cutting. Along with the focus on

requirements for the auto industry, the event had a large number of tools and machines catering to aerospace, wind energy and medical sectors – few of the new growth sectors in the country. The all-round focus was on technology that would enable customers achieve high productivity, better tool life and cost-effective solutions. Industry experts are of the view that the focus was not on pricing of machines, but on the machining technology and cost-per-component. Realising the urgent need for skilled development, IMTMA Technology Centre launched a finishing school programme ‘Finishing School In Production Engineering’, exclusively for fresh engineers from educational institutions. The programme focusses on all practical aspects of modern machining-from reading an engineering drawing through measurements and quality controlincluding machining processes, CNC programming & operation, process planning, tool materials, selection of cutting tools and optimising machining parameters, limits, fits & tolerances, GD & T and selection of instruments.

The Jagruti-IMTMA Youth Programme Acknowledging the lack of skilled manpower in the machine tool sector, IMTMA took up the initiative to address this pressing concern. Organised in collaboration with ‘UDAAN’ – a young machine tool entrepreneur’s club to nurture, develop & enhance business leadership within the fraternity, IMTMA is committed to develop future machine tool manpower. The special initiative for 3rd and 4th year students of mechanical engineering courses was being concurrently conducted with the IMTEX event. The sponsored two day event included activities such as guided tour of the exhibition, visit to various stalls, in-depth explanation of the latest technologies & R&D efforts, and key visits to machine tool companies in the city. As the 3rd JAGRUTI programme concluded, Rajendra S Rajamane, Chairman – ‘UDAAN’ said, “There is a huge gap between technology and engineering education. Students need to witness this practically. In addition, they need to understand that the machine tool industry is not only about lathe machines, but that it has moved to the next level. Also, engineering students need to factor-in that the industry provides opportunity for electronics, electrical, mechanics and telecom, as well. The JAGRUTI initiative stresses on the fact that machine tool industry is a growth-oriented and challenging career path.”

Report

iews V â&#x20AC;&#x2122; ors

t Visi

In the process of upgrading our manufacturing facilities in a big way, we will be modernising 3,000 machines at an investment of ` 6,800 crore in the next 5 years. Besides this, we have major capacity augmentation projects in the pipeline, especially for manufacturing of ammunitions and armoured vehicles. We are looking at the market to get total machining solutions rather than purchasing stand-alone machines. Events like IMTEX help us to know what the latest available options in the world market are, as well as the companies that can give us total machining solutions in the areas we want.

Dinesh M Gupta,

IOFS DGOF & Chairman, Ordnance Factory Board, Ministry of Defence, Govt of India

We continuously upgrade our products. For this, we need latest machine tools so that we can enhance productivity and quality. Events such as IMTEX help us in finding first-hand information on the latest technologies (suiting our needs) available worldwide on a single platform. Also, we are looking at new machine tool manufacturers who can provide us the latest solutions at a competitive price.

Anshu Bhatnagar & A K Verma,

DGM (CMT & IP), BHEL

Over the years, IMTEX has grown rapidly, and has become more demanding as the number of exhibitors increase every year. We are into sheetmetal working, and consider this event as the best platform to find more business and gain know-how of the current scenario in the industry. The event provides Indian companies an excellent opportunity to find new technologies, which will help local manufacturers to meet global standards.

Felix Reichardt,

Executive Director, KERN LASERS (India) Pvt Ltd

This was my third visit to IMTEX, and the quality of machines displayed at the event is of high standard. We were satisfied with the overall management of the event too. The exposure provided by the event enabled us to increase our knowledge base and determine competitive prices for our products. A lot of technical information can be gained from such exhibitions.

M Venkataiah,

Director, Kinetic Motor Company Ltd

The recent edition of IMTEX had a lot to offer to the machine tool industry. With the variety of machine tool equipment that was on display, it became easy for industry players to gain product knowledge, which is probably the most important requirement of any industry today. Technology exchange is the biggest advantage of such exhibitions. With interactive platforms like IMTEX, networking becomes easier.

Rajiv Chopra,

CEO, Amtek Auto Ltd

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Also, the highlight of the event was awards given to Shailesh Sheth, Past President, IMTMA, and A V Sathe, Chairman, Pragati Automation. Sheth received the H R Gupta Lifetime Contribution Award constituted to recognise top contributors in the industry, while Sathe was honoured with Vinod Doshi Outstanding Entrepreneur Award, an initiative to encourage top entrepreneurs of the industry.

Trend-setting platform IMTEX 2011 featured over 800 exhibitors and 750 machines, with a total value of ` 1,400 crore. A multitude of visitors walked through the stalls seeking specific solutions and wanting to strike long-term partnerships with leading manufacturers. The other noteworthy feature of the event was that manufacturers and distribution partners were present under one roof. Also, the machines were offered at discounted prices. The growing enthusiasm of the market also saw many manufacturers offering contests to visitors and giving them Ipods, Ipads, pen drives, etc as gifts and prizes. As a whole, the mood of the event was euphoric, indicating revival and growth of the industry. Considered as one of the largest exhibitions across South & South East Asia, the event delivered on its promise of growth and development.

Book Shelf Editors: Mamoru Mitsuishi, Kanji Ueda and Fumihiko Kimura Price: ` 12,800

Fundamentals of Fluid Power Control This book is an ideal source of reference for practising engineers, and can be a textbook for advance courses in fluid power control. It is aimed at undergraduate students in second year and beyond entry stage to fluid power. The material on the background of fluid power and the operation of components & systems will also appeal to technicians. This book discusses the various aspects of fluid power, indicating its need, circuit symbol, various standard circuits and fluid properties for different applications.

Manufacturing Systems and Technologies for the New Frontier This is a valuable source of knowledge and provides good base for future work for researchers, scientists, engineers and managers in industries interested in manufacturing technologies. It will also be a useful source of reference for graduate students of manufacturing. This book is a collection of hundred papers concerned with all manner of new directions in manufacturing system presented at the 41st CIRP Conference on Manufacturing Systems. The high-quality literature presented in this volume includes reports of work, both from scientific and engineering standpoints, and several plenary & keynote papers addressing the current demand and likely future trends in manufacturing systems.

Author: John Watton Price: ` 6,000

Available at: Wisdom Book Distributors, Hornby Building, 1st floor, 174, D N Road, Mumbai 400 001 • Tel: 022-2207 4484/6631 8958 • Telefax: 022-2203 4058 • Email: thadam@vsnl.com 150 MODERN MACHINE TOOLS - March 2011

Product Update This section gives information about the national and international products available in the market

Multispindle automat

CNC milling machine

Wickman Machine Tools offers multispindle automat machines in ranges of 16 mm to 80 mm bar capacity and in checker range up to 150 mm. These machines can be fitted with auto bar loading and in case of checker machines it can be fitted with auto loading mechanism. In Wickman multies there is no need to change cams when components are changed thanks to quadrant mechanism. Multispindle automats are widely used in automobile component manufactures, hydraulic fittings manufacturers, aerospace industries, etc. Multispindle automats are useful in medium to high volume components production. These automats are superior to single spindle automats in production, reliability and versatility & when compared to CNC turning centre, there is a huge advantage in cycle-time savings as simultaneous operations takes place in multies.

DMG/Mori Seiki India offers ULTRASONIC 10 CNC milling machines. This is a milling method allowing the efficient machining, especially of hard and brittle materials, such as ceramics and synthetic materials. The ULTRASONIC 10 combines this advanced production technology with a highly compact machine design, especially devised for small and medium-sized dental laboratories. Due to simultaneous five-axis machining, all features can be produced in one clamping position. When combined with an optional automation system, the ULTRASONIC 10 represents an ideal component within an industrialised and productive process chain. Highlights of this machine are: five-axis precision machine for all dental indications in all materials; compact, only requiring a 2 mÂ˛ footprint, delivery dimensions 800 x 1,800 mm (width x height); integrated swivel rotary table (4th/5th axis) with torque technology, -20Â°/+120Â° swivel range; water-cooled high-frequency spindle with HSK-25 and maximum 42,000 rpm as standard, can be automated with small, integrated four-fold round blank automation, or, as an alternative, with a PH 2 | 120 linear magazine; integration of a blow/extraction unit in the spindle; and high-performance and operator-friendly Siemens 840D solution line.

Wickman Machine Tools (India) Pvt Ltd Bengaluru - Karnataka Tel: 080-4154 0117-19, Fax: 080-4112 7856 Email: admin@wickmanindia.in

Vertical turning centre Cosmos offers YouJi four-axis palletised vertical turning centres. The four-axis VTL provides high productivity and precision in one machine. Quality machine construction guarantees quality machining results. Automatic pallet changer makes for speedy pallet changes. Proprietary pallet system maintains holding pressure. High-torque spindle tackles heavy duty machining and fine finishing. Integrate with other machines to gain a Flexible Manufacturing System (FMS) and quick & easy programming with Fanuc 18TC 2 Path control. YouJi alloy wheel vertical centres are the productive solution for aluminium wheel manufacturers and companies with similar production needs. Integrated chuck (pallet) changers and four-axis turning make these machines extremely productive. Machine flexibility is ensured thanks to a high-torque spindle motor that drives the spindles via belts. This provides plenty of power for heavy-duty machining and high speed for fine finishing.

DMG/Mori Seiki India Bengaluru - Karnataka Tel: 080-4089 6500, Fax: 080-4113 1285 Email: info@dmgmoriseiki.com

Mounting frame stays for large hose Kabelschlepp offers mounting frame stays for safe and reliable routing of large hoses. Often, large-diameter hoses must be routed safely and reliably in parallel with cables. The new mounting frame stays for the UNIFLEX advanced 1665 from Kabelschlepp handle this task even when hoses have a diameter larger than the clear height of the chain links. Depending on the installation situation, the mounting frame stays can be attached to the inner radius or outer radius of the cable carrier. The new mounting frame stays are available with various inside heights of 114 mm, 139 mm, 164 mm and 189 mm, so that appropriate hose routing solutions are available for any hose diameter.

Cosmos Impex (India) Pvt Ltd

Kabelschlepp India Pvt Ltd

Vadodara - Gujarat Tel: 0265-392 7000, Fax: 0265-392 7001 Email: bina@cosmos.in

Bengaluru - Karnataka Tel: 080-4115 8997, Fax: 080-4115 8998 Email: gm@kabelschlepp.in

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Product Update Automotive cleaning system D端rr Ecoclean offers 179W KVI automotive cleaning system. This system combines proven cleaning methods such as targeted injection flood washing and spraying; blow off and vacuum drying. Universal design provides ease and flexibility for future modifications. The machine is compact in size still maintenance and user-friendly with good access from all the sides. The 179W KVI is suitable for both manual and automatic loading systems. Individual workpieces or palletised parts are placed and loaded into the process chamber, where all applications such as cleaning, high-speed air drying and optional vacuum drying take place. The component movements can be precisely adapted for specialised cleaning requirements. The experienced system design ensures low-energy consumption; optimised usage of cleaning media and chemicals leads to low cost per unit for industrial parts cleaning. Durr Ecoclean Pune - Maharashtra Tel: 020-3058 5001, Fax: 020-3058 5000 Email: info.india@ecoclean.durr.com

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Product Update Magnetic chuck East Coast offers Magnaslot, an electro permanent magnetic chuck. Magnaslot includes a magnetic bed with all steel monolithic working surfaces; a magnetic bed with T-slots, facilitating clamping of magnetic and non-magnetic materials; a magnetic bed, which leaves no passage for coolant to seep in. The working surface of the magnetic chuck is machined from a single block of mild steel, wherein the poles are demarcated by making slots in the top surface obviating the need to utilise filler material. It has rigid and robust construction. Universal clamping can be directly on magnetic chuck. It has maximum accuracy due to homogeneous surface. It is 100 per cent leak proof. Once clamped on the precision machine table, it assures 100 per cent safety to the original machine bed. Magnaslot acts perfect to the clamping of magnetic and non-magnetic workpieces. The Magnaslot magnetic chucks are well suited for the work of big workpieces in the heavy-duty cutting. The installation of the machine is also easy with through holes and clamping sideways on the cross side. East Coast Enterprisers Ltd Kolkata - West Bengal Tel: 033-2242 4617, Fax: 033-2242 6568 Email: info@sardamagnets.com

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Product Update Ball turning & burnishing machine

Mr Samir Gandhi Executive Director Gandhi Automations Pvt. Ltd. “We are pleased to be associated with SEARCH Magazine for many years now, it has provided us a steady return on our advertising and has helped us to expand our business. One must advertise here to experience growth in one’s business.”

ETA Technology offers ball turning and burnishing machine for operations on components like inner ball joint, outer ball joint and ball valves. It consists of a steel fabricated frame, which is mounted with one spindle head for job rotation and the other a rotary spindle head for the tool and burnishing roller. The sphericity achieved is 4 µmm, surface finish within 0.1µRa and diameter within 15 µmm. A hydraulic power pack is built into the bottom of the frame for job clamping through collet. The electrical cabinet is built into the frame at its side and a centralised lube unit is provided. A total enclosure with hinged and sliding doors provides for operator safety. The machine runs in auto cycle for both turning and burnishing operations with manual loading and unloading. A chip chute, provided in the frame, directs the chips to the chip bin kept at the rear of the machine. The machine has a PLC-based servo motor control system. As a special feature, the tool position for various diameters can be set by servo motor. It is done by just entering the diameter of job to be turned. The machine comes with 802D controller with three-axis 1FK042 with analog spindle. ETA Technology (P) Ltd

sales@geapl.co.in

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Bengaluru - Karnataka Tel: 080-2836 1487, Fax: 080-2836 0581 Email: info@etatechnology.in

Product Update Optical 3D surface metrology system Accurate Engineering offers Alicona Imaging’s high-resolution optical 3D surface metrology system. InfiniteFocus offers the functionality of a micro coordinate measurement machine for form measurement and the ability to measure roughness like a surface metrology system. Form and roughness are measured with only one system. It tackles large measurement areas and volumes with a vertical resolution of up to 10 nm. It offers high-resolution measurements on complex components, various material properties and varying surface finishes. This also applies to specimens with small radii and angles. In addition, every measurement is provided with surface colour information registered to the 3D data. It is easy to measure micro-precision parts as well as micro and nano-structures on large components. Tribology and corrosion investigation are as common applications as wear & tolerance measurements in tool industry. Forensics and medical technology benefit from the same advantages as paper and print industry. Accurate Engineering Pvt Ltd Pune - Maharashtra Tel: 020-6603 9000, Fax: 020-2687 0858 Email: accurate@vsnl.com

Mr L. R. Katrat Managing Director - CEO Katlax Enterprises Pvt. Ltd. “We have been a regular advertiser of our products in leading publications such as SEARCH, Modern Machine Tools and Modern Plastics & Polymers of Infomedia 18 Ltd. We are associated with the publication house for more than 12 years and are utilising these magazines to promote our products aggressively and receiving good response.”

info@katlax.com

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Pg No. 156 MMt Mar-2011 Ad Name: Engexpo MMt Mar-2011 Ad Name: Engexpo

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MMt Mar-2011 Ad Name: Engexpo Pg No. 157 MMt Mar-2011 Ad Name: Engexpo

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Product Update CNC twin-spindle turning machine Meiban Engineering Technologies offers Muratec MW50G twin-spindle machine with gantry loader, is currently the smallest of the range of machines. It handles workpieces up to 50 mm diameter, weighing up to 500 g. Main feature is the highspeed gantry loader strokes of up to 180 m/min and minimum productivity of 17 second per workpiece. Most widely installed applications are: automotive – four-wheeler valve tappets, airbag parts, two-wheeler hubs, gearbox parts, fuel Injection parts, etc; and general – bearing rings, white goods, etc. Muratec’s automation solutions include not just loading and unloading the workpieces from the chucks, but also full range of peripherals for workpiece feed-in, Poka-Yoke, turnaround from one operation to next, washing, post-process gauging, feedout, transfer and line layouts. MW50G is also ideally designed for high-precision turning applications where surface finish and tolerances are highly critical. Muratec supplies most suitable and cost-effective total solutions to achieve highest level of productivity with minimum machine idle times. Meiban Engineering Technologies Pvt Ltd Bengaluru - Karnataka Tel: 080-2649 1229, Fax: 080-2649 1239 Email: office@meibanengg.com

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Product Update Double-column vertical machining centre S & T Engineers offers DCV series advanced double-column vertical machine series from YCM Supermax that delivers one of the best craftsmanship, which is designed for highaccuracy machining. DCV comprises the next level of machining dies & moulds strengthened with two-piece structures. Axes are supported with roller-type guideways driven directly by a powerful motor with dual nut ball screw. This ensures the machining capability from precision reflector mould to car bumper moulds. Y-axis is supported by three roller guideways for Z-axis headstock to move steadily & smoothly supported by hardened & ground box ways for high machining stability. The machine is powered with 22 kW spindle motor power ranging spindle speed option from 4,500 rpm to 20,000 rpm. High-speed machining mode with manual guide i Functions and i Operation Plus delivers the best cutting rigidity & smooth movement during 3D contouring operations. S&T Engineers Coimbatore - Tamil Nadu Tel: 422-259 0810, Fax: 422-257 3629 Email: stengine@md3.vsnl.net.in

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Product Update Metal arc disintegrator

CNC cycle time reduction software

Sparkonix offers metal arc disintegrators for applications in automotive i n d u s t r y, coalfields, cement plants, d e f e n c e organisations, earth moving & farm equipment, forging shops, gearbox manufacturers, moulds & dies, machine tool, nuclear power plants, oil exploration, railways, steel plants, ship building, textiles, windmill equipment, etc. From tabletop applications to the most critical engineering applications, these metal arc disintegrator machines are ideal in removing broken drills, taps, studs, bolts without damaging the parent material.

Cadem Technologies offers software that increases profits in CNC turning and machining centres by enabling their power to be utilised to the maximum. Cutting parameters are automatically selected for highest efficiency machining. Cycle time and spindle power for each operation are accurately calculated and displayed. The new cycle time trimmer feature enables even a novice to decide appropriate cutting parameters to reduce cycle time - making best use of the spindle power while not overusing the spindle. Conversational screens and extensive automatic decision support features reduce the programmerâ&#x20AC;&#x2122;s skill. Features like automatic tool gouge prevention, auto safe tool path travel, etc eliminate collisions and part rejection. An operator with machining knowledge can do the programming, and there is no need for a skilled engineer. Training time is less than half a day.

Sparkonix India Pvt Ltd Pune - Maharashtra Tel: 020-2747 0643, Fax: 020-2747 6452 Email: sparkedm@vsnl.net

DRO system for milling machine Electronica Mechatronic Systems offers MT100 DRO, a small easy-to-use DRO for tilting axis of milling machine. This is used to measure the tilting angle of the milling machine spindle. This unit helps in easy alignment of spindle angular moment making it easier for angular drilling. The head can be brought to zero position easily. The IP67 magnetic reader head is offers robustness. It is easy to install magnetic tape on circular surfaces, which enables the angular measurement. DRO system operates on battery (std A4 size alkaline), which provides absolute measurement. Electronica Mechatronic Systems (India) Pvt Ltd Pune - Maharashtra Tel: 020-2422 4440 Fax: 020-2422 1881 Email: drosales@electronicaems.com

Cadem Technologies Pvt Ltd Bengaluru - Karnataka Tel: 080-2663 4767 Fax: 080-2634 2732 Email: sales@cadem.com

CNC chucker Lakshmi Machine Works Machine Tools Division offers LC 40 CNC chucker. This machine comes with high rigidity, unmatched reliability, hardened & ground guideways, large diameter turning and good repeatability.

Important specifications include: chuck diameter of 400 mm, internal free turning diameter of 315 mm, maximum turning length of 400 mm and spindle power of 18.5/15 kW. Lakshmi Machine Works Ltd Coimbatore - Tamil Nadu Tel: 0422-236 0512, Fax: 0422-236 0029 Email: mtdsales@lmw.co.in

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Product Update Special purpose machine Arrow Machine Tools offers special-purpose machines designed and supplied for tie rod end processing from tube. These machines are specially made on customer requirements mainly for second operations like drilling, tapping, milling & slitting. The job is held in the centre and both sides the operations are done simultaneously. A gravity-operated chute is provided on the machine to load up to ten tubes. Tubes can be picked on first in first out basis. If one tube is picked up, the next tube automatically replaces its place. There are three workstations and a dummy station in the machine. Each station performs different operations on the job. The tubes can be loaded on the stations automatically with the pick & place arrangement inbuilt in the machine. The pick & place unit has five pairs of arms. Each arm has a gripper at its end. The gripper is attached to the base of the unit. Two hydraulic cylinders fixed at the top of the machine move the pick & place unit up and down. Another hydraulic cylinder moves the pick & place unit to and fro. One pair of clamping units is provided on each station. The function of the clamping unit is to clamp the job to do operation on the job and to unclamp when the operation are over. Operations of the machine is monitored and controlled utilised an onboard PLC and HMI. The PLC can be placed on the electrical panel and the HMI on the interface panel. Arrow Machine Tools Chennai - Tamil Nadu Tel: 044-2658 2694, Fax: 044-2658 6524 Email: arrowmt@rediffmail.com

Vegetable oil-based cutting oil Blaser Swisslube India offers vegetable oil-based cutting oils that can improve productivity in gear cutting operations (higher cutting parameters). These oils are capable of increasing hob life substantially in addition to almost nil smoke and mist. Advantages of these cutting oils are: vegetable based oil, regenerative raw materials, good skin compatibility, more readily biodegradable, and reduced emissions at work place. Benefits include: higher tool life, higher cutting speed & feeds, low mist & smoke and good lubricity. This oil is suitable for hobbing, shaping, shaving, gear generation, gear grinding. This is also well suited for steel alloys, stainless steel, titanium, titanium alloys and cast iron. Blaser Swisslube India Pvt Ltd New Delhi Tel: 011-4165 7778/ 7037, Fax: 011 2696 4886 Email: india@blaser.com

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Product Update CNC dimensional measurement system OGP Multisensor Metrology offers SmartScope ZIP速 250 multisensor CNC dimensional measurement system for a range of applications. The AccuCentric速 5:1 motorised zoom lens auto-calibrates with every magnification change, and provides accurate non-contact video measurement of a wide range of parts within its 250 x 150 x 200 mm XYZ measurement volume. This durable benchtop system features fast stage speed and a heavyduty cast base with Y-axis centre drive for stability. A variety of add-on lenses are available for increased optical flexibility. Additional sensors are supported - including TTL and DRS lasers, touch probes, and micro-probes - for full 3D measurement in a single part setup. Multiple sensors can be used on a single system and can be used in any order within an automatic measurement routine. Powerful MeasureMind速 3D MultiSensor metrology software accepts all sensor data points, placing them in a common 3D reference frame. Easy-to-use yet capable Measure-X速 metrology software is optional. OGP Multisensor Metrology India Pvt Ltd Bengaluru - Karnataka Tel: 080-4204 6272 Email: info@ogpnet.com

Gear shaving machine Premier offers PSS 300 series three-axis gear shaving machine. This is compact & rugged suitable for finishing operation of gears up to 4 mm module & workpiece diameter up to 300 mm. It is capable to machine spur & helical gears of both shaft and ring type components. Shaving cycles such as plunge, under pass, progressive diagonal & parallel are also possible. Crowning & tapering operations can be done. It comes with operator-friendly dialogue programme for easy setup. Standard features include: precision ball screw for X, Y & Z axes; LM guideways for X, Y & Z axes; machine mounted control panel; machine pendant; manual chip tray; manual and hydraulic tail stock on table; fully enclosed splash guard; crowing and taper shaving; dialogue programme; and AC for CNC cabinet. Optional features can be: chip conveyor, steady rest, autodoor opening and manual closing, auto loader and fume extractor. Premier Ltd, Machine Tools Division Pune - Maharashtra Tel: 020-6631 0000, Fax: 020-6631 0371 Email: mtdsales@premier.co.in

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Product Update Software CG Tech offers numerical control (NC/CNC) simulation, verification, optimisation and analysis software for manufacturing. The VERICUT速 software is used for simulating CNC machining in order to detect errors, potential collisions, or areas of inefficiency. VERICUT enables users to eliminate the process of manually provingout NC programs. It reduces scrap loss and rework. The program also optimises NC programs to both save time and produce high-quality surface finish. VERICUT simulates all types of CNC machine tools. It runs standalone, but can also be integrated with leading CAM systems such as Catia V5, Unigraphics, PTC, MasterCAM, Delcam, EdgeCAM, and GibbsCAM. CG Tech India Bengaluru - Karnataka Tel: 098452 12147, Mob: 098452 12147 Email: info.india@cgtech.com

