Modern Machine Tools - March 2013 by Infomedia18

MMT February - 13

Ad Name: Big Daishow - Pg No. 17

MMT March - 13 Ad Name: Precihole Pg No. 18

MMT March - 13 Ad Name:Korea Pg No. 19

MMT March - 13 Ad Name: Samchully Pg No. 20

MMT March - 13 Ad Name:Hyundai Pg No. 21

MMT February - 13 Ad Name: Gelco Pg No.22

Editorial

NEEDED: Bigger Canvas … > 24 hrs!

Initiatives, engagements, newer opportunities, unique concepts, exciting events, community gatherings, bountiful content, special features … it’s getting difficult to contain so much in one magazine each month, with each day being packed with a PUNCH!! The machine tool industry is on a swirl for sure and we, at MMT, are getting tizzy catching the action that is the Indian machine tool sector … and liking it very much! We are living the most exciting times in our lives … a sentiment reflected by each company and each person who is part of this magical machine tool industry of India! To begin with, MMT, along with TAGMA, will be hosting a very interesting three-city summit in June. Tooling Summit 2013 is positioned as the ‘change’ that the die & mould industry wants to be! It’s inspirational, engaging, educating & enabling, to briefly summarize the value proposition. Going by the response that this event is already garnering, we are all set to deliver the solutions to this deserving industry segment. Staying with the die and mould industry, which incidentally is the focus sector for MMT this month, our cover shout says it all! ‘Dragons Striking Tiger’s Den’ creatively summarises business threat from competitive markets. This is to state the fact that in recent times, the competition from Eastern countries has increased, which is affecting Indian business. These countries not only provide good technology but have also become highly cost-effective over the years. The rapid development in these countries is affecting Indian business—known for its cost-effective products. Although India was late in gaining momentum at the right time, we are certainly not the underdogs. The Indian die, mould and allied industry is estimated to be over `13,000 crore in size and growing. Currently, it is also estimated that about 40% of this is imported from several countries, notably China, Taiwan, Thailand, Japan, Germany, France and Italy. Even at the reduced growth rates this year, the size of the tooling industry is expected to grow to about `23,000 crore by the year 2016. Talking about opportunities and being plum with prospects, MMT is also part of the UNIDO initiative, along with IMTMA, to host the most exciting communion of the machine tool community and more specifically, the UNIDO cluster members. To be held in Goa (the place is just the tip of the iceberg of excitement), the event—aptly called LEAP (Lead, Educate, Apply, Prosper)—is a truly inspirational event aimed at enthusing SMEs to dream more, achieve more and aspire more … a spirited gathering, we promise, in more ways than one! And our partnership with UNIDO helps us to offer yet another exciting initiative around environment-friendly manufacturing practices called Green Shoots! And saving the best for the last, this edition of MMT gets all the more special with the initiation of a very special column by Mr TK Ramesh, CEO, Micromatic Machine Tools Pvt Ltd. He, as we all know, is the Marketing Guru of the `1200-crore Ace Micromatic Group. Through his column ‘Vantage Point’ in MMT starting this month, he will share his insights, analyses and experiences with respect to the approach that our industry needs to adopt for branding, marketing and advertising its competence globally. So, do you finally agree that we need a bigger canvas and more than 24 hours in a day to do justice to the task at hand? We imagine a nod!

MMT Mentor Shailesh Sheth

Corporate Strategy Advisor

Archana Tiwari-Nayudu archana.nayudu@network18publishing.com

February 2013 - MMT

Contents 46

Special Focus

Robotics & Automation

Special Focus

robot trivia .................................... 46 leaders opine ................................. 48 well-crafted solutions.................. 46 automation snapshot...................... 53 myths & tips .................................... 68

iNSIGHTS & OUTLOOK Dies & Moulds

Insights & Outlook expert insight ................................. 74 tooling summit 2013....................... 76

iNDUSTRY FOCUS Aerospace Machining

evENT

Engineering Expo aurangabad 2012 ........ 122

threat analysis................................ 78 mim technology............................... 80 need gaps ........................................ 84 techno focus .................................. 86

Leap Initiative

Think big dreAM BIG ..... 116

one q many views ............................ 88

industry Focus combating challenges .................. 90 offset policies ............................... 92 sme insights ................................... 96 facility visit .................................... 104 new age materials.......................... 108 material matters ........................... 110

iN cONVERSATION WITH Carlos M cardoso

President and CEO, Kennametal Inc

changing role of simulation ....... 114

next edition highlights

42 Special Focus: Measuring & Inspection Insights & Outlook: Automotive Machining

Looking For A Specific Product?

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

eg. MMT EDM and send it to 51818

Energy Management mACHINING THE GREEN WAY

..... 118

rEGULAR SECTIONS

Editorial ....................

Sarathi Sutras .......... 29 News, Views & Analysis .....................

Technology & Innovations ...............

Tenders ...................... 128 launch pad ................

130

Products ...................

132

List Of Products .......

147

List Of Advertisers ...

153

Founder & Editor, Network 18 Raghav Bahl President & Editorial Director, TV 18 Senthil Chengalvarayan Editor Archana Tiwari-Nayudu Editorial Team Debarati Basu (Bengaluru), Nishant Kashyap, Nedra Pereira Raah Kapur pRODUCT dESK Avinash Pandey, Rishab Kothari, Dharitri Dalvi Art Director Varuna Naik design team Sandeep Upadhyay Chief Photographer Mexy Xavier Photography Neha Mithbawkar, Joshua Navalkar business CONTROLLERS Akshata Rane, Lovey Fernandes, Shefali Mahant Deepak Bhatia, Ashish Kukreti, Shwetha ME, Jayashree N

printing Executive Vice President Ananth R Iyer Assistant General Manager - PPC Shekhar Khot

Production Team

Surekha Karmarkar, Ravikumar Potdar, Ravi Salian, Sanjay Shelar

Overseas contact China 1001 Tower 3, Donghai Plaza, 1486 Nanjing Road, West, Shanghai 200040, China Tel: +86-21 6289 – 5533 Ext. 368, Fax: +86-21 6247 – 4855 (Craig Shibinsky) Email: craig@ringier.com.hk Ringier Trade Media Ltd

Hong Kong 9/F, Cheong Sun Tower, 118 Wing Lok Street, Sheung Wan, Hong Kong Tel: +852 2369 – 8788 Ext. 21, Fax: +852 2869 – 5919 (Octavia Au-Yeung) Email: octavia@ringier.com.hk Ringier Trade Media Ltd

Ringier Trade Media Ltd Taiwan Room 3, Fl. 12, No. 303, Chung Ming S. Rd., Taichung, Taiwan Tel: +886-4 2329 – 7318 Ext. 16, Fax: +886-4 2310 – 7167 (Sydney La) Email: sydneylai@ringier.com.hk Ringier Trade Media Ltd

germany, austria, switzerland Tel: +41-44 734 0472, Fax: +41 44 734 0680 Email: info@islerannoncen.ch USA Tel: (513) 527-8800 Fax: (513) 527-8801 Email: dhight@gardnerweb.com

USA Alfredo Domador, 6505 Blue Lagoon Drive, Suite 430 Miami, FL. 33126, USA Tel: (305) 448-6875, Fax: (305) 448-9942

Group CEO, Network 18 B Sai Kumar CEO-NETWORK 18 PUBLISHING Sandeep Khosla EVP-Human Resources Sanjeev Kumar Singh Associate Vice President Sudhanva Jategaonkar ADVERTISING Sales Shashin Bhagat (Ahmedabad) shashin.bhagat@network18publishing.com Mahadev B (Bengaluru) mahadev.b@network18publishing.com Hari Hara Subramaniam (Chennai) hari.s@network18publishing.com Balakrishnan S (Coimbatore) Balakrishnan.s@network18publishing.com Mukesh Yadav (Delhi) mukesh.yadav@network18publishing.com Dominic Dsouza (Hyderabad) dominic.dsouza@network18publishing.com Ameya Gokhale (Indore) ameya.gokhale@network18publishing.com Sandeep Arora (Jaipur) sandeep.arora@network18publishing.com Abhik Ghosal (Kolkata) abhik.ghosal@network18publishing.com Inder Dhingra (Ludhiana) inder.dhingra@network18publishing.com Olwin Dsouza (Mumbai) olwin.dsouza@network18publishing.com Rohit Dass (Pune) rohit.dass@network18publishing.com Vipul Modha (Rajkot) vipul.modha@network18publishing.com Chirag Pathak (Vadodara) chirag.pathak@network18publishing.com Marketing Team Ganesh Mahale, Akshaya Jadhav

NEWSSTAND AND SUBSCRIPTIONS Distribution Head Sunil Nair DEPUTY GENERAL MANAGER Manoj Palsay senior Manager - Subscriptions Sheetal Kotawdekar Co-Ordinators Rahul Mankar, Anant Shirke, Sarita Quadros, Chaitali Parkar, Kamlesh Mathkar, Vaibhav Ghavale

SERVICES Subscription Services For subscription queries, write to chaitali.parkar@network18publishing.com or call +91 22 30034631-34 or toll free 1800 200 1021 Permissions For subscription to copy or reuse material from MODERN MACHINE TOOLS, Write to mmtedit@network18publishing.com • Monthly Issue Price: ` 100 • Annual Subscription: ` 799

Views and opinions expressed in this magazine are not necessarily those of Network18 Media & Investment Ltd (Network18)*, its publisher and/or editors. We at Network18 do our best to verify the information published but do not take any responsibility for the absolute accuracy of the information. Network18 Ltd does not accept the responsibility for any investment or other decision taken by readers on the basis of information provided herein. Network18 does not take responsibility for returning unsolicited material sent without due postal stamps for return postage. No part of this magazine can be reproduced without the prior written permission of the publisher. Network18 reserves the right to use the information published herein in any manner whatsoever. Printed by Mohan Gajria and published by Lakshmi Narasimhan on behalf of Network18. Executive Editor: Archana Tiwari-Nayudu Printed at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Network18, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai - 400 028. MODERN MACHINE TOOLS is registered with the Registrar of Newspapers of India under No. MAHENG / 2008 / 24347. Network18 does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition. *Ownership of this magazine stands transferred from Infomedia18 Ltd (Infomedia18) to Network18 Media & Investments Ltd (Network18) in pursuance of the scheme of arrangement between Network18 and Infomedia18 and their respective shareholders and creditors, as approved by the Hon’ble High Court of Delhi and the necessary approval of Ministry of Information and Broadcasting is being obtained.

March 2013 - MMT

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

ByMerchant Shailesh Sheth of Dreams

Buyer Maturity

they did not have resources to fund R&D. And lo and behold, n any transaction, there is a buyer and a seller. Both the supply chain started collapsing. To turn this over, the same should have equal importance. In the previous issues auto company had to do a lot of work in order to rebuild the of MMT, we have spoken extensively about how the supply chain. This example has gone down in supply chain costumer is king, how businesses ought to be customer management history as the wrong way to cut costs and the centric, etc. So, it is only right that we now talk about wrong vendor management policy. the other side of the coin—the buyer’s responsibility: his role In contrast, an example that shows effective cost reduction in a commercial transaction. The entire supply chain needs to through a mutually beneficial relationship is Maruti Suzuki. be healthy, so that progress can be made. Most buyers will try The company has set targets for its suppliers to cut costs by 3% to negotiate; it is their right and duty. Who among us does per year-costs first and then prices. It support its suppliers with not like a good deal? However, the buyer should be conscious a knowledge hub of engineers who have that he does not short charge his supply expertise in all sectors of R&D. This hub chain in his quest to get a better bargain “It is easy to dodge our works with the suppliers to identify areas every time! In an attempt to get a good of cost reduction, to the extent that they deal, the buyer should not over squeeze responsibilities, but we cannot are even okay with a component being the supplier such that the supplier finds dodge the consequences of redesigned as long as it fits the purpose himself in a resource crunch. Such dodging our responsibilities.” and will go on to reduce costs. The costs practices lead to an unhealthy supply - Sir Josiah Stamp saved are then mutually shared. This is chain. The supplier, to sustain himself, mature purchasing behaviour that keeps will cut corners on areas such as R&D supply chain healthy and motivated. and Future Development. As a customer, What I am saying is that there is need for a partnership one may have a choice to go to another supplier, but when approach. An approach that recognises the importance of over squeezing the suppliers for a bargain becomes a habit, the supply chain to be healthy and profitable. Trends in the you will only be hurting your own supply chain. In addition to market—whether things are taking an upward turn creating a reputation for being a price squeezer, or a downward fall—should be shared. This will nobody will want to supply to you or at least help both parties plan better and become more enjoy doing so. resourceful. A point to add as well is in today’s History has a good example: A famous market, buyers also need to treat all their suppliers European car giant wanted to cut costs the same. For instance, Indian customers pay 100% drastically to keep above the competition. On to foreign suppliers against shipment but it is not inspection, they found that all their in-house the same for Indian suppliers. The commercial processes were on the right track and the only framework for buying and selling must be universal. place to cut costs was on the prices of the vended parts. Additionally, the more India advances, the more the global So, they started calling their vendors and demanding price practices will need to be followed. reduction on components. Their brand was big enough for suppliers to not object. However, there was no effective cost User responsibility and accountability are very necessary reduction that was achieved and then passed on to the car for the supply chain to thrive. One must remember that in the company. Vendors just cut their profit margin to retain the value chain, the buyers are suppliers to another set of buyers auto giant as a client. But this situation could only go on for and perhaps the saying ‘treat others like you would like to be a short while, after which the suppliers too felt the pinch, and treated’ should not be taken lightly.

Going Global with Exhibitions:

Art or Science?

end of an exhibition, most companies ask he Indian industry is themselves: Was the expo worth it? Was going through an image the investment justified? transformation in the global market and it has to take For a successful expo experience, the measured steps forward. While tables need to be turned. An expo should observing and analysing the growth path instead start with questions: What is our of various countries, it has been my desire goal? Which market segment to target? to see the ‘Brand India’ image strongly What does that segment need? The portrayed at the global platform. With idea is not to fill the pages of the query this column, ‘Vantage Point’, I will share book but to lay the foundation for future my insights, analyses and experiences with businesses. Most Indian companies try respect to the approach that our industry to achieve an amalgamation of goals and needs to adopt for branding, marketing fail in most of them. Exhibitions and advertising its competence globally. should start with a Every month, thorough homework this column will of the market and ol to focus on the niche selection of specific e Striking machin areas of branding and goals. Your goal s does not business relation the key mantras of might just be to irect than d e or m y an t marketing—usually assess the market or ge achine to generate dealers m d se cu fo at n underestimated by the participatio shows. Such & partnerships or industry. As the world exhibitions and ol to market readies itself for simply showcase rich dividends events can give a new season of global your capability. rience, in terms of expe industrial exhibitions, let Each goal comes ent, forging m op el ev d ct u us understand the art of with a chain prod ing d il bu d an s ip exhibitions through this theory, where relationsh s. inaugural column. each link or d bran step has its Capital equipment own significance to the relationships are longcumulative progression towards a logical term and are forged over conclusion. time on the foundation of touch & feel, performance & experience. Striking Another pertinent confusion is: Where machine tool business relations does not to exhibit? With a huge array of expos in get any more direct than participation almost every country, it is a challenge to at focused machine tool exhibitions and choose one expo over the other. Hence, shows. This is a time-tested strategy that you first need to understand your target has proved its worth over decades. A market. For instance, EMO is not just sneak peek into the strategies and budgets the gateway to Europe but an access to of the world’s most successful machine the American, Chinese, Vietnamese and tool companies and you are bound to other ecosystems. Participating in bigger find exhibitions figuring strongly. But are shows help build contacts, smaller shows Indian companies optimising the scopes help create a strong base in the fringe and opportunities of the exhibitions? Do markets & gain experience. we understand the nuances of exhibiting? No matter which expo, we need Most Indian companies gear up to put to shred our myopic approach and their machines into place weeks prior to take upon focused manufacturing in the exhibition, gather enquiries during order to be expo ready. Exhibition is a the show and then spend a week’s time serious business. It is a science. Work following up on the enquiries. By the upon it!!!

TKR

TK Ramesh, the CEO of Micromatic Machine Tools Pvt Ltd, is the Marketing Guru of the `1200-crore Ace Micromatic Group. The epitome of business analytics and a veteran in strategy dynamics, he envisions a glorious ‘Brand India’ pennant fluttering over the global machine tool arena in the near future.

March 2013 - MMT

News, Views & Analysis

Aero India 2013 enthralls Bengaluru and the global market

ero India 2013, the five-day biannual military and aerospace show, garnered a lot of interest with the participation of 25 countries and 650 domestic and foreign aerospace manufacturers. AK Antony, Defence Minister, inaugurated the show in the presence of Ajit Singh, Civil Aviation Minister; Jagadish Shettar, Chief Minister; NAK Browne, IAF Chief and Naina Lal Kidwai, FICCI Chief. The show and aviation exhibition was organised by the Defence Ministry along

COMSOL opens new office in New Delhi

OMSOL, the leading provider of multiphysics simulation software, has opened a new technical sales and support office in New Delhi. This expansion is a result of the successful introduction of COMSOL Multiphysics software in the Indian market through the company’s office in Bangalore. With this new office, COMSOL further strengthens its presence in Delhi and other areas in North India—the hub of various government organisations, academic institutes and major manufacturing companies. “A strong presence in India is the key for growing our software business. In New Delhi, we see a great opportunity to enter one of the world’s leading high-tech communities,” says Farhad Saeidi, President, COMSOL AB.

with the Indian Air Force, DRDO, Department of Space and Union Civil Aviation. Aero India 2013 showcased the latest international technology in military and civil aircraft, avionics and sub systems as well as radars in the defence and aerospace sectors and evoked a lot of attention from the international market. “Self-reliance in defence is our focus area. We want to create a strong defence industrial base in the country. There are big opportunities for major international aerospace

companies to enter into new alliances and forge partnerships with the Indian industry and set up base in India,” said Antony in his inaugural address at Yelahanka Airbase in Bengaluru. The show also hosted a scintillating display of performance by LCA Tejas, the Tiger Moth aircraft, which has been resurrected recently as part of the IAF vintage flight; the Flying Bulls, who are considered one of the world’s leading aerobatic display teams from the Czech Republic and various others.

GW Precision achieves record-breaking cutting feed rate

n a live demonstration during IMTEX, GW Precision Tools India Pvt Ltd—manufacturer of customised solid carbide tools— created a record in itself by achieving a record-breaking cutting feed rate. The company aimed at achieving a feed rate of 4 mm/revolution with an RPM of 2800 cutting at a depth of 40 mm in a cast iron block. The maximum feed rate normally ´ The operation in progress to achieve the highest feed rate. achieved by the industry varies from tool geometry by giving special attention 0.25 to 0.4 mm/rev, which is oneto the pointed angles whereby the cutting tenth the feed achieved by GW Precision. edge was strengthened. Christopher “We used a cutting speed of 2400 and Zoller, Director, ZOLLER India Pvt reached a feed rate of 8500, which is Ltd, after the demonstration, remarked, equivalent to 3.5 mm/rev approximately. “This is very impressive. Cutting tools are We are constantly working towards continuously undergoing revisions to get achieving a feed rate which is more than higher performance and higher feet rates. 4 mm/rev,” said Tosher Hormusjee, This will increase the productivity and Director, GW Precision Tools India Pvt make part faster with high efficiency.” Ltd. The feed rate was achieved with new

Karnataka unveils new aerospace policy

agadish Shettar, Chief Minister, Karnataka, unveiled the state government’s new aerospace policy. This is the first such policy statement in the country. Recognising the fact that the expenditure on aerospace and defence equipment in the next 10 years will amount to more than `5 lakh crore, the policy aims to develop Karnataka as 32

MMT - March 2013

the hub of the aerospace industry. The mission to develop the state as a hub would be undertaken in two phases. The policy envisages the establishment of clusters in the south, central and northern regions of the state. It will provide subsidies to units investing in these regions, subject to a maximum of `50 crore. The policy aims to support

small industries in order to enable them to enhance value addition, especially at the lower end of the supply chain. It hopes to explore new overseas markets and adopt the PPP model to develop the infrastructure for the industry. It also lays emphasis on the development of the Maintenance, Repair and Overhaul (MRO) segment of the industry.

News, Views & Analysis Maini inks MoUs with Assystem & Alten Group at Aero India 2013

aini Precision Products Pvt Ltd signed two separate MoUs with the Assystem & Alten Group during Aero India 2013. The collaboration with Assystem aims at offering a wider range of aerospace services to the Indian market, at a time when the various defence procurement projects of the Indian Ministry of Defence are in their final stage. Assystem’s long experience in setting up assembly and manufacturing processes willbe greatly complemented by MPP’s expertise in design, manufacturing, delivery and testing services on parts and tools. Together, they offer the capacity to support the building of a new production unit at world-class standards in India. The first MoU is intended towards enlarged collaboration aimed at supporting European OEMs (civil and defense) while increasing their international footprint. On the other hand, Alten Group, the European leader in engineering and technology consulting, partnered with the Maini Group to offer specialised system engineering and design-to-manufacturing services to global Aerospace and Defence (A&D) equipment manufacturers. As part of this

Global launch of the cutting tool brand, Carboloy

arboloy, a global brand for cutting tool, became a part of the Dormer Group, and is now taking the next step to offer customers the best possible tooling solution in manufacturing. “It is with pleasure that we announce the global launch of our new brand, Carboloy, for tools and inserts, which is a perfect match to our offer of rotating tools, says Fabrizio Resmini, President, Dormer Tools. The innovative history of Carboloy dates back all the way to the 1920s, when a General Electric scientist started experimenting with tungsten carbide. In 1928, a special Carboloy department was formed that made breakthrough advancement in cemented carbide technology and its metalworking applications. In the following

MMT - March 2013

´ Maini signs MoU with Assystem at Aeroshow 2013

partnership, Alten and Maini will combine their expertise in design, manufacturing and technical support to offer complete design-to-manufacturing and customer support services to aerospace and defence equipment manufacturers.

decades, Carboloy’s innovation flourished, which further strengthened its reputation for solving customers’ everincreasing demands for greater productivity, quality and costeffectiveness. “Our common success is built on five pillars: consistency in product quality, durability of tool life, versatility in offering a focused tool assortment with wide application coverage, security in the delivery performance and, most importantly, simplicity in every aspect of working with Carboloy,” explained Lars-Erik Lindgren, Brand Manager & President. Gautam Ahuja, Managing Director, Dormer Tools India Pvt Ltd, said, “Carboloy will present a perfect fit for most manufacturing industries in India requiring metal cutting tools.”

VERICUT® software completes 25-year milestone

GTech, the developer of VERICUT software, celebrated a quarter century of leading the development of numerical control (NC) programme simulation and analysis software. CGTech began when Jon Prun, the company’s founder and president, recognised the need to verify NC tool path programmes without wasting valuable CNC machining time on a proveout part. CGTech then created VERICUT® software—the world’s first widely available, productive method—to test NC machine tool paths without using a machine tool. VERICUT revolutionised NC programme verification by simulating material removal using a 3D solid model. CGTech has experienced remarkable growth in recent years, and its customer list consists of thousands of companies in virtually every manufacturing industry, including every major aerospace and automotive company.

News, Views & Analysis

New Mobilcut cutting fluids deliver performance benefits for Vodafone McLaren Mercedes

xxonMobil’s recently introduced range of Mobilcut water soluble metalworking fluids is helping the Vodafone McLaren Mercedes Formula 1™ cars to gain a competitive edge on the track. The new Mobilcut series, alongside proven products, such as Mobilmet neat cutting oils, Mobil DTE hydraulic oils and Mobil Vactra slideway oils, are in use at the McLaren Technology Centre in Woking, thus helping the team to realise new component designs and machine new metals and compounds. “‘ExxonMobil provides us with the right industrial lubricants and tailor-made services to make our machines run more smoothly and efficiently,” said Simon Roberts, Operations Director, McLaren Racing. A complete range of highperformance multi-purpose lubricants,

the latest additions to the Mobilcut line, under the Mobilcut 100, 200 and 300 series comprise milky emulsions, high performance micro-emulsions and fully synthetic fluids. They are designed to offer a long service life, good operator acceptability and easy waste

Atlas Copco inaugurates second compressor manufacturing facility in India

tlas Copco, inaugurated its new compressor manufacturing plant at Pune in the presence of Horst Wasel, President, Quality Air Division, on 21 Feb, 2013. Also present were Filip Vandenberghe, Managing Director, Atlas Copco (India) Ltd. and Rudy Verstrepen, Vice President, Compressor Technique Operations. Atlas Copco also celebrates 140 years of industrial excellence with a range of activities in more than 90 countries where it has its own operations. Spread over 23 acres, the built-up area of 19,000 sqm includes a manufacturing plant and an office building, in addition to a well-equipped canteen and other employee amenities. The company has

MMT - March 2013

made investment of `100 crore in this plant. The factory is built in accordance with LEED principles. It will cater mainly to the domestic market. Celebrating 140 years is a fantastic opportunity to strengthen customer focus and relations further, to translate our values into daily activities, and to capture synergies,” said Filip Vandenberghe, Managing Director, Atlas Copco (India) Ltd. Our history guarantees long-term industrial experience as well as innovative products and solutions to current and new customers, to suppliers as well as to current and future employees.” Atlas Copco India has three plants in Pune and one each in Nashik in Maharashtra and Hyderabad.

management. The high-performance, long-lasting micro-emulsion cutting fluids in particular have been designed to meet the wide variety of applications and operations where flexibility, inventory management and machine downtime are of paramount importance. From cast iron and carbon steels to aluminium, drilling, grinding, reaming and tapping, Mobilcut products show multi-functionality and high machining performance in critical machine tools. “Regardless of whether a company specialises in producing components for F1 cars, nuts and bolts, complex gear sets or high precision valves, keeping its equipment running efficiently is the key to optimising performance and productivity,” said Shankar Karnik, Asia Pacific Mobil SHC Brand Manager, ExxonMobil Lubricants Pvt Ltd.

UCIMU and ASSOCOMAPLAST to inaugurate Italian Technology Centre in Pune

wo prestige associations—UCIMU-SISTEMI PER PRODURRE (The Italian Machine Tools, Robots and Automation Manufacturers’ Association) and ASSOCOMAPLAST (The Italian Plastics and Rubber Processing Machinery and Moulds Manufacturers’ Association)—are set to launch an innovative project called Italian Technology Centre (ITC India). The technology centre will be launched on 6 March in Pune and will be first point of reference in India for 11 Italian companies, namely, BLM SpA, COLGAR SpA, GIUSEPPE GIANA SpA, ISTECH SEGATRICI SpA, LOSMA SpA, MILLUTENSIL Srl, OMERA Srl, PRODUTECH Srl, ROSA ERMANDO SpA, STREPARAVA HOLDING SpA and TRIA SpA. Indian companies can now get immediate feedback to their queries. Fresh enquiries and technical solutions can also be discussed. The office will be presided by Dr Giancarlo Losma (Immediate Past President of UCIMU Italian Machine Tool Manufacturers Association) through its Indian SPV (Rare Tech Projects Pvt Ltd - Mr Sandeep Chadha, Director - www.raretech.org).

Technology & Innovation VERICUT Programming and Simulation Software

he need of the hour for manufacturers of Automated Fiber Placement (AFP) and Automated Tape Laying (ATL) machines is the use of machineindependent offline NC programming and simulation software. Because manufacturers of AFP and ATL machinery typically supply in-house offline NC programming software, which supports only their machine, they need to adopt multiple software applications to implement multiple machine brands. Therefore, CGTech has introduced composite software products that are machine-independent and hence can support multiple

USPs



Suitable for ALT and AFP machines Can simulate all types of  CNC machines  Can also work with other CAM systems machine brands using a single software application. The software VERICUT Composite Applications—VERICUT Composite Paths for Engineering (VCPe), VERICUT Composite Programming (VCP) & VERICUT Composite Simulation (VCS)—allow for a high-quality set of ATL features

to be created, ensuring cost and time efficiency. Using the software, a simulation can be created, which can measure and inspect to ensure that the NC programme follows manufacturing standards and requirements. Following this, a report showing simulation results and statistical information can be automatically created.

Super-precision Bearings

he machine tool industry needs to deliver high performance to attain success. A few of the many requirements in a machine are extended speed capability, a high degree of running accuracy, high system rigidity, low heat generation, and low noise & vibration levels. The new generation of SKF super-precision bearings is able to meet the everincreasing performance requirements of precision applications. Made from NitroMax, a new generation highnitrogen stainless steel with superior corrosion resistance, the bearings have enhanced fatigue strength and provide

USPs



Improves performance and machine uptime  Optimised chamfers for improved mounting accuracy  Increases service life of lubricants

a high degree of impact toughness. This ultraclean steel can extend the bearing service life in applications under good (full-film) as well as critical (thin-film) lubrication conditions. The optimised bearing series design allows for higher speed capability, reduced friction, noise & vibration levels, lower weight, easier handling, more accurate preload control and improved system rigidity. In addition, these balls are considerably lighter and harder than steel balls that provide a higher degree of rigidity and run considerably faster than a comparable all-steel bearing.

HyIntensity Fibre Laser Cutting System

recision cutting is a prerequisite in the machine tool industry. This is why Hypertherm, a US-based manufacturer of advanced cutting systems, has released a new 3 kW fibre laser system—the HyIntensity® Fibre Laser HFL030—and has a recommended cut capacity of 3/4 inch (20 mm) for mild steel, 1/2 inch (12 mm) for stainless steel and 3/8 inch (10 mm) for aluminium. It comes complete with pre-developed cutting processes. As a result, the system can cut thicker 38

MMT - March 2013

USPs



Allows for high-precision fine feature cutting  Can cut thicker materials at faster rate  Simplifies table design requirements and integration materials in some cases much faster than many higher powered competitive systems. In other words, the 3 kW

system has the cut capacity of other 4 kW fibre laser systems and does not compromise on cut quality. Compared to CO 2 laser cutters, the fibre laser cutting process significantly simplifies table design requirements and integration.

Technology & Innovation EPLAN Solutions

ime is of essence in the machine tool sector and EPLAN solutions help in speeding up the completion of coiling and winding equipment projects by 30%. Timeconsuming product development steps, such as device tagging, wire numbering, and machine design standardisation, have been simplified and accelerated. EPLAN electrical drawings help in expediting the production of documentation and improve accuracy. EPLAN Software & Service develops engineering solutions that accelerate the product engineering process. Interdisciplinary expert systems ensure a maximum of productivity and

data integration. In addition, including archiving and reusing recurrent content is also offered through this solution, negating the need to rebuild parts using the software. In comparison to using CAD software, where an assignment could take two weeks, the EPLAN

USPs

 

Quick turnaround time Closer integration of electrical and fluid design  Error-free terminal diagrams generated automatically

solution can get the same work done in about 23–24 hours. The solution provider develops tailor-made PDM and PLM concepts and provides comprehensive services such as customising, consulting and training. Innovative development competence, a consistently practical approach and international presence are the success factors.

Six-axis Industrial Robots

eiko Epson Corporation has introduced a new series of vertical six-axis industrial robots—the C4 and the C4L. The C4 can handle payloads up to 4 kg and boasts a 20% shorter cycle time. The C4L is a slim, long-arm (900 mm) model that maximises space efficiency. The C4 series is designed for the precision assembly of small parts, and their highly compact size makes them ideal for tasks such as electronics assembly and automotive parts transport. They operate at high speeds with outstanding precision and can deliver very high throughput and handle heavy payloads. Epson increased the acceleration of these

robots by using its unique technology to control vibrations even when transporting heavy payloads. These speedy, slim and lightweight manