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Editorial

Flexibility to the Fore

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obots have just about come of age, and like any outsider have to earn their acceptance, the same phenomenon applies for robots on shop floors! In fact, its sheer necessity was questioned, performance was doubted, relevance was debated and pricing was decried.

However, that was in the past and most of the doubts around these mean machines have been cleared. In the last decade, there has been a surge in robots being integrated in the production process and the level of automation continues to increase.

An increasing number of robots are being used and their capability to not only learn but also act autonomously is being tried and tested. Then again new age robots are able to adapt themselves to different situations, supporting the trend toward flexible, customer-specific manufacturing. From 1960, when the industrial robots marked their presence with the first industrial robot—the Unimate which worked with the die casting machines at a General Motors plant—to now, robots have come a far way in its evolution life cycle!

There is sound reasoning behind it. In a global competitive marketplace, each company has to react quickly to changes in its production requirements and the ever changing competitive landscape. When facing the increasing need for small and medium-sized capacity changeover, changes in parts, and increased production rates; robotics can enable companies to adapt very quickly when faced with such challenges.

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

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

Shailesh Sheth Media Chairman, IMTMA & Past President, IMTMA

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

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

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

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

According to reports by the International Federation of Robotics (IFR), Asia tops the chart in the robotics market with an increase of 132 per cent to about 70,000 units. The sales in these markets almost tripled and the main drivers of growth in this segment were the automotive, electronics and the metal industry, which heavily invested in robots. As per the report, a further increase of about six per cent per year on an average growth is expected between 2012 – 2014 during which, this segment would attain a level of about 167,000 units.

There are numerous new fields of applications in which robotic technology is not widespread today, due to its lack of flexibility and high costs involved when dealing with varying lot sizes and variable product geometries. New robotic applications will soon emerge from new industries and from SMEs, which cannot use today’s inflexible robot technology or which still require several manual operations performed under strenuous, unhealthy and hazardous conditions. Investing in robotic equipment can be a big leap for a small business as well.

As we dedicate this edition to robotics, we are helping our readership to increase productivity in labour-intensive industries through a scalable robot automation approach, thus providing competitive solutions for new manufacturing paradigms, new products and innovative business models.

Competitive manufacturing of the future will increasingly depend on the progress of robotic technologies and the availability of safe and cost-effective robotic products and related services. This in turn will have an impact on end-user industries, existing robot automation manufacturers and system integrators, new start-ups in robotics and product-related service-industries.

Robots are special, in that they both enable flexible knowledge-based production and are a complex knowledge-based product by themselves.

Automated manufacturing is now just a fact of life; you can either get with the times or get left behind. It’s not such a difficult choice to make…is it?

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

Archana Tiwari-Nayudu archana.nayudu@infomedia18.in

March 2012 - MODERN MACHINE TOOLS

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Contents Insights & Outlook Robotic Machining ........................................................... 100 Metalworking Fluids .......................................................... 102 Case Study ......................................................................... 106

Special Focus ROBOTICS

Insights & Outlook AUTOMOTIVE MACHINING

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99

Facility Visit Tata Motors Pimpri Plant .................................................. 90

Automation Trends - Factory Automation Gauging Future Industrialisation Prospects ....................... 114

Special Focus Industrial Robots ............................................................... 48 Robotising Smaller Floors .................................................. 50 Robot Optimisation ........................................................... 54 One Q Many Views .......................................................... 62 Robotics Advantage ........................................................... 72 Opinions and More - FANUC India Pvt Ltd ................. 74 Opinions and More - KUKA India................................... 78

In Conversation With

Energy management - Volkswagen AG’s ‘Think Blue. Factory’ Machining Excellence doesn’t Have to Cost the Earth ..... 120

Technology Insight - Precision Levelling Line Sheet Metal Tapes Changing the Definition of Excellence ............................... 123

Strategy - Customised Orders It’s Easier than You Think ................................................... 126

Event Preview - Modern Machine Shop Creating Business Opportunities for SMEs ......................... 130 Regular Sections Editorial ...................................................................... 19 Foreword...................................................................... 29

Malcolm Howard Principal Engineer-Body & Trim – Tata Motors European Technical Centre Plc ............... 38

News, Views & Analysis .............................................. 32 Technology & Innovation............................................ 36 Event List .................................................................. 128 Products .................................................................... 131 List of Products ........................................................ 152 List of Advertisers .................................................... 158

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NEXT EDITION HIGHLIGHTS Special Focus: Dies & Moulds Insights & Outlook: Measuring & Inspection

Cover illustration: Hemant Lambe

March 2012 - MODERN MACHINE TOOLS

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March 2012 - MODERN MACHINE TOOLS

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Foreword

Robotically Arming India Robots are finally moving out of the realm of science fiction and onto the shop floors. Asimov’s “I Robot” written in 1940s is coming true in the 21st century India.

With a population of 1.2 billion, it is a sad irony that manufacturers in our country face shortage of manpower.

In my travels across industrial towns and in all my meetings with customers, the story is always the same although reasons vary based on region—unreliability of labour, poor work ethics, etc.

Industrial robots are made for handling repetitive jobs like welding, material handling, painting or related inspection, flawlessly and consistently. Robotisation addresses work which is either unsuitable or impossible for humans, like handling heavy work pieces, pouring molten metal, welding with heavy guns or painting. Even in case labour is available, there is fatigue that sets in and thus, results in efficiency loss. Further, human intelligence lends itself to training and can graduate to more differentiated value additions within the factory environs.

Contrary to general perception, Robots are now commonly found not just among the large auto makers with their assembly lines, but, also in small job shops (less than 10 machines) in India. Current population in India is about 5000 robots of which about 600 are in SME. Demand is growing at high double digits.

The two most popular robotic applications are loading/ unloading of work pieces from machines, and welding.

The underlying promise is achievement with 100 per cent reliability. India’s top car maker turns a car around in 12 seconds. It is no accident that, this same car maker is also the largest single user of the most reliable robots in the world. Some robots have critical features

like 3D vision, touch sensing, line tracking, etc all of which contribute significantly to productivity. Intelligent features such as seam tracking bring an edge to robotic welding which is impossible for even a skilled operator to match. Additionally, robots are used for painting and yield significant benefits in worker safety, waste reduction, savings in paint and assured uniform finish.

The robotic revolution in India has been driven by the automotive industry which commands greater volumes than general industry. However, we encounter strong demand for robots wherever there is a pressure on volume production. Demand exists across India. Apart from the hubs around Gurgaon, Pune, Chennai, there is active demand for robotisation even in less industrially intense places like Kolkata, Vishakhapatnam, Cochin and Thoothukudi.

Indian manufacturers are practical and take up robotisation to facilitate marked increase in volumes; as also to maximise assured return on investment. So long as there is clarity of purpose and planning, we have found that robotisation always pays off handsomely.

Robots make a sound investment and typically pay back within two years.

The greatest vote of confidence is, when small customers come back with repeat orders. It is clear that robot population will continue to grow strongly in India easily reaching installed base of 15,000 units by the year 2017.

Sonali Kulkarni, President & CEO – FANUC India Pvt Ltd

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News, Views & Analysis

Marathwada Stronghold All Set to Rule Manufacturing

Archana Tiwari-Nayudu (left) moderates the panel discussion comprising of Umesh Dashrati, Mukund Kulkarni, Mansingh Pawar,

Milind Kelkar and Jayant Soni

Capturing the manufacturing opulence of Aurangabad, Infomedia 18 in association with Aurangabad Industrial Suppliers Association, organised a panel discussion on the investment lucrativeness and manufacturing competitiveness of Aurangabad. Acting as the prelude to the maiden edition of Engineering Expo Aurangabad, the panel discussion was truly an awe-inspiring and enriching experience for the manufacturing fraternity of Marathwada. A report…

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panel discussion on ‘The shifting status…from Why Aurangabad To Why Not Aurangabad?’ was jointly organised by Infomedia 18 in association with Aurangabad Industrial Suppliers Association (AISA) recently. The endeavour was taken as part of its value additions intended to bring together the manufacturing and dealer community of Aurangabad to discuss the critical issues related to the region’s growth as well as with an aim and intent to position Aurangabad & the neighbouring regions as the most sought after manufacturing hub. Adding advantage to Aurangabad, this was as industry enabling initiative planned along with Engineering Expo Aurangabad – the maiden edition of which was organised from February 17-20, 2012.

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Engaging Panel Discussion The panel discussion witnessed engaging participation and intense discussions along with the formulation of an action plan on ways and means to elevate & equip manufacturing in and around Aurangabad. It included industry captains like Anna Saheb Shinde, Regional Officer, MIDC, Aurangabad; Mukund Kulkarni, President, CMIA & MD, Expert Group Solutions; Mansingh Pawar, MD, Ratnaprabha Motors & Past President, MACCIA; Milind Kelkar, MD, Grind Master; Umesh Dashrati, MD, Rucha Engineers and Jayant Soni, President, AISA. This panel discussion was moderated by Archana Tiwari-Nayudu, Executive Editor, Modern Machine Tools.

Speaking during the discussion, Pawar opined that almost 70 per cent

of Marathwada’s industrialisation has happened in Aurangabad. So, Aurangabad and the regions under its vicinity not only add to the economy of Aurangabad, but also to the GDP of India. Aurangabad is brimming with growth, positivities and potential. According to him, “This is the reason why Aurangabad is attracting major investments and envious projects.

There is no alternative to Maharashtra than Aurangabad.”

Adding to Pawar’s viewpoint, Dashrati interjected, “It is not the question of why Aurangabad or why not Aurangabad; rather, it is the question of only Aurangabad!”

Adding facts and stats to the discussion, Kulkarni, while bringing out the uniqueness of Aurangabad as the most lucrative investment destination, informed, “The region is a matured

News, Views & Analysis industrial base… take the growth rate of Maharashtra, it will be around 7.56, and take the top 9 cities that contribute to the growth figures of Maharashtra; you will find Aurangabad in that list.

The city contributes `7,000 crore to the government’s kitty, which includes the taxes and the earnings. Aurangabad contributes the maximum state excise duty. You will find Aurangabad as the top contributor because of the presence of breweries here. The region also hosts the maximum number of USA FDIapproved companies. The city is the major automotive hub. Pune is called the Detroit of India and Aurangabad is an extension of this region. The city exports to 72 countries and is also a prominent pharma hub.”

From Dealers Market to Manufacturing Hub Aurangabad was earlier known as a ‘dealers’ market’ and now, it is also turning into a manufacturing hub. In this scenario, the dealer community is aligning to the growth prospects that newer opportunities will bring. Adding the dealers perspective in the discussion, Soni opined, “The shift is from traditional trading to techno trading. Now, most of

the first generation techno traders are keeping pace with the growth of the sector. They are shifting their thought process and are now into solution selling.

They are trying to understand the real need of the industry and are working very closely with the manufacturing fraternity even in terms of technical requirement of the industry. In this way, they are aligning themselves with the new age needs of manufacturing companies.”

Kelkar, the first generation entrepreneur who is now exporting to other countries, talked about how Aurangabad has changed for entrepreneurs and how the atmosphere is conducive for the growth of new ideas and businesses. He elaborated, “I started my company, Grind Master, in 1984, when it was still considered to be a sleepy tourist town, and there was a shortage of technically everything. I used to travel every Monday to Mumbai to procure and purchase components & supplies to assemble a machine. My friends in Mumbai and Pune would often tell me that just because you belong to Aurangabad, you are starting a machine building facility there; but otherwise, there is no scope for growth in this region. I am happy to prove them

wrong today. Just look around and all you will see is growth and potential for further growth.” He added, “But if we are growing, the world around us is growing even faster. So, we must keep pace with the growth of the world. I believe we need to train our workers, technicians, traders, sellers and marketing managers.

That is the way to gain a strong foothold in future.”

Adding the advantage dimension, Kulkarni informed, “CMIA has got the Marathwada Auto Cluster and is thus ploughing an investment of Rs80+ crore in the region, which will be invested in building state-of-the-art products and a process development facility. This will immensely help SMEs upgrade themselves to the world standards given the fact that individually they will not be able to invest so much on the product and process development. That is a big plus for the region, as thriving SMEs add the inclusive growth advantage to the region.”

Answering the volley of questions, the panel along with the audience of 80+, which included MDs, CEOs, dealers, manufacturers and SMEs, ascertained not only engaging, but also enabling discussion. archana.nayudu@infomedia18.in

Tata Steel Conferred with the Prestigious CII-ITC Sustainability Prize 2011

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ata Steel bagged the Sustainability Prize at the CII-ITC Sustainability Award 2011’s ceremony in the ‘Category A’ for Large Business Organization (for companies with turnover of above 500 crore).

On behalf of the Company, Sanjiv Paul, Vice President, Corporate Services – Tata Steel received the Sustainability Prize from Anand Sharma, Union Minister of Commerce, Industry and Textiles – Government of India. Reiterating the values that the company has always adopted as a benefactor for the community, Paul said, “Sustainable development means valuing the interdependence of environmental, social and economic aspects so as to 34

MODERN MACHINE TOOLS - March 2012

aim at improving the quality of life for everyone, now and for generations to come.”

Further he added, “In Tata Steel we understand that whatever choices we make and all the actions that we pursue today impact everything in future. I can proudly state that we have build on a legacy of caring and our commitment is based on achieving business success through responsible social, environmental and economic practices that help build happy communities. I would like to extend my heartfelt thanks to CII-ITC Sustainability Awards for acknowledging Tata Steel’s efforts in regards to the same.”

Tata Steel had already received the Sustainability Prize in the year 2006,

2007, and 2008 for Large Business Organization; and in the year 2009 and 2010 for Commendation for Significant Achievement.

Tata Steel’s CSR initiatives have been recognized with many awards.

Since 2006, the company has showcased an exceptional track record of receiving this coveted award initiated by the CIIITC Centre of Excellence for Sustainable Development.

The annual CII-ITC Sustainability Awards are given out to recognize and reward excellence in economic, environmental and social performance.

They are conferred to Indian businesses that demonstrate excellent performance in the area of Sustainable Development.

News, Views & Analysis

Igniting Minds to Automate Industry through IT

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ndia has for long been a major IT hub of the world and with the magnitude of industrial development, automation has been the key trend observed in most Indian shop floors. However, if the two giant industries are made to work in tandem, the growth opportunities that would evolve from this concoction will be unimaginable.

With an attempt to instigate this thought and broaden the horizon of understanding on technological developments in the industry, ISA Bangalore organised a technical talk which was attended by industry professionals and students.

The talk on Information Technology & Automation: ‘Greater than the Sum of the Two’, was presented by Dr Sudhir

Dr Sudhir Dixit addresses the future trends

when IT will play a major role to automate the Indian industry

Dixit, Director, Hewlett-Packard Labs, India. The talk focussed on the role of ICT on the key vertical markets. The discussion led to some of the key case studies of automating shop floors with the effective inclusion of advanced research at Hewlett-Packard Labs. Dr Dixit’s primary research interests are in

PTC Organises Live TechForum in India

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he product development company PTC, organised its first ever PTC Live TechForum in Mumbai. One of the most awaited technology events in India, bringing together PTC solutions experts and best-in-class industry presenters to share the latest PTC technology updates, present real-world best practices, and educate on how to use PTC solutions more effectively.

The technology doyens at PTC elaborated on its two most ambitious products, Creo 1.0 and Windchill 10.0 that were launched recently besides its other solutions like Mathcad. At the customer session customers like TATA Motors Limited and L&T MHI articulated the benefits that they derived through the deployment of PTC solutions.

“We are glad to hold TechForum in India. PTC has seen great traction and acceptance of its solutions in the Indian market. The event has help us to cognise the demand of the ever evolving market, as well as, understand the requirements of our customers”, expressed Rafiq Somani, Area Vice President and Country Manager – PTC India.

Greg James, SVP, Corporate marketing – PTC said “In the recent past India has established itself as one of the largest markets for machine tools and manufacturing solutions & TechForum aids in building the required rapport”.

broadband communications, humandevice multi-modal interactions, content networking, mobile devices, bio-inspired computing and communications and services and applications.

“Automation has been going on for a long time. The IT sector is making a huge difference in automation. In future, a vast majority of work will be done through automation and IT, but in areas where the level of complexity cannot be handled by machines, humans will have a major role to play,” said Dr Dixit.

Amidst enthusiastic response from the participants, Dixit discussed the immense opportunities that the IT can offer to the market to make the globe one small world.

DIE MOULD INDIA 2012 Promises the Latest in Technology

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he 8th Biennial Die & Mould India International Exhibition is scheduled at the Bombay Exhibition Centre, Goregaon, Mumbai from April 19 – 22, 2012. This exposition provides an ideal opportunity for the die and mould industry to upgrade its know-how and keep pace with the latest developments in this segment. It also provides an unique opportunity for the die & mould and the entire tooling related industry to witness the latest technologies in this niche sector.

The exhibitors profile includes die & mould, press tools, mould base & standard parts, hot runner system, tool steel, heat treatment, texturising, gauges, CAD/CAM systems related to dies & moulds, die spotting, machine tools for dies & moulds, C.N.C milling/machining centre, EDM, etc.

Organised by the Tool & Gauge Manufacturers Association of India (TAGMA), in Mumbai, 1998—the event has today steadily grown into the largest exposition in this segment with international participation from over 25 countries.

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TECHNOLOGY & INNOVATION Controlled Partial Penetration Welding

Research scientists at the Fraunhofer Institute for Physical Measurement Techniques IPM in Freiburg, resolve corrosion issues faced by galvanised car bodies using controlled partial penetration welding technique

Courtesy: © Fraunhofer IPM

Perfect Welds for Car Bodies

In the new surface welding process the laser produces a perfect seam. Bottom left: Weld seam profile – the penetration depth is controlled without damaging the bottom surface

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s if controlled by an invisible hand, the welding head on the robot’s arm races along the sheet metal parts.

Where the laser hits, sparks fly and the metal glows red hot. The process lasts just a few seconds. The outer door panel and the door frame are now welded together perfectly. A thin weld seam extends along the join, but it can only be seen on one side. From the other side of the welded car door the join is invisible. This is a perfect weld – the kind every car manufacturer dreams of, because it could be used anywhere on the car body. Expensive work to hide the seam, such as folding the sheet metal or covering with trim would no longer be necessary.

Research scientists at the Fraunhofer Institute for Physical Measurement Techniques IPM in Freiburg have turned this car makers’ dream into reality. ‘controlled partial penetration welding’ is how experts refer to the process in which the laser does not burn right through all the sheets of metal – in contrast to full penetration welding, where a hole briefly forms in the melt pool. Instead, the weld seam is controlled to penetrate the lower sheet without damaging the 36

MODERN MACHINE TOOLS - March 2012

bottom surface. Up till now, however, it was not possible to precisely control this type of welding and produce a seam that meets the requirements in respect of strength.

“As we do not weld through the sheet, basically we cannot see what we are doing,” states Andreas Blug, project manager at Fraunhofer IPM, outlining the problem. But they found the solution using an innovative camera that generates temperature images. This enables the system to recognise how deep the laser has penetrated into the sheets. Where it burns into the metal, causing it to melt, the images show a hot region. If the bottom of the melt pool reaches the gap between the upper and lower sheets, the conduction of heat is interrupted and a cooler point can be seen. This is referred to as the full penetration hole. From the relative frequency of this full penetration hole the system calculates the penetration depth into the lower sheet. A software program then adapts the output of the laser to the specific requirements. “The process is closed loop controlled in real time,” Blug explains. An extremely rapid camera system is needed for this – which is the key to Fraunhofer IPM’s innovation.

The system is based on cellular neural networks (CNN). A tiny processor is integrated in each pixel. They all work simultaneously and speed up the analysis of the individual images enormously, whereas in conventional image processing systems a few processors process the data consecutively. “In this way the system analyzes up to 14,000 images per second,” says Blug. This compares with the usual rate of only 1,000 to 2,000 images per second.

Together with colleagues from the IFSW Institut für Strahlwerkzeuge at Stuttgart University and the Institut für Grundlagen der Elektrotechnik und Elektronik (IEE) at Dresden University of Technology, the Fraunhofer IPM research scientists have now developed a prototype which perfectly controls the surface welding process, offering car makers a further great benefit in comparison with full penetration welding: zinc does not vaporise on the bottom side of the weld. The corrosion problems encountered on galvanised car bodies are therefore a thing of the past.

Courtesy: Fraunhofer Institute for Physical Measurement Techniques IPM Heidenhofstraße 8 l 79110 Freiburg, Germany l www.ipm.fraunhofer.de

IN CONVERSATION WITH Malcolm Howard Malcolm Howard, Principal EngineerBody & Trim –Tata Motors European Technical Centre Plc, provides Archana Tiwari-Nayudu with insights into the manufacturing of Formula 1 cars and how the emergence of this industry will impact the Indian machine tools and automobile sectors

Formulae for Efficient Manufacturing of Formula 1 Cars Q Detail the machine tools utilised

for manufacturing Formula 1 cars.

Despite this clinical sophistication of F1 cars, the manufacturing process is a strange mixture of high-tech and handicraft. The setup does not differ very much from most car factories– no robots, conveyor belts or huge pressing machines.

Computer-controlled machine tools, ultrasonic cutting machines, Electric Discharge Machining (EDM) and 5axis milling machine tools technologies, are side by side with hand-built jigs and autoclaves.

F1 cars are crafted one-by-one, with great care and attention. It’s rare to build more than five parts of the any type before revising and improving the design. “Each year we start the season with a car that is 95 per cent new compared with the end of last year. Yet before the end of the season we’ll have replaced or modified 75 per cent of the components again.”

Q How does machine tools

selection affect the speed and endurance of F1 cars?

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No business or industry sector is exempt from trying to find smarter ways to increase productivity, improve quality and reduce or control costs. The F1 sector is no exception. 5-axis technology could be used to machine a diverse range of components. The ability to accurately machine the 3D data from the designer’s CAD design to a finished part using CADCAM in ‘One Hit’ is essential.

The power, machining capability, accuracy, inherent flexibility and process reliability of a 5-axis machine, and its ability to machine parts faster, better and more economically, are the key drivers.

The machine can handle everything from heavy-duty roughing right through to fine finishing operations.

EDM technology has become increasingly important to the F1 teams and is considered to be a ‘core’ technology alongside other, more conventional machining methods. Components such as suspension uprights—which in the past were manufactured from steel and involved a considerable amount of fabrication—have been completely

redesigned and transformed in recent years. Today they are wire-profiled from solid pre-moulded MMC (Metal Matrix Composite)-derivative blanks.

Q Performance of machine tools in

fast cars under extreme conditions A good example is—a suspension upright—the component that links the suspension wishbones to the axle and the wheel. Owing to the multitude of functions the upright has to accommodate, it is subject to enormous stresses. This is particularly the case under braking when the upright must withstand the loads from downforce, the braking event and also suspension movement. EDM is a non-contact process; therefore no stresses are created in the workpiece material, which in turn helps maintain part integrity.

The previous fabrication of uprights was prone to failure—with cracking, especially on the welding joints, being a specific problem. As the parts are able to be machined from solid blanks, they are more reliable, are stiffer and have

Malcolm Howard a higher load bearing. High accuracies within a few microns and exceptional surface finishes are the hallmarks of EDM technology and can be achieved on one machine in a single set-up.

Also failures can be avoided by being able to turn the 3D CAD design into 3D parts using CAD/CAM techniques to ensure the results of CAE analysis and physical testing are achieved.

Detail the Carbon Fibre Production Process in the F1 Environment.

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Q Detail the evolution on Indian

shop floors and how this will affect the dynamics of machine tools and the manufacture of SUVs. F1 car manufacturing is rocket science compared to standard car-making economics. While manufacturing half a million cars, saving £1, a time on a single component makes a big difference to the total profit. When building a dozen cars, the cost of hand-building them from some of world’s most expensive raw materials is negligible next to the opportunity to squeeze a worldbeating performance from continually refining your product. Saving £1 (on a part) matters enormously to engineers working on production cars, but saving a tenth of a second matters more to F1. It doesn’t have to be efficient, but it does have to be high performance.

At TML we use 5 axis machines in our prototype shop, for one offs to 100 off parts. We also use them in our Powertrain & tooling manufacture. We are constantly looking at new technologies from F1 to improve our processes.

Q What are the materials used in F1

and the latest machining processes?

Carbon fibre is the most widely used material in a Formula 1 car accounting for around 75 per cent of its construction.

Composites are defined as ‘materials in which two or more constituents have been brought together to produce a new material consisting of at least two chemically distinct components, with resultant properties significantly different to those of the individual constituents’ The first vehicle to use carbon fibres in a volume environment is Bayerische Motoren Werke AG (BMW) and will be

Cutting The sheets of material are trimmed to pre-determined patterns, utilising incredibly high tech cutting machines. The cloth is also very sticky indeed, having been doused in epoxy resins. A computer-controlled ultrasonic cutting machine slices the precisely measured sheets of resin-impregnated carbon fibre cloth. Until it is cut, the carbon fibre has to be stored at - 18 °C, because it begins to harden at room temperature. An ultrasonic cutting machine is not a luxury—its speed and accuracy are vital. Some detailed cutting work is also performed by hand.

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Moulding The cut sheets are laid into moulds of pre-determined patters in a special airconditioned clean room. This pattern of interwoven matting is what gives the finished component its strength. The material is then put in a vacuum bag.

Once the parts have been put in the vacuum bag, they are moved to the autoclave. The autoclave is a sealed vessel that applies pressure (between two and six times normal atmospheric pressure) and heat. The pressure, combined with the vacuum bag, ensures that components fit the moulds exactly, while the heat (usually between 130°C and 140°C) hardens the resin. Since this process is computer controlled, the design team can change the programs as necessary.

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Assembly Once the process is accomplished, the parts are sent to the assembly teams for finishing. Even parts formed to such precise specifications as the suspension wishbones must be detailed by human hands to fit properly. This ensures that all parts can fit together properly. If drilling or other machining is required, the parts are sent back to the CNC division. Some components go through steps 2, 3 and 4 a number of times as most of the carbon fibre components have honeycomb cores made of things like Kevlar and Nomex as well as foams and most commonly aluminium. These give carbon fibre parts additional strength and make them less brittle. But the way carbon fibre shatters has lead to great steps forward in car safety and it would be very difficult to pass the tough FIA crash tests with anything other than a car made of carbon fibre. Typical parts made from carbon fibre and other composites also include- Chassis, bodywork, front wing, rear wing, floor, wishbones, steering wheel, crash helmet (with Kevlar also).

the BMW i3, an all-electric car designed to meet the mobility needs of drivers in highly populated urban areas throughout the world. The ‘Life’ module part of the design is the passenger compartment made from high-strength, extremely lightweight carbon fibre-reinforced plastic (CFRP). The use of this hightech material across large sections of the car ensures the Life module is remarkably light helping to improve the BMW i3’s range and performance.

Q Explain the importance

of automation in the F1 manufacturing process.

Due to the limited number of parts required, automation is not a prime requisite for F1. However, we are working on automating F1 type processes, so that they can be used in mass production.

The need to meet ever changing demands with respect to weight/ performance, quality etc can only be achieved with new design techniques, materials and processes. To achieve this, the machine tools must be ‘cutting edge’ to deliver the components to the precision, quality and cost that OEM’s aspire and Tata Motors is planning to be at the forefront of this technology. archana.nayudu@infomedia18.in

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ROBOTICS Special Focus Industrial Robots ........................................................................... 48 Robotising Smaller Floors .............................................................. 50 Robot Optimisation ...................................................................... 54 One Q Many Views ..................................................................... 62 Robotics Advantage ...................................................................... 72 Opinions and More - FANUC .................................................... 74 Opinions and More - KUKA Robotics ......................................... 78

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SPECIAL FOCUS Industrial Robots

Mechanically

ARMING Manufacturing Wonders

The changing dynamics of the Indian industry has made robotics a necessity for every shop floor today. The speed of manufacturing, detailed precision and meeting unparalleled quality levels, are the reasons which have prompted the rise of robots. A decade back, robots were an engineer’s dream; Debarati Basu finds out how that dream is fast becoming a reality today on Indian shop floors

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s India has poised itself in the midst of global attention, it is time now for the Indian manufacturing sector to prove its mettle and match up to global requirements of quality, precision, volume and speed of delivery. Known to the world as a cost effective destination for outsourcing, managing an Indian shop floor is no longer a ‘cheap’ haven for the domestic manufacturers; given the economic unrest and dearth of skilled manpower.

This is the time, when most shop floors are realising the dire need to automate their manufacturing process for ramping up production and quality parameters.

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Robots thus have come up as a natural solution to meet the demand.

However, it is essential to understand how robots can be incorporated in the manufacturing system, so as to harvest optimal benefits.

Robo Stats According to reports by the International Federation of Robotics (IFR), Asia tops the chart in the robotics market with an increase of 132 per cent to about 70,000 units. The sales in these markets almost tripled and the main drivers of growth in this segment were the automotive, electronics and the metal industry, which heavily invested in robots. As per

the report, a further increase of about six per cent per year on average growth is expected between 2012 and 2014 during which, this segment would attain a level of about 167,000 units.

While the automotive industry has been the driver of automation in the Indian manufacturing industry, an equally huge impetus is expected from the growing domains of aerospace, medical equipments and consumer durable goods segment in future.

In the Indian manufacturing scenario, while the lack of skilled man power boosts the need for robotic solutions, the increasing criticality in the manufacturing process is also

Industrial Robotics compelling manufacturers to vouch on reliable solutions to increase efficiency, maintain quality and reduce the cycle time of the entire process.

Over the decade, given the technological advancements, the cost of implementing robotic solutions has also declined. The industry is now moving towards making intelligent robots with additional features like robotic vision and force sensing which has been changing the dynamics of robotic application.

What to Robotise?

Most Indian shop floors, still ponder on the need to implement robotics and automate the shop floor. A major portion of the manufacturing industry deals with jobs which are repetitive in nature. Manufacturers should first determine the areas of production where robots are the most effective replacement for manual operations.

A long term vision while investing is required on the shop floor.

While a typical manual efficiency ranges from 65 – 75 per cent, robotic cell efficiencies usually shoot up to 90 – 95 per cent. Furthermore, while the Indian industry is trying hard to make a mark in the global markets in providing consistency in the quality of products, a robotic solution comes in as a necessity. Providing similar level of quality and precision in the first and the hundredth batch of components is the key to strike a level of confidence in the global market. While manual operation does not assure a consistency in quality, robotic applications provide the assurance.

Also, the complexity in the manufacturing process today has made human interference difficult, thus increasing the dependence on robots.

Robotic Optimisation Simply introducing robots to a shop floor is not a solution for higher productivity.

These machines need to be intelligently blended into the system for optimal response. The new age robotic solutions aim for multi-purpose operations. So, along with the loading and off loading

Where to Incorporate Robots

In areas that are unsafe for humans In jobs that are not economically viable in a high wage economy In repetitive operations In jobs which needs minimal human interference In complex operations which demands high precision

Challenges in Automation

Reorganise the manufacturing operation to blend robotics in the system Change the mindset of shop floor workers Train the shop floor engineers to operate the robots Availability of space to encompass robots Deal with a longer return on investment after implementing robots

activities, the industry today needs robots to be involved in performing numerous operations at the same time.

The industry has made more progress than ever in this segment. To utilise the industrial robots optimally, the role of a robot is effectively changed by tweaking its software and hardware parts so that the same robot can be used in a completely different operation if the manufacturing operation alters with customer demand. On the other hand, efforts are being made to make robots immensely efficient by changing the end of arm tooling (EOAT) operations.

So with high-speed loading and unloading operation, robots today are simultaneously doing other operations like deburring, palletizing, testing, etc.

However, care needs to be taken on the way the shop floor is structured. It is highly critical to add EOAT operations which are in tandem to the manufacturing process to avoid unnecessary extension in cycle time. In such a situation, it is crucial to know how the parts should be presented to the robot. If the parts

come in bulk, they can probably be bulk fed, but if they are from a previous machining operation, a different method needs to be considered.

Emerging Developments The developments in the area of robotic applications are increasing by leaps and bounds. Innumerable researches are being carried out in the field of robotic vision for improving precision in detection process.

While conventional robots are sightless, parts handling demands precision fixturing to assure successful, repetitive presentation of parts to the robot’s grippers. With vision, robots can routinely adjust to variations in part placement. Robotic vision is being developed to a point where it is relatively inexpensive to use a fixtureless conveyor that presents parts to a camera and feeds back part position and orientation to the robot.

Future Outlook Cost was probably one of the hurdles that deterred the progress towards complete automation. However, the magnitude of work which is pouring in and the pressure to sustain the quality demands has made it imperative to deploy a robotic force in shop floor processes.

While automotive industry generates an unparallel demand for robotic solutions, the role of a robot has profusely changed over the years.

Apart from the basic role in material handling, robots today are used in a wide rage of industries like packaging, jewellery making, part handling, medical equipments manufacturing and many more.

However, implementation of robotics does not necessarily imply exclusion of a human work force.

Amidst all the efforts to automate shop floors, human intervention would always remain an integral part of the system.

The Indian shop floors now need to strike a balance to incorporate robotic solutions to enhance productivity and efficiency. debarati.basu@infomedia18.in

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SPECIAL FOCUS Robotising Smaller Floors

SHAKING HANDS

with Mechanical Arms

Robotic application is no longer just an option for large industries. The road to robotic automation might not be smooth, but this is the direction which most companies are now moving towards. Debarati Basu visits one such small scale industry which adopted robots on its shop floor; and finds out how small players can efficiently make robots a part of their manufacturing operation.

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sk any small or mid-sized company if robots can be a shop floor reality amidst all the economic mêlée and cost struggle; and the prompt answer to it is – ‘If it’s not now, it’s never. ’They sure have a point, for today, to be able to play by the global rules and standards, perfection and quality assurance undoubtedly has an upper hand over compromise on cost.

Mechatronics, a Bengaluru based small scale industry learnt the trick long time back when most SMEs did not dare to dream of robots. This young company which started 37 years back first introduced robotics on its shop floor in 1998 when the concept of having mechanical arms doing the jobs only fascinated the others.

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This attempt back then was not a success and the company retraced its operations back to its human work force. The company, which specialises in welding and fabrication of automobile components, has since then grown from 10 workers to 400 employees in its three units in Bengaluru declaring an annual turnover of Rs 25 crore. The company has made three attempts before successfully robotising its shop floor.

“In 1998, robotics was a new concept in itself and we were one of the first companies in Bengaluru to take up a robot at that time for our welding operations. But we did not have a good experience. Instead we faced quality and speed problems. We took it up again in 2003 for a short while and then after a gap of five years we incorporated

robotisation in 2009 and this time we got everything right and it is working for us,” BNV Raman, CEO, Mechatronics.

One of the major and consistent customers for the company has been TVS Motors to whom they have supplied pressed and fabricated parts since their very first TVS moped rolled out in the market.

Why Robots?

Against 45 welders, the company has incorporated three robotic welders. But surprisingly the company does not boast of any dramatic improvement in the production capacity with the integration of robots.

“Increasing production was never really our criteria. Welding by nature is not an easy process. It generates a lot of

Robotising Smaller Floors fumes and hazardous lights, from which humans as welders need to be protected from. Robots come in as a replacement as they protect the humans from the health risk,” explains Raman.

The other reason where robots come in as a replacement is when SMEs take up de-scaling as a strategy. In an age of growth and better opportunity, most skilled welders choose to work with larger companies rather than joining an SME. In such a scenario, robots come in as a replacement to generate better quality jobs and sustained productivity without depending on skilled workers.

The downside however remains the cost of the robots which will always be more expensive than the Indian work force.

Strategising Robot-friendly Shop Floors Making the first big investment to incorporate robotics is certainly the primary step. While the European brands are more expensive than the Japanese, the optimal return on the investment depends on the choice of robots. Mechatronics went for the mid range robots after an indepth research on what their operations really require.

Raman divulges that while the finances are tough to get, the payback of the investment for any mid sized robot is almost 5 to 7 years. This is an area

How to Invest in Robots

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Know your specifications. A 7-axis robot will be rendered useless if a 5 axis robot can be used optimally for machining operation Study the quality of the robot in terms of. repeatability, accuracy, precision and other features Not everything can be robotised.

Understand your shop floor requirements and incorporate robotics for appropriate operations.

It is not important to invest in bigger brands or compromise with cheaper products. Invest judicially MODERN MACHINE TOOLS - March 2012

where laying out the right strategy pays.

An abrupt implementation of robots for the sake of mechanisation is certainly not the idea. Mechatronics took a slightly different approach.

Among all the different products that they manufacture, they decided to completely robotise only one product.

Unlike other companies, they chose not to adopt the mix of manual and robotic welding strategy. The approach helped by giving them a lot of control over the entire process with which they could manage the interactions a lot easier with the human interface.

“Along with the quality of welding, we saw a 15 per cent improvement in

BNV Raman, CEO – Mechatronics Nobody in India manufactures robots and this would be the next big opportunity as there are several companies in India who are moving towards robotisation. As of now we completely depend on imported robots.

the consumable usage, like wires and gas, etc because welding is a process which uses a lot of consumables like inert gas and MIG welding wire,” said Raman.

However, productivity increase is an area where different companies have different experiences depending on the type of welding operations.

The strategy to strike equilibrium between man and machine to subsequently increase productivity is by using the strength of a robot and the brains of human. Shop floor engineers can be spared the monotonous cycle of manufacturing and instead give them space to think and cull out ideas to improve the manufacturing process.

“One of our shop floor engineers suggested that a particular operation be split into two sittings instead of one so that it is easier for the robots to do

Obstacles in Implementing Robotics

Technical hiccups: How to get the robots do your job correctly Financial crunch: Robots are any day expensive than man power.

Focus on the long term ROI Training human interface: No robot can work in isolation.

Train shop floor engineers to manage the robots efficiently.

the operation. We designed separate fixtures accordingly and that improved productivity by 40 per cent. You can see a difference in productivity when shop floor personnel give you ideas because they are able to visualise the process better and can give productive suggestions which educated engineers and managers find difficult to observe,” said Raman.

Challenges for SMEs The cost of the machine still remains the main constraint for most SMEs to make an investment. Apart from the machine, capital for amalgamating new age robotics with the long followed manufacturing process is also essential.

“We have been giving feedback that companies need to make robots smaller in size and affordable by SMEs. If the robotics industry can break the ` 10 lakh barrier, the Indian industry will embrace robotics in a big way. Most people today do not go into robotics because of the cost,” justifies Raman.

The small and mid-sized companies, form the backbone of the Indian manufacturing industry. Instead of confining itself to smaller projects, this segment is exploring its potential and striving to bag bigger international contracts to prove its mettle. But a dearth of skilled engineers amidst the rising quality parameters has pinched this segment hard. Investment in robotics undoubtedly has become a necessity for the smaller companies to make a bigger mark in the industry. debarati.basu@infomedia18.in

SPECIAL FOCUS Robot Optimisation 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.

Get Set Robo!

A weakened dollar combined with increased global demand has many factories scurrying to increase production and hiring. And while there is a larger pool of potential employees, it has always been difficult—especially for smaller firms—to find qualified people.

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weakened dollar combined with increased global demand has many factories scurrying to increase production and hiring.

While there is a larger pool of potential employees, it has always been difficult— especially for smaller firms—to find qualified people.

Manufacturing has always been cyclical, and forward-thinking companies should be using the current manufacturing environment to streamline, improve efficiencies and position themselves to be competitive during the next downturn. While we can’t control the general manufacturing environment or the relative strength of the dollar, we can control manufacturing efficiencies, productivity and the cost of per piece labor.

Robotic part handling is one solution.

Over the past decade, the price of robotic systems has been declining while the speed and technology available has increased.

Cycle times less than 30 seconds have become commonplace. Well-engineered systems can often achieve cycle times less than 10 seconds. Additionally, robotic vision and force sensing have brought about a new generation of “intelligent” manufacturing cells.

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Robots can be integrated into the workzone of a machine tool to perform load and unload functions

The first step in determining whether robotic part handling is the right choice for a particular shop involves identifying operations that entail a great deal of manpower and that are repetitive in nature. While today’s robotic cells can ‘think’ to a degree, a shop that is new to robotics is better off starting

with a relatively simple application to begin with. Here are a few tips to keep in mind when researching robotic part handling.

Look for applications that are highly repetitive in nature. While an operator might be able to outpace a robotic cell in the short term, it is not possible

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Robot Optimisation to match robotic efficiencies in the long term. Typical manual efficiencies range from 65 to 75 percent. Robotic cell efficiencies are usually in the neighborhood of 90 to 95 percent.

Look for multi-shift work or jobs that are requiring overtime to be paid out. The more labor cost that can be replaced with a robotic cell per year, the faster the payback. A reasonable ROI for a robotic cell is typically in the 18 to 24 month range, while paybacks of 12 months or less are not unheard of.

Take into account the full cost of labor. This ‘burdened’ rate includes any benefits that the company pays out as well as the employer’s share of payroll taxes. Typically, a burdened labor rate is approximately 30 per cent higher than the nominal labor rate.

If this will be the first robotic cell, try to look for an application that requires minimal or no part change-over.

If tooling change-over is necessary every couple of hours, or even every shift,

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the full benefits of automation will not be seen.

Additionally, an application should be ‘automation friendly,’ meaning that it comes ready to be automated.

If a machine tool will be tended, an automation interface should be purchased from the machine tool builder.

Alternately, there are companies that can provide aftermarket interfaces, or when all else fails, an electro-mechanical interface can be created.

Also, operator accessibility should be considered. Even a fully automated cell will require intervention on occasion for such things as making tool offsets, changing tools, and so on. While the cheapest and easiest solution is often to put the robot directly in front of equipment, this can create problems in the long run.

Another aspect to ponder is how the parts should be presented to the robot. If the parts come in bulk, they can probably be bulk fed, but if they are coming from a previous machining

operation, a different method may need to be considered. Robot vision has developed to a point where it is relatively inexpensive to use a ‘fixtureless’ conveyor that presents parts to a camera and feeds back part position and orientation to the robot. Part trays are another solution that can provide high part density, and hence, a long part queue in a small footprint.

While these tips should provide a good starting point from which to consider robotics, it is highly recommended to bring in the services of a skilled integrator. A shop’s staff knows its own application better than anyone from outside the business, but sometimes it helps to get a fresh set of eyes on the problem.

Performing a quick return on investment (ROI) calculation will give companies a good idea of which applications might be a good fit for a robotic cell.

Courtesy: Modern Machine Shop Magazine

SPECIAL FOCUS One Q Many Views

Can Robots Replace Manual Operations on Indian Shop Floors

A decade back, the idea of a swank automated shop floor meant elimination of man power. But the mindset today is changing. The International Federation of Robotics (IFR) claims that Robots are proving to be job generators instead. But can the Indian industry claim similar fate for its manufacturing sector? Is the shop floor mindset changing with time? Debarati Basu creates a common platform for the industry leaders to debate on whether the nation which heavily depends on blue collar jobs is ready to robotise its manufacturing process? Also, how effectively can the industry strike a balance between increased productivity without hampering employment opportunities Manjunath H S, Sr Manager, National Sales, Robot Dept – FANUC India Pvt Ltd Robots are not a replacement of the work force. Instead, they are the supportive elements. One cannot eliminate human workforce because they are the brains behind the machine. Also, incorporating robots would not mean reducing manpower.

While robots are needed to do the repetitive processes quicker with consistent efficiency and quality, the human work force can be utilised effectively in other productive areas like checking on the overall quality and improvement of process, etc. Till now, operators were used only in loading

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and unloading operations but with robots in place, humans can now look into the process itself and contribute their intelligence in process enhancement.

This balance between human and robots on shop floors will enhance productivity and the process of manufacturing itself will get refined with improved quality and reduced cycle time. A few years back, it was perceived that robotics may lead to losing jobs, but now people on the shop floor are open to the idea of making robots a part of the system.

With this change in the mentality, the manpower available in the shop floor will be more involved in enhancing the quality of work.

One Q Many Views BNV Raman, CEO – Mechatronics Robots cannot be a 100 per cent replacement of human workforce, at least in the present form. You need to be very careful with what kind of components you want to robotise.

Out of the 45 parts that we make, our study found that there are not more than 20 components that you can robotise with effective results. The reasons being, robots cannot do some aspects of welding and there are some other processes which are so small that it is financially not viable

to involve robots in those areas.

The fear of robots replacing human is still there in the industry at some level even though most people do not express it. But, we need to understand that the growth of the Indian industry is much higher than the growth of the robotics industry. The replacement is practically impossible.

Today the shortage of skilled welders is the main reason of incorporating robots. It is practical to replace robots in jobs which humans should not do. The intelligence of the human work force should instead be used to think of better ways of increasing productivity.

Dr Sudhir Dixit, Director &Chief Technologist – Hewlett Packard Labs India IT today is playing a major role in automating the manufacturing industry without replacing humans.

In the near future, you will see that humans will be doing the kind of work which is more conducive to human environment than being on the shop floor. However, this does not suggest displacement of humans. Instead, automation will move them from shop floor operation to backend operations which would lead to better results of the company as well as the employees. Humans

obviously play a significant role in the system because they cannot be completely removed from the loop. But the Indian manufacturing industry is quite efficient and is effectively incorporating automation.

A human interference is always needed because it is difficult for an automated system to envision much ahead of time, the various factors that can possibly go wrong. At times, humans can diagnose the problems much faster. In future, a vast majority of work will be done through automation and IT, but in areas where the level of complexity cannot be handled by machines, humans will have a major role to play.

Raj Singh Rathi, Managing Director – KUKA Robotics India Robots can never replace humans.

Even though robots have been a part of foreign shop floors for many years, this has never been the case there either. There are various factors to be considered here. Robot is just one additional tool given to the operator.

This machine might have the competence of doing the job of many operators but it still needs to be guided by a human operator to keep a check on the entire process. This is where humans and robots strike

Striking Balance So, while robots can never replace humans completely, the trick is to cull out ways in which manufacturing operations can be effectively automised to get the best productivity results. As the industry is moving towards robotisation, it has also evolved its shop floor operations.

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a balance. It is a misconception that investing in robots would mean handling multiple tasks by robots and replace humans on the job. We can never completely replace human interference. Also, it is wrong to assume that one robot can handle 10 different tasks at a time.

A robot will only perform according to the task given.

Incorporating robots does not mean reducing employment opportunities instead we are using the available resources optimally and in an effective way to thereby prevent wastage of resources. Robots however will bring in better quality and more quantity products which is a necessity for the industry today.

from handling painstaking monotonous jobs to becoming the think pad for the industry to develop ideas on productivity enhancements.

A report by Metra Martech and the International Federation of Robotics (IFR) claims: “In world terms, three to five million of jobs would not exist if automation and robotics had not been developed to enable

cost effective production of millions of electronic products.” The rising demand for quality and precision has certainly made it imperative to robotise the manufacturing procedures, but with time, the Indian shop floors too will learn to strike that balance between man and machine. debarati.basu@infomedia18.in

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SPECIAL FOCUS Robotics Advantage

10 GOOD REASONS to Invest in

ROBOTS

Robots have been proven to deliver a host of benefits in a wide variety of applications. End users introducing robots to their production processes have typically seen a significant transformation in their productivity and efficiency, with higher levels of output, product quality and flexibility among the many improvements reported.

Reduce Operating Costs

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Using robots enables you to reduce both your direct and overhead costs, making a dramatic difference to your competitiveness. Take energy, for example. With no requirement for minimum lighting or heating levels, robots offer a great opportunity to cut your energy bills. Current estimates point to a potential saving of 8 per cent for every 1°C reduction in heating levels, while savings of up to 20 per cent can be achieved by turning off unnecessary lighting.

Robots can also eliminate the costs associated with manual workers, not only in terms of wages, but also additional costs associated with training, health and safety and employee administration.

Improve Product Quality & Consistency

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With robots you can produce a consistently high quality finishing of materials, as the machine will not suffer from tiredness, distraction or the effects of repetitive and tedious tasks. Their inherent accuracy and repeatability also means that you can count on a high quality finish for every product produced.

Improve Quality of Work for Employees

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With robots you can improve working conditions for your staff. They’ll no longer have to work in dusty, hot or hazardous environments. In addition, by teaching them how to use robots they can learn valuable programming skills and do work that is more stimulating.

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Robotics Advantage

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Increase Production Output Rates Robots can be left running overnight and during weekends with little supervision, so you can increase your output levels and meet your client’s order deadlines. A robotic solution will not need time away from production for breaks, sickness, distractions or lapses of concentration. Robots now can also be programmed to handle new products off-line, ensuring new products are introduced for faster production.

Increase Product Manufacturing Flexibility Robots can provide flexibility to your production line. Once the processes you require are programmed into the robot controller, you can easily switch from one to another and maximise your spend investment by using robotics equipment for a variety of products.

Reduce Material Waste and Increase Yield By using robots, you can vastly increase the quality of your production. You will have more products finished first time to the standard required by your customers, and reduce the amount of breakages and waste produced as a result of poor-quality or inconsistent finishing. With products being produced to such a high level each time, you will gain greater yields.

Comply with Safety Rules and Improve Workplace Health & Safety Robots can readily take over unpleasant, arduous or health-threatening tasks that may be currently undertaken by manual workers. By using robots, you can decrease the likelihood of accidents caused by contact with machine tools or other potentially hazardous production machinery or processes. They can also help to eliminate ailments associated with repetitive or intensive processes, such as repetitive stain injuries (RSI) and vibration white finger.

Reduce Labour Turnover and Difficulty of Recruiting Workers

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The high precision demanded by today’s industrial processes requires the highest levels of skill and training. With highly skilled manual workers becoming harder and more expensive to employ, robots can provide an ideal alternative. Once programmed for your process, they are ready to begin work with none of the costs associated with recruitment or ongoing training of people. Robots can also offer greater flexibility, both in terms of work patterns and the ability to handle different production tasks.

Reduce Capital Costs (inventory, work in progress) With robots you can reduce the cost of consumables used and reduce wastage. By moving products faster in production, businesses can better predict the production rate and ensure a fast and efficient service is delivered.

Save Space in High Value Manufacturing Areas Robots can be placed on shelf systems, on walls or even on ceilings. They can also be programmed to work in confined spaces so you do not lose valuable floor space.

Courtesy: ABB

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SPECIAL FOCUS Opinions and More In an age which is defined by high speed productivity and quality, robots are now becoming an irreplaceable shop floor necessity. Manjunath H S, Sr Manager-National Sales (Robot Department) – FANUC India Pvt Ltd. explains to Debarati Basu the changing dynamics of Indian shop floors and the advancements in the robotics sector

Q How is robotics on the Indian

shop floors evolving? What are the factors promoting robotics usage in India?

Manjunath H S, Sr Manager-National Sales (Robot Department) – FANUC India Pvt Ltd.

The reality of fully automated operation cells is not far off 74

MODERN MACHINE TOOLS - March 2012

companies. Lately, as the robotics industry has commenced the creation of solutions for the nonautomotive segment, the industry has started to realise the advantages in it. Robotics today is a part of almost every sector as the industry focuses on high quality products with minimal errors caused due to human interference.

In India, the first change over in the field of automation took place in the automobile industry. It was anticipated that this segment will quickly adopt and optimise upon this technology. However the fear that automation would replace human employment Q What other emerging sectors opportunities is what slowed can robotics target? down its inception in the early Robotics plays a major role in years. Globally companies had non-automotive segments as well adopted automation long ago, due because; it is not the numbers, but to its obvious advantages; however, the quality which is more critical. it was only post the 2008 – 09 Operations like welding, recession that Indian companies palletising, handling, painting, etc followed suit. People realised that are some of the areas where robots India’s industrial growth potential can be more effective. Lately we is high and thus, the expansion have found that the earth moving plans were accelerated. But with equipments sector is coming up in expansion plans, came the need a big way. There is a lot happening for cost effective production, in this segment and they are skilled work force and stabilised generating a lot of enquiries for production facilities to meet the robotic solutions. international demands. Shortage The metal pouring operation of labour intensive work forces is also a segment where robotics along with added quality concerns play a major role as human are some of the major issues in interference is very difficult in this this area. area. Precise parameters like the For jobs which are repetitive pour volume and the temperature in nature and require a substantial control which are to be monitored number of skilled personnel, at severe conditions are precisely automation is a simplifying handled by FANUC Robots. All solution. The automobile segment these operations are being done deals with large scale production intelligently by the robots. Even and automation is the only way the Indian railways have started that this issue can be resolved. using robots in welding and metal However, there has been a handling processes. misconception that automation There was a time when people is required only in automotive doubted the capabilities of a robot

Opinions and More but now the industry is generating the need for robots in the most unique operations. Things are changing and the reality of fully automated operation cells is not far off.

Robotics is also foraying into new avenues of operations in sectors like the medical appliances, testing equipment, domestic appliances, packaging industry, jewellery making industry and handling industry, etc.

Q For managing manufacturing

complexities, are PC-Based Robotic Controls better or do OEM Robotic Controls meet the needs?

Applying robotics is all about incorporating intelligence in mechanical devices. We at FANUC build the control system along with its dedicated software, motors, encoder, etc. Such single source development and common integration helps to get a highly reliable product and control the entire system on precise parameters. When you know the strengths and lacunae of your own system, it is easier to commence governing it.

In case of a PC based robotic control, you have to write in a logic which corresponds to the parameters of others which is not easy because the user and the manufacturer are different.

The reason why FANUC commands more than 65 per cent share in the automation world is because we build the entire system under the same roof and supply highly reliable robots. This way, the product becomes extra reliable and behaves the way you want it to.

Q Vision guidance is a critical

aspect in robotics; share the latest developments in this technology?

Vision integration is an important criterion as the industry needs to increase the flexibility in automation. There are new developments happening in the area of 3D vision like, the high definition vision system. Certainly improvements in the vision systems will lead to incorporation of automation solutions in varied applications enhancing the 76

MODERN MACHINE TOOLS - March 2012

profile of automation. Presently, we are working on projects like, random bin picking of components with 3D Vision.

Q Has there been any evolution

in robotics to make them more productive in harsh environments?

Working of Robots in harsh environments brings in the aspect of product reliability. In India, environments are harsh, the shop floor conditions are in the improvement stages and there is variation in temperature and humidity levels across the country. Ensuring a negligible failure rate in such conditions is a challenge.

Keeping these factors in mind, FANUC’s R&D team continuously works on devising methods to increase the product reliability. In our control systems we have developed features like the Error Correction Codes (ECC) which helps in drastically reducing the breakdowns.

Q The industry today is in need

of multi purpose robots. What is the kind of demand trend generated by the industry?

As we move towards the Total Automatised cells, robots will be utilised for doing multiple operations in the cell. This helps in preventing human interference and decrease the cycle time.

Robots will not only handle materials, they also do the assembly, palletising, testing, measurements, intermediate process of machining like the deburring, deflashing, etc.

A basic robot can do multiple operations but the End of Arm Tooling (EOAT) makes all the difference.

If the cycle time permits, there are various activities which one robot can do. But such multi-utility of robots can effectively take place only in a fully automated setup.

Q How will the control technology

help add precision to the field of robotics?

Nano technology is being effectively incorporated by FANUC in all its

products. FANUC is continuously working on this effective implementation in their control technology along with the effective feedback system to give highest precision in automation solutions. We are also making continuous improvements in increasing the intelligence levels of the robot by development of products like the vision system, force sensors, vibration sensors (accelerometer), servo guns, etc, which will lead to making the process more precise and efficient.

Q How can Robotic Automation

be transformed as a practical solution in low-volume production?

In non-automotive industry, robotic solutions are not based on the volumes but, on the consistent quality generated for the entire range of production.

In non volume segments, like medical equipment or the earth moving equipments’ segment, the precision in process is more critical. The first product and the tenth product should have the same level of quality. This is difficult to be maintained by humans. Manpower turnover is also a problem in both low-volume and high volume industries. This factor is also considerably contributing an impetus to the usage of Robotic solutions.

Q What are the major challenges

faced by Indian shop floors in incorporating robotics?

Mindset and cost are certainly the basic challenges. Generally Indian industries take up automation as the last option on the shopfloor. The industry needs to understand that it is not the cost but the value that the product will earn in a longer run. Industries should be flexible to work on their process, flow lines, to accommodate robots in their units. Certainly it is a challenge to make people realise that robots are for improvement of their quality, quantity, an income earner for long period, but things are changing fast. debarati.basu@infomedia18.in

SPECIAL FOCUS Opinions and More

Not only automotive, but, many other engineering sectors are also looking for robotic solutions Robotic and automated solutions are gradually gaining prominence on Indian shop floors, this has given momentum to the manufacturing industry in the nation. Raj Singh Rathee, Managing Director – KUKA India, informs Nishant Kashyap; about the changing dynamics of robotic solutions in India

Q In what ways are Indian shop

floors changing their adoption of robotic solutions?

As the manufacturing industry is growing in the country, we are observing a great increase— especially since 2011—in the number of companies opting for robotic solutions. The biggest concern for adopting robotic solutions is productivity and quality. The cost of automated and robotic solutions has gone down in recent years, which is also one of the reasons for industrial adoption of this technology. Volumes are increasing on the robot production side making it possible to maintain a particular price level of robots. Which 78

MODERN MACHINE TOOLS - March 2012

is the major reason behind several companies adopting robots.

Change in the price of robotic solutions is not as high as the market touching. For example if market is changing by 10 per cent, robotic solutions price is not changing by 10 per cent, it may just change by few per cent, but the technology remains the same.

The usage of robots has always been high in the automotive industry.

In India most of the demand comes from the automobile industry and its suppliers. The use of robots in the industry was around 80:20 per cent by automobile to others, however, in the recent past, the figure has changed and

has gone up to 70:30. It clearly shows that not only automotive but many other engineering sectors are also looking for robotic solutions. Reasons for this increasing adoption includes, the cost, productivity and quality that have been changed and moreover, the business is also expanding. Earlier there were not many companies in India, now many local companies are also supplying the defence auto solutions; this is also enabling business expansion.

Q What are the merging sectors

for robotic solutions?

Apart from the auto and energy sector, the winds and solar energy industry is

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Opinions and More greatly adopting the use of robotics. Mass handling of the products manufactured in a company is driving the demand for robots. The machining sector is also adopting robots as an operator to handle various operations. Currently the productivity and the time requirement have changed. It is now easy to plan it in such a way where one robot can operate many operations. Another area which is coming up in a big way is the medical sector. Industries like the plastics processing industry for moulding processes like injection moulding are also demanding robots.

Q What are the challenges faced by

robot manufacturers and users?

The biggest challenge faced today, are the expectations from the robotic solutions, which arise from the awareness of SMEs. People think that if we are buying the robot it will handle the multi-operations and will replace humans, whereas, it cannot completely replace the human requirements. Many people think that the robot can perform 10 jobs at a time but, many a times that is not true as it works according to the task programmed.

The biggest challenge faced by user companies is during the initial stages, when selecting the best robotic solutions arise. To overcome this issue, we are supporting the companies in initial stages in terms of robot consultant. We send our consultant to these companies and forward suggestions for customising robotic solutions as per their product needs and we explain to them how to perfectly optimise the robot and increase the productivity.

Q What are the demand drivers

and future prospects of industrial robots in India?

Demand drivers arise from a mix of the industry, the biggest demand is coming from auto and its supplier; and it will continue in future, other sectors which demand for high precision will also go for robotic solutions. Sheet metal processing industry will also play a vital role in growth of industrial robots.

Q Robotic solutions are

best considered for harsh environments, what are the materials used for building these robots?

We divide the robot in two segments one is manipulator and second is controller.

Both are connected by the set of cables, so the part of the robot which is known as the manipulator is the one working in a harsh environment. Considering the construction of the manipulator, it is made by aluminium and steel.

wrong to assume that one robot can handle ten different tasks at a time.

A robot will only perform according to the task given. Incorporating robots does not mean reducing employment opportunities instead we are using the available resources optimally and in an effective way to thereby prevent wastage of resources. Robots however, will bring in better quality and more quantity products which is a necessity for the industry today.

Q Is Kuka considering setting up a Q Can robots ever completely

substitute human intervention on shop floors?

Robots can never replace humans.

Although robots have been successfully carrying out several shop floor operations in developed nations, the fact that remains is that robots have never completely substituted humans

“Robots have been successfully carrying out several shop floor operations in developed nations, the fact that remains is that robots have never completely substituted humans on any shop floor.�

facility in India?

The possibility of producing robots in India is not viable because the market size is very small for a robotics company to manufacture, so we are nowhere close to producing robots here. The market size level does not justify that a single company can consider manufacturing, 1000 robots per year is nothing for the robot producer.

I do not think manufacturing is possible now or in the very near future as, a lot of things have to be changed such as, government policies, processes, technician systems that we have, etc. To produce, export and import, there are various factors, approval and permissions which are required and also, various types of taxes need to be considered before we start manufacturing. All these factors have led manufacturers to produce elsewhere rather than manufacturing in India and exporting.

Q Pointers for the Indian on any shop floor. There are various factors to be considered here. Robots are just additional tools given to the operator. This machine might have the competence of doing the job of many operators but, it still needs to be guided by a human operator to keep a check on the entire process. This is where humans and robots strike a balance.

It is a misconception that investing in robots would mean handling multiple tasks by robots and replacing humans on the job. We can never completely replace human interference. Also, it is

manufacturing Industry?

Robots are an investment for a high quality and companies should trust in robotic solutions. Robots are not going to say good bye after one or two years, they last for 15 years on an average.

It is a long term investment. If you divide the cost of robotic solutions over the period of 10 years, it is not very expensive. Also, it is not an expensive way to switch to high quality productivity solutions. nishant.kashyap@infomedia18.in

March 2012 - MODERN MACHINE TOOLS

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FACILITY VISIT Tata Motors Pimpri Plant

DRIVEN PRODUCTION The culture of putting people above everything else, even profitability, is truly a Tata culture.

With the corporate world, globally, finally waking up to fathom the simple math of motivated manpower = enhanced productivity and profitability, Tata Group has been living by this prevailing anthem for more than a decade. A visit to the Tata Motors Pimpri plant just reaffirmed this fact. The lush green campus, with state-of-the-art shop floors is where legends are created, the innovative vehicle manufacturing just happens to be one aspect of this ‘people’s factory’. Archana Tiwari - Nayudu provides an inside view

V

isionary JRD Tata instilled the culture of putting the interest of the employee before everything else — a factor that provides the company an edge in this era of high attrition and lack of skilled workforce. Motivated manpower can move mountains, it is rightly said!

And it shows and how... A visit to the Tata Motors Plant in Pimpri, Pune was inspiring and heartwarming. The popular notion of a monotonous assembly line with cold robots working mechanically and with workers adding their bit in the car assembly line gets nullified the minute you enter the lush green environs and a warm ‘namaskaar’ greets you instead of a businesslike handshake. Before drooling over the state-of-the-art assembly line that awaited us in this Pimpri campus, the colours were added with the warm welcome, as the bouquet of flowers presented on arrival was very a pleasant 90

MODERN MACHINE TOOLS - March 2012

surprise for professionals who had ‘just work’ on their minds. We were told that this again was truly a Tata way of welcoming guests, as ‘atithi devo bhava’, which can be loosely translated as ‘guests are like God’ — a belief and tradition that Tata lives by…we were slowly warming up to be one with the Tata family.

All loaded already, a racy corporate film in a mini auditorium was a perfect prelude to the whole Tata Motors experience and we were all set to witness what makes Tata a world leader in whatever it does. But not before we had an insightful interaction with R Bhaskar, Plant Head – CVBU, Tata Motors, Pimpri. A veteran in this field, he provided the future outlook of the Tata Motors Pimpri plant along with giving insightful inputs pertaining to the future of their business. Binding it with the past, he reminisces how this company and its people have risen in times of difficulty and turned challenges into advantages.

According to R Bhaskar, “We believe that the four critical elements for any shop floor are the four Ms – man, machine, material and method. We have created many channels of communication, where the top management shares the company’s vision with each member of the company. Even in tough times, our Chairman has encouraged us to give our best. Even in times of crisis, which happened in 2000, when we incurred a huge loss – the biggest corporate loss of around `500 crore – every Tata Motors employee was secure. There were no job cuts. Everybody’s salaries were paid on time. In fact, even bonuses were paid. This is to say that the security and assurance that the company provided at the time of crisis was reciprocated by every single employee who stood by the company in these trying times.”

He adds, “Nobody was held responsible for this loss, but each one of us felt the moral responsibility. This

Tata Motors Pimpri Plant was a turnaround time for the company, as we, the employees, took it as a challenge to turn failure into fortunes.

Product innovation, people innovation, process innovation was the outcome of a motivated team with a mission to give back to the company what it got. And the rest is history.”

A different strategy, which is beyond business, as somebody rightly said that most of the business decisions are driven by emotion, we just create logical and factual reasoning to substantiate & support these emotional decisions. As we were leaving his office, he recommended that we visit the award-winning training centre, Asia’s largest tooling division, the state-of-the-art Aria assembly line; the Stamping line, called Hitachi press line, which is the plant’s oldest line; the D3 Chasis line, which is the most productive line, where 56 types of models are produced. We already know that our day was packed with action. Here’s presenting the best in class procedures and practices prevailing at the Tata Motor’s Pimpri plant.

Competitive Advantage: In-house Expertise & Facilities Engineering Research Center (ERC) Research provides the much-needed inspiration for the birth of new ideas, which, in turn, breathes new life into products. World-class automotive research & development are key factors that contribute to the leadership of Tata Motors. The Engineering Research Centre in Pune was set up in 1966 and is among the finest in the country.

It has been honoured with two prestigious awards — ‘The DSIR National Award for R&D Effort in Industry – 1999’ and ‘The National Award for Successful Commercialisation of Indigenous Technology by an Industrial Concern – 2000’.

With a team of highly qualified & motivated engineers and scientists at work, the Tata Motors Engineering Research Centre has enabled pioneering technologies and products. Every vehicle is developed in close conjunction with customer needs, virtually simulated,

prototyped and then operated in realtime on the most arduous terrain.

ERC has got almost all the facilities that are available all over the world, so all the tests can be done in-house. As one of the production engineers informs, “We can create a temperature of up to -500 to +500, in the chambers to test the vehicles under extreme climates. There are many other facilities like the Crack facility. So, all the tests and validation happens in-house, where there is enough capacity and new age testing and validation devices & design capabilities.

This is a huge advantage.

supreme capability in the engines and gearboxes. That’s our strength, and so, we manufacture our own engines and gearboxes, which is the heart of the vehicle, as far as commercial vehicles are concerned.

The process is faster as we have our own capabilities being utilised in critical parts of vehicle manufacturing. Earlier, we used to use special purpose machines, but now, we have flexible machining set ups where the programming can be changed. It provides flexibility and the tooling can be adapted as per requirement. We also have our own tool engineering division, so all the aspects required for core manufacturing are on the house, while the capability and capacity are available in-house. That’s an edge.”

Simultaneous Engineering In addition, this plant boasts of hosting Asia’s largest tooling division, which is a full-fledged tool room. It makes dies for all the components of vehicles. Hence, be it design aesthetics or other components, these are all made in-house, though some are outsourced. The simultaneous engineering is perhaps the biggest advantage, which has compressed the timelines and improved the plant’s turnaround time. It is also one of the major contributors for a slew of new product launches.

“Earlier, if we took four years to launch a vehicle, now we can do it in two. And that is the reason we could launch 30 plus products in the last year, no other company can boast of such figures. Winger, Ace, the Prima truck are all example of this integrated and simultaneous engineering,” Bhaskar informs, adding, “We have a

Testing Tracks: Looking for Failures There are state-of-the-art testing tracks separately made for commercial vehicles and passenger vehicles. The testing in-charge, who took us to test drive Aria on these tracks, explained the critical importance of testing. The 2.8 km-long passenger car testing track is used for checking vehicle performance, accelerating, engine performance and any leakages after top speed. Imagine driving at the speed of 140 km/h, on the satin-like tracks; call it the perks of the job, we envied him!

For the commercial vehicle durability test cycle, there are testing tracks called the Torture tracks, having witnessed the same, it is a befitting name. Our testing in-charge informs, “It is a destructive test. This vehicle will be test run on these

PEOPLE POWER We learn every day, every day we come here to make this company more progressive and more profitable. Why would we want to work for any other company, when we have our own company? We know that the company will take care of our families, and so, we take care of the company.

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Tata Motors Pimpri Plant tracks, till something fails. It is for us to identify the weakest link so that we can rectify the problem before it hits the road. There are cycles of different levels.

The commercial vehicles are loaded with a minimum of 25 tonne weight.”

A well-equipped torture track enables rigorous and exhaustive testing of modifications before they are used as regular fitments.

Award-Winning Training Centre CVBU Customer Support has won the Prestigious ‘Golden Peacock National Training Award’ in 2011. CVBU Customer Support was adjudged the winner, based on its existing capabilities, initiatives & achievements in training for its dealer workforce, customer technicians, drivers and institutional customers in India and overseas. The award identifies training, which offers tangible benefits to the business/organisation or to the community.

In the training centre, a mock shop floor is created for training purpose. Class 10 pass outs are trained here and after training, they are inducted in any of shop floors. These technically trained workforce match the ITI-trained students in every respect.

The training centre in-charge informed that every year “we train around 400-odd workforce”. One can see the components made by students, being proudly displayed at this training centre.

Integrating Customers’ Wish List In today’s time, it is very important to hear what your customers have to say, and not only that, there has to be a plan and a process in place to integrate the voice of these customers in the actual product. Bhaskar explains, “We started capturing the voice of the customer and the flow of the voice of the customer to the production process was handled by a full-fledged dedicated team called the new products introduction team. This team goes to the market, conducts a market survey, interacts with the sales and marketing teams of the customers and gets an understanding of their needs.”

THRUST ON DEFENCE

To help the armed forces keep pace with change, the Tata Group has brought the advantage of constant mobility to the defence sector. For nearly five decades, it has been providing the wheels and a wide range of defence solutions that help make the nation’s borders impregnable. Moreover, Tata vehicles have been supporting the police and paramilitary forces in maintaining law and order, besides providing reliable protection for VVIP security.

Case in point, he adds, “A classic example was the birth of Ace. There was no vehicle in that segment. When we asked customers about their wish list, the three-wheeler consumers said that they would like to have a four-wheeler, which is safer, more stable and would elevate their status. Then they also needed a better looking vehicle. And, of course, the last mile connectivity, as India is growing, we will have more and more hub and spoke like structures. So, keeping all the wish lists and aspirations of the three-wheeler consumers in mind, the Ace was born. This is also the first product, which went through the whole cycle of getting the ideas from the customers, then the information is passed on to the ERC, where they created a model to suit the needs. In fact, we called the select group of customers to give their feedback on the vehicle created. And post their recommendations; the vehicle was further modified to suit the needs and aspirations of the ultimate customers.

Then, it went through a very rigorous validation process.”

People Power Working with hands…and heart The craftsmanship of skilled labour can never be replaced by machines and this reality was in motion at all the assembly lines of both the passenger vehicles as well as commercial vehicles. While the

company has created a people-friendly environment, taking into consideration all their needs and efficiency enhancing infrastructure, a will to give in their best cannot be dictated; it has to be cultivated and nurtured so that it becomes a culture of that company. While moving around, many shining examples were seen. For instance, workers take personal pride in every vehicle that is manufactured by their company. While interacting with them, they referred to the vehicle as ‘my vehicle’ and the pride in what they created was evident. Then again, it was difficult to find a worker who has worked in this plant for less than 15-20 years, in this day and age of attrition, this was a rare example.

The much hyped and talked about union-management relationship in every other plant was what can be best described as ‘harmonious’. As one of the plant in-charge explains, “It is not that we never have arguments about the schedules or other mundane things, but we always resolve the matter amicably.”

The ‘tea & nassta’ point, a regular feature in all the shop floors and centres that we visited, while being a refreshment break area, was more like a ‘friends catching up with each other place’. Interestingly, this is the only place and time where you would spot workers chit-chatting. When they are at work, it is undiluted concentrated work, without any diversions or distractions.

The best part…nobody has to be told to do so, as one of the workers shrugs and says, “It is our culture”. He adds, “People feel totally involved and more than working, they own the company. They see this company as a part of their family. It is a great institution in its own right.”

And this people-friendly culture is not new. In fact, the company’s founding father, the great visionary, JRD Tata, truly believed and lived this culture to the core. Because the company cares for its people, the people contribute more and more, without being told to do so. The workers do not just work with their hands, they work with their hearts as well. archana.nayudu@infomedia18.in

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Integrating Automotive Industry Application of industrial robots is the reigning trend in the automobile industry, it requires speed, precision and short lead times. Industrial products today are increasingly individualised with quick time-to-market. Nishant Kashyap finds out why the automotive industry prefers robotic solutions and the future prospects in these areas

R

obots in the automotive industry are largely used as assembly line workers. With precision programming and steel-reinforced strength, robotic arms can piece together major auto body parts in seconds. They can perform jobs in a matter of few minutes that would normally require great physical effort and two or three human beings to accomplish. By using a robot, auto companies reduce the risk of heavy parts collapsing on humans. Since robots are tireless, it costs a company less to assemble a vehicle.

At first people thought that entire auto assemblies could be handled by 100 MODERN MACHINE TOOLS - March 2012

robots. But there is always a need for human technicians. Also, the cost of robots in performing minor assembly or quality control is not as efficient as hiring a human being to do it.

Demand Driver Currently the main drivers of the growth are the electronics and metal industries, these industries increased their robotics investments considerably in the recent years. Although the automotive industry is the biggest consumer of robotic solutions, yet the increase in demand for robots from this industry is average. The latest features and functions in industrial robots are

enabling the machine tools industry to gain a competitive edge over others.

The Indian automobile and automotive parts industries are currently flooded with demand for all types of vehicles, especially small segment cars and two-wheelers such as motorcycles and mopeds. However, this upward swing has spelt more pressure on car manufacturers to deliver quality products within a short time. This in turn has generated a domino effect on the manufacturers of automotive machining to provide effective solutions to meet the rising demands. As Original Equipment Manufacturers (OEMs) battle to raise productivity amid shortages of trained

Courtesy: KUKA India

INSIGHTS & OUTLOOK Robotic Machining

Robotic Machining labour and restrictive employment laws, robotic solution seems to be the best solution. With adoption of industrial robots productivity in the automotive industry is substantially growing, as compared to other manufacturing sectors in India, and is pushing the levels of performance.

Since many global companies have made their presence in India, the demand for robotic solution has increased significantly. In future also, it is projected to be the same.

Auto Industry Requirements Robots have proved to be the best production technology as they offer the advantages of maximising the flexibility of operations, productivity and high performance. The reasons that forced automotive industry to adopt robotic solution are explained as follows: Job Efficiency - By replacing human workers with robotic workers, the automotive industry was able to assure that certain jobs would be performed specifically to their expectations. Robots are not limited like humans when it comes to performing many assembly jobs like painting, finishing, welding, riveting, and installation. Robots also don’t have restrictions with moving heavy objects or issues of fatigue.

Barring any computer errors, robots will almost always get the job done quicker and more efficiently than a human possibly could. Robots are able to be programmed to perform precise intricate duties at much faster speeds than any human could be expected to.

Safety - One of the benefits of robots in the automobile industry is the elimination of humans needing to perform jobs that are dangerous or pose health risks. Because the robots are so efficient, there is no issue with human errors causing accidents or injuries to themselves and others around them. Robots are the best solution in harsh environment. Robots are able to withstand exposure to extreme heat,

chemicals in the air, and general physical contact with parts and structures. There are a lot of jobs that pose high risk to a human in the automotive industry that simply makes more sense to have a robot perform. The use of robotics in crash-test dummies is also a job that a human would never be able to perform safely. Robots have simply made the work place safer by taking over these jobs.

Cost Effectiveness - The use of robots in the manufacturing area of the automobile industry has saved millions of dollars over the years.

By replacing employees with robots, the automobile industry was able to double and triple their production times. In some ways it came down to simple money saving issues as robots

was how large a portion of spot-welding applications can automobile companies handle with a more compact robot that contributes to more cost-effective production lines for customers?

The demand posted by the automobile industry has been taken by the robot manufacturers positively; this has resulted in many new developments in this field. The spot welding robot is the most important component of a mechanised spot welding installation.

Welding robots are available in various sizes, rated by payload capacity and reach. Robots are also classified by the number of axes. A spot welding gun applies appropriate pressure and current to the sheets to be welded. There are different types of welding guns, used for different applications, available.

Future Prospect Manjunath H S Sr Manager, National Sales Robot Dept, FANUC India Pvt Ltd For jobs which are repetitive in nature and needs large number of skilled work force, automation came as a solution. The automobile segment certainly requires it because they are the volume players and deals with large scale production

do not require time-offs and can work continuously. A robot can work twenty-four hours a day without a break, and continuously perform the same mundane tasks over and over again; virtually non-stop. Even with the expenses of maintenance and occasional breakdowns, robots just make more sense economically for the automobile industry.

Robot in Spot Welding With the focus on the automotive industry and specifically on spot welding, there was demand for a robot that would be easy to use but, without sacrificing capacity or reach. Producing a costeffective solution was also an important factor for automakers. The challenge

Automation has dramatically altered factories across the globe. Modern industrial robots offer multiple advantages. They have single-handedly transformed products, facilities, and companies. Recent developments have made industrial robots more userfriendly, affordable, and intelligent than ever before.

Industrial robots are more accessible and affordable today than ever before.

Now standard robot models are mass produced. They are easily available to meet the ever-increasing demand.

This in turn has led to a steady price drop for new robots. At the same time, a burgeoning used robotics market offers more opportunities for low-cost models.

All these reasons clearly state that the degree of automation in the automotive industries is expected to increase in the future as robots push the limits towards flexibility regarding faster change-over-times of different product types (through rapid programming generation schemes), capabilities to deal with tolerances (through an extensive use of sensors) and costs (by reducing customised work-cell installations and reuse of manufacturing equipment). nishant.kashyap@infomedia18.in

March 2012 - MODERN MACHINE TOOLS 101

INSIGHTS & OUTLOOK Metalworking Fluids

The Chronicle of LIQUID SOLUTIONS

T

he consumption of metal removal fluid in India is dominated by three end-user industries: transportation equipment, machinery and fabricated metal products, with transportation equipment being the largest. Growth of metalworking fluids will be mainly determined by growth of the automotive industry in the region. Other important industries are the primary metal industry and the general machinery industry. At the same time, the increasing number of new entrants, more sophisticated customers and soaring raw material prices put high competitive pressure on existing suppliers. Besides the new global entrants, many small local companies have emerged as suppliers to the low-end metalworking fluids segment. Moreover, many suppliers have to absorb the high raw material costs to gain a competitive advantage, especially while supplying to the public sector and OEMs.

Indian Metalworking Industry Trends

The economic growth experienced over the last several years in India is expected to continue for couple of years, albeit at a somewhat reduced, but still respectable, pace due to a slowing of the global economy. This slower growth rate will be reflected in the growth rate of the consumption of metalworking fluids. The growth rate, however, will differ considerably.

Major reasons for these differences include the use of metalworking fluid products with a longer sump-life, as well as improved housekeeping.

102 MODERN MACHINE TOOLS - March 2012

Soluble cutting oil is the most popular type and will remain so because this type of oil is the preferred choice in small machine shops. The users prefer cheap, general-purpose cutting oil.

Moreover, the slack environmental regulations for the disposal of soluble cutting oil further encourage its use.

At small and mid-size companies, no shift has been detected; however, a distinct shift has been noted toward high performance semi-synthetic/synthetic fluids at large manufacturing companies and particularly at Original Equipment Manufacturers (OEMs) that are willing to opt for alternative fluids to meet operational needs or to counter the problems that arise from using lowquality water. The improving quality of after-sales service is also influencing this change.

Changing Role of Metalworking Fluid Manufactures With the phenomenal growth in this industry, companies specialising in providing cutting-edge products and solution in metalworking fluids play a pivotal role. Companies have been working with the customers not only as a supplier but also as a partner. They are acting as a process consultant to help them sustain competition and rising cost pressures by reduction in their overall cost related to the manufacturing process. Companies are continuously working on metalworking technology by offering next generation products for increased productivity, protection of machines and components and offering eco-friendly products.

New age machines with new applications with least cycle

Metalworking Fluids time and high speed will help to meet the inventory and thereby supply goods on time.

Environment, Health and Safety Metalworking fluid manufacturers are committed to an effective safety, health and environmental management system designed to operate globally in a manner which protects the environment as well as the health and safety of customer, suppliers and neighbors.

However in India SHE implementation is quite variable with some customers. Some customers are quite aware and willing to implement the same in terms of products while a large majority are not willing to go the extra mile and are sticking to old products. Local laws are also quite weak and lagging behind in this respect.

Some initiative must be taken from the government to support metalworking fluid manufacturers who are taking lead in implementing eco-friendly products.

Quaker Chemical is one of the leading specialty chemical companies was the first to offer Polyolester based Fire Resistant hydraulic fluid which offers better lubrication, improved corrosion protection and easier waste disposal/reclamation. It can replace antiwear and mineral oil based hydraulic fluids used in application where fire hazard exists. These Hydraulic fluids have been specially formulated for critical applications in forging, surface and underground mining.

Customers’ Proximity and Network It is also very important for the Metalworking Fluid Manufacturers to offer end to end solutions to customers in every process and an excellent example for this would be programs like onsite Chemical Management Services for Automotive OEMS & Key Accounts.

Coolant management program is designed anticipating customer’s future needs. They need to work closely with their customers, help them derive value addition in terms of overall cost reduction - through the use of best quality metalworking fluids along with 104 MODERN MACHINE TOOLS - March 2012

R&D forms the basis of leadership in

metalworking fluids

the complete coolant related solutions.

By implementing these metalworking fluid related best practices in customers manufacturing process, we become partners in our customers’ progress to attain the best position in our business. metalworking fluid manufacturers with extensive industry knowledge and process expertise to understand the specific issues, solve particular problems, and implement demonstrated solutions. As a result our customer will experience improvements in productivity, quality and profitabilityimmediately and into the future.

Advanced Metalworking Fluid Technology Consumption of metalworking fluids typically has a negative correlation with new technological developments, be it for longer-lasting metalworking fluids or new machining technology, like dry machining, Minimal Quantity Lubrication (MQL), near-net shape casting etc.

High-tech cutting tools support a new generation of machine tools. This is required to support machining parameters and process compatibilities. Current processes, such as high speed machining and the machining of materials such as titanium, require high-speed cutting tools. Significant advances have been made during the recent years in the development of new cutting tool material and tool coating. While many new tool materials are designed to provide higher degree of wear resistance and overall machining performance, the quality of and performance of the metalworking fluid can have a large effect on the

ultimate values and benefit obtained from these advances. It is necessary in the design of new metalworking fluids, to have an understanding of both the properties of the tool material and the principal mechanism of failure. From this understanding, the critical properties and qualities of a metalworking fluid can be identified properly and new fluid technology that matches the advances offered by the new materials can be developed and used. Cost reduction, productivity, process improvements, high lubricity, good transparency, stability and waste avoidance are the key factors to be considered.

As the Metalworking fluid industry matures, a shift to high-performance products will occur, thereby causing the market to shift from performance driven to results driven.

Future Prospects Strong growth in automotive, power and engineering sectors is creating new market opportunities for metalworking fluid manufacturers. With the automotive manufacturing rising up and new manufacturing technologies coming in, the future of metalworking fluid technology also needs to gear up to meet customers’ tomorrow’s expectations and needs. We need to understand, what the customer would need tomorrow. Will it just be—Total service provider—with overall cost reduction through value addition and supply of good quality Metalworking fluids, or do we need to come up with something totally new!

We need to think ahead and think fast on these lines.

Syed Md Samim, is the Marketing Manager of Quaker Chemical India subsidiary of Quaker Chemical corporation USA which is a leading global provider of process chemicals, chemical specialties, services and technical expertise to a wide range of industries including steel, aluminum, automotive, mining, aerospace, tube and pipe, coatings and construction materials. It works closely with renowned universities of US and OEMs to develop new age emerging technologies in this field.

E-mail: syeds@quakerchem.com

INSIGHTS & OUTLOOK Case Study

More Effective Camshaft Machining A leading manufacturer of high-performance valve train components installed a twin spindle/twin-turret lathe to bring camshaft machining work in-house. Here, the company explains how it has become more effective using its multifunction lathe to produce small batches of custom racing camshafts.

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hen I first spoke to Billy Godbold, he was at a track watching a professional drag racing team test a custom camshaft. Godbold is the engineering group leader for Comp Cams, the valve train component manufacturer that supplied the camshaft. One month earlier, Comp Cams’ design group had just started contemplating camshaft materials and geometries for this application.

Moving from design to completed billet camshaft so quickly would not have been possible years ago when the company outsourced the machining of its high-end racing camshafts.

Today, Comp Cams machines small batches of racing camshaft cores on a twin-spindle/twin-turret lathe from Okuma. (Camshaft cores are camshafts that have their primary features machined, but still require subsequent heat treating and grinding operations.)

Bringing this machining capability inhouse enabled the company to greatly speed turnaround of custom camshafts for professional racing applications because it no longer had to wait weeks or months to receive camshaft cores. It can now manufacture as many as 12 M4 powder-metal tool-steel camshaft cores in a single eight-hour shift.

Godbold explains that Comp Cams’ traditional expertise was in grinding camshafts, not machining them. So when the decision was made to install the seven-axis multifunction lathe in 2008, the company relied heavily on the expertise and advice of its equipment suppliers to establish an effective machining process. Comp Cams continues to tap those resources today as it strives to minimise cycle times for camshaft cores.

106 MODERN MACHINE TOOLS - March 2012

Bringing twin-spindle/twin turret lathe

technology in-house...

Luckily for me, “you can’t sell if you don’t tell” is the motto of Paul “Scooter” Brothers, one of Comp Cams’ owners as well as chairman of the board for the Specialty Equipment Market Association.

In keeping with the spirit of that saying, company representatives weren’t shy about detailing how they’ve become better at using the advanced lathe during my visit to their Memphis, Tennessee facility.

Succeeding at Speed The camshaft portion of Comp Cams’ product line is evenly divided into three segments: high-performance/nonracing applications; hobbyist racers; and engine builders for NASCAR, NHRA and other professional race teams. The custom billet camshafts machined in the company’s Memphis facility are used by the professional race teams.

Originally, the prolonged camshaftcore delivery times had the company considering adding a “conventional” cell to produce the small batches that race teams required. Such cells typically include a saw to cut barstock to length; lathes to face the front and rear of the camshaft, add centers and groove the lobe layout; mills to machine details in the front and rear camshaft faces;

and additional mills to machine the lobe profiles. Most of these operations required multiple time-consuming setups, too.

The company ultimately decided to go a different route after Godbold met with Larry Schwartz, who at that time was Okuma America’s president (he’s now the machine tool builder’s chief strategy officer). The men discussed alternate ways to manufacture camshaft cores that would minimise change-overs and simplify setups for production runs of 20 or so pieces. Schwartz’s idea was to use a twin-spindle/twin-turret lathe.

Keeping a bar either clamped between the spindles and/or partially inside of them would enable complete machining of camshaft cores in one setup. Plus, the twin spindles could perform some operations simultaneously.

The company selected an Okuma LT300-MY. Godbold says that in many ways, the initial concept and programming execution were greater hurdles than the slight machine modifications that were needed for this application. The primary mechanical change to the machine was increasing the size of the sleeves in the main and subspindles so a 70-mm-journal camshaft could pass through them. The company reasoned that because the machine offered a great deal of rigidity and each of its spindles provided 30 horsepower, the lathe would have no problem machining the tough M4 powder-metal tool steels (rated at 30 HRc) common to its billet racing camshafts.

Prior to the lathe’s delivery, Comp Cams sent what it thought was a very difficult camshaft core to Okuma’s facility for machine prove-out: a 70mm-diamter NHRA Pro Stock camshaft with nine journals. Kevin Kraieski,

Case Study an applications engineer for Okuma, created the initial part programs and machined the first sample parts. Kraieski set up the part program using multiple variable-style sub-routines for commonly required operations, such as grooving between lobes, milling lobe profiles, drilling and tapping bolt hole patterns, and more. This made it possible for Comp Cams to easily reprogram the complex machine for any number of camshaft designs without starting from scratch each time.

Improving finish in the grooves between the lobes and increasing lobe machining speed proved to be challenging during testing. However, Tim Whitmore, an OEM project manager for Iscar, work closely with Kraieski to iron out the tooling issues.

By the time the machine was delivered to Comp Cams, it could complete a M4 camshaft core in 75 minutes.

The photos on the following page show how camshaft cores are produced on the lathe. An operator manually slides a pre-cut bar into the main spindle, pulls the bar out a few inches to a stop, and clamps it. The lathe then turns and mills features into what will become the front face of the cam. Next, the subspindle moves into position, grabs the machined face and pulls out the bar approximately 10 inches. Grooving and lobe milling are completed on that segment of the bar. Once machining on that section is completed, the subspindle clamps onto some of the newly machined journals and pulls the bar farther out of the main spindle to enable grooving and lobe milling of the back half of the camshaft. (Performing these operations in two small sections minimises the risk of deflection, vibration and chatter.)

Finally, the subspindle consumes nearly the entire bar to enable turning and milling work on the back face of the camshaft.

Comp Cams has refined this process to the point that it can now machine camshaft cores in 35 to 45 minutes.

That said, the company had to overcome some initial machining hurdles in order to achieve these faster cycle times.

108 MODERN MACHINE TOOLS - March 2012

Early Challenges As it turned out, the “really difficult” camshaft Comp Cams sent to Okuma for testing proved easier to machine than its other camshaft models. That’s because the camshaft’s nine journals provided more clamping points for the subspindle than a typical five-journal camshaft. Consequently, the original subspindle jaws were not long enough to clamp across at least two journals on the five-journal models (this was necessary to ensure adequate support during machining). Installing lengthier 6-inch jaws enabled the subspindle to clamp across two or more journals on any type of camshaft the company manufactures. The main spindle always clamps solid barstock, so longer jaws are not necessary for that spindle.

Workpiece slippage inside the jaws also proved to be problematic at times because some camshaft materials are more difficult to clamp tightly than others. The solution was applying a tungsten-alloy coating from Carbonite Metal Coatings on the gripping surface of the jaws. This particular coating is applied via electrofusion, which creates a metallurgical bond that is said to be stronger than spray-on coatings. The coating has virtually eliminated linear and angular workpiece slippage from occurring during machining.

Another early challenge was getting used to P codes, which are used to synchronize the motion of the two turrets. P codes not only ensure that the turrets don’t interfere with each other

... Machining simulation is performed after a program is created for a new camshaft design. After that, a dry run is performed on the lathe followed by a test part created from low-cost mild steel. Once the process is verified, production can ensue in the specified material

...enables Comp Cams to produce billet

racing camshafts much quicker than when it outsourced camshaft machining

when performing separate operations, but also can signal them to perform identical operations simultaneously.

For example, if a programmer wants to face a part with the upper turret and then drill the end of it with the lower turret, those operations have to be synchronised because they obviously can’t be performed at the same time.

If the programmer assigns a P10 value to the upper turret and a higher P20 to the lower turret, the upper turret will continue all of its necessary motions until it encounters a higher P value in the program code. If the next P code it encounters is higher than the P code assigned to the lower turret, the upper turret will wait until lower turret is done. However, if the same P code is applied to both turrets, they will work simultaneously.

Unless a camshaft has an odd number of grooves, the lathe performs turning and grooving operations using both turrets simultaneously when the bar is held between spindles. Because the upper turret is optimised to run close to the main spindle and the lower one is set up to run close to the subspindle, the company does not perform pinch turning. However, Godbold estimates that simultaneous cutting enables the lathe to remove material 30 percent faster primarily because the tool pressure is balanced. In addition, starting the grooving operations at the middle of each section of bar and moving out toward the spindles leaves more stock at either end of the bar section. This

Case Study ensures rigid support to prevent chatter and also eliminates flexing at weak areas of the bar, which could possibly pinch or break a grooving tool.

Benefitting from Standardising Each turret on the LT-300MY has 12 tool stations. Daniel Freeman, the R&D technician for Comp Cams who commonly programs and helps run the lathe, says the company takes full advantage of those 24 total stations. Approximately two-thirds of them rarely change. In addition, tools in several stations are mirrored on both the upper and lower turrets to facilitate the simultaneous machining operations.

Each turret has three different grooving tools. Two of those perform roughing operations. The wider of the two is used as often as possible, while the thinner one is used only when space is tight. The third grooving tool is used for finishing, leaving behind a quality, burr-free surface finish while holding dimensional tolerances of less than 0.010-inch on all linear dimensions along a 24-inch-long camshaft.

The upper turret has two vertically oriented end mills of different diameters that remain in their respective live stations. These are used in conjunction with the machine’s Y-axis movement to perform lobe milling. The narrower 0.75-inch end mill has one less insert than the 1-inch end mill, so the feed rate has to be reduced when that tool is used. Tools in the upper turret’s five horizontal live stations often don’t change either. These perform drilling, tapping, reaming and other operations on the front face of a camshaft.

The lower turret contains center drills used for both the front and rear camshaft faces. This turret also has live horizontal stations set up to create features such as vent holes. Two stations contain miscellaneous tools. These include a multifunction drilling/boring tool that is typically used to create counterbores, and a large indexableinsert drill that machines bores on the rear of a camshaft.

110 MODERN MACHINE TOOLS - March 2012

Camshaft core machining begins with a bar

clamped in the main spindle that extends out a few inches

The company uses Exsys/Eppinger Preci-Flex ER32 quick-change adaptors for some of its live-tooling work. Each adaptor can accommodate a drill, tap or mill for use in that single station. During setup, each tool is separately installed in the adaptor and touched off. During a production run, a program stop pauses the machine and prompts the operator to change the tool in the adaptor station to the next tool needed. The operator can change the tool in less than one minute, and touch-off isn’t necessary because the offset for each tool was determined during setup. Freeman says tools in the adaptor extend out a couple inches farther than normal, but this does not present any clearance issues.

The company has also standardised on coolant, using the same Castrol Syntilo 9918 synthetic coolant for machining that it does for grinding. Godbold says the company could save money by using a lower-cost coolant, but it appreciates the consistent performance the advanced coolant offers. Comp Cams plans to install an 8,000-gallon central coolant system with a single main paper filter system to supply both the machining and grinding areas in the facility.

One advantage of standardisation is that it minimises the number of tools that must be touched-off for a new job.

Typically, an operator has to install and touch-off only a few drills, reamers and taps during setup for a new job. Tool standardisation also enables programmers to quickly and easily determine whether additional tooling is needed for a new project. Ultimately, standardization has

enabled Comp Cams to reduce changeover times for most new jobs from an entire day to just a few hours.

With that said, the company continues to work closely with Rex Luxmore, its Iscar tooling representative, who Freeman says is proactive about keeping him up to date with new tooling developments. For example, Luxmore’s recommendation of grooving tools with a new coating resulted in a 30- to 50-percent improvement in tool life. This assistance is critical, Freeman notes, largely because of the challenging materials such as M4 powder-metal tool steel that the company frequently machines. This tool steel is not only very unforgiving, but it will work-harden quickly if cut too slowly or lightly.

A Bit of Advice Comp Cams’s goal is to be a leading developer of innovative valve train components, Godbold explains. Machining is viewed as a means to that end. Mr. Godbold says companies with a similar approach are well-served to recognize their manufacturing limitations, especially when considering the addition of a complex lathe like the LT-300MY. It’s best to devote some time to learning the ins and outs of such a machine before depending on it for production, he notes.

Scooter Brothers certainly understood that when the twin-spindle/twin-turret machine was delivered. As long as long as the company became more effective using the lathe during the first few months and was able to achieve a half-throttle-level of production within a year, Brothers was not going to be discouraged.

Godbold believes this approach made all the difference in the world. He humbly says that Comp Cams proves that a shop with only conventional turning and milling experience can successfully integrate a complex multifunction machine without necessarily being outstanding at machining or programming. However, this requires establishing solid relationships with equipment suppliers that are willing to help a shop achieve its goals. Finding trusted people to work with means everything, he says.

Courtesy: Modern Machine Shop Magazine

AUTOMATION TRENDS Factory Automation

Gauging Future Industrialisation Prospects For many years, integrated, intelligent and dependable control systems have been the focus of standardisation organisations, industrial consortia and research groups. The solutions have, however, been hard to reach, partly due to the complexity of the issue and partly because of conflicting commercial interests. Nishant Kashyap takes a look at some of the recent developments and trends in factory automation

R

ecent trends in automation are characterised by geographical distribution and functional integration.

On the technical level, the goal is to easily connect devices and software components from different vendors. Functionally, there is a need for interoperability of control functions on different hierarchical levels ranging from field equipment to process control, operations management and various internet-based service applications.

Today’s automation solutions are varied, but all of them help to make businesses more efficient, more productive—and more successful in the global market. Industrial automation provides a platform for all the relevant engineering disciplines—from energyefficient power transmission to precision instrumentation and control technology.

Industrial Robotics Since the inception of industrial robots, definition of automation has changed. It has made almost all the work automated on shop floor. Nowadays all robots are multi-programmable, automatically controlled and reprogrammable in three or more axes. They are normally used to replace or reduce the dependency on man power, they are expert in welding, painting, packaging, material handling, assembling, product inspection, etc all these tasks are performed with high114 MODERN MACHINE TOOLS - March 2012

speed and accuracy. Basically robots are designed as articulated robots; articulated robots are used in loading tool, bakery, steel factory and foundry industry.

Domain Models and Architectures It has long been the goal of the industry to integrate the operating units of a plant in order to produce products at a minimum cost and at a maximum performance. This has led to closely coupled production units, minimised in-process inventories, and maximum use of energy and material resources.

More recently, integration has expanded to multiple plants, business processes and supply chains. To make worldclass manufacturing networks possible, tight quality control and scheduling, and therefore novel process control and information systems, are a necessity.

These technologies can be used in the development of such large-scale systems.

However, also higher-level standards and reference models are necessary to define the common terms, information content

5

Key Technologies for Industrial Automation

Control/Diagnostics Communication Electronics Materials Software

and function structure of an application domain. The purpose of these models is to improve common understanding and cooperation between the numerous parties involved, and to provide a sound basis for computerised tools and data exchange.

Modern Trends In modern days the purpose of using automation is not just increasing productivity and reducing costs, but it has also shifted to broader issues, such as increasing safety, quality and flexibility in the manufacturing process. Nowadays with the help Distributed Control System (DCS) of wireless network, and in combination with the self-tuning, self-diagnosing and optimising features, it is possible to make both startup activity and operational routines of a complicated process much easier and more efficient. DCS also offers process modelling and simulation, something that can improve operator training a great deal.

Sensing the importance of factory automation Indian SMEs, along with big manufacturing players have also installed it in their system, which has made India a lucrative destination for industrial automation system. As the latest research and developments have maintained or reduced the cost of automated system, adoption of this system will also surge in the Indian industry. nishant.kashyap@infomedia18.in

MMT Mar-2012 Ad Name:Expo Pg No. 115

MMT Mar-2012 Ad Name:Shuter Pg No.116

MMT MAR-2012 AD NAME: PARISHUD PG NO. 117

MMT MAR-2012 AD NAME: SATRA PG NO. 118

ENERGY MANAGEMENT Volkswagen AG’s ‘Think Blue. Factory’

Machining Excellence doesn’t Have to Cost the Earth Is it possible to achieve optimisation and conservation all at the same time. METAV 2012 brings users’ and manufacturers’ skills together to seek a golden median Volkswagen AG’s ecological strategy called ‘Think Blue. Factory’ and Bruns-wick University of Applied Science, was recently awarded the German Raw Material Efficiency Prize by the country’s German Federal Ministry of Eco-nomic Affairs and Technology. Commissioned by Volkswagen’s plant in Baunatal, the award-winning scientists from Lower Saxony are researching the potential energy savings achievable with machine tools

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ith its ‘Think Blue. Factory’ campaign, Volkswagen is optimising its manufacturing operations worldwide in terms of resource-economy and energy-efficiency. As exemplified by Baunatal: the automaker is installing a transparent energy management system there, scheduled for completion by 2013. Dirk Sauermann, who heads the energy team, prioritises a ‘transparent depiction of energy consumption’ at machinery and component manufacturers.

IWF Scientists Research for Volkswagen Volkswagen is receiving assistance from the Product and Life-Cycle Management Department of the Institute for Machine Tools and Production Technology (IWF) at Brunswick University of Applied Science, headed by Professor Christoph Herrmann.

From 2010 onwards, the IWF team has been working together with Volkswagen’s facility in Baunatal in the field of energy-efficiency and resource-economy. “The plant possesses around 5,000 machine tools, with plenty of relevant data available. This means that for the first time we can use trend analyses to derive statements on how 120 MODERN MACHINE TOOLS - March 2012

Volkswagen AG’s ‘Think Blue. Factory’

the energy consumption of machine tools has developed over time”, reports scientist André Zein. “Our analyses show that the energy requirements of different machinery concepts for the same machining job can differ by a factor of five. This forms the motivation for our research into efficient solutions.”

“We addressed the key question: what exactly is an energy-efficient machine tool?” explains Professor Herrmann.

“This enabled a benchmark to be deter-mined: what does the minimum achievable energy consumption look like?” For this question, the plant in Baunatal proved to be the right partner, since thanks to the large number of machines there the people from IWF could use time-series analyses, for example, to determine how the electrical connected load has developed historically since the first machine tools were purchased in 1930.

51 Energy Saving Approaches The experts from Brunswick have developed 51 approaches for saving energy at the plant in North Hesse, 19 of which have already been successfully verified in the plant itself, and another 32 are still in trialling status awaiting further exploration. What’s involved here are not merely the obvious and familiar measures, such as more energy-efficient motors, but also some approaches that are fundamentally new. “Together, we have found out how much energy can be saved if less material has to be removed, because the component concerned is preformed significantly closer to the final contour”, explains the Professor.

André Zein, Business Engineering graduate and scientist Our analyses show that the energy requirements of different machinery concepts for the same machining job can differ by a factor of five. This forms the motivation for our research into efficient solutions.

“In times where the user is not running his machines at full load, there are several levers available for saving energy”, says Professor Hermann. “One option in concatenated production operations is to plan the process chain so skilfully that no waiting times occur.”

Here, he explains, a lot of energy can be saved, since up to 70 per cent of the total energy consumption is accounted for by the basic requirement. “So one measure consists of shutting down the machine as far as possible when no production runs are ongoing”, explains André Zein.

“This means the mission statement for the sector is to design a machine tool with a minimised base load that is ready for operation and reaches its operating temperature within a very short time-frame.”

What feedback and conclusions has Volkswagen’s plant in Baunatal derived from the project’s results? “The analyses obtained during the course of the project and our daily empirical feedback show that existing lines can be optimised for enhanced energy-efficiency only with substantial expenditure of time and money”, says Dirk Sauermann, who heads the energy team. “What we’re targeting here is co-operation with the machinery and component manufacturers. Besides optimising the machines’ energy consumption, since 2011 we have also been focusing on systematically factoring energy-efficiency into new machinery procurement.”

Simply Measure and Evaluate But how can machine tools users proceed without the options of a large

Professor Christoph Herrmann, Head Product & LifeCycle Management Dept – Institute for Machine Tools and Production Technology (IWF) at Brunswick University of Applied Science Energy optimisation should be just as much a matter of course as time optimisation.

Dirk Sauermann, Head of Energy Team – Volkswagen’s plant in Baunatal, Kassel There is a need to stress on transparent depiction of energy consumption at machinery and component manufacturers.

corporation open to them? “Here we have developed a standard procedure geared to the capabilities of small and mid-tier companies, for acquiring the requisite data when they possess only machines with relatively old control systems, for example”, explains Professor Herrmann. “My advice is: they should use simple, sturdy measuring instruments with a simple, standardised evaluation program.” He is also hoping for more transparency from the machinery manufacturers. “I really like the idea of an energy passport, stating how much energy a machine will consume in a particular application, and how it performs there”, he comments.

He thinks it’s vital that users practice mutual feedback not only with each other, but also with the manufacturers in this field. “The METAV is an obvious opportunity for this, since it’s particularly conducive to exchanging ideas, and the networks function exceptionally well.”

Courtesy: Institute for Machine Tools and Production Technology (IWF), Brunswick, Germany, METAV 2012 and Volkswagen AG.

March 2012 - MODERN MACHINE TOOLS 121

TECHNOLOGY INSIGHT Precision Levelling Line Sheet Metal Tapes

Changing the Definition of Excellence The sheet metal technology has evolved over time to adapt to the changing needs of performance and quality required by the producers of different goods. Levelling is an essential process for today’s products. As the quality requirements of the most diversified manufacturers of metal goods has rapidly increased, the lines of sheet metal levelling has gained great importance to play a bigger role in sophisticated processing plants

R

equirements of higher precision and productivity and the use of materials with higher performances, such as high-strength sheet metal, prepainted, stainless steel, galvanised, tinplate, cold and hot rolled are the factors that have added to the development of new flattening lines capable of processing with high accuracy and short deadlines to large volumes of coil.

Plates that Claim More The recent high-precision flattening line (1500 x 3 mm) for the processing

of tape with thicknesses from 0.5 to 3 mm, produced for a well known service center, is one of the most important production examples. It consists of a loading zone, a decoiler, a tape feeder to the leveller, a leveller, a flying shear, a stacker conveyor (for the discharge of waste), a stacker (designed for the storage of delicate materials) and a weighing system. The entire line is over 30 m long.

The single reel can load coils up to 20 ton with an internal diameter of 500 mm extended up to 1800 mm. The decoiler is driven by an AC motor with inverter which has a pneumatic brake,

an emergency brake and a press roll with a motorised rubber roller to ensure the careful handling of delicate tapes and discharge to the metal strap. It also has alignment slides with self centering mechanism of hydraulic expansion.

The loading cradle is powered with AC inverter for the translation movement, while the vertical displacement is achieved by hydraulics.

The cradle is able to make a large vertical travel to allow even the load of coils of small dimensions, the contact surface is covered with nylon to avoid damaging the material and coils in preparation are positioned in dedicated grooves.

March 2012 - MODERN MACHINE TOOLS 123

Precision Levelling Line Sheet Metal Tapes A Levelling of Excellence The most important features here are flexibility and versatility. Sheets are getting smaller and diversified and should be able to quickly switch from one batch to another using the shortest possible time for the restart.

The entry table was designed to allow the processing of coils with diameters ranging from 500 to 1800 mm and is therefore equipped with a wide travel range. The longitudinal and rotational motions are obtained with the hydraulic system. The board is equipped with two rubber rollers for the entry and pulling and three rollers for the conduct of the yield.

The trimming station is required to cut the beginning of the head of the coil, if it is damaged. All components of the line are clearly critical in terms of characteristics of precision and productivity, but certainly the leveller is the core of the line because it gives the characteristics of flatness and quality of endplate. It is equipped with 19 rollers (Nine upper which are identical and ten lower) and seven back up rollers which are independent, moving on wedges not on the classing screws. This solution allows a more uniform discharge and prevents flexion of the back bending and is much better compared to the one supported just in two points.

Regarding the yearly scheduled machine re-adjustment, the seven back up rollers are manually adjustable and not through motors, such as the lower rollers. The movements of the tilting on the half moon with CAM are all independent, each made with a single electric motor programmed and displayed on the control panel. The vertical displacement of the entire top bank is driven independently by two big screws on the right side and two on the left side, in this way is easier to adjust the tilt on the operator side or opposite.

One of the problems of levellers typically is their elongation during operation. The CAMU leveller of latest generation has been completely redesigned to suit processing highstrength materials and therefore has a 124 MODERN MACHINE TOOLS - March 2012

Strengths

Rigidity: By focusing on the design for the processing of materials with high resistance.

Great versatility: The line is suitable for production of limited batches of sheet, with only the introductionof new parameters of the new coil is able to quickly resume working.

High productivity: Each work phase is optimised in execution speed in a global economy cycle.

Modular: A high standardisation of the various modules, allows always a very precise and technically advanced customisation

very high rigidity. One of the major tasks was the strengthening of the columns and their construction in heattreated steel, beside that has been given greater rigidity to the lower bank and to the upper deck.

Great Quality After leveling, there are plasticising rolls which are driven by AC motor with inverter, while the braking is achieved through pneumatic brakes. The phase of tape cutting with flying shear is obviously very dependent on the quality results of the leveling phase, but the expectations in terms of productivity and quality are very important. The quality of the cut is very high and with very small burrs because it uses a very fast shear (cutting time is 0.5s), which moves on a guide ball with grinded rack.

At the end of the line is the discharge area of the sheet metal and cut scraps. With regard to the material, it runs on two conveyors with different speeds. The second conveyor is faster than the first and also has the task of removing the short pieces to allow a more efficient stacking part. The stacker with rotating arms, operated by air, is also designed for delicate materials.

The mix of measures to adapt to the various programmed sizes is obtained automatically. There are encoders. The

operation is programmed and displayed from the control panel. From a functional standpoint, a hydraulic platform with a photocell decreases with increasing stack of sheets stacked. The sheet does not fall over each other, as it is supported by some side rollers arranged to withstand sheets of width 1500 mm and not allow them to bend in the center.

The retaining head is provided with damper to avoid damaging the sheets, particularly thin and delicate, when they come in contact. The stacker has three sides equipped with pneumatic palletisers. The unloading area is driven by chains, when the stack of plate is full, the platform is lowered to the level of chains and then moves to the discharge.

Final is the weighing phase, with value displayed on a console.

Considering the length of the line there are two pulpits for the command and control: the first one (near decoiler) with pushbuttons for easy loading and to control the levelling and flying shears; the second one with all related commands of the unloading area. The components used are of high quality and the system of lubrication, centralised and carefully realised, provides a generous lubrication to all points where there is a sliding or sliding bearings. The wear of the parts is extremely limited and therefore the line has a high reliability and can work longtime without any problem.

Know-How and Optimisation All components are designed and manufactured taking into account multiple parameters of flexibility, versatility, precision and productivity.

From the characteristics of individual machines and equipment it is understood that each phase or area of the plant could become a bottleneck if the flow of the cycle was not evaluated step by step in line with the required results. Companies operating in sectors such as plasma cutting, laser, punching on modern machines, benefit from this.

Courtesy: Camu Srl - Via dell’Artigianato, 20 – Bressanvido (Vicenza) – ITALY – www.camu.it – info@camu.it

STRATEGY Customised Orders

It’s Easier than You THINK Back when Henry Ford marketed the Model T to the masses, the idea was simple, yet revolutionary.

Ford’s engineers used interchangeable parts to make the same car every time. Any valve would fit any engine; any steering wheel would fit any chassis. As a result, low-skilled labourers could quickly assemble the cars, driving down the price dramatically. The only downside was they were all the same

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oday, the market is radically different and it is driving a revolution in the engineering world. Manufacturers have been forced to tailor make their winning products to the customer’s unique requirements and rise to the challenge–standardise, but customise.

Customers now demand ‘personalised’ products, and they are loyal to manufacturers who respond fastest.

For manufacturers, the challenge is how to offer more of these personalised features without complicating the design and manufacturing process. Anyone can make a super-personalised product with unlimited funds and resources. The trick is how to deliver that product quickly and at a competitive price.

Step One: Ask the Hard Questions Companies such as Dell, Herman Miller, and Siemens/ABB have been offering personalised products for many years. So how can your company enter the competition?

To begin with, you must re-evaluate your current engineering process. Ask yourself the following questions.

Have you ever Lost a great customer opportunity because it took too long to accurately estimate their custom order?

Gone straight from order to production without validating the design—and been left with expensive but useless scrap on the factory floor?

Found that you spend too much time in corrective action after the customer’s requirements have been supposedly “locked”?

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Had difficulty reusing existing product configurations because the new order has been tweaked just a little?

If you answered ‘yes’ to even one of these questions, you are not alone. The fact is that nearly 90 per cent companies rely on some sort of manual process for developing and managing the wide variety of configurations they support.

Step Two: Align Your Product Platforms with Business Strategies So how do you catch up to your competitors? In short, you have to find an easier way to offer customised products.

Product designs need to be less complex, but still be innovative. Designers need to reuse existing part designs seamlessly in their new products. Switching to modular product architecture—an approach that builds configuration flexibility into the design—is the answer.

And although the benefits of such a shift are clear, finding the right balance of cost savings and product differentiation is a major challenge for most companies.

It is not about adopting yet another solution; it’s about designing a flexible architecture that meets your company’s specific objectives.

First, you need to align your products and product platforms to your business strategy of meeting your customers every requirement. And as you begin a migration of this magnitude, consider how the following market trends will affect your company’s future growth and profitability.

Customers are Demanding: More personalised products Superior customer service Instant feedback on their orders

Error-free product configurations Higher product quality In a few years, mass customisation will be the norm, not the exception. Sr. VP and Chief Economist Michael Cox, Federal Reserve Bank of Dallas, who noted in The Right Stuff: America’s Move to Mass Customisation that “Mass Customisation offers consumers the best of both worlds. It embodies the good qualities from the era of hand production—custom design and individualised service. It retains the most significant gain from the era of mass production—low cost.”

Step Three: Modular Design and Configuration Management It is a simple idea with powerful consequences. In order to deliver more personalised products, you need to get closer to your customers. Adopting a modular product architecture will help your company better support your customers’ unique requirements.

To that end, manufacturers are streamlining the engineering process to allow: The capture of all customer, engineering, and manufacturing requirements to develop rules and constraints for configuring single or multiple product platforms; Design automation by creating and publishing automatically configurable product designs; and Designers and non-designers—and ultimately customers—to easily and automatically configure the design for a specific application by selecting/specifying variables and

Customised Orders using predefined business and design constraint logic.

Taking control of configuration management is the key. The traditional product structure is often too inflexible for handling modern configuration requirements. What is needed is a more modular approach, one in which the traditional product structure is embedded with the configuration intelligence: generic definitions of outsourced and manufactured parts tied together by specific rules and constraints.

Typically, changes—inevitable in the highly dynamic nature of product development—are what slows the customisation process down the most.

The structure must be able to absorb and respond these changes quickly and efficiently. Capturing variability and modularity in the structure can help you with ever-changing customer needs.

By adopting a modular product structure, your company can capture and store engineering intelligence digitally.

What’s more, it can automate the variant creation design and generation to better manage multiple design configurations, accommodate design alternatives, and design improvements.

The benefits are clear. Not only can a modular product structure help you deliver products to market faster, it allows you to modify—and most importantly, customise—designs to meet individual customers’ needs.

Step Four: Automate Bit by Bit Even small changes in your process and technology can make a huge impact towards your Customise-To-Order goals.

Your objective here is to reduce product complexity, increase part reuse, and achieve greater product differentiation all in the name of delivering to your customer’s unique requirements. Beyond simple manual processes, there are three levels of configuration management that can help your company realise the benefits of a Customise-To-Order strategy.

Model-Centric—Generic CAD Structure Some of the sophisticated CAD tools

48%

Percentage of new designs that are modifications of existing designs

Since 48 per cent of new designs are

modifications of existing designs, the speed of developing new products is greatly enhanced by the ability to reuse previous product configurations

provide ability to capture variability within the CAD structure, e.g. family of parts, inter-changeability features, constraint equations, and more. For any company, small or large, capturing the design using a 3D CAD solution brings a host of benefits, including the ability to: Capture engineering configuration and variability early in the design phase; Involve customers up front in the design phase to decrease quality issues later on; Reduce numbers of physical prototypes; and Generate engineering deliverables (drawings, cost rollups) quickly.

Not only will these benefits save valuable time for manufacturers, they will be an important selling point to customers, as they are able to get customised products faster—and for less money—than ever before.

Enterprise—Heterogeneous System with Product Data Management For many smaller companies, the Model Centric structure may provide all the customisation their customers need. But medium-sized and larger companies may find the second stage of configuration management—Enterprise—to offer even greater benefits, including: Enhanced customer intimacy; Decreased total product development costs; Increased product customisation; and

Improved operational efficiency.

An Enterprise structure, however, brings many more challenges than a simple CAD structure. Not only will you need to manage heterogeneous MCAD structures, you will have to handle ECAD and software structures as well.

Extended Enterprise or Optimal—Generic Product Structures and PLM This is where manufacturers can realise the full potential of their Customiseto-Order goals. Extended Enterprise includes: Fully integrated engineering configuration management; Extended enterprise applications; and Rules-based integrated generic structures with tight integration to legacy systems.

The beauty of the Extended Enterprise structure is that everyone— from the customer to the supplier to the manufacturer—is part of the value chain.

Managing the variability and modularity of such structures at the Enterprise level helps connect all members of your team so they can quickly collaborate across all the boundaries of the Enterprise. As a result, your company is able to optimise the product development cycle.

Taking it to the Next Level Making the leap to modular design and variant generation is indeed an evolving process. The key is to make improvements gradually. It is only a matter of time before mass customisation becomes the norm. If your company is flexible enough to begin offering customers the customisation they crave at a price they can afford, then you are well on your way to leading—and reaping the benefits of—the product marketing revolution.

Rafiq Somani, Area Vice President and Country Manager, PTC India, He has been responsible for driving growth of PTC India’s PLM solutions across key industry verticals such as automotive, industrial, aerospace and defence, consumer, infrastructure, publishing to name a few.

March 2012 - MODERN MACHINE TOOLS 127

Event List - National

AURANGABAD Maharastra Oct 5-8, 2012

PUNE

CHENNAI LUDHIANA INDORE

Madhya Pradesh Punjab Maharastra Tamil Nadu Nov 2-5, 2012 Nov 22-25, 2012 Dec 21-24, 2012 Jan 10-13, 2013

AURANGABAD Maharastra Feb 1-4, 2013

RUDRAPUR Uttarakhand Feb 23-26, 2013

India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumactics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.

1st Cross Road, Ambattur Industrial Estate, Chennai 600 058 Tel: +91 44 2625 8619 Fax: +91 44 2652 0814 Email: info@acmee.in Website: www.acmee.in

For details Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028.

Mob: 09819552270 Fax: 022 3003 4499 • Email: engexpo@infomedia18.in • Web: www.engg-expo.com

Modern Machine Shop The event offers an ultimate platform to demonstrate potential and futuristic technologies in the product segment to a large cross-section of business visitors, from the entire engineering industry; April 5-8, 2012; India Expo Mart, Greater Noida For details contact: Indian Machine Tool Manufacturers’ Association Bangalore International Exhibition Centre, 10th Mile, Tumkur Road, Madavara Post, Bengaluru Tel: +91 80 6624 6600 Fax: +91 80 6624 6661 Email: info@imtma.in Web: www.imtma.in

DIEMOULD India 2012 The 8th edition of this international exhibition will provide an ideal opportunity for the die & mould industry to upgrade its know how and keep pace with the latest developments in this segment; April 19 – 22, 2012; Bombay Exhibition Centre, NSE Complex, Goregaon, Mumbai.

For details contact: Tool & Gauge Manufacturers Association of India (TAGMA) A-33, NandJyot Industrial Estate, Safed Pool, A K Road Mumbai - 400 072

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Tel: +91 22 28526876 / 28508976 Fax: +91 22 28503273 Email: mumbai@tagmaindia.org Website: http://www.tagmaindia.org

Automotive Engineering Show 2012 The premier event on automotive components will demonstrate the latest technology in the automotives segment; April 26-28, 2012; Auto Cluster Exhibition Centre, Chinchwad, Pune.

For details contact: Focussed Event Management Pvt Ltd, Head Office : Plot No. F/11 & F/12, Camlin Fine,WICEL Compound, Opp. SEEPZ Main Gate, Andheri (East), Mumbai – 400 093 Tel: 91-22-3201 9137 Fax: 91-22-2832 4404 Email: info@focussedevents.com

ACMEE 2012 The event will showcase various innovations made in automobile and engineering industries over the past few years and act as a forum for exchanging diverse product information, technical details and development of new business contacts; June 14 -18, 2012; Chennai Trade Centre, Chennai For details contact ACMEE 2012- AIEMA Technology Centre,

AMTEX 2012 AMTEX (Asian Machine Tools Exhibition) has constantly strengthened its position as one of the largest shows of machine tools, machineries and manufacturing technologies in the Asian region. The event will showcase the latest advances in machine tools and manufacturing solutions; July 27-30, 2012; Pragati Maidan, New Delhi.

For details contact Triune Exhibitors Pvt LTD 25, 3rd Floor, 8th Main Road Vasanthnagar, Bangalore 560 052 Tel: +91 80 4330 7474 Fax: +91 80 2235 2772 Email: info@triuneexhibitors.com Web: www.triuneexhibitors.com

METALLURGY INDIA 2012 The fourth International exhibition on metallurgical technology products and Services will be visited by plant machinery and equipment manufacturers, suppliers, distributors, dealers, automotive component manufacturers, Central Government and State Government ministry officials component manufacturers and many more; October 30 - November 1, 2012; Bombay Convention & Exhibition Centre, Mumbai For details contact Messe Düsseldorf India Pvt Ltd 1, Commercial Complex, 2nd Floor Pocket H & J, Sarita Vihar New Delhi 110 076 Tel: +91 11 2697 1056 Fax: +91 11 2697 1746 Email: DughL@md-india.com Web: www.md-india.com

Event List - International

EXPO MANUFACTURA 2012 An important international business forum for the processing and manufacturing industry, the event will integrate new technologies and latest innovations in the processing and manufacturing industry; March 6 – 8, 2012; Cintermex, Mexico.

For details contact: Kara Swagart E J Krause & Associates, Inc 6430 Rockledge Dr Suite 200, Bethesda, MD 20817 Tel. +1 301 493 5500 Fax. +1 301 493 5705 Email: swagart@ejkrause.com Web: www.expomanufactura.com

MACH 2012 MACH organised by the Manufacturing Technologies Association (MTA), attracts almost 450 exhibitors and over 20,000 visitors who will showcase some of the best innovations and latest developments from the manufacturing technologies sector; April 11 – 16, 2012; NEC Birmingham, UK For details contact The Manufacturing Technologies Association 62 Bayswater Road, London, W2 3PS, United Kingdom Tel: +44 (0) 20 7298 6400 Fax: +44 (0) 20 7298 6430 Email: info@mta.org.uk Web: www.mta.org.uk

China CNC Machine Tool Fair China CNC Machine Tool Fair (CCMT) has been successfully held since 2000 in Shanghai every year. It has developed into one of China’s biggest machine tool and metal-working exhibitions; April 16 -20, 2012; Nanjing International Expo Center, China.

For details contact: IMAG - Internationaler Messe - und Ausstellungsdienst GmbH Am Messesee 2, 81829, München Germany Phone: +49-89 9492 2113 Fax: + +49-89 9492 2114

Email: reinhard.willenbuecher@imag.de Web: www.imag-db.de

SIMTOS 2012 SIMTOS 2012 will be divided into six brand pavilions by exhibit product ie metal cutting and die & mould working, press & metal forming, cutting-off & welding tools & related equipment, CAD/CAM, measuring system & robotics and motion controls; April 17 – 22, 2012; Korea International Exhibition Center (KINTEX), Seoul Korea.

For details contact: 4th Fl Tower Crystal Building, 1008-1 Daechi-dong, Kangnam-gu, Seoul, 135-280, South Korea Tel: +82-2-3453-2721 Fax: +82-2-6280-2721 Email: intl@simtos.org Web: www.simtos.org

AUSTECH 2012 The show exhibits with new manufacturing technologies and techniques to cut costs.

More than 10,000 decision-makers regularly attend Austech and National Manufacturing Week to get ideas, find innovative ways of making things and solve manufacturing problems; May 8 - 11 2012, Sydney Showground Sydney Olympic Park, Australia.

For details contact AMTIL Suite 1, 673 Boronia Road Wantirna, 3152, Victoria, Australia Tel: +61 3 9800 3666 Fax: +61 3 9800 3436 Email: kwarren@amtil.com.au Web: www.amtil.com.au

503/23 K S L Tower 14th Floor Sri Ayuthaya Road, Kwaeng Thanon Phayathai, Khet Rajathewee, Bangkok 10400 Thailand Tel: +66 0 2642 6911 Fax: +66 0 2642 6919 E-mail: info-th@ubm.com Web: www.ubmthailand.com

BIEMH The 27th edition of the event will showcase latest developments and technologies from leading companies in their specialty; may 28 – June 2, 2012; Bilbao Exhibition Centre, Bilbao, Spain.

For details contact: Bilbao Exhibition Centre Ronda de Azkue 1, 48902 AnsioBarakaldo Tel: 34 94 40 40 000 Fax: 34 94 40 40 001 Email: bec@bec.eu Web: www.biemh.com

MTA VIETNAM 2012 The 10th exhibition will serve as a platform to network with pioneers from machine tools, precision engineering and metalworking technology sector; July 3 – 6, 2012; at Saigon exhibition & Convention Centre, Ho Chi Minh City, Vietnam For details contact: Singapore Exhibition Services Pte Ltd 1 Jalan Kilang Timor 09-02 Pacific Tech Centre Singapore 159303 Tel: +65 6233 6638, Fax: +65 6233 6633 Email: mta@sesallworld.com Web: www.mtavietnam.com

INTERMACH 2012 The show focuses exclusively on industrial machinery and aims at introducing the latest high-tech machinery and cutting edge technology from around the world; May 1720, 2012; at Bangkok International Trade & Exhibition Centre (BITEC), Thailand.

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

For details contact: UBM Asia (Thailand) Co Ltd

March 2012 - MODERN MACHINE TOOLS 129

Event Preview

Creating Business Opportunities for SMEs After the enormous success of IMTEX Forming 2012, it is time for Indian engineering SMEs to gear up for another mega event. Catalysing growth to the next level is the second edition of Modern Machine Shop, Noida, scheduled to be held from April 5 – 8, 2012. Organised by the Indian Machine Tool Manufacturers’ Association (IMTMA), the exhibition is all set to provide excellent opportunities for engineering SMEs. Nishant Kashyap previews the opportunities

M

odern Machine Shop 2012 (SME) – a one-stop shop for engineering SMEs – in its second edition will be the ultimate destination to demonstrate potential and futuristic technologies in the field of metal working machinery, low-cost automation, material handling and quality control systems and equipment, together with offthe-shelf production aids, accessories, consumables, software & consultancy to address today’s rapidly changing productivity and quality requirements.

Modern Machine Shop 2012, a businessto-business (B2B) exhibition, aims to bring about progressive change in job shops that instill quality, efficiency and productivity, with upgraded machine and technology.

Highlights of MMS 2012

Showcasing a spectrum of innovative industrial technologies and solutions under one roof Offering a unique opportunity and a spectacular forum for forming partnerships between engineering professionals, system integrators and customers Offering a cost-effective marketing base with potential business visitors Witnessing large attendance from decision makers that count Providing larger market reach in a four-day period Brand positioning among the best Seminar & conference.

business delegations from the Indian Railways and Indian Ordnance Factory besides special OEMs teams.

Remniscing First Edition: 2008 The exhibition’s first edition was a huge success and served as a platform for companies to exhibit their products and services; interact with potential buyers; get new business leads and forge new partnerships. Held at Pragati Maidan, New Delhi, from April 25 – 29, 2008, the exhibition brought together 111 exhibitors. This has reinforced the faith of exhibitors in the event. This is evident from the fact that this year’s edition has more number of exhibitors and foreign participants. In 2008, there were many international exhibitors from Italy, Japan, Korea, Taiwan, Turkey and the UK, including group participation from Germany. It was attended by high-level 130 MODERN MACHINE TOOLS - March 2012

Destination Noida North India has achieved impressive economic growth rates over the last decade with the investment increasing manifold. The city’s geographical location makes it a prominent business destination for companies vying to tap the north Indian market. The exhibition location will create opportunities for companies looking to find new customers and enhance their business in North India. The expo will provide good exposure to companies that want to reach out to OEMs. Additionally, there would be a good number of overseas participation from Austria, Australia, Belgium, Canada,

Czech Republic, Finland, France, Germany, Greece, Holland, Hong Kong, Israel, Italy, Japan, Korea, China, Romania, Russia, Singapore, Spain, Sweden, Switzerland, Taiwan, Thailand, the Netherlands, Turkey, UAE, the UK and the USA as well.

Profile Exhibits Metal cutting machines Metal forming and sheet metal working machines Welding, plastic processing machines Machine tool accessories Material handling equipment Hand tools Energy-efficient devices Low-cost automation.

Visitors OEMs Tier I-IV supply chain SME machine & job shop Companies from the bottom of the supply chain pyramid.

Just like in the past editions, Modern Machine Shop’s forthcoming event also promises to provide an ideal business platform with significant growth in terms of exhibitors, visitors and innovative technologies displayed.

Modern Machine Shop 2012 is set to outperform the success of 2008 with more number of visitors and exhibitors and with a focus to benefit participants and promote SMEs. Modern Machine Shop 2012 is determined to play a key role in the growth & development of the engineering industry. nishant.kashyap@infomedia18.in

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

Tapping chuck The QCSL non-reversible tapping chuck is specially developed for builders of heavy machinery, turbines, motors, nuclear reactors and other such types of heavy equipment. Capacity of the tapping chuck ranges from M30 to M200. This chuck is available in Morse Taper, ISO Taper or in special shanks.

The tapping chuck is suitable for heavy jobs and for tapping on higher diameter. It is provided with length compensation features that allow the tap to act as its own lead screw.

IMI Machine Tools Pvt Ltd Ahmedabad - Gujarat Tel: 02764-233983 Email: imi@imitoolsindia.com Website: www.imitoolsindia.com

Cylindrical grinding machines The model SWIFT-500 CNC cylindrical grinding machine is designed to cater to customers’ requirements of high accuracy, productivity and reliability of performance. This machine is suitable for production as well

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Products as toolroom applications. The machine is available with Siemens 802D CNC system and are 2-axis and single spindle controlled.

Hi-Life Machine Tools (P) Ltd Ahmedabad - Gujarat Tel: 079-22821615, Mob: 09898083890 Email: info@hilifegroup.com Website: www.hilifegroup.com

Reversible tapping attachments These new, low-weight, high-speed reversible tapping attachments are suitable for use with standard HSS taps on any drilling machine vertically or horizontally, for right or left hand tapping of blind or through holes. Made of alloy steels with all moving parts hardened and ground to precision, this tapping attachment is available in capacities ranging from 2-3 mm. An ultra-sensitive and smooth operating ball-clutch protects the tap against breakage when, tap is bottomed in a blind hole or core hole is shallow or tap is dull.

Tools & Appliances Corporation Ahmedabad - Gujarat Tel: 079-22740375, Mob: 09624812180 Email: taco@imitoolsindia.com Website: www.imitoolsindia.com

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Indexable engraving tools The Nine9 indexable engraving tools have high speed up to 20,000 rpm. The feed rate is 0.08-0.05 mm/rev. These tools have 45째/60째 engraving inserts for making serial number, product code, dial scale, sign, logo outline and almost any character.

No reshape is required and the tool length remains unchanged. The indexing engraving tools have excellent repeatability and are suitable for all materials.

Stitch Overseas Pvt Ltd Gurgaon - Haryana Tel: 0124-4755400, Mob: 09313361202 Email: stitch@vsnl.com Website: www.stitchtools.com

Power chuck The model 4T is a four-jaw two motion type power chuck. It is a crank-type chuck with two pairs of two jaws self-center independent of each other, and is used mainly on turning, CNC, special-purpose machines, etc. It has construction of high rigidity and clamping accuracy.

The 4T series is suitable for square

Products bar and other non-uniform shaped workpieces. Installation is the same as normal power chuck and these are replaceable with each other.

Autogrip Machinery Co Ltd Changhua Hsien - Taiwan Tel: +886-4-8223719 Email: sales@autogrip.com.tw

Servo press Equipped with the latest version of servo motor technology from Japan, the SD1 series servo press has greater ability, and is applicable to interchange curve graph as expected, free forming limitation, challenge top rated press technology. Salient features include powerful, rigid, precise, high torque, low rpm rotational speed, servo motor especially designed for presses, pressure stabiliser system for servo unit, changeable curve, excellent forming capability, and friendly environmental energy saving.

Goodwill Imex Bengaluru - Karnataka Tel: 080-26278815 Email: gwimex@gmail.com

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Products Internal and radius grinding machine The Danobat Overbeck IRD-200 internal grinding machine achieves short changeover times. It is the smallest of the three-model IRD range of high-precision grinding machines with radius option.

Maximum internal grinding diameter is 100 mm, workpiece swing is 200 mm and maximum workpiece weight is 30 kg. The machine is suitable for machining of dies and punches, for example, the integrated B-axis of the workhead, which has a swivelling rage of +95째/-25째, combines with 3-axis interpolative software to allow the grinding of different radii without manual re-setting of the pivot points.

Danobat Grupo Machine Tools India Pvt Ltd Pune - Maharashtra Tel: 020-66094531 Email: danobatgroupindia@danobatgroup.com

Multi-spindle heads These multi-spindle heads are used for drilling and tapping applications. The heads are available in both adjustable and fixed type centre distances. These can be fitted on all types of machines, like conventional drilling and tapping machines, machining centers or any other type of automatic drilling and tapping machines. Features include: equipped

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MMT Mar-2012 Ad Name:Quaker Pg No.135

MMT Mar-2012

Ad Name:SNK Pg No. 136

MMT Mar-2012 Ad Name:Korea

Pg No. 137

MMT Mar-2012 Ad Name:Electronica

Pg No. 138

Products to deliver precisely what users need, smallest centre distances, high-spindle accuracies, customised multi-spindle heads as per requirements, compact, rigid and sturdy design, special multispindle heads for carbide tools, through-coolant operations can be done, optimise production cost.

Suhner India Pvt Ltd Bengaluru - Karnataka Tel: 080-27831108

Mob: automation.i Email: blroffice.in@suhner.com Website: www.suhner.com

Base circle discs These discs are made of high alloy tool steel and hardened to 60 HRC. The discs are sub-zero treated for dimensional stability and calibrated at 20°C under standard room conditions. Design is as per customers’ requirements. The manufacturing range is from 40 mm to 300 mm.

Cyclo Instruments Pvt Ltd Satara - Maharashtra Tel: 02162-240406, Mob: 09922424224 Email: cycloinstruments@sify.com

Colour scanner This next generation professional high-tech colour scanner is available in different widths 44”, 55” and 60” with many optional facilities and optional accessories. The scanner from the ROWE Scan 600 series sets new standards providing a superior quality and user-friendliness. An optical resolution of 2400 x 1200 dpi (max up to 9600 dpi) and scan width up to 60” combined with high-speed and productivity is available. The ROWE Scan 600 is Energy Star compliant and easy to use.

Mehta Cad Cam Systems Pvt Ltd Ahmedabad - Gujarat Tel: 079-26840551, Mob: 09227985780 Email: design@mehtaindia.com Website: www.mehtareprosystems.com

Synthetic grease The ONWO synthetic high-speed grease is available with technology from UK for high-speed CNC machine spindles, which operate up to 12 lakh DmN value.

It provides excellent performance at low operating and start-up temperatures. Low viscosity base oil and additive package offers excellent lubricity even at high speeds. Other features are lower friction

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Products when operating therefore lower running temperatures, quiet running and suitable for silent running electric motors, extremely good protection against corrosion in wet/humid environments, etc.

Raj Petro Specialities P Ltd Chennai - Tamil Nadu Tel: 044-42288900, Mob: 09791037818 Email: onwo@rajgrp.com Website: www.rajgrp.com

Modular boring system The model B72 large diameter modular boring system is flexible. Its flexibility allows the system to easily adapt to process various more big sizes and depth of the hole of the diameter. The modular boring system assemble with taper shank, plate, large diameter body, balance holder, cutting insert holder and reverse cutting insert holder. It has two system, one is

Compression moulding press This compression moulding press uses two plates to push together plastics,rubber, bakelite and composite materials into a mould.

It is available in hot and cold varieties. The press has a large number of applications for a variety of industries.

Any industry that can benefits from the creation of ultra-dense composite moulds can make use of the machines. Technical specifications are products range from 15-500 tons, table size length up to 2000 mm x width up to 2000 mm, construction is plate fabricated/4 pillar, operation is by relay or contactors/PLC/NC, etc.

PMP Machine Tools Rajkot - Gujarat Tel: 0281-2366202, Mob: 09825072272 Email: info@pmpmachines.com Website: www.pmpmachine.com

Multi-spindle automatic lathe The multispindle automatic lathe is offered in CNC, non-CNC and partly CNC version. This machine is also available in 6-spindle and 8-spindle types right from 20 mm diameter to 67 mm diameter bar sizes. The machine is also equipped with chucking system together with automatic loading and unloading magazines.

Tajmac-ZPS as Malenovice - Czech Republic Tel: 420-577-531111, Mob: 09845370604 Email: dwivedi@tajmac-zps.cz Website: www.tajmac-zps.cz

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Products adjustable twin cutter roughing & semi-finishing boring system; and the other is finishing cutter fine boring system.

Stanny Machine Tools Co Ltd Taichung Hsien - Taiwan Tel: +886-4-26710805 Email: stanny88@ms45.hinet.net Website: www.stanny-tool.com

Vertical turning lathe The model PTA 40 small-type vertical turning lathe is used to facilitate effective machining of components in petrochemical, pumps and valve manufacturing, automotive and oil & gas industries. It has international standard components and significant features, like precision class LM guideways, rigid, high-precision, high speed & thermally stable spindle, preloaded and precision class ball screws, CNC controller; high-speed traverse; self-centring, hydraulic clamping with low & high pressure, higher load carrying capacity; and elaborate safety features.

Premier Ltd Pune - Maharashtra Tel: 020-66310000, Mob: 09372279092 Email: mtdsales@premier.co.in Website: www.premier.co.in

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Products Precision drilling machine The Supreme ITCO precision drilling machine has drilling capacity of 20 mm in steel and 22 mm in brass, silver and cast iron. This drilling machine is available in simple and geared model. Spindle is made from alloy steel, hardened & ground and is supported in alloy steel quill carrying two taper roller bearings. The spindle is four-splined, which drives through broached sleeve made of alloy steel. Additional four speeds are obtained from gear set. All moving parts are ground finished.

Indian Engg Corp Ludhiana - Punjab Tel: 0181-2299789, Mob: 09814465427 Email: itcodrill@gmail.com

Laser cutting system The Sirius automationready flying optics laser cutting system is used for fast, efficient sheet metal processing. This system is designed to provide efficient processing of parts at optimal speeds and accelerations to suit the part geometry, offering reliable cutting performance at an affordable price-performance ratio. It is optimised

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Products with additional features and automation capabilities and provides quick and precise positioning and consistently accurate laser processing. The combination of a dynamic machine with an excellent laser beam quality allows high-speed laser cutting.

LVD Company NV Gullegem - Belgium Tel: +32-56-430511 Email: marketing@lvd.be

Internal grinding machine This conventional and non-conventional international grinding machine caters to the needs of modern industries for high accuracy and production. Main features include auto cycle with programmable feed and auto dressing with dressing compensation, workhead spindle running on precision anti-friction bearings, workhead can swivel up to 30 degrees for grinding taper bores, DC drive of workhead for infinitely variable speed, Turcite-B coated on slideways, separate hydraulic & electric units housed outside the machine and centralised lubrication system.

Hi-Life Machine Tools (P) Ltd Ahmedabad - Gujarat Tel: 079-22821615, Mob: 09898083890 Email: info@hilifegroup.com Website: www.hilifegroup.com

Reinforced cut-off wheels The Tailin reinforced cut-off wheels are made from high quality abrasive grains with a unique weave of extra high tensile fibre glass reinforcing and specially formulated resin bonds offering reliable performance and safety for metal cutting (hard steel, structure steel, iron, etc).

K E Jawadwala Mumbai - Maharashtra Tel: 022-23411220 Email: kejawadwala@hotmail.com www.kejawadwala.com Website: www.kejawadwala.com

Mechanical press brake The mechanical press brake is widely accepted in industries for continuous production runs and in areas requiring accuracy and repeatability coupled with high production. Frame of the press brake is of robust steel construction of rigid and interlocked design. It is stain-free and supports the ram and bed against undesired deflection under permissible load condition. Ram and bed is made from steel plates of suitable thickness machined for straightness and parallelism of the working

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Products surface. Power is transmitted to the ram through two individual gear drives for uniform load distribution throughout the length.

Weldor Engineering Pvt Ltd Rajkot - Gujarat Tel: 0281-2360242, Mob: 09227755533 Email: weldor@weldor.com Website: www.weldor.com

Lathe machine The Balaji VGH series geared head heavy-duty lathe and extra heavy-duty machine is available with different heights of centre ranging from 267 mm to 455 mm, length of bed ranging from 1675 mm to 6100 mm, admit between centres ranging from 525 mm to 5000 mm and main spindle hollow ranging from 50 mm to 104 mm. This lathe machine has 12 numbers of speeds ranging from 30 to 1060 RPM. All gears are of 20 MN CR5 materials and hardened and ground. The main spindle nose is A 2-6 and A 2-8 designed.

Vinit Engineering Works Rajkot - Gujarat Tel: 0281-2311734, Mob: 09879022052 Email: vinit@balajilathe.com Website: www.balajilathe.com

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Products Solid carbide reamer The solid carbide reamer comes with LH helixRH cut, RH helix-RH cut and straight flute geometry for entire solution of reaming operations. The combination of helix geometry along with H6 tolerance parallel-shank, offers the highest concentricity and rigidity during the reaming operation. Unique flute design of the Blood reamer is the 2-axis alignment of amount-ahead-of center (AAC) geometry, which distributes the load equally to each tooth thereby increasing the life of reamer. The solid carbide reamer cuts at its chamfered edges and a standard 45-degree chamfer angle provides effective cutting action for most workpiece materials.

Robin Precision Products Pvt Ltd Rajkot - Gujarat Tel: 0282-287634, Mob: 09909912010 Email: info@bloodtools.com Website: www.bloodtools.com

Milling and turning centre The Soraluce F-MT milling and turning centre combines high-performance milling and vertical turning operations in a single machine. This provides the possibility of manufacturing complex components in one machine, offering remarkable versatility which leads to effective real time saving and the associated cost savings for end users. The compact solution is based on the Soraluce FL model, integrating a flexible working area that is configured to customers’ needs with one or multiple working stations with fixed tables and rotary tables usable for both milling and turning operations.

Danobat Grupo Machine Tools India Pvt Ltd Pune - Maharashtra Tel: 020-66094531 Email: danobatgroupindia@danobatgroup.com

Disc grinder The model G10SB 100 mm disc grinder contains a powerful motor of 600 W with no load speed of 12000 RPM. It is a high-performance grinder with lightweight shockproof double insulated engineering plastic body.

The disc grinder finds application in all weld dressing work, foundry grinding and in cutting of risers and runners. It is especially useful where fast and continuous cutting is required for continuous production, grinding and cutting work.

Nippon Electrical Industries Ahmedabad - Gujarat Tel: 079-22822750, Mob: 09376710401 Email: marketing@nipponpowertools.com Website: www.nipponpowertools.com

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Products Colour mark sensor The LX-100 series digital colour mark sensor detects any marking because it is equipped with red, green and blue LED light emitting element. To expand the functionality, the sensor comes with dual mode: mark mode (ultra high-speed response) and colour mode (high-precision mark colour discrimination) to suit any application. Other special features include four-digit digital display, super simple teaching, external teaching, 12-bit A/D converter, D-code, key lock, timer, NPN or PNP outputs, IP67 protection, etc. All this comes in the size of 57 mm (W) x 24 mm (D) x 38 mm (H) body.

Lubi Electronics Ahmedabad - Gujarat Tel: 079-22205471, Mob: 09825569559 Email: info@lubielectronics.com Website: www.lubielectronics.com

Rear cylinder press brake The rear cylinder press brake is available in a wide range of sizes from 2000 mm to 4000 mm length x 2 mm to 20 mm thickness with capacity ranging from 30 ton to 500 ton. It offers many superior advantages compared to competition,

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Products like synchronised operation due to superior hydraulic systems, bending operation at slow speed with faster return travel to cut down idle time optional ball-roller tables for easy movement of jobs, quick die changing system, etc. Both CNC and PLC-based versions are available.

Kawa Press Systems Pvt Ltd Rajkot - Gujarat Tel: 0281-2461102, Mob: 09825389169 Email: info@shaileshmachines.com Website: www.shaileshmachines.com

Low and high-voltage motor The motor has output of 0.12 up to 315 kW. It is self-ventilated TEFC type. This motor exceeds EFF1 top premium efficiency. Other features are B3T mounting, IP55 degree of protection, terminal block, squirrel cage rotor/ aluminium die-cast, V-ring on both endshields, stainless steel nameplate AISI 316, etc. Applications are in pumps, fans, crushers, conveyors, machine tools, milling applications, centrifugal machines, presses, elevators, looms, grinders, woodworking, cooling, packaging equipment, etc.

Weg Electric (India) Pvt Ltd Bengaluru - Karnataka Tel: 080-41282007 Email: info-in@weg.net Website: www.weg.net/in

Lathe machine The light-duty type RXZ series lathe machine is designed to create objects that have symmetry about an axis of rotation.

This machine is used for accurately machining comparatively hard materials.

Technical specifications are height of centre 175 mm, width of the bed 240 mm, maximum swingover bed 350 mm, maximum swingover slide 190 mm, spindle bore 40 mm, spindle nose 6 tpi, spindle speed ranges form 45 to 900 rpm, cross slide travel 200 mm, lead screw 4 tpi, tail stock sleeve MT-3 and power required is 1.5 HP. Bhavya Machine Tools Ahmedabad - Gujarat Tel: +91-079-40087900 Email: info@bhavyamachinetools.com Website: www.bhavyamachinetools.com

Power shearing machine The Slidewall power shearing machine is constructed sturdily and designed for accuracy and dependability by employment of latest technology and experience. It is designed from mild steel to take heavy loads. Bed and upper beams are fabricated from mild steel to withstand and absorb heavy loads designed specially to

148 MODERN MACHINE TOOLS - March 2012

Products adjust the blade clearance as required. Clutches, brakes and drives include revolving key clutch, linked with the main gear that engages every time when the foot pedal is pressed.

Godson Bending Systems Pvt Ltd Rajkot - Gujarat Tel: 0281-2361467, Mob: 09879079267 Email: godsonindia@hotmail.com Website: www.godson-india.com

Vertical machining centre The model VM-2 vertical machining centre is designed for mould industries. It is a high-performance machine with a 30” x 20” x 20” work cube, 36” x 18” table, 12000 rpm inline direct-drive spindle and highspeed control with full look-ahead. Highprecision linear guides on all axes further increase rigidity and stiffness, while providing a low coefficient of friction and long-term reliability. High-speed brushless servos, combined with finepitch ball screws and high-resolution digital encoders, ensure ultra-precise positioning and extreme repeatability.

High pressure screw pump The high pressure screw pump is easy to use, quite in operation due to ground screws and has long life as the screws are specially treated. It has variable pressure either manually or electronically and have variable flow through dual speed motor. Motor power ranges from 0.5-90.00 kW. Rajamane Industries Pvt Ltd Bangalore - Karnataka Tel: 080-28524262, Mob: 09986055750 Email: coolantpump@rajamane.com, Website: www.rajamane.com

Haas Automation, Inc California - USA Tel: +1-805-2781800 Email: sales@mtscnc.com Website: www.haascnc.com

Indexing table The Fibrotakt indexing table is used for precision divisions and the absorption of high machining forces. Different versions and drive types ensure optimum device selection for the respective application. Even for heavy structures, the flush-mount rotary table for rotary transfer machines combines minimum switching times with maximum precision and rigidity. It features a nonlifting indexing table, girth gear drive and easy access from below.

Fibro GmbH Weinsberg - Germany Tel: +49-7134-730 Email: info@fibro.de Website: www.fibro.com

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Products 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.

Place of Publication: Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (W), Mumbai-400028.

2. Periodicity of Publication: Monthly 3. 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. Executive Editor’s Name: Archana Tiwari-Nayudu 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.

Is the owner of Modern Machine Tools.

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 20-02-2012: a. Network18 Media & Investments Limited 503,504 & 507, 5th floor, Mercantile House, 15 Kasturba Gandhi Marg, New Delhi-110001 b. ACACIA Conservation Fund LP Citibank N A, Custody Services 3rd Flr, Trent House, G Block, Plot No. 60, Bkc, Bandra - East Mumbai 400051 c. Pramod Premchand Shah & Kalpana Pramod Shah Agra Building, 1st Floor, 121/4 Mg Road, Mumbai, Maharshatra India 400023 d. ACACIA Institutional Partners, LP Citibank N A, Custody Services 3rd Flr, Trent House, G Block, Plot No. 60, Bkc, Bandra - East Mumbai 400051 e. SPS Capital & Money Management Services Pvt Ltd 66, Tamarind Lane, 4/5, Haji Kasam Bldg, 1st Floor, Fort, Mumbai Maharashtra India 400023 f. Sanjiv Dhireshbhai Shah 201-203,sapphire Complex, Nr Cargo Motors, C. G. Road, Ahmedabad, Gujarat India 380006 g. The Oriental Insurance Company Limited The Oriental Insurance Company Limit Oriental House, P B 7037, A25/27, Asaf Ali Road, New Delhi 110002 h. Accurate Finstock Pvt. Ltd. 9th Floor, Shikhar, Adani House Nr. Mithakhali Six Road Navrangpura, Ahmedabad 380009

I, Lakshmi Narasimhan, Hereby Declare That All Particulars Given Above Are True To The Best Of My Knowledge And Belief.

Dated: 20th February 2012

Sd/Lakshmi Narasimhan Signature Of The Publisher

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Core drill The HSS-XE/ASP core drill is used in portable magnetic drill machines.

Universal shank/ Weldon shank can be used in any brand of magnetic drilling machines, for example, BDS, NITTO, Fein, Rotabroach, Miranda, KPT, Bosch, Rallywolf, Kraft, Allcut and Unibore.

The HSS solid drill comes in diameter ranging from 6-16 mm in 30 mm cutting length. HSS drill line cutter is available in diameter ranging from 17-27.5 mm in 40 mm cutting length, with internal cooling. The HSS core cutter comes in diameter ranging from 12-60 mm in 25/50/75/110 mm cutting length.

Amrit Enterprise Kolkata - West Bengal Tel: 033-22319244, Mob: 09836615555 Email: nipul.hemani@rediffmail.com Website: www.amritenterprise.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

List of Products To know more about the products featured in this magazine, fax us on 022-3003 4499 or tear and post to us the ‘Product Inquiry Card’ by following the 5 easy steps given there. Alternatively, you may also write to us at michael@infomedia18.in or call us on 022-3003 4684, and we will send your inquiries to the advertisers/companies directly to help you source better.

Sl. No Product 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56

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3-axes high-speed machining centre ............. 97 3D printing system ......................................................... 70 5-axis high-speed machining centre .............. 97 5-axis machining centre ........................................63, 68 5-face double-column milling machine ....COC, 136 5-face machining centre ...................................160-161 Abrasive belt grinder ..................................... 131 Aerosol multi-spray ........................................................ 53 Air treatment .................................................................... 20 Airline fluid ........................................................................ 53 All-geared auto-feed pillar/radial drill machine .. 15 All-geared radial drill machine .................................. 15 Angle encoders ...............................................................BIC Angle heads ....................................................................134 Appliance switch ............................................................. 33 Assembly and high-temperature grease ............... 53 Auto-feed pillar/radial drill machine ....................... 15 Automatic grinding machine ...................................153 Automation ...............................................51, 58, 66, 105 Back spot facing ............................................. 147 Back-geared auto-feed radial drill ............................ 15 Back-geared fine-feed machine ................................ 15 Balancing system .........................................................BGF Ball bearing ....................................................................... 65 Ball screw .........................................................................107 Band saw machine ......................................................... 18 Bar feeder ........................................................................... 75 Bars .....................................................................................147 Base circle discs .............................................................140 Bearing ................................................................................ 30 Bellow ................................................................................145 Bench grinder .................................................................131 Bench grinder-cum-polisher .....................................131 Bench polisher ...............................................................131 Bench-type drilling machine ....................................145 Billet shearing machine ................................................ 16 Boring machine ............................................................... 18 Boring ................................................................................147 Bottle boring machine ................................................147 BTA/ejector counter boring machine ..................... 24 BTA/ejector drilling machine...................................... 24 Building automation ...................................................... 66 Cabinet ............................................................ 116 Cable and hose carrier ................................................144 Cable assembly ..............................................................143 Cable carrier ...................................................................... 30 Cable conduit ................................................................... 33 Cable connector .............................................................. 30 CAD/CAM software......................................................... 10 CAM follower ..................................................................140 CAM grinding machine...............................................117 CAM works.......................................................................133 Carbide end mill tool.....................................................BC Carbide end mill .............................................................. 45 Carbide metal working tool ......................................163 Carbide tool...........................................95, 113, 155-156

152 MODERN MACHINE TOOLS - March 2012

Sl. No Product 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112

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CBD .....................................................................................111 CED coating machines .................................................. 66 Centerless grinding machine ........................... 17, 117 Centre drill ............................................................88-89, 96 Ceramic .............................................................................163 Cermet...............................................................................163 C-frame power press ..................................................... 16 Chain oil.............................................................................. 53 Chain .................................................................................... 30 Chemlok coating machine .......................................... 66 Chrome bar and shaft .................................................147 Chuck jaw........................................................................... 58 Chuck ................................................................................... 75 Clamping tool...................................................................BC Cleaner ..............................................................................135 CMM ...................................................................................151 CNC angular cylindrical grinding machine ........... 17 CNC cutting machine .................................................... 66 CNC double-column machining centre ................. 14 CNC equipment ............................................................... 37 CNC grinding machine ...............................................153 CNC guillotine shear ...................................................... 46 CNC horizontal borer..................................................... 63 CNC horizontal boring and milling machine 14, 68 CNC horizontal machining centre ............................ 14 CNC horizontal turning centre................................... 14 CNC hydraulic press brake .......................................... 46 CNC hydraulic turret punch presses......................138 CNC laser cutting machine...................................46, 66 CNC lathe ..................................................... 11, 22, 47, 63 CNC machine tools ......................................................... 67 CNC machine ......................7, 8-9, 18, 97, 98, 160-161 CNC machining centre ...........................................56, 97 CNC milling machine ...................................................142 CNC multi-tasking centre............................................. 14 CNC oxyfuel cutting machines .................................. 66 CNC plasma cutting machines................................... 66 CNC precision lathe........................................................ 59 CNC press brake .............................................................. 18 CNC punch press............................................................. 46 CNC small machining centre ...................................... 56 CNC tool ...........................................................................105 CNC turning centre ........................................................ 97 CNC turning machines ................................................117 CNC turn-mill centre ...................................................... 14 CNC vertical machining centre ...........................14, 97 CNC vertical turning lathe ........................................... 14 CO2 laser marker series ..............................................157 Coating machine ............................................................. 66 Coating plant .................................................................... 66 Coating system ................................................................ 66 Collet chuck....................................................................... 59 Colour mark sensor ......................................................147 Colour scanner ...............................................................140 Compression moulding press ..................................141 Compressor oil ................................................................. 53

Sl. No Product 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167

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Connection cable ............................................................ 44 Connector ......................................................... 30, 61, 143 Control cabinet ................................................................ 61 Control panel accessory ............................................... 33 Control panel .................................................................... 61 Control system ................................................................. 61 Controlling machine tools ..........................................BIC Conventional precision lathe ..................................... 22 Coolant pump ................................................................131 Coolant.......................................................... 26, 35, 55, 69 Cooling tower................................................................... 20 Coordinate measuring machine..............................141 Core drill ...........................................................................150 Coro mill .......................................................................... FGF Coro thread .................................................................... FGF Corrosion preventive ...................................................135 Counter and power supply ......................................... 79 Countersink ........................................................ FIC, 12-13 Coupling ...........................................................................148 Crank pin grinding .......................................................117 Crush blade ....................................................................... 43 Cutting fluid ....................................................................135 Cutting machine.............................................................. 66 Cutting oil .................................................... 26, 35, 55, 69 Cutting tool ........................ 28, 31, 41, 43, 45, 95, 113, ........................................................137, 163, 164, 155-156 Cycle time reduction & programming software ....... 86 Cylindrical grinder .......................................................... 11 Cylindrical grinding machines .................................131 Deep-hole drilling machine............................. 24 Deep-hole drilling sub-contracts .............................. 24 Desktop printer................................................................ 70 DFMPRO............................................................................133 Diamond lapping and polishing system.............BGF Diamond tools................................................... FIC, 12-13 Didactic equipment for training ............................... 61 Die coater ........................................................................... 43 Die/mould machine ..........................................COC, 136 Diode end pumped laser marker............................157 Diode side pumped laser marker ...........................157 Dip spin coating machine ........................................... 66 Disc grinder .....................................................................146 DNC system for networking CNC machine........... 86 Drawing and forming compound ..........................135 Drill machine..............................................................15, 42 Drill tool ..............................................................................BC Drill ....................................................................................... 45 Drilling machine .........................................145, 160-161 Drilling tool............FIC, 12-13, 41, 113, 137, 155-156 Drive technology............................................................BIC E-drawings publisher ..................................... 133 Element shrink disc ......................................................140 Encoder ........................................................................44, 79 End mill ..................................................................88-89, 96 Engineering tool.............................................................. 28 Engineer’s files ................................................................. 96

List of Products Sl. No Product 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194

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Exhibition - EngineeringExpo...................................115 Exhibition - Tagma .......................................................112 Expansion joint ..............................................................145 Exposed linear encoder ...............................................BIC Facing .............................................................. 147 Factory automation........................................................ 66 Fiber laser marker .........................................................157 Filter bag ..........................................................................145 Flexible shaft grinder...................................................131 Floor automation ..........................................................125 Fluidised bed coating machine ................................. 66 Forging heater ...............................................................118 Forging machine ...........................................................118 Forging press .................................................................... 16 Form measurement........................................................ 25 Freewheel-oneway-clutch .........................................140 Friction drop hammer ................................................... 16 Friction screw press ....................................................... 16 Gang drill machine ......................................... 145 Gantry automation .......................................................125 Gantry/NC boring and milling machine................. 47 Gear cutting machine.......................................COC, 136 Gear milling solution ..................................................... 93 Gearbox ............................................................................148 Geared drill machine ...................................................145 Geomcaliper ....................................................................133 Glide coating machine .................................................. 66

Sl. No Product 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221

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Gomet bearing ................................................................. 65 Graphics overlay and decal .......................................133 Grease .................................................................................. 53 Grinding machine ...............................................117, 153 Grooving & parting tool ............................................... 95 Grooving...........................................................................147 Ground thread taps..................................................88-89 Guide rods .......................................................................147 Guillotine shear................................................................ 46 Gun drill ............................................................... FIC, 12-13 Gun drilling and reaming machine.......................... 24 Hammer ............................................................. 16 Handling system module............................................. 61 Handy probe ...................................................................111 Handy scan ......................................................................111 Hard chrome plating bar ...........................................147 Hard cut end mill ............................................................ 45 Heavy-duty CNC ............................................................140 Heavy-duty cycling duical bearing .......................... 65 H-frame power press ..................................................... 16 High-frequency spindle ..............................................134 High-precision tool holder .......................................... 23 High-pressure hydraulic clamping system.........BGF High-pressure screw pump .......................................149 High-speed centerless grinding machine ............. 17 High-speed drill tap centre ......................................... 63 Hold back .........................................................................140

Sl. No Product 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247

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Hole-making tool ............................................................ 43 Horizontal boring mill ......................................COC, 136 Horizontal machining centre.......................... 7, 63, 97 Horizontal milling machine............................COC, 136 Hydraulic and gear oil ................................................... 53 Hydraulic oil ...................................................................... 26 Hydraulic press brake .............................................18, 46 Hydraulic surface grinding machine .....................153 Hydraulic ............................................................................ 75 Hyper CAD ......................................................................... 10 Imaging and vision systems ............................ 66 IMTS 2012 - International Manufacturing Technology Show .........................................................143 Incremental rolling dies................................................ 77 Indexable engraving tools.........................................132 Indexable tool .................................................................. 45 Indexable tooling ..........................................................150 Indexing table ................................................................149 Induction heating machine.......................................118 Induction heating system ..........................................118 Induction machine for surface hardening ..........118 Inductive proximity switch.......................................... 33 Industrial control and sensing device..................... 79 Industrial cooler ............................................................... 20 Industrial robot ....................................................103, 109 Inner & outer race grinding ......................................117 Interface electronics......................................................BIC

March 2012 - MODERN MACHINE TOOLS 153

List of Products Sl. No Product 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310

Pg No

Internal and radius grinding machine ..................134 Internal grinding machine................................. 17, 144 Internal thread grinding .............................................117 Inverter/variable frequency drive ............................. 79 Iron and steel part .......................................................... 43 Iron worker ........................................................................ 46 ISO milling and turning insert.................................... 45 Jewellery polisher .......................................... 131 Keyless transmisson element ........................ 140 Label ................................................................ 133 Lamiera-2012 business exhibition..........................132 Lamp pumped laser marker .....................................157 Large size horizontal machining centre......160-161 Large size machining centre .........................COC, 136 Laser cutting machine ........................................ 46, 157 Laser cutting system ....................................................143 Laser engraving machine ..........................................157 Laser marking machine ..............................................157 Laser tool............................................................................ 85 Laser welding machine...............................................157 Lathe chuck ....................................................................... 58 Lathe machine........................................18, 42, 145, 148 Lathe .......................................................................................7 LEDs ...................................................................................... 33 Length gauge ..................................................................BIC Lens mould ........................................................................ 43 Level controller ................................................................ 79 Linear rod .........................................................................147 Live tooling for CNC lathes .......................................134 Live tooling for Swiss lathes .....................................134 LM shaft ............................................................................147 Load break switches ...................................................... 33 Low and high-voltage motor ...................................148 Lubes.............................................................................26, 69 Machine measurement ...................................BIC Machine tool accessories ............................................. 28 Machine tool protection system ............................BGF Machine tools .................................................. 28, 44, 105 Machine vice ..................................................................BGF Machining and grinding fluid ..................................135 Magnetic modular encoder .......................................BIC Masonry drill ..................................................................... 96 Material testing ................................................................ 25 Maxshot ............................................................................111 Measured value acquisition and display...............BIC Measurement equipment ............................................ 25 Measurement system ..................................................141 Measuring and monitoring relay .............................. 79 Measuring gauge ..........................................................141 Measuring machine......................................................141 Measuring tool ...............................................................141 Mechanical press brake ..............................................144 Mechanical shear ............................................................ 46 Membrane keypad .......................................................133 Metal cutting tool ........................................................... 57 Metrascan.........................................................................111 Metrology equipment ................................................... 25 Metrology instrument & solutions .........................151 Micron drill ........................................................................ 43 Miling tool.......................................................................... 43 Military circular connectors.......................................143 Milling and turning centre ........................................146 Milling centre.......................................................................7

154 MODERN MACHINE TOOLS - March 2012

Sl. No Product 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372

Pg No

Milling cutter ................................ FIC, 12-13, 88-89, 95 Milling grade.................................................................. FGF Milling head ...........................................................160-161 Milling machine ............18, 41, 42, 137, 160-161, BIC Milling solutions .............................................................. 80 Milling tool ........................................... 113, 155-156, BC Milling-cum-drilling machine ..................................... 15 Mimic panel.....................................................................133 Modular boring system ..............................................141 Modular tooling system ................................ FIC, 12-13 Mold changing system ...............................................149 Mold component ............................................................ 43 Monitoring of grinding systems.............................BGF Motion control ................................................................. 79 Motor and drive.............................................................148 Motor protection circuit breaker .............................. 33 Multi functional tool ...................................................... 95 Multi-functional turret................................................... 75 Multi-media software for learning CNC milling technology ............................................... 86 Multi-spindle automatic lathe..................................141 Multi-spindle heads......................................................134 NC/CNC hydraulic press brakes .................... 138 Neat oil ................................................................................ 26 Needle roller bearing..................................................... 65 Optical measurement ...................................... 25 Paint shop equipment ..................................... 66 Paint shop machine ....................................................... 66 PCB & CBN tool ..............................................................163 PCB based membrane keypad.................................133 PCB drill............................................................................... 43 Pedestal buffer ...............................................................131 Pedestal grinder ............................................................131 Photoelectric sensor ...................................................... 79 Pillar drilling machine ...........................................15,145 Pilot light ............................................................................ 33 Pipe bending machine................................................118 Piston bar .........................................................................147 Planner milling machine .............................................. 18 Planning machines .......................................................140 Planomilling machine..................................................140 Plasma cutting machine............................................... 46 Plate bending machine ................................................ 18 Plugs and socket ............................................................. 33 Pneumatic .......................................................................... 75 Position display unit .....................................................BIC Post processor .................................................................. 10 Power chuck....................................................................132 Power chucking cylinder.............................................. 11 Power shearing machine ...........................................148 Power source .................................................................... 71 Power supplies ................................................................. 44 Preci chuck ........................................................................ 60 Precision drilling machine .........................................143 Precision gear cutting tool .............................COC, 136 Precision switch ............................................................... 33 Precision turned components..................................143 Press brake......................................................................... 46 Pre-treatment systems .................................................. 66 Process automation and control equipment ....... 61 Process monitoring sensor .......................................... 85 Productivity tracking system for CNC machine .. 86 Programmable logic controller.................................. 79

Sl. No Product 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435

Pg No

Programmable terminal ............................................... 79 Proximity sensor .............................................................. 79 Quick die change system ............................... 149 Quick mould change system ....................................149 Rack and pinion .............................................. 148 Rack rolling dies .............................................................. 77 Rack ....................................................................................116 Rack-type spline rolling machine ............................. 77 Radial drill machine........................................................ 15 Reamer ............................................ FIC, 12-13, 88-89, 96 Rear cylinder press brake ...........................................147 Reinforced cut-off wheels..........................................144 Reversible tapping attachments .............................132 RFID ...................................................................................... 79 Robot .................................................................................103 Robotic automation .....................................................125 Roller ..................................................................................148 Rolling oil .........................................................................135 Rotary encoder................................................................BIC Rotary indexing table .................................................BGF Rotary switch .................................................................... 33 Rotary......................................................................................7 Rust preventives .................................................... 26, 135 Safety light curtain........................................... 79 Safety protection devices ............................................ 33 SCADA and DCS implementation............................. 66 Screw press......................................................................133 Sealed linear encoder...................................................BIC Self-adhesive tape ........................................................134 Shaft .........................................................................147, 148 Shearing machine ................................................. 18, 138 Sheet metal machine..................................................... 42 Single limit switch .......................................................... 33 Sinking EDM ....................................................................163 Slant/flat bed .................................................................... 63 Sleeve bearing.................................................................. 65 Slotting machine ............................................................. 42 Small size ball bearing .................................................. 65 Solid carbide drill and mill .......................................... 57 Solid carbide reamer............................................ 57, 146 Solid carbide special drill and mill ........................... 57 Solid carbide special reamer ...................................... 57 Solid carbide tool ..........................................................164 Solid-state laser cutter ................................................157 Special hydraulic expansion technology ............... 58 Special induction hardening machine.................... 71 Special-purpose machine ..........................................140 Spindle nose tooling...................................................... 95 Spindle probe ................................................................... 85 Spindle speeder .............................................................134 Spindle ....................................................................146, 148 Spline rolling machine .................................................. 77 SPMs ..................................................................................... 24 Spur and helical gear...................................................148 Standard induction hardening machine................ 71 Stationary work holding............................................... 58 Super precision bearing ............................................... 65 Surface grinding machine .......................... 18, 63, 153 Switching relay................................................................. 79 Synthetic grease ............................................................140 Tandem press brake....................................... 138 Tap ..................................................................FIC, 12-13, 96 Taper boring machine.................................................147

MMTJan-2012 Ad Name: L&T Pg No. 155

MMTJan-2012 Ad Name: L&T Pg No. 156

List of Products Sl. No Product 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 476 477 478 479 480 481 482 483 484 485 486 487 488 489

Pg No

Tapping chuck................................................................131 Temperature controller ................................................ 79 Tensioner nut .................................................................140 Thread gauge ................................................................... 60 Thread mill......................................................................... 93 Thread rolling machine ................................................ 77 Thread whirling tool ................................................... FGF Threading tool..................................................................BC Thrush ball bearing ........................................................ 65 Timer .................................................................................... 79 Timing belt & pulley ....................................................148 Tool bit ................................................................................ 96 Tool holding system ...................................................... 58 Tool monitoring sensor ................................................ 85 Tool monitoring system ............................................BGF Tool path simulator for CNC milling and turning......86 Tool room machine ........................................................ 42 Tooling system .......................................................131, BC Touch probes...................................................................BIC Track rollers .....................................................................140 Transparent gel ................................................................ 53 Tubing accessory............................................................. 61 Turn mill centre ............................................................... 68 Turning centre.......................................................160-161 Turning holder ................................................................. 95 Turning tool ...............................................................43, BC Turning..............................................................41, 137, BIC Turret punch press ......................................................... 46 Turret ................................................................................... 11 Twin-spindle compound grinding machines....... 17 Twist drill ...............................................................88-89, 96 Ultra high-pressure apparatus........................ 43 Universal cylindrical grinding machines ................ 17 Vacuum chuck................................................... 75 Valve sensor ...................................................................... 44 Valve terminal .................................................................. 61 Valve..................................................................................... 61 Ventilator..........................................................................134 Vertical and horizontal machining centre ............. 47 Vertical lathe machine .................................................. 68 Vertical machining centre...................... 7, 63, 11, 149 Vertical turning lathe .........................................140, 142 Vision sensor ..................................................................... 79 VMC/HMC machines ....................................................139 VMCs .................................................................................117 VTLs ...................................................................................... 18 Water soluble .................................................... 26 Wear parts.......................................................................... 95 Wear resistant tools ....................................................... 43 Wire-cut EDM..................................................................163 Wood-working machine............................................... 42 Workholding solutions...............................................BGF Workpiece clamping solutions ................................119 Worshop machine & accessories .............................. 42

Looking for a speciďŹ c product?

We will ďŹ nd the product for you. Just type MMT (space) Name of the Product and send it to 51818 eg, MMT (space) Lathe and send it to 51818.

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March 2012 - MODERN MACHINE TOOLS 157

List of Advertisers Advertiser’s Name & Contact Details

Pg No

Addison & Co Ltd T: +91-44-37180030 E: gunasekarank@addisonmail.com W: www.addison.co.in

88-89

Asso For Manufacturing Technology T: +703-827-5270 W: www.imts.com

143

Autotech Machine Tools Sales & Services T: +91-20-27130091 E: sales@autotechcnc.com W: www.autotechcnc.com

8-9

Bhavya Machine Tools T: +91-79-40242800 E: info@bhavyamachinetools.com W: www.bhavyamachinetool.com

42

Big Daishowa Seiki Co. Ltd T: +81-729-828277 W: www.big-daishowa.com

23

Blaser Swisslube India Pvt Ltd T: +91-124-4994000 E: india@blaser.com W: www.blaser.com Cadem Technologies Pvt Ltd T: +91-80-26634767 W: www.cadem.com Carl Bechem Lubricants(India) Pvt Ltd T: +91-80-22010800 E: info@bechemindia.com W: www.bechem.com

Pg No

Advertiser’s Name & Contact Details

Pg No

Durga Bearing Pvt Ltd T: +91-22-6876073 E: inquiry@durgabearings.com W: www.durgabearings.com

65

G W Precision Tools India Pvt Ltd T: +91-80-40431252 E: info@gwindia.in W: www.gwindia.in

57

EFD Induction Ltd T: +91-80-7820404 E: sales@efdgroup.net.

W: www.efd-induction.com

71

GEM Equipments Ltd T: +91-22-3267800 E: sales@geminida.com W: www.gemindia.com

20

Electronica Hitech Machines Pvt Ltd T: +91-20-30435400 E: marketing@electronicahitech.com W: www.electronicahitech.com

138, 139

Emuge India Pvt Ltd T: +91-20-39310000 E: marketing@emugeindia.com W: www.emugeindia.com

119

115

69

Engineering Expo T: +91-9819552270 E: engexpo@infomedia18.in W: www.engg-expo.com

86

Ermaksan Machinery T: +91-224-2947500 E: sinan.bilgin@ermaksan.com.tr W: www.ermaksan.com.tr

35, 55

Ceratizit India Pvt Ltd T: +91-33-24947146 E: info@ceratizitindia.co.in W: www.ceratizit.com

95

Coatec India T: +91-172-5063436 E: info@coatecindia.com W: www.coatecindia.com

66

Creaform India T: +91-11-65022218 E: india@creaform3d.com W: www.creaform3d.com

111

Dijet Industrial Co Ltd T: +91-22-40121231 E: ravisane@dijet.co.jp W: www.dijet.co.jp

45

Doosan Infracore India Pvt Ltd T: +91-80-42660122 E: sandesh.kumar@doosan.com W: www.doosaninfracore.com

14

158 MODERN MACHINE TOOLS - March 2012

Advertiser’s Name & Contact Details

46

ESA Eppinger GmbH T: +91-9900588559 E: tramaiah@eppinger.de W: www.eppinger.de

131

Essor International Inc W: www.essor.com.tw

142

Femco India T: +91-20-40147870 E: sales@femcoindia.com W: www.femco.com.tw

68

Festo Controls Ltd T: +91-80-22894100 E: info_in@festo.com W: www.festo.com

61

Finechrome Shafts Pvt Ltd T: +91-22-29204209 E: finechromespl@yahoo.co.uk Forging Machinery Manufacturing Co T: +91-161-5011755 E: info@nkhammers.com W: www.nkhhammers.com

147

16

Forwell Precision Machinery Co., Ltd 149 T: +886-4-8345-1960 E: forwell@forwell.com; forwell@forwellnb.com W: www.forwell.com

Geometric Ltd T: +91-22-67056880 E: inquires@camworks.com W: www.camworks.com GSK CNC Equipment Co. Ltd T: +91-9886835186 E: gskwang@hotmail.com W: www.gsk.com.cn

133

37

Gudel India Pvt Ltd T: +91-20-25459531 E: info@in.gudel.com W: www.gudel.com

125

Guhring India Pvt Ltd T: +91-80-40322500 E: info@guhring.in W: www.guhring.in

FIC

Haas Automation India Pvt Ltd T: +91-20-32935433 E: sales@haasindia.com W: www.HaasCNC.com

7

Heidenhain Optics & Electronics (I) T: +91-44-30234000 E: info@heidenhain.in W: www.heidenhain.in

BIC

Hitech (India) Private Ltd T: +91-40-27260152 / 9391011758 E: hitechconnector@gmail.com W: www.hitechconnector.com

143

Hitek Engineers T: +91-44-26545463 E: hitekengineers@yahoo.co.in

150

Hwacheon Asia Pacific Pte Ltd T: +91-20-30429140 E: sales@hwacheonindia.com W: www.hwacheon.com

98

Hyundai Wia India Pvt Ltd T: +91-9940653703 E: mvhari@gmail.com W: www.hyundai-wia.com

67

IFM Electronics India Pvt Ltd T: +91-231-2672770 E: info@ifm-electronic.in W: www.ifm-electronic.com

44

List of Advertisers Advertiser’s Name & Contact Details

Pg No

Advertiser’s Name & Contact Details

Pg No

Advertiser’s Name & Contact Details

Pg No

Igus India Pvt Ltd T: +91-80-39127800 E: info@igus.in W: www.igus.in

30

Macht Exim Llp. T: +91-79-40087600 E: bhavin@machtexim.com W: www.machtexim.com

18

Nikon India Pvt Ltd T: +91-124-4688 500 E: nind.Inst@nikonoa.net W: www.nikon-instruments.jp/eng/

151

Indian Machine Tool Mfg. Association T: +91-80-66246902 E: augustin@imtma.in W: www.imtma.in

94

Madaula, S.A T: +91-9940222875 E: madaulaindia@gmail.com W: www.madaula.com

134

NMTG Mechtrans Techniques Pvt Ltd T: +91-79-22821527 E: nmtg@nmtgindia.com W: www.nmtgindia.com

140

Indian Machine Tool Mfg. Association T: +91-80-66246600 E: imtma@imtma.in W: www.imtma.in

122

Indian Tool Manufacturers T: +91-22-25852559 E: ltmth@hathway.com W: www.indiantool.com

96

Intraaction Electronics T: +91-79-23287226 E: info@intraactionindia.com W: www.intraactionindia.com

133

ISGEC Heavy Engineering Ltd T: +91-120-3301001 E: trading@isgec.com W: www.isgec.com

63

Jyoti CNC Automation Pvt Ltd T: +91-2827-287081 E: info@jyoti.co.in W: www.jyoti.co.in

97

Kabel Schlepp India Pvt Ltd T: +91-80-41158997 E: gm@kabelschlepp.in W: www.kabelschlepp.com

144

Kinol Lubes Pvt Ltd T: +91-11-41425477 E: info@kinol.in W: www.kinol.in

26

Korloy Inc. T: +82-2-2522-3181 E: export@korloy.com W: www.korloy.com

137

Kuka Robotics (India) Pvt Ltd T: +91-124-4635774 E: pradeep@kuka.in W: www.kuka.in

103

Larsen & Toubro Ltd T: +91-22-67051093 E: sm.haridas@larsentoubro.com W: www.larsentoubro.com

113, 155-156

Marposs India Pvt Ltd (Bleed) T: +91-124-4735752 E: surender.sood@in.marposs.com W: www.marposs.com

85

Mehta CAD CAM Systems Pvt Ltd T: +91-79-26840551 E: sales@mehtaindia.com W: www.mehtaindia.com

157

Metrol Corporation India Branch Off T: +91-80-42105031 E: sales@metrolindia.com W: www.toolsensor.com

56

Micromatic Machine Tools T: +91-80-41492285 E: mmtblr@acemicromatic.com W: www.acemicromatic.com

11

Mitsubishi Heavy Industries India Pvt Ltd T: +91-11-41021234 E: mtdsales@mhiindia.com W: www.mhiindia.com Mitutoyo South Asia Pvt Ltd T: +91-11-26372090 E: delhi@mitutoyoindia.com W: www.mitutoyoindia.com

COC

25

MMC Hardmetal India Pvt Ltd T: +91-80-23516083 E: mmcindia@mmc.co.jp W: www.mitsubishicarbide.com

164

MTAR Technologies Pvt Ltd T: +91-40-44529901 / 44529904 E: ballscrews@mtar.in, unit3@mtar.in W: www.mtar.in

107

MTE Industries Pvt Ltd T: +91-40-23777571 E: info@mteindustries.com W: www.mteindustries.com

77

Neway Cnc Equipment (Suzhou)Co. Ltd T: +91-281-276-7100 E: newaycnc@gmail.com W: http://www.newaycnc.com

47

Nicolas Correa S.A. T: +91-20-25654891 E: india@correanayak.eu W: www.correanayak.eu

80

NN Combined Engineering Agencies Pvt Ltd BGF T: +91-40-27844279 / 27898579 E: mail@nncea.com W: www.nncea.com Objet Ap Ltd T: +852-2174 0111 E: info@objet.com W: www.objet.com

70

Omron Automation Pvt Ltd T: +91-80-40726400 E: in_enquiry@ap.omron.com W: www.omron-ap.com

79

Openmind Cadcam Technologies (I) Pvt Ltd T: +91-80-30504647 E: Info.India@openmind-tech.com W: www.openmind-tech.com

10

Optical Gaging (S) Pte Ltd T: +65-6741-8880 E: kelly@smartscope.com.sg W: www.smartscope.com.sg

141

Oriental Machine Tools Co T: +91-22-23423524 E: omtc@omtc-online.com W: www.omtc-online.com

28

Para Mill Precision Machinery Co Ltd T: +886-4-2680-0678 E: para.mill@msa.hinet.net W: www.paramill.com

142

Paragon Machinery Co Ltd 17 T: +886-4-2539-5678 E: info@paragoncnc.com; teresahsieh@ringier.com.hk W: www.paragoncnc.com Parishudh Machines Pvt Ltd T: +91-120-3205167 E: parishudh@goindigroup.com W: www.goindigroup.com

117

Pinnacle Engineering Enterprise T: +91-2752-230552 E: mail@pinnaclegrinder.com W: www.pinnaclegrinder.com

153

Poojitha Flex Technologies T: +91-40-23720663 / 9441643743 E: poojithaft_bellows@yahoo.com, pflexbellows@gmail.com W: www.poojithaflextech.com

145

March 2012 - MODERN MACHINE TOOLS 159

List of Advertisers Pg No

Prakash Engineering T: +91-278-2438241 E: sales@prakashmachines.com W: www.prakashmachines.com

15

Pramet Tools India Pvt Ltd T: +91-124-4703825 E: pramet.info.in@pramet.com W: www.pramet.com

41

Precihole Machine Tools Pvt Ltd T: +91-22-25836780 E: info@precihole.co.in W: www.precihole.co.in

24

Advertiser’s Name & Contact Details Seco Tools India Pvt Ltd

Pg No 31

T: +91-2137-667300 E: seco.india@secotools.com W: www.secotools.com/in Shuter Enterprises India Pvt Ltd

116

T: +91-44-32407116 E: 32407116@shuter.in W: www.shuter.in Siddhapura Engineering Works

145

T: +91-278-2428054 E: drills@dataone.in W: www.siddhapuradrills.com

Precimac Solutions T: +91-20-32538701 E: aketkar@precimac.com W: www.precimac.com

146

Quaker Chemical India Ltd T: +91-33-22822181 E: admin@quakerchemindia.com W: www.quakerchem.com

135

Quattro Engineering India Ltd T: +91-80-25585439 E: bangalore@quattroengg.com W: www.quattroengg.com

105

Siemens Ltd W: www.siemens.com Snk India Pvt Ltd E: info@snkindia.co.in W: www.snkc.co.jp

W: www.socconoa.com Sofimu Srl

Sandvik Coromant India T: +91-20-27104725 E: rupali.kavi@sandvik.com W: www.sandvik.coromant.com/in

FGF

Sarabsukh Machine Tools T: +91-1871-223893 E: sarabsukhbatala@yahoo.co.in W: www.sarabsukhmachines.com

140

Satra International T: +91-11-25415437 E: satra_international@rediffmail.com W: www.satrainternational.in

118

Sreelakshmi Traders

60

Tungaloy India Pvt Ltd T: +91-22-61248888 E: info@tungaloyindia.com W: www.tungaloy.co.jp.in

43

Tussor Machine Tools Ind P Ltd T: +91-422-3200183 E: info@tussorindia.com W: www.pinachoindia.com

22

Vargus Ltd T: +91-9730028248 E: vishal@vargusindia.com W: www.vargus.com

93

Vijay Machine Tools Pvt Ltd T: +91-22-24950886 E: elmeco@elmacovijay.co.in W: www.elmacovijay.com

131

Wexper India Ltd T: +91-124-2210020 E: rajan.vaid@wexper.com W: www.wexper.com

163

Yaskawa Robotics India Ltd T: +91-124-4758534 E: sales@motoman.co.in W: www.motoman.com

109

E: sreelakshmitraders@gmail.com W: www.sreelakshmitraders.com BC

E: sales@taegutec-india.com W: www.taegutec-india.com Tagma

The Jaws Mfg Co T: +91-20-26877842 E: jaws@jawsindia.com W: www.jawsindia.com

134

T: +91-44-24343343

Taegutec India Ltd T: +91-80-27839111

33

Weizmann Engineering T: +91-44-22280595 E: weizmann_engg@yahoo.com W: www.weizmann.in

W: www.ucimu.it 147

Teknic T: +91-22-26592392 E: teknic@vsnl.com W: www.teknic.co.in

132

T: +39-2-26255244 E: promotion.adv@ucimu.it

Samtec Tools & Accessories Pvt Ltd T: +91-20-32941330 E: info@samtectools.com W: www.samtectools.com

Schunk Intec India Pvt Ltd T: +91-80-41277361 E: info@in.schunk.com W: www.schunk.com

148

T: +91-20-32420959 E: sales@socconoa.com

53

Pg No

136

T: +91-124-4203471

Socco Noa Automation Comp Llp

Raj Petro Specialities Pvt Ltd T: +91-44-42288900 E: francis@rajgrp.com W: www.rajgrp.com

51

Advertiser’s Name & Contact Details

112

T: +91-22-28526876 E: mumbai@tagmaindia.org

YG Cutting Tools Corporation Pvt Ltd T: +91-80-43543636 E: admin@yg1india.com W: www.yg1.co.kr

75

12-13

W: www.tagmaindia.org Takamatsu Machinery Co Ltd T: +91-81-76-2741403

59

E: h.nakagawa@takamaz.co.jp W: www.takamaz.co.jp 58

Techtronics India Ltd T: +91-124-2370555 E: info@techtronics.in W: www.techtronics.in

160-161

Looking for a specific product?

We will find the product for you. Just type MMT (space) Name of the Product and send it to 51818 eg, MMT (space) Lathe and send it to 51818.

COC - Cover on Cover FGF - Front Gate Fold FIC - Front Inside Cover BIC - Back Inside Cover 162 MODERN MACHINE TOOLS - March 2012

BGF - Back Gate Fold BC - Back Cover

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MODERN MACHINE TOOLS

March 2012

MODERN MACHINE TOOLS

March 2012

Reg No: MH / MR / WEST / 235 / 2012 – 2014 RNI No: MAHENG / 2008 / 24347 Licence to Post at Mumbai Patrika Channel Sorting Office, Mumbai GPO., Mumbai 400 001 Date Of Posting 1ST & 2ND Of Every Month / English & Monthly.

Date Of Publication: 28th of Every Month

168

Reg No: MH / MR / WEST / 235 / 2012 – 2014 RNI No: MAHENG / 2008 / 24347 Licence to Post at Mumbai Patrika Channel Sorting Office, Mumbai GPO., Mumbai 400 001 Date Of Posting 1ST & 2ND Of Every Month / English & Monthly.

Date Of Publication: 28th of Every Month

168