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Product Update High-performance CNC machining centre Jyoti CNC offers K2X Five series high-performance CNC machining centre. Process reduction time and machining cost reduction are special features successfully proven by this machine, that are new technical challenges for all mechanical companies such as the ones in aeronautic, automatic, medical, energy and many more sectors for dynamic and efficient working. The machine comes with five-axis powerful algorithms in torque, speed, acceleration and jerk. Direct measurement is possible on all five axes. Step-up structure in base is provided for dynamic behaviour, which absorbs pulse cutting forces and those induced by accelerations of moving bodies. The machine has bridge-type architecture with fixed gantry of cast iron with high stiff ribs to attenuate tensional stresses, comfortable dimensioning of static parts and bases of machine. Dynamic parts are out of spheroid cast iron. Other important features include: Table with Rotary Integrated Motor (TRIM) concept in A & C axis and A-axis based on step-up structure of 45° enabling swivelling angles and C-axis rotation on table disk. TRIM makes machining at high speed in 4th & 5th axis perfect. Electro spindle comes with 24,000 rpm (HSK 63-A) as standard with 20 kW power. Different spindle taper and power options available with vibratory monitoring. 20-tool ATC is standard and options are available for more. Jyoti CNC Automation Pvt Ltd Rajkot - Gujarat Tel: 02827-287 081/2, 287412, Fax: 02827-287 811 Email: info@jyoti.co.in

CNC wire-cut EDM Sodick offers CNC wire-cut EDM machine model VZ300L. This is a perfect entry-level wire EDM with all Sodick’s salient features. The linear motor drives combined with high-resolution linear glass-scales is the ideal drive method, which maintains highspeed and high response retaining initial positioning accuracy for years. Users will everlastingly enjoy the remarkably reliable machining performance. The VZ series versatility are equipped with functions as standard; such as, Heart-NC on board programming, advanced corner control, automatic float control, new power supply with perfect active control discharge technology, and more. Sodick’s in-house made superior ceramics are standard for precision machining. Sodick Technologies India Pvt Ltd Bengaluru - Karnataka Tel: 080-4114 6861, Fax: 080-4114 6860 Email: bangalore@sodick.co.in

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Product Update Vertical milling machine MAG India Industrial Automation Systems offers NBV 700 5X vertical milling machine. Configured as a 5-axis machine with an NC tilting/rotary table (C- on A-axis), this machine is capable of machining complex workpieces in a single setup. Whether it is angled cuts or complex free forms, even 5-axis simultaneous machining is possible with an A-axis tilting range of +90° to -120°. The NBV 700 MT (mill-turn) even turns the milling machine into a turning machine. Equipped with a high-speed rotary table, (C-axis up to 1000/rpm) and the tilting/rotary axes for 5-axis machining – both precision components from CORCOM – allow for drilling, milling, tapping and turning capabilities on just one machine. The NBV 700 also sets standards regarding energy efficiency and environment. The standard version of the machine runs without hydraulics; tools are clamped by disc springs and unclamped pneumatically. The same applies to the Aaxis clamping on the tilting/rotary table. A ‘green machining’ feature of MAG machining centres is a new power saving mode that automatically levels speed and acceleration to provide an ideal balance of performance and energy consumption. Realtime energy consumption plus energy saving settings are displayed on a monitor during machine operation. The NBV delivers outstanding machine performance, with the ideal balance of processing time and energy consumption, while enhancing the service life of mechanical components and the machine’s long-term accuracy. MAG India Industrial Automation Systems (P) Ltd Bengaluru - Karnataka Tel: 080-4067 7000, Fax: 080-4160 0777 Email: sales-india@mag-ias.in

Software module Geometric offers two new modules of CAMWorks. The Volumill is an advanced tool for high-speed roughing dedicated for 2.5-3-axis milling. It helps in reducing cycle time up to 80 per cent and reducing cycle time up to 50 per cent and increasing the tool life. ElectrodeWorks is an electrode extraction tool utilised for EDM machines applicable for dies & moulds industry. This tool helps the toolmaker extract the electrodes with spark gap calculation automatically, fast and easily with few mouse clicks. Geometric Ltd Mumbai - Maharashtra Tel: 022-6705 6500 Fax: 022-6705 6891 Email: cw.marketing@geometricglobal.com

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Product Update Form tap with replaceable carbide insert Komet Group offers new range of JEL速 MOREX HML form taps to include the JEL速 MOREX R type. This innovative concept with replaceable carbide inserts on a reusable basic body guarantees considerable tooling cost savings, while providing a responsible approach to managing resources. This thread forming process utilised for making internal threads offers an alternative to thread cutting and has a range of benefits. The process of cold-forming without machining is particularly well-suited for producing threads, which are highly stressed. In the new JEL速 MOREX R, the brazed carbide inserts are replaceable. Apart from the fact that no chips are created during the thread forming process, any problems relating to chip removal during thread creation and extensive cleaning of components to remove chips are eliminated. The new JEL速 MOREX R form taps with replaceable carbide inserts have a flexible HSS-E shank that can compensate for small alignment errors, while the carbide and hard forming edges offer maximum tool life. Komet Precision Tools India Pvt Ltd Bengaluru - Karnataka Tel: 080-2807 8000, Fax: 080-2807 8100 Email: sales.in@kometgroup.com

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Product Update Ultrasonic cleaning machine Bosch offers rotary drum ultrasonic cleaning machine. Components include distributor type fuel injection pump housing & CR cylinder. Operation includes aqueous cleaning with ultrasonic, rinsing, air blow and vacuum drying. Salient features include: state-of-the-art rod type ultrasonics used; bulk loading of parts for high productivity; multistage processing in a single working chamber; process optimisation for â&#x20AC;&#x2DC;component type changesâ&#x20AC;&#x2122; through operator panel; full stainless steel execution; and PLC-based control system. Bosch Ltd Bengaluru - Karnataka Tel: 080-2299 6148, Fax: 080-2299 2724 Email: jc.ravishankar@in.bosch.com

Integrated measuring system Schneeberger offers AMS, an integrated measuring system for absolute distance measurement/long axis machine tools. This system provides safe magneto-resistive sensing and is used for machine tool applications up to 6 m. Major benefits include: absolute position information on machine power up, exchange of reading head without need for referencing, one reading head for all sizes and completely interchangeable rails and reading heads. The company also offers profiled ball & roller guideways (Monorail), components for creative machine concepts, special rail guides, gear racks, linear bearings, miniature guideways and slides. Schneeberger India Pvt Ltd Mumbai - Maharashtra Tel: 022-2263 2372, Fax: 022-2263 2371 Email: a.joshi@schneebergerindia.com

Double-sided insert TaeguTec India offers Chase2Mold economical double-sided inserts. Important features include: Unique double-sided round inserts with shredded and conventional ones; unique insert and cutter pocket structure for strong and robust clamping (anti-rotating system); free-cutting geometry for all materials; and when machining with a long overhand cutter, it is recommended that the shred type insert is used to reduce the cutting load. TaeguTec India Pvt Ltd Bengaluru - Karnataka Tel: 080-2783 9111, Fax: 080-2783 9123 Email: sales@taegutec-india.com

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Product Update Ballbar system Renishaw Metrology Systems offers ballbar system, QC20-W. This is a completely new design featuring a Renishaw-developed linear sensor and Bluetooth® wireless technology. This design offers benefits in ease of use & enhanced durability and allows the QC20-W to be used for testing even in ‘closed door’ manufacturing, where access for wiring can raise safety and procedural issues. The new design also allows testing in three orthogonal planes through a single reference point. A single, simple hardware set up means quicker testing and the ability to produce a representative volumetric measurement of positioning accuracy. The QC20-W ballbar retains the principle of a simple CNC circular program, and powerful software. Together, these can quickly diagnose and quantify machine positioning errors including, servo mismatch, stick-slip errors, backlash, repeatability, scale mismatch and machine geometry as well as giving an overall circularity error value. Renishaw Metrology Systems Pvt Ltd Bengaluru - Karnataka Tel: 080-6623 6000, Fax: 080-6623 6060 Email: india@renishaw.com

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Product Update Hydraulic guillotine shearing machine Weldor Engineering offers hydraulic guillotine shearing machines. These machines are useful to stainless steel (SS) manufactures, SS architectural hardware manufacturers, SS laboratory equipment & laboratory furniture manufactures, etc. Machines with variable rake angle are available from 6-16 mm (SS) having length from 1,525-8,000 mm. The machines have been designed and developed through structural analysis technique. Main concept of this machine is accurate and distortion-free shearing of costly materials like SS, copper, brass, etc at desired angle. The features like frame, rake angle (variable), stroke adjustment rod with limit switch, roller guides, hydraulic power pack, cylinders, hydraulic hold down, blade clearance arrangement, back gauge, etc are so designed that it has proved to be successful in operation with smooth running. Other products offered are mechanical, hydraulic & pneumatic press brake, power press and trimming & blanking press, double-action deep-drawing hydraulic press and nibbling machine. Weldor Engineering Pvt Ltd Rajkot - Gujarat Tel: 0281-236 0242, Fax: 0281-236 0466 Email: weldor@weldor.com

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Product Update Synthetic high-speed grease Raj Petro Specialities offers a premium synthetic high speed grease with technology from UK for high-speed CNC machine spindles, which operate upto 12 lakhs DmN value. The product is trusted by major auto component manufacturers. The benefits of PAO base oils utilised in ONWO high-speed grease are: it provides excellent performance at low-operating and start-up temperatures; its low viscosity base oil and additive package offer excellent lubricity even at high speeds; low friction when operating, therefore lower running temperatures; quiet running and suitable for silent running electric motors; good protection against corrosion in wet/humid environments. The synthetic base oils offer longer grease life and is compatabile with bearing seal materials like NBR; FKM; PTFE, etc. The highspeed grease is recommended for high-speed applications in machine tools, textile industries, small electric motors in medical & dental equipment, etc. ONWO synthetic highspeed grease is available in 1; 3 & 18 Kg packs. Raj Petro Specialities Pvt Ltd Chennai - Tamil Nadu Tel: 044 - 4228 8900, Fax: 044 - 4228 8912 Email: onwo@rajgrp.com, Website: www.rajgrp.com

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Dear Reader, ‘MODERN MACHINE TOOLS’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the machine industry. You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 3000 words, while that of a product write-up should not exceed 200 words. The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format. The final decision regarding the selection and publication of the articles shall rest solely with ‘MODERN MACHINE TOOLS’. Authors whose articles are published will receive a complimentary copy of that particular issue and an honorarium cheque. Published by Infomedia 18 Ltd, ‘MODERN MACHINE TOOLS’ is the leading monthly magazine exclusively meant for manufacturer and user fraternities of the machine trade. Well supported by a national readership of over 1.25 lakh and strong network of 25 branch offices across India, this magazine reaches out to key decision makers among the Indian manufacturers of machine products, machinery and allied sectors. Also, by virtue of tie-ups with global media majors, it ensures that advertisers are able to promote their products and services across the globe at no extra cost. So get going and rush your articles, write-ups, etc… Thanking you, Yours sincerely,

Manas R Bastia Editor Infomedia 18 Limited ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W) Mumbai 400 028 India

D +91 22 3003 4669 T +91 22 3024 5000 F +91 22 3003 4499 E manas@infomedia18.in W www.infomedia18.in

Product Update Section bending machine Godson Bending Systems offers section bending machines, which are designed and built according to the latest technology. The material and components used are thoroughly tested in all practical bending situations. With these machines, the bending operation can be carried out with minimum manual efforts. The main frame of the machine is of all-steel welded construction, proportional and welded to a structural steel base, stress-relieved and machined. All three rolls are made out of heat-treated alloy steel. All shafts, pinions and gears are also made from alloy steel. Rolls are driven by a specially designed gearbox and electric brake motor or hydraulic motor (whichever is suitable). The two lower rolls are adjustable through individual gearbox and brake motor or through hydraulic cylinders. The hydraulic unit is protected against overload and non-return valves eliminate the possibilities of changing position during the bending operations. The machine is available in two different versions, electromechanical and hydro-mechanical. Godson Bending Systems Pvt Ltd Rajkot - Gujarat Tel: 0281-236 1467, Fax: 0281-236 1873 Email: godsonindia@hotmail.com

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Product Update Bushes and brass bearing Saurashtra Industries offers various kinds of bushings, brass bearings and nonferrous metal components from brass, gunmetal, leaded bronze, leaded tin bronze, tin bronze, phosphor bronze, aluminium bronze, barium bronze and aluminium for use in diesel and marine engines various types of pumps, electric motors, tractors, earthmoving & mining machinery, air & gas compressors, industrial machinery and auto industry.

cutter, the power consumption is similar to the positive cutters available in the market. The unique design of the cutter with a captive screw offers positional security and extra close pitch option. Available insert grades are TT8020 & TT8300 for general milling of stainless steel & steel, and TT6030 & TT6300 for general cast iron milling. Taegu Tec India Pvt Ltd Bengaluru - Karnataka Tel: 080-2783 9111, Fax: 080-2783 9123 Email: sales@taegutec-india.com

Saurashtra Industries Rajkot - Gujarat Telefax: 0281-236 1943 Email: info@saurashtrabrass.com

CNC surface grinding machine Pinnacle Engineering Enterprise offers three-axis CNC surface grinding machine, model 3X CNC 8040. This machine is designed and developed to cater to all surface grinding applications utilising special accessories, which include profile grinding and creep feed grinding jobs. High-spindle motor power can be offered against requirements. This is a sturdy and rigid machine with all castings adequately ribbed to withstand heavy grinding forces. All three axes slides move on one ‘V’ and one flat guideway with turcite lining. The guideways, along with ball screws, are lubricated with automatic re-circulating type lubrication system having low oil level signal and pressure drop signal system. The movements are through ball screws and ball screw support unit with super precision bearings. Servo motors are directly coupled with ball screws with zero backlash servo couplings. The complete assembly – turcite lined guideways with auto lubrication system, servo motor with servo coupling coupled to ball screw with auto lubrication - gives highly sensitive mechanism to achieve micronic slides movement with stick slip free motion. Grinding spindle housing is a cartridgetype unit assembled with super precision spindle bearings grease packed with imported grease for long trouble-free service. All the machine controls are through CNC controls. Other models can also be offered in PLC and CNC versions.

Shot blasting machine MEC Shot Blasting Equipments offers airless special 50 hp 6 W special shot blasting machine. This is a special-purpose heavy machine to blast clean truck frame rails & channels of high strength steel 110-130 KSI in a single pass only by high powered six wheels each 50 hp of diameter 21” x 5” blade width rotate at 2,250 revolution per min. Out of six wheels, two are kept inside the blast cabinet with open type wheel housing to achieve the surface finish SSPC-10 at work-piece speed 45 ft/min and SSPC-6 to SSPC7 up to 60 ft/min by providing variable frequency drive to three roller conveyors. A special abrasive air wash system of approximately 5 m length is designed. The approximate weight of the machine is 40 tonne. Important safety features incorporated include: robust big maintenance platform along with safety railings at a level of 7.5 m height from floor, maintenance platform for wheels at a level of 1.5 m from floor, zero speed sensors, heavy duty silencers to the high-volume blower powered by 40 hp motors to control the noise level, compact but highly efficient cartridge type dust collector to control dust emission of 20 mg per normal cu m of filtered air and powder coated IP-55 protected control panel with efficiently programmed PLC. MEC Shot Blasting Equipments Pvt Ltd Jodhpur - Rajasthan Tel: 0291-274 0609, Fax: 0291-274 2409 Email: mail@mecshot.com

Radial drilling machine Pinnacle Engineering Enterprise Surendranagar - Gujarat Tel: 02752-231 167, Fax: 02752-231 913 Email: mail@pinnaclegrinder.com

Mill cutter Taegu Tec offers LS plus mill cutter with new insert geometries for general milling applications. The insert is with six cutting edges for economical milling. Unique insert design with higher thickness provides more strength during higher feed rates with a depth of cut of 13 mm, and has better resting pads for effective seating and better rigidity. Though being a negative

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Powermatic Engineers offers universal radial drilling machine of 38 mm capacity with fine-feed or auto-feed arrangement. It comprises the latest technology & well-designed parts made up of special materials. The spindle and ram are made up of material EN-8 and also hardened to increase the hardness. All gears are made of EN-8 and cut helically to achieve perfect transmission ratio. Powermatic Engineers Ahmedabad - Gujarat Telefax: 079-2562 0703 Email: response@drillmachineindia.com

Product Update Circular saw Unique Saws & Machinery offers circular saws. These are highly durable, disposable type of saw blade suitable for cutting various types of ferrous & non-ferrous materials. With its original tooth and gullet shape for effective sawdust disposal, the saw blade is effective in cutting round and other shaped material. The saw blades are available in cermet tipped, carbide tipped and carbide tipped TiAlN coated. Cermet tipped circular saw blades are used for general steel cutting and low carbon steel equivalent to St-3. Carbide tipped circular saw blades find applications in stainless steel cutting equivalent to ta-3. Carbide-tipped TiAlN coated saw blades are used for special cutting applications equivalent to ti-3. Unique Saws & Machinery Pvt Ltd Indore - Madhya Pradesh Tel: 0731-400 2281, Fax: 0731-405 2579 Email: info@uniquesaws.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

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International Products CNC threadmill machine

Work pallets

Ernst Reime offers CNC threadmill machine for manufacturing threads. To optimise the machining times, the company has added the tool holder NES-TS with closer pitch to the threading system NES with reverse cutting plates. The new NES-TS permits high-feed speed for the millers, thereby substantially reducing cycle times. The carbide reverse cutting blades screwed onto the tool holder guarantee highprocess safety. The cutting edge outside the cutting zone thus have additional protection and are not damaged by chips. The lateral refrigerating coolant outlet permits the usage not only for blind holes but also for through holes in horizontal and vertical machining direction. The NES/NES-TS allows for manufacturing threads of the types M, MF, UNC, UNF and G dimensioned between 20 mm and 110 mm. The reverse cutting blades themselves are of multiple pitch design, and therefore can be utilised for several thread sizes. Due to this feature the system is flexible, saves inventory cost and reduces the number of tools required. Selected carbide metals with adapted coating and cutting edge geometry designed for the corresponding pitch value allow machining dimensionally exacting threads on CNC machines, even in the most difficult machining conditions.

System 3R Far East offers a range work pallets, Delphin BIG. Customers with work pallets of up to 10,000 kg or more can achieve the benefits of reduced set-up times on machines with better repeat accuracies of 0.005 mm. This pallet is especially suitable for large casting moulds, machine frames & bodies, and any other extra-large workpieces. This consists of conical chucks that are freely positioned on the machine table and matching couplings that are bolted into the fixtures, jigs or workpieces. The conical chucks, made of hardened steel, are connected to the work pallets by the matching couplings. These matching couplings perform the positioning functions and come in three different forms: two-axis positioning, single-axis positioning, and no positioning but only clamping. System 3R Far East Pte Ltd Singapore Tel: +65-6289 4811, Fax: +65-6289 3011 Email: seowyong.tay@system3r.com

Non-contact dimensional measurement system

IEMCA bar feeding systems are useful for turning automation that should be employed for high-volume turning operations and shorter cycle time. Bar feeders can not only boost the manufacturing productivity by up to 35 per cent but at the same time reduce dependence on manpower, while ensuring high-precision machining. The machine can be used for bar diameters of 1-to 80 mm, for lengths of 1-6 m bars, for both sliding & fixed headstock lathes. ELITE 112 is the most unique bar feeder in the industry that is capable of handling bar diameters from 0.8-12 mm, with length of bar varying from 2,100-3,700 mm.

RAM Optical Instrumentation offers Pinnacleâ&#x201E;˘ 250, a large format, non-contact dimensional measurement system for high-volume, high-capacity operation in production environments ranging from clean rooms to factory floors. Featuring exclusive dual-magnification optics, advanced image processing, choice of powerful metrology software & data analysis tools and linear motors with exceptional acceleration & velocity performance, Pinnacle encompasses advanced technologies to provide the highest accuracy, unmatched inspection throughput, and excellent Mean Time Between Failure (MTBF) performance. It is an excellent choice for product design/development and near-line process monitoring applications in advanced manufacturing environments. This precision metrology system is specially designed for dimensional measurement applications requiring the highest levels of accuracy and reliability. Its state-of-theart dual-magnification optical system utilises two cameras for near-instantaneous magnification changes. Multi-colour LED illumination systems allow the usage of monochromatic red, green, blue or white light for high-resolution imaging of the toughest applications.

IEMCA

RAM Optical Instrumentation

Faenza (RA) - Italy Tel: +39-546-698000, Fax: +39-546-46338 Email: iemca@igmi.it

Arizona - USA Tel: +1-480-295-3150, Fax: +1-480-889-9059 Email: info@ramoptical.com

Ernst Reime Vertriebs GmbH Feucht - Germany Tel: +49-9128 91 16-0, Fax: +49-(0)9128 91 16-10 Email: noris@noris-reime.de

Bar feeding system

184 MODERN MACHINE TOOLS - March 2011

International Products Mould making solution Open Mind Technology offers hyperMILL, a complete tool- and mould -making solution. The software provides advanced five-axis technology combined with a wide range of 2D & 3D strategies and HSC functions. This is a CAM solution that gives the flexibility to produce a broad product palette. The company has also been developing integrated automations; these reduce manual input and minimise machine running times. The streamlined user interface shared by all the modules is intuitive and has been designed for daily use. Dialog windows with graphical support and menu-controlled data entry mean that many of the programming steps are self-explanatory. Plausibility checks ensure that all entered data is valid. hyperMILL automatically detects erroneous entries, highlighting them in red and providing correction suggestions as part of the error messages. The main advantage of such a consistent approach to user interaction is that one can program even seldom-used machining strategies safely and reliably.

high precision, retaining various functions of CNC cylindrical grinder, and applicable to angle & speed control. Fast and easy transferring custom-made grinding program is possible when operated with Palmary-developed CAD/CAM software. With an optional sound frequency anti-crush-proof system, consistent grinding operations are ensured. Palmary Machinery Co Ltd Taichung - Taiwan Tel: +886-4-2492 9799, Fax: +886-4-2492 9499, Email: palmary@grinding.com.tw

Open Mind Technologies AG Wessling - Germany Tel: +49 (0) 8153/933500 Fax: +49 (0) 8153/933501 Email: info@openmind-tech.com

CNC cylindrical grinder Palmary Machinery Co offers OCD 3260 CAM series CNC cylindrical grinder, designed for high efficiency, high accuracy and maximum operational convenience. Main structure of the CNC cylindrical grinder, when in combination with angle control of spindle by C axis is capable of grinding various specially shaped workpieces. Working spindle carries with precision angle decoder, high resolution of angle control reaching up to 0.1 mm. The feed axis is equipped with close loop control optical scale to reach

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International Products Special drill

Mr Hitesh Shah Managing Director H.G.SHAH & Co â&#x20AC;&#x153;We are pleased to be associated with SEARCH & MODERN MACHINE TOOLS Magazine since last 7 years. We are very much satisfied with Ad Spending as it generated relevant inquiries. The magazine is targeted to the right audience & has wider reach. We are looking forward for long-term tieups with the magazine.â&#x20AC;?

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Dormer Tools offers the Elect Sâ&#x201E;˘ drill range, developed specifically for the machining of materials known collectively as Heat Resistant Super Alloys (HRSA). High-temperature resistant alloys such as titanium, Inconel and waspalloy can be difficult to machine for two principle reasons. First, they generate high-cutting forces during machining, leading to high pressure and heat, which in turn tends to result in work hardening. Second, because they are able to withstand high temperatures, the heat generated during drilling is retained within the workpiece and transferred to the tool, resulting in premature drill failure. In addition to internal coolant holes, several features of the Elect Sâ&#x201E;˘ drills combine to lower the occurrence of work hardening. Another key attribute of the Elect Sâ&#x201E;˘ drills is a smooth-flow coating that acts as a thermal barrier, protecting the substrate from the extreme heat generated at the cutting edge. Available in two lengths to support drilling to 3 x diameter (R507) and 5 x diameter (R503), the Elect Sâ&#x201E;˘ drills can be of particular interest to anyone involved in the production of high-value components or requiring a high degree of precision such as aerospace subcontracting, oil & gas and nuclear industries. Dormer Tools Ltd Sheffield - UK Tel: +44 (0) 114 293 3892 Email: simon.winstanley@dormertools.com

Broaching machine Varinelli offers electromechanical drive table up broaching machine, RISH-M. This machine with satellite roller screws comes with continuously adjustable pull. Main ram and slides on profiled rails are by means of linear re-circulating ball guides. Solid frame with thick walls guarantees an under-load running without vibrations. Electrical cabinet is installed on the right side of the machine, while push button panel installed on the machine front. Broach tools lifting and disengagement take place by means of lifting slide, while the function is also to keep tools in position while broaching. The machine is equipped with a loading shuttle table on which are installed the workholding parts. Varinelli Srl Milan - Italy Tel: +39-039-607317, Fax: +39-039-607312 Email: sales@varinelli.com

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International Products Digital servo actuator Atos offers new digital servo actuators, which provide electrohydraulic solution to the imperative demand for easier subsystems configuration. These are smart actuators integrating many functions in a single, compact and programmable motion control unit. These include low friction servo cylinder, with integral position and force transducers to allow accurate movements with no stick-slip phenomena coupled with high translation speeds. High-performance servo proportional valve equipped with on-board electronics ensures best hydraulic regulation and failsafe features. Integral digital driver and axis controller are designed for electro hydraulics motion control to improve performances. Digital servo actuators introduce a new automation architecture based on distributed intelligence and Fieldbus interfacing for direct integration into existing communication networks: CANopen or Profibus-DP. They are independent units with two basic operational modes. The slave control precisely performs in real-time the motion closed loop control, according to external analog or Fieldbus position reference signals. Atos SpA Sesto Calende - Italy Tel: +39-0331-918306 Email: info@atos.com

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International Products Camshaft inspection gauge Adcole Corporation offers Adcole 1310 high-speed camshaft inspection gauge. This features a new graphic display that lets operators visually monitor throughput with green, yellow and red plots depicting in-tolerance, reaching control limits and out of tolerance status. Providing gauge room accuracy on the production floor, this end-of-line gauge offers user-programmable measurement parameters, easy part set-up changes, and 0.1 µm resolution per data point or 3,600 data points per revolution. Enabling the direct correlation between an audit gauge and production floor, this gauge utilises the same technology as all Adcole gauges and can process up to 200 parts per hour. It can measure 10 or more parameters including radius, profile, taper, crown, timing angle, diameter, velocity, acceleration, run-out, roundness, and concentricity. Adcole Corporation Massachusetts - USA Tel: +1-508-485 9100, Fax: +1-508-481 6142 Email: breece@adcole.com

Bevel gear cutting machine Gleason Corporation offers Phoenix® 280C bevel gear cutting machine. Users can reduce cycle times by as much as 35 per cent on the production of bevel gears and pinions up to 280 mm in diameter. The machine has a high-speed automatic loader that cuts workpiece changeover to five seconds for gears, and seven seconds for pinions. It is an ideal solution for automotive manufacturers seeking reduced workpiece costs on the highest volumes, and jobbers requiring greater flexibility to change rapidly from one part type to another. Non-productive cycle times are further reduced through the usage of an on-machine inspection device, which eliminates much of the time required to remove and inspect parts in a quality lab after a cutter change or when preparing to produce a completely new part or family of parts. The time required to chamfer/deburr gears has been greatly reduced too, with an auxiliary chamfering spindle that chamfers/deburrs a gear in parallel to the one being cut, rather than as an operation typically performed in sequence after cutting. The Phoenix® 280C is easier to service and maintain, with simplified guarding to improve access to service areas, and new features like a servo door system, with robust rails, to provide improved reliability as compared to conventional pneumatic door systems. Gleason Corporation New York - USA Tel: +1-585-473 1000, Fax: +1-585-461 4348 Email: sales@gleason.com 188 MODERN MACHINE TOOLS - March 2011

International Products Ball-shaped milling cutter Mikron Tool offers a new ball-shaped milling cutter, MiquMill Radiuschamfer. Due to its 300o cutting range, it is universal and can be used wherever difficult deburring operations have to be performed. Available with ball diameters starting from 1 mm and due to an extra long neck, this new tool reaches also hidden angles and edges. The positive cutting geometry allows a sharp cut and thus a perfect deburring without forming of secondary burrs. It easily removes ductile, flexible burrs too and can be used for all kinds of metals. These features make it a â&#x20AC;&#x2DC;jack-of-all-tradesâ&#x20AC;&#x2122; because it can be adopted not only for front and back chamfering, but also for various inner and outer contour machining operations, for intersections of bores and milled shapes. The standard executions with a ball diameter from 1 mm to 6 mm and a usable length of 4 x d are available. Customdesigned executions with project-specific dimensions are also available. Mikron Tool SA Agno Bioggio - Switzerland Tel: +41-91-6106500, Fax: +41-91-6106683 Email: mto@mikron.com

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International Products Grinder Palmary Machinery offers grinders specially developed for engine valves, an indispensable item for the automobile industry. The machine is collocated with auto loading & unloading attachment. The grinding wheel and workpiece clamping spindle adopt hydrostatic design. It can not only raise the stability and run out, but also conform to the demands for each kind of engine valve by different angle. The machine is easy to control, and it is effective to reduce the cost of the manual control and increase the profit of the products. Palmary Machinery Co Ltd Taichung - Taiwan Tel: +886-4-2492 9799, Fax: +886-4-2492 9499 Email: palmary@grinding.com.tw

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

Statement about ownership and other particulars about Modern Machine Tools, as required to be published in the ﬁrst issue every year after the last day of February. 1. 2. 3.

Place of Publication: Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (W), Mumbai-400028. Periodicity of Publication: Monthly Printer’s Name: Mr. Mohan Gajria Nationality: Indian Address: Infomedia 18 Ltd, Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (W), Mumbai-400028. 4. Publisher’s Name: Mr. Lakshmi Narasimhan Nationality: Indian Address: Infomedia 18 Ltd, Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (W), Mumbai-400028. 5. Editor’s Name: Mr. Manas Bastia Nationality: Indian Address: Infomedia 18 Ltd, Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (W), Mumbai-400028. 6. Names and addresses of Individuals who own Modern Machine Tools & partners or shareholder holding more than 1% of total capital of Infomedia 18 Limited (formerly known as Infomedia India Limited), Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (W), Mumbai-400028. Details of the shareholders of Infomedia 18 Limited who are holding more than 1% of the paid up equity share capital of the company as on 11-02-2011: a. Television Eighteen India Limited, 601, 6th Floor, Hotel Le-Meridian, Raisina Road, New Delhi-110001. b. Soumen Bose, (acting in capacity of trustee of Infomedia 18 Merger Trust for the beneﬁt of India Advantage Fund II) Flat - 11, Neelam, 2nd Floor, Road 14 B, Off Linking Road, Khar(West), Mumbai - 400052 c. ACACIA Partners, LP, Citibank N.A., Custody Services, 77, Ramnord House, Dr. A.B. Road, Worli, Mumbai- 400018 d. Sanjiv Dhireshbhai Shah, 702, Silicon Towers, Behind Samar theshwar Mahadeo, Law Garden, Ahmedabad - 380 006. e. ACACIA Conservation Fund LP, Citibank N.A., Custody Services, 77, Ramnord House, Dr. A.B. Road, Worli, Mumbai- 400018 f. The Oriental Insurance Company Ltd, Oriental house, P. B. 7037, A-25/27, Asaf Ali Road, New Delhi - 110002 g. ACACIA Institutional Partners, LP, Citibank N.A., Custody Services, 77, Ramnord House, Dr. A.B.Road, Worli, Mumbai-400018 h. Optimum Securities Private Limited, 3, Amba Bhuvan, 29, Sion Circle, Sion (West), Mumbai-400022 I, Lakshmi Narasimhan, hereby declare that all particulars given above are true to the best of my knowledge and belief. Dated: 16th February 2011 Sd/LAKSHMI NARASIMHAN Signature of the publisher

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Product Index Sl. No

Product

Pg No

Sl. No

Product

Pg No

Sl. No

Product

Pg No

AC drive............................................................. 91

50 C frame power press ........................................ 12

99 CNC machining centre........................................ 15, 129

Adaptor...................................................................111, 164

51 Cable & hose carrier.....................................................173

100 CNC milling machine.......................FIC, 147, 152, 168

Aerosol multispray ......................................................... 55

52 Cable carrier....................................................................132

101 CNC oxy-fuel cutting machine................................... 26

Air treatment ..................................................................151

53 Cable connector ............................................................132

102 CNC plasma cutting machine .................................... 26

Air-conditioner................................................................. 79

54 CAD/ CAM software ....................................................... 22

103 CNC prass brake ............................................................203

Airline fluid ........................................................................ 55

55 CAM shaft/ crank shaft grinding machine ..........167

104 CNC precision lathe.............................................. 57, 129

Aluminium endmill..................................................10, 11

56 Camshaft inspection gauge......................................188

105 CNC punch press............................................................. 40

AMS integrated..............................................................136

57 Carbide..............................................................................164

106 CNC surface grinding machine................................182

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

58 Carbide burr...............................................................10, 11

107 CNC system .....................................................................143

10 Angle head ......................................................................169

59 Carbide endmill .............................................................101

108 CNC threadmill machine............................................184

11 Antivibration tool..........................................................112

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

109 CNC tooling.....................................................................164

12 APFC panel ........................................................................ 79

61 Carbide indexable grooving solution ..................BGF

110 CNC tool-store cabinet ...............................................155

13 Appliance switch............................................................. 19

62 Carbide rod........................................................................ 61

111 CNC turning centre ............................. 14, 15, 129, 131

14 Assembly & high temperature grease .................... 55

63 Carbide routhing endmill .....................................10, 11

112 CNC turning mill.............................................................. 17

15 Automatic drilling machine ......................................155

64 Carbide tool ........................................... 10, 11, 164, 181

113 CNC twin-spindle turning machine .......................162

16 Automatic grinding machine...................................156

65 Casting ...............................................................................FIC

114 CNC vertial machining centre..................................129

17 Automatic tapping machine ....................................155

66 CE marked CNC vertical machining centre..........FIC

115 CNC vertical lathe ................................................. 17, 179

18 Automation ....................................................................... 26

67 CE marked milling machine.......................................FIC

116 CNC vertical machine..................................................179

19 Automation equipment .............................................147

68 CED coating machine.................................................... 26

117 CNC vertical machining center.................................. 15

20 Automotion controller................................................171

69 Centeleess grinding machine .................................... 23

118 CNC vertical turning lathe.........................................179

21 Automotive cleaning system....................................153

70 Centre drill.......................................................................164

119 CNC wheel turning machine ...................................... 17

22 Automotive oil ................................................................. 95

71 Centreless........................................................................... 27

120 CNC wire-cut EDM ........................................................170

23 Ball joint .......................................................... 163

72 Chain..................................................................................132

121 CNC/tooling ............................................................ 85, 181

24 Ball turning & burnishing machine........................156

73 Chain oil.............................................................................. 55

122 CNC/VMC machine..................................24, 49-52, 133

25 Ballbar system ................................................................175

74 Chemlok coating machine .......................................... 26

123 Coating machine............................................................. 26

26 Ball-shaped milling cutter .........................................189

75 Chiller.................................................................................181

124 Coating plant.................................................................... 26

27 Bandsaw machine.........................................................203

76 Chuck.................................................................................164

125 Coating system ................................................................ 26

28 Bar feeding system.......................................................184

77 CI castings........................................................................179

126 Collet chuck............................................................. 57, 164

29 Battery charger ..............................................................123

78 Circular saw.....................................................................183

127 Combination boring ....................................................112

30 Bearings ............................................................................132

79 Clamping collet..............................................................173

128 Combined drills & countersink ...........................10, 11

31 Bed type ...........................................................................165

80 Clamping series .............................................................128

129 Command panel system ............................................149

32 Bellow................................................................................187

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

130 Complete tooling solution .......................................BGF

33 Bending machine..........................................................122

82 CMC...................................................................................... 14

131 Compressor oil................................................................. 55

34 Bevel gear cutting machine......................................188

83 CNC.........................................................................7, 15, 127

132 Conduits and connector system............................... 19

35 Billet shearing machine................................................ 12

84 CNC angular cylindrical grinding machine........... 23

133 Cone pulley light duty lathe machine-VLM model 175

36 Blade .................................................................................... 85

85 CNC controller................................................................125

134 Cone pulley medium duty lathe machine ..........175

37 Boring bar/boring head................................................ 18

86 CNC cutting machine .................................................... 26

135 Cone pully heavy duty lathe machine..................175

38 Boring machine ...................................................165, 203

87 CNC cycle time reduction software .......................165

136 Connector ................................................................ 47, 132

39 Botek pr채zisionsbohrtechnik GMBH.....................BGF

88 CNC dimensional measurement system..............168

137 Console system..............................................................149

40 Brass wire .........................................................................170

89 CNC equipment............................................................... 25

138 Contactors & bi-relay...................................................125

41 Brine chiller......................................................................189

90 CNC grinding machine ...............................................156

139 Control cabinet................................................................ 47

42 Broaching machine ......................................................186

91 CNC guillotine shear...................................................... 40

140 Control panel.................................................................... 47

43 Brush research manufacturing ..............................BGF

92 CNC horizontal boring & milling machine............ 17

141 Control panel accessories............................................ 19

44 BT /ER tool holder.........................................................187

93 CNC horizontal machining centre................. FIC, 129

142 Control system................................................................. 47

45 BTA / ejector counter boring ...................................158

94 CNC hydraulic press brake .......................................... 40

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

46 BTA / ejector drilling....................................................158

95 CNC laser cutting machine...................................26, 40

144 Conventional precision lathe ...................................139

47 Building automation...................................................... 26

96 CNC lathe ............................................129, 131, 139, 147

145 Cooling tower.................................................................151

48 Burr ................................................................................10, 11

97 CNC machine solution ...............................82, 106, 107

146 Copper anode ................................................................170

49 Bushes and brass bearing..........................................182

98 CNC machines ........................... 8, 9, 15, 117, 129, 203

147 Core drill ...........................................................................175

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192 MODERN MACHINE TOOLS - March 2011

Product Index Sl. No

Product

Pg No

Sl. No

Product

Pg No

Sl. No

Product

Pg No

148 Coromill ........................................................................... FGF

196 Electro permanent magnetic chuck/ tool/ lifter .... 16

245 H frame power press........................................ 12

149 Corothread ..................................................................... FGF

197 Enclosure cooling unit ................................................149

246 Hammer...........................................................12, 183, 191

150 Counter & power supplie............................................. 71

198 Enclosure system ..........................................................149

247 Handling system module............................................. 47

151 Countersink .......................................... 10, 11, 37, 58, 59

199 Encoder............................................................................... 71

248 Hard chrome plated bar.............................................153

152 Custom design cutting tool........................................ 18

200 End mill......................................................... 162, 164, 189

249 Hard cut endmill ...........................................................101

153 Customized solution....................................................112

201 Endmills/facemill............................................................. 18

250 Harmonic filter ...............................................................123

154 Cutter................................................................................... 85

202 Engis corp USA..............................................................BGF

251 Havy duty machine tool....................................200-201

155 Cutter grinder................................................................... 62

203 ER clamping nut ............................................................187

252 Heavy duty lathe machine .......................................... 62

156 Cutting machine.............................................................. 26

204 Exhibition - Blech India 2011...................77, 177, 178

253 High frequency spindle ..............................................169

157 Cutting tool............................................................................

205 Exhibition - Engineering Expo ....141, 142, 159, 160

254 High performance drill...........................................10, 11

..................31, 33, 41, 45, 65, 101, 121, 135, 162, 181

206 Expandable mono block-reamer ............................111

255 High performance endmill...................................10, 11

158 Cylindrical .......................................................................... 27

207 Expansion joint ..............................................................187

256 High precision roll shop machine .................200-201

159 Deburring solution........................................... 97

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

257 High precision tool holder .......................................... 39

160 Decimal endmill........................................................10, 11

209 Factory automation ...................................26, 81

258 High speed drill .............................................................181

161 Deep hole drilling machine ......................................158

210 Fan & filter unit..............................................................149

259 High-performance CNC machining centre .........170

162 Deep hole drilling solution ......................................BGF

211 Feed finger ......................................................................173

260 High-speed centerless grinding machine ............. 23

163 Deep hole drilling subcontract................................158

212 File ......................................................................................181

261 HMC............................................................................ 14, 115

164 Deep-hole drilling machine ......................................172

213 Filter bag ..........................................................................187

262 HMI .....................................................................................171

165 Demagnetiser................................................................... 16

214 Five axis machining centre ......................................... 87

263 Holder................................................................................189

166 Diamond cutting & processing system ................119

215 Flanging machine .........................................................122

264 Hollow bar ......................................................................... 43

167 Diamond super finishing tools for honing application....BGF

216 Floor automation ..........................................................161

265 Horizontal & vertical machining center ...............167

168 Diamond tool .....................................................37, 58, 59

217 Fluidized bed coating machine................................. 26

266 Horizontal boring mill............................................... COC

169 Didactic equipment for training ............................... 47

218 Forging press.................................................................... 12

267 Horizontal machinery center....................................176

170 Die/mould machine ................................................... COC

219 Form tap with replaceable carbide insert...........173

268 Horizontal milling machine..................................... COC

171 Digital servo autuator .................................................187

220 Free cutting brass rod & wire...................................170

269 Horizontel machining center ........................................7

172 Dip-spin coating machine ........................................... 26

221 Friction drop hammer................................12, 183, 191

270 HSM & HPM centre......................................................... 21

173 Distribution transformer .............................................. 79

222 Friction screw press ....................................................... 12

271 Hydraulic & gear oil........................................................ 55

174 Double-column vartical machining centre.........164

223 Frictionless slide ............................................................136

272 Hydraulic angle lockvise.............................................164

175 Double-sided insert......................................................174

224 Galaxy biglia CNC turn-mill center................. 48

273 Hydraulic guillotine shearing machine ................176

176 double coulmn milling machine........................... COC

225 Gantry automation.......................................................161

274 Hydraulic press brake.......................................... 40, 203

177 Drill ............................................................ 10, 11, 101, 111

226 Gas spring ........................................................................183

275 Hydraulic punching machine...................................122

178 Drill chuck arbor............................................................164

227 Gear cutting machine ............................................... COC

276 Hydraulic steel working machine...........................122

179 Drill machine.........................................................102, 165

228 Gear hobbing machine...............................................167

277 Hydraulic surface grinding machine .....................156

180 Drill mill.............................................................................164

229 Gear milling....................................................................... 97

278 Hypercad ............................................................................ 22

181 Drill tap center ...................................................... FIC, 115

230 Gear shaving machine ................................................168

279 Imaging & vision system ................................. 26

182 Drill tool..............................................................................BC

231 Geared head heavy duty lathe machine .............175

280 Indexable angle cutter................................................189

183 Drilling & milling tool ..................................................112

232 Geared head medium duty lathe machine ........175

281 Indexable tool ................................................................101

184 Drilling head ...................................................................155

233 Glide coating machine.................................................. 26

282 Inductin motor...............................................................171

185 Drilling tool ................................ 37, 41, 45, 58, 59, 121

234 Gold purity (XRF) system ...........................................119

283 Induction pipe bending machine..................200-201

186 Drive...................................................................................171

235 Grease...........................................................................55, 95

284 Inductive proximity switche ....................................... 19

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

236 Grinder ..............................................................................190

285 Industrial control & sensing device ......................... 71

188 DRO system for milling machine ............................165

237 Grinder ................................................................................ 62

286 Industrial cooler.............................................................151

189 Ecocut .............................................................. 137

238 Grinding machine................................ 27, 72, 156, 167

287 Industrial cooling system...........................................189

190 Edge preparation machine ..............................200-201

239 Grooving & parting tool ............................................... 61

288 Industrial oil ...................................................................... 95

191 EDM wire..........................................................................170

240 Guide bushe....................................................................173

289 Instrument lathe............................................................147

192 EDM centre........................................................................ 21

241 Guillotine shear................................................................ 40

290 Integrated measuring system ..................................174

193 Electrical connector......................................................163

242 Gun drill................................................................37, 58, 59

291 Interface electronic .......................................................BIC

194 Electro magnet separator ............................................ 16

243 Gun drilling......................................................................158

292 Internal grinding machine....................................23, 27

195 Electro magnetic lifter................................................... 16

244 Gun reaming...................................................................158

293 Invertor/variable frequency drive............................. 71

March 2011 - MODERN MACHINE TOOLS 193

Product Index Sl. No

Product

Pg No

Sl. No

Product

Pg No

Sl. No

Product

Pg No

294 Iron worker ........................................................................ 40

343 Microbore tool ................................................................. 18

392 Pipe cutting machine .........................................200-201

295 Iso & milling insert........................................................101

344 Mill cutter.........................................................................182

393 Piston pump ........................................................... 90, 153

296 Iso turning insert...........................................................101

345 Milling........................................................ 41, 45, 121, BIC

394 Planner milling machine ............................................203

297 Isolation transformer ..................................................... 79

346 Milling centre.......................................................................7

395 Plano milling machine ................................................179

298 Jobber length drill......................................10, 11

347 Milling cutter .....................................37, 58, 59, 61, 189

396 Plasma cutting machine............................................... 40

299 Johs boss gmbh & co kg...........................................BGF

348 Milling grade.................................................................. FGF

397 Plate bending machine ....................................122, 203

300 Large enclosure .............................................. 149

349 Milling machine..................................62, 102, 165, 203

398 Plate cutting machine........................................200-201

301 Large size machining centre .................................. COC

350 Milling tool ........................................................................BC

399 PLCâ&#x20AC;&#x2122;s..................................................................................... 91

302 Laser cutting machine ...........................................28, 40

351 Miniscale...........................................................................136

400 Plugs and socket ............................................................. 19

303 Laser cutting system....................................................119

352 Mistubishi CNC wire EDM............................................ 14

401 Portable coolant purifying system........................... 99

304 Laser marketing - engraving system.....................119

353 Modular boring..............................................................112

402 Portable oil skimmer with variable speed............. 99

305 Laser welding machine...............................................167

354 Modular tooling system .................................37, 58, 59

403 Position display unit .....................................................BIC

306 Laser welding system..................................................119

355 Mould ................................................................................165

404 Post processor.................................................................. 22

307 Lathe ......................................................................7, 62, 175

356 Mould changing system.............................................185

405 Power chuck ...................................................................128

308 Lathe machine ........................................... 102, 179, 203

357 Motion control ................................................................. 71

406 Power distribution component...............................149

309 LED........................................................................................ 19

358 Motor protection circuit breaker .............................. 19

407 Power saver....................................................................... 79

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

359 Mould making solution ..............................................185

408 Power source..................................................................109

311 Level controller................................................................ 71

360 Mounting frame stays for large hose....................152

409 Powrgrip system............................................................179

312 Limit switche..................................................................... 19

361 Multi functional tool...................................................... 61

410 Pre tereatment system.................................................. 26

313 Linear guideway............................................................136

362 Multi-media union........................................................183

411 Precision gear cutting tool...................................... COC

314 Linear motor thread & gear grinder........................ 53

363 Multispindle automat..................................................152

412 Precision ground bar...................................................153

315 Linear technology voltage stabiliser .....................123

364 Multi-spindle drilling and tapping head..............155

413 Precision measuring instrument............................... 67

316 Linear way vertical machining centre...................117

365 Multispindle head.........................................................169

414 Precision parts machining........................................... 18

317 Liner bearing...................................................................136

366 N/C spotting drill........................................10, 11

415 Precision switche ............................................................ 19

318 Liner guide ......................................................................136

367 Nickel silver wire ...........................................................170

416 Precision switches single & multipal ....................... 19

319 Live tooling for CNC lathe .........................................169

368 Non-contact dimensional measurement system.....184

417 Precision tool holding collet.....................................187

320 Live tooling for swiss type lathe .............................169

369 Oil / coolant cooler......................................... 189

418 Press brake ........................................................................ 40

321 Load break switche ........................................................ 19

370 Oil cooler..........................................................................181

419 Process automation and cntrol equipment.......... 47

322 LV motor............................................................................. 91

371 Online B2B marketplace...................................105, 193

420 Programmable logic controller ................................. 71

323 Machine........................................................... 122

372 Optical 3D surface metrology system...................158

421 Programmable terminal ............................................... 71

324 Machine centre ................................................................ 17

373 Or-laser welding system............................................... 14

422 Proximity sensor.............................................................. 71

325 Machining centre............................................................ 15

374 Other automation accessorie...................................143

423 Pull stud............................................................................164

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

375 Paint shop equipment ..................................... 26

424 Punching machine .......................................................122

327 Magnetic chuck .............................................................155

376 Paint shop machine ....................................................... 26

425 Push button ...................................................................... 19

328 Magnetic crack detector .............................................. 16

377 Panel air-conditioner ...................................................189

426 Quick change collet........................................ 173

329 Magnetic drilling machine ........................................175

378 Panel cooler ....................................................................181

427 Quick die change system...........................................185

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

379 Part ejector ........................................................................ 99

428 Quick mold change system ......................................185

331 Magnets for billet handling / coil handling.......... 16

380 Paul horn gmbh ...........................................................BGF

429 Radial............................................................... 165

332 Manual feed drilling machine..................................155

381 PC enclosure ...................................................................149

430 Radial drill .......................................................................... 62

333 Mapal dr kress kg.........................................................BGF

382 PCD &carbide reamer..................................................111

431 Radial drilling machine...............................................182

334 Marine oil ........................................................................... 95

383 Perforated panets cupboard ....................................155

432 Reamer .............................................. 37, 58, 59, 135, 164

335 MCC & PCC enclosure .................................................149

384 Permanent magnet chuck........................................... 16

433 RFID ...................................................................................... 71

336 Measured value acqusition and display................BIC

385 Permanent magnet tool............................................... 16

434 Roatry .....................................................................................7

337 Measuring & monitoring relay for 1ph/3ph ......... 71

386 Permanent magnetic lifter .......................................... 16

435 Robotic automation.....................................................161

338 Measuring system.........................................................136

387 Permanent magnetic separator ................................ 16

436 Rod end ............................................................................163

339 Mechanical shear ............................................................ 40

388 Phosphor bronze wire.................................................170

437 Roll turning lathe ..........................................................179

340 Metal arc disintegrator ...............................................165

389 Photo electric sensor..................................................... 71

438 Roll turning lathe machine ......................................... 62

341 Metal cutting tool........................................................... 13

390 Pilot light............................................................................ 19

439 Rotary cam switche........................................................ 19

342 Metric endmill ...........................................................10, 11

391 Pipe bending machine............................ 122, 200, 201

440 Rotary cylinder ...............................................................128

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194 MODERN MACHINE TOOLS - March 2011

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Product Sourcing Just Got Simpler

1 See the index page in this issue. Every product carries a number. 2 Choose products of your choice from the list. 3 Write their serial numbers (as per the index page) of your chosen product/s one-by-one in the boxes. 4 Fill in your complete contact details. 5 Send it to us at the address printed overleaf.

-1 TIPIN THE BDOUXCETS

UR O L FIL TH PR OF YO D WI ER/S E S N ND MB NU OICE A CH

-2 TIP SE ENSUILRLEIN Name:___________________________________________________Designation:_________________________________________ Company:_______________________________________________________________________________________________

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03/2011

City:_________________________________________Pin:_______________________State:__________________________

Product Index Sl. No

Product

Pg No

Sl. No

Product

Pg No

Sl. No

Product

Pg No

441 Rotary damper ...............................................................183

491 Special induction hardening machine..................109

541 Toolroom machine.......................................................117

442 Rotary encoder................................................................BIC

492 Special line boring tool ..............................................111

542 Tool-stor cabinet ...........................................................155

443 Rotary joint & union.....................................................183

493 Special purpose machine ..........................................166

543 Tool-stor trolley .............................................................155

444 Rotating union ...............................................................183

494 Special purpose machine ................................. FIC, 179

544 Touch probe ....................................................................BIC

445 Safety light curtain .......................................... 71

495 Special reaming tool....................................................111

545 Transparent gel................................................................ 55

446 Safety protection device .............................................. 19

496 Special refrigeration equipment.............................189

546 Tslot milling cutter .......................................................189

447 Saw blade.........................................................................189

497 Special theard milling tool........................................111

547 Tubing accessorie ........................................................... 47

448 SCADA & DCS implimentaion .................................... 26

498 Special tool......................................................................164

548 Turneykey solution.......................................................111

449 Sealed linear encoder...................................................BIC

499 Spindle nose tooling ..................................................... 61

549 Turning...................................................... 41, 45, 121, BIC

450 Section bending machine .........................................181

500 Spindle speeder.............................................................169

550 Turning centre, double column machining centre ....115

451 Self adhesive tape.........................................................169

501 SPMS ..................................................................................158

551 Turning holder ................................................................. 61

452 Sensitive part loading/unloading............................. 99

502 Standard & special PCD-tool ....................................111

552 Turning machine...........................................................167

453 Service ................................................................................. 21

503 Standard endmill......................................................10, 11

553 Turning tool ......................................................................BC

454 Servo controlled voltage stabiliser ........................123

504 Standard fine boring tool ..........................................111

554 Turnkey projects (energy)............................................ 79

455 Servo motor ....................................................................171

505 Standard induction hardening machine .............109

555 Turret punch press ......................................................... 40

456 Servo motors & drive...................................................143

506 Standard machine element ......................................157

556 Twin-spindle compound grinding machine......... 23

457 Servo stabiliser (air cooled)......................................... 79

507 Standard theard milling tool....................................111

557 Twist drill..........................................................................164

458 Servo stabiliser (oil cooled)......................................... 79

508 Static voltage stabiliser...............................................123

558 Uabos tooling system .................................... 111

459 Shaft ...................................................................................166

509 Steel collet .......................................................................173

559 UIT.......................................................................................123

460 Shaft loading .................................................................... 99

510 Steel working machine...............................................122

560 Ultrasonic cleaning machine....................................174

461 Shaping machine ............................................................ 62

511 Step drill ...........................................................................175

561 Universal cylindrical grinding machine.................. 23

462 Shearing machine.........................................................203

512 Stepper motors & drive ..............................................143

562 Universal radial drilling machine ............................175

463 Sheet metal machine ........................................102, 122

513 Straight flute drill.....................................................10, 11

563 UPS ............................................................................. 79, 123

464 Shock absorber ..............................................................183

514 Stub length drill........................................................10, 11

564 USA....................................................................................BGF

465 Shot blasting machine................................................182

515 Surface grinder ....................................................156, 203

565 Valve.................................................................. 47

466 Side lock adaptor ..........................................................164

516 Surface grinding machine .........................................156

566 Valve terminal .................................................................. 47

467 Silicon bronze wire.......................................................170

517 Swiss precision tool......................................................179

567 Vane pump.............................................................. 90, 153

468 Simatic HMI panel.........................................................125

518 Switching relay ................................................................ 71

568 Vegetable oil-based cutting oil ...............................166

469 Siphon system................................................................183

519 Synthetic high speed grease....................................179

569 Velocity & feed controller ..........................................183

470 Slotting machine...........................................................102

520 Tapping head.................................................. 155

570 Ventilator..........................................................................169

471 Small junction/distribution box ..............................149

521 Taps ..............................................................37, 58, 59, 181

571 Vertical boring lathe ....................................................179

472 Smart CNC .......................................................................137

522 Taps (cold forming/nss)..............................................111

572 Vertical machining centre ..................... 7, 20, 75, 176

473 Smart ZNC........................................................................137

523 Tct broach cutter...........................................................175

573 Vertical milling machine.............................................172

474 Software............................................................................169

524 TCT hole saw...................................................................175

574 Vertical turning centre................................................152

475 Software module...........................................................172

525 Telecom .............................................................................. 79

575 Vertical turning lathe...................................................179

476 Solar cell scribing system...........................................119

526 Tempurature controller ................................................ 71

576 Vision sensor..................................................................... 71

477 Solenoid valve........................................................ 90, 153

527 Thread milling .................................................................. 97

577 VMC ..........................................................................115, 147

478 Solid carbide drill .................................................. 13, 111

528 Thread milling cutter..................................................... 92

578 VMC machine .................................................................129

479 Solid carbide drill with IC............................................. 13

529 Thread rolling system.................................................... 35

579 Voltage stabiliser...........................................................123

480 Solid carbide reamer ..................................................... 13

530 Thread turning................................................................. 97

580 V-tec double column VMC .......................................... 14

481 Solid carbide reamers with IC .................................... 13

531 Thread whirling tool ................................................... FGF

581 VTL ......................................................................................203

482 Solid carbide special drill............................................. 13

532 Threading solution ......................................................... 97

582 Wall-stor system............................................. 155

483 Solid carbide special mill ............................................. 13

533 Threading tool........................................................111, BC

583 Water chiller....................................................................189

484 Solid carbide special reamer ...................................... 13

534 Timer.................................................................................... 71

584 Wear part............................................................................ 61

485 Solid mono block reamer ..........................................111

535 Tool.....................................................................................164

585 Wear parts and consumables to automation solution.... 21

486 Spade drill...................................................................10, 11

536 Tool grinder....................................................................... 62

586 Wire cut EDM.................................................................... 20

487 Spare part .......................................................................... 21

537 Tool holder ......................................................................179

587 Wood working machine.............................................102

488 Special boring bar ........................................................111

538 Tool holder-external ...................................................... 18

588 Work pallet ......................................................................184

489 Special drill ......................................................................186

539 Tool room machine......................................................102

589 Workstation.....................................................................155

490 Special fine boring tool ..............................................111

540 Tooling system.................................................................BC

590 Worshop machine & accessories ............................102

COC - Cover On Cover

FGF - Front Gate Fold

FIC - Front Inside Cover

BIC - Back Inside Cover

BGF - Back Gate Fold

BC - Back Cover

March 2011 - MODERN MACHINE TOOLS 199

Advertisers’ List Advertiser’s Name & Contact Details ABB Ltd T: +91-80-22949560 E: sanaj.natarajan@in.abb.com W: www.abb.co.in Ace Designers Ltd T: +91-80-22186700 E: acedesigners@acemicromatic.com W: www.acedesigners.co.in Agie Charmilles (South East Asia)Pvt T: +91-80-40798019 E: info@in.gfac.com W: www.gfac.com/sg

Pg No 91

131

Autogrip Machinery Co Ltd T: +886-4-822-8719 E: sales@autogrip.com.tw W: www.autogrip.com.tw

128

Autotech Machine Tools Sales & Services T: +91-20-25690044 E: autocnc@vsnl.com W: www.autotechcnc.com

8-9

Baker Gauges India Ltd T: +91-20-66093800 E: bakerbmi@bakergauges.com W: www.bakergauges.com

Bharat Bijlee Ltd 171 T: +91-22-24306237 E: vishwajyoti.vengurlekar@bharatbijlee.com W: www.bharatbijlee.com Bharat Fritz Werner Ltd T: +91-80-28395745 E: bfwmarketing@bfw.co.in W: www.bfwindia.com

FIC

Bhavya Machine Tools T: +91-79-40242800 E: info@bhavyamachinetools.com W: www.bhavyamachinetool.com

102

Advertiser’s Name & Contact Details

Pg No

Advertiser’s Name & Contact Details

Cutfast Tools T: +91-9811038569 E: cutfast@yahoo.com W: www.cutfasttools.com

175

Ermaksan Machine Ltd, Sti T: +91-224-2947500 E: sinan.bilgin@ermaksan.com.tr W: www.ermaksan.com.tr

Dijet Industrial Co Ltd T: +91-22-40121231 E: ravisane@dijet.co.jp W: www.dijet.co.jp

101

Erwin Junker Maschinenfabrik GmbH T: +91-20-26053896 E: info@junker.in W: www.junker.in

DMG Deckel Maho Gildemeister (India) T: +91-80-40896500 E: info@dmgmoriseiki.com W: www.dmgmoriseiki.com

129

Factory Automation Technology Co.,Ltd T: +886-5-213-3166 E: mark@femco.com.tw W: www.femco.com.tw

Drake Manufacturing T: +330-847-7291 W: www.drakemfg.com

Drass Mechatronics & Machinery Pvt T: +91-80-23478764 E: drassmechatronics@hotmail.com W: www.drassautomech.com

Pg No

Ferrocare International T: +91-20-26830655 E: info@ferrocare.com W: www. ferrocare.com

153

Festo Controls Ltd T: +91-80-22894100 E: info_in@festo.com W: www.festo.com

DT Technologies Cz S.R.O T: +91-4122-3628701 E: info@dttechnologies.com W: www.dttechnologies.com

173

East Coast Magnets (P) Ltd T: +91-40-23098262 E: info@sardamagnets.com W: www.sardamagnets.com

Forging Machinery Manufacturing Co T: +91-161-5011755 E: info@nkhammers.com W: www.nkhhammers.com

EFD Induction Limited T: +91-80-7820404 E: sales@efdgroup.net. W: www.efd-induction.com

109

Forwell Precision Machinery Co., Ltd T: +886-4-8345-1960 E: forwell@forwell.com W: www.forwell.com

185

24, 133

Freeze Tech Equipments Pvt Ltd T: +91-44-42152387 E: info@freezetechequip.com W: www.freezetechequip.com

181

Electronica Machine Tools Ltd T: +91-20-24232900 E: vrn@electronicagroup.com W: www.ElectronicaEMT.com

137

GW Precision Tools India Pvt Ltd T: +91-80-40431252 E: info@gwindia.in W: www.gwindia.in

Electronica Hitech Engineering Pvt T: +91-20-30435400 E: hitech@electronicahitech.com W: www.electronicahitech.com

Finechrome Shafts Pvt Ltd T: +91-22-29203647 E: finechromespl@yahoo.co.uk

153

Big Daishowa Seiki Co. Ltd T: +81-729-828277 W: www.big-daishowa.com

Ceratizit India Pvt Ltd T: +91-33-24947146 E: info@ceratizitindia.co.in W: www.ceratizit.com

Elesa-Ganter India Pvt Ltd T: +91-120-4726670 E: info@elesaganter-india.com W: www.elesaganter-india.com

157

Galaxy Machinery Pvt Ltd T: +91-80-26625771 E: blr@galaxymachinery.com W: www.galaxymachinery.com

CNC India Tools & Services (P) Ltd T: +91-80-42602119 E: pv@cnc-india.com W: www.cnc-india.com

Emag India Pvt Ltd T: +91-80-42544400 E: info@india.emag.com W: www.emag.com

167

Gallus India T: +91-124-4141434 E: info@gallusindia.in W: www.gallusindia.in

Coatec India T: +91-172-5063436 E: info@coatecindia.com W: www.coatecindia.com

Emtex Marketing Pvt Ltd T: +91-11-41540362 E: apsinghal@emtexmarketing.com W: www.emtexmarketing.com

147

Gem Equipments Ltd T: +91-22-3267800 E: sales@geminida.com W: www.gemindia.com

Cobra Carbide T: +91-8110-415003 E: sales@cobracarbide.com W: www.cobracarbide.com Cosmos Impex (India) Pvt Ltd T: +91-265-3927000 E: sales@cosmos.in W: www.cosmos.in

10-11

82, 106

Emuge India Pvt Ltd T: +91-20-39310000 E: marketing@emugeindia.com W: www.emugeindia.com Enggineering Expo T: +91-9920401226 E: engexpo@infomedia18.in W: www.engg-expo.com

141, 159

GSK CNC Equipment Co Ltd T: +91-9886835186 E: gskwang@hotmail.com W: www.gsk.com.cn Gudel India Pvt Ltd T: +91-20-25459531 E: info@in.gudel.com W: www.gudel.com

151

161

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202 MODERN MACHINE TOOLS - March 2011

Advertisers’ List Advertiser’s Name & Contact Details

Pg No

Guhring India Pvt Ltd T: +91-80-40322500 E: info@guhring.in W: www.guhring.in

Haas Automation India Pvt Ltd T: +91-20-32935433 E: sales@haasindia.com W: www.HaasCNC.com

Advertiser’s Name & Contact Details Jin Year Precision Co Ltd T: +886-4-2523-2817 E: liu0930@ms58.hinet.net W: www.jinyear.com.tw Jyoti CNC Automation T: +91-2827-287081 E: info@jyoti.co.in W: www.jyoti.co.in

Pg No 164

Heidenhain Optics & Electronics (I) T: +91-44-30234000 E: info@heidenhain.in W: www.heidenhain.in

BIC

Kabel Schlepp India Pvt Ltd T: +91-80-41158997 E: gm@kabelschlepp.in W: www.kabelschlepp.com

173

HG Technology Co Ltd T: +886-4-7362-725 E: hg.tech@msa.hinet.net W: www.hgt.com.tw

162

Kao Fong Machinery Co. Ltd T: +886-4-2566-2116 E: phoebes@kafo.com.tw W: www.kafo.com.tw

176

Hong Ji Precision Machinery Ltd T: +886-4-2422-1095 E: hongji_jasonlin@hotmail.com W: www.hong-ji.com.tw

172

Kim Union Industries Co., Ltd T: +886-4-2533-1131 E: kimunion88@gmail.com W: www.threadrolling.com.tw

166

Huen Chen Machinery Co Ltd T: +886-4-2561-6338 E: huenda@huenchen.com.tw W: www.huenda.com.tw

165

Kinematics Machines Pvt Ltd T: +91-253-2312172 E: kinematicsmachines@gmail.com W: www.kinematicsmschines.net

115

IGUS India Pvt Ltd T: +91-80-39127800 E: info@igus.in W: www.igus.in

132

Komet Precision Tool India Pvt Ltd T: +91-80-280780000 E: info.in@kometgroup.com

111

Kwality Tubes and Capillaries T: +91-141 2330476 E: papriwal@sancharnet.in W: www.vaishalimetal.com

174

Lexis Tooling Systems T: +91-422-2610571 E: sales@lexisindia.com W: www.lexisindia.com Liang Lih Machine Co Ltd T: +886-4-2426-1151 E: w2957151@ms18.hinet.net W: www.ktk-tpm.com.tw

IMT Exim (India) Pvt Ltd T: +91-44-45540442 E: innoexim@gmail.com W: www.imtexindia.com

India Mart Intermesh Ltd T: +1800-200-4444 E: pr@indiamart.com W: www.indiamart.com

105, 193

Indian Machine Tool Manufactuers’ Association T: +91-80 -66246600 E: imtma@imtma.in W: www.imtma.in Indian Oil Corporation Ltd W: www.iocl.com

206

Inter Ads - Brooks Exhibitions Pvt T: +91-124-4524200 E: blech.india@interads.in W: www.blechindia.com

77, 177

ISMT Limited T: +91-20-41434100 E: sachin.joshi@ismt.co.in W: www.ismt.com

Intel Trade Fairs & Expositions Pvt Ltd T: +91-22-28803977 E: intelexpo@vsnl.net W: www.intelexpo.com

190

JP Machine Tools Pvt Ltd T: +91-161-2531156 E: info@jpmachinetools.com W: www.jpmachinetools.com

LMT India Pvt Ltd T: +91-44-24405137 E: sales@lmt-tools.co.in W: www.lmt-tools.co.in

Makino India Pvt Ltd T: +91-80-28419500 E: slim@makino.co.in W: www.makino.com

Metcut Toolings Pvt Ltd T: +91-836-2333092 E: info@metcutindia.com W: www.metcutindia.com

135

Millitronics Cnc Machines T: +91-98-45902876 E: sales.india@milltronics.net W: www.milltronics.net

117

Misumi India Pvt Ltd T: +91-20-66470000 E: sales@misumi.co.in W: www.misumi.co.in

Mitsubishi Heavy Industries India P T: +91-11-41021234 E: mtdsales@mhiindia.com W: www.mhiindia.com Motherson Techno Tools Ltd T: +91-120-2510045 E: swayam@mttl.motherson.com W: www.motherson.com

COC

183

143

187

Neri Engineering T: +91-80-28374885 E: sales@nerigroup.in W: www.nerigroup.in

BGF

155

NN Combined Engineering Agencies Pvt Ltd T: +91-40-27844279 E: mail@nncea.com W: www.nncea.com

203

Maco Corporation India Pvt Ltd T: +91-33-24758371 E: rdutta@macocorporation.com W: www.macocorporation.com

183

Maco Corporation India Pvt Ltd 200-201 T: +91-33-40224106 E: prbhowmick@macocorporation.com W: www.macocorporation.com 169

Omron Automation Pvt Ltd T: +91-80-40726400 E: srirams@ap.omron.com W: www.omron-ap.com

Open Mind Technologies Asia Pacific T: +91-80-30504647 E: Info.India@openmind-tech.com W: www.openmind-tech.com

Palmary Machinery Co., Ltd T: +886-4-2492-9799 E: Roger@grinding.com.tw W: www.grinding.com.tw

Para Mill Precidion Machinery Co Ltd T: +886-4-2680-0678 E: para-mill@umail.hinet.net W: www.paramill.com Paragon Machinery Co Ltd T: +886-4-2539-5678 E: info@paragoncnc.com W: www.paragoncnc.com

FINALIZE SUPPLIERS @ 204 MODERN MACHINE TOOLS - March 2011

Pg No

NK Forging & Rolling Industries T: +91-161-2223666 E: info@forginghammer.com W: www.nkhhammer.com

Macht Exim Llp. T: +91-79-40087600 E: bhavin@machtexim.com W: www.machtexim.com

Madaula, S.A T: +91-9940222875 E: madaulaindia@gmail.com W: www.madaula.com

Advertiser’s Name & Contact Details

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Advertisers’ List Pg No

Advertiser’s Name & Contact Details

Pg No

Pathak Machine Tools Pvt Ltd T: +91-161-2510401 E: ritesh12@hotmail.com W: www.pathakeuromachines.com

122

Sandvik Coromant India FGF T: +91-20-27104725 E: coromantindia.communications@sandvik.com W: www.sandvik.coromant.com/in

Pinnacle Engineering Enterprise T: +91-2752-230552 E: mail@pinnaclegrinder.com W: www.pinnaclegrinder.com

156

Schneeberger India Pvt Ltd T: +91-22-22632372 E: a.joshi@schneebergerindia.com W: www.schneeberger.com

Poojitha Flex Technologies T: +91-40-23720663 E: poojithaft_bellows@yahoo.com W: www.poojithaflextech.com

187

136

Seco Tools India Pvt Ltd T: +91-2137-667300 E: seco.india@secotools.com W: www.secotools.com/in

Servomax India Ltd T: +91-40-44436666 E: dharmesh@servomax.net W: www.servomax.net

Pramet Tools India Pvt Ltd T: +91-124-4703825 E: pramet.info.in@pramet.com W: www.pramet.com

158

Siemence T: +91-22-24987529 E: machinetool.india@siemens.com W: www.siemens.com/simumerik

125

Precihole Machine Tools Pvt Ltd T: +91-22-25836780 E: info@precihole.co.in W: www.precihole.co.in

112

R K Steel Smith T: +91-9825300059 E: rksteelsmith@gmail.com W: www.rksteelsmith.com

155

Sigma Engineers T: +91-240-6600606 E: info@sigmatoolings.com W: www.sigmatoolings.com

Raj Petro Specialities Pvt Ltd T: +91-44-42288900 E: francis@rajgrp.com W: www.rajgrp.com

Sreelakshmi Traders T: +91-44-24343343 E: sreelakshmitraders@gmail.com W: www.sreelakshmitraders.com

Rajindra Machines (P) Ltd T: +91-161-2223666 E: info@forginghammer.com W: www.nkhhammer.com

189

Rittal India Pvt Ltd T: +91-80-23519792 E: info@rittal-india.com W: www.rittal-india.com

149

Suvik Electronics Pvt Ltd T: +91-79-23212001 E: info@suvik.com W: www.suvik.com

Robin Precision Products Pvt Ltd T: +91-2827-287631 E: info@bloodtools.com W: www.bloodtools.com

164

Taegutec India Ltd T: +91-80-27839111 E: sales@taegutec-india.com W: www.taegutec-india.com

S&T Engineers T: +91-422-2590810 E: sales@stengineers.com W: www.stengineers.com

127

TAGMA T: +91-22 28526876 E: diemould@tagmaindia.org W: www.tagmaindia.org

Sahajanand Laser Technology Ltd T: +91-79-23287461 E: marketing@sahajanadlaser.com W: www.sahajanandlaser.com

119

Sahil Alloys & Machine Tools (P) Ltd T: +91-1871-241925 E: surajfoundry@vsnl.com W: www.sahilalloys.com

179

Sameer Linkages Pvt Ltd T: +91-265-2638941 E: response.slpl@sameerlinkages.com W: www.sameerlinkages.com

163

Starragheckert Machine Tools Pvt Ltd T: +91-80-42770600 E: purchaseindia@starragheckert.com W: www.starragheckert.com

Advertiser’s Name & Contact Details

Pg No

Tungaloy Singapore (Pte) Ltd T: +91-11-47470762 E: dan@tungaloyindia.com W: www.tungaloyindia.com

121

Tussor Machine Tools Ind P Ltd T: +91-422-3200183 E: info@tussorindia.com W: www.pinachoindia.com

139

U-Tech Associates T: +91-80-23390309 E: udaya@u-techindia.com W: www.u-techindia.com

Vardhaman Enterprise T: +91 09322490805 E: vardhamanenterprie@rediffmail.com Vargus Ltd T: +91-9899073393 E: prasad@vargusindia.com W: www.vargus.com

181

175

169

Vinit Engineering Works T: +91-281-2312091 E: vinit@balajilathe.com W: www.balajilathe.com

179

Walson & Company T: +91-20-24331400 E: info@walsonindia.com W: www.rego-fix.com

123

Walter Tools India Pvt Ltd T: +91-20-27104800 E: service.in@walter-tools.com W: www.walter-tools.com

Werner Finley Pvt Ltd T: +91-80-23289889 E: info@wernerfinley.com W: www.wernerfinley.com

189

49-52

154

Yamazaki Mazak India Pvt Ltd T: +91-20-27351417 E: sudhir_patankar@mazakindia.com W: www.mazak.com

YG Cutting Tools Corporation Pvt Ltd T: +91-80-43543636 E: admin@yg1india.com W: www.yg1.co.kr

58-59

Takamatsu Machinery Co Ltd T: +81-76-2741403 E: h.nakagawa@takamaz.co.jp W: www.takamaz.co.jp Teknic T: +91-22-26592392 E: teknic@vsnl.co.in W: www.teknic.co.in

The Jaws Mfg Co T: +91-20-26830655 E: info@ferrocare.com W: www. ferrocare.com

Trumpf India Pvt Ltd T: +91-2066-759800 E: sales@in.trumpf.com W: www.laser-cutting-for-less.com

Yih Troun Enterprise Co Ltd T: +886-2-8521-3035 E: faye@cut-tools.com.tw W: www.cut-tools.com.tw

189

Yuang Hsian Metal Industrial Corp T: +886-4-761-3688 E: ta@yhm.com.tw W: www.yhm.com.tw

170

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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March 2011 - MODERN MACHINE TOOLS 205

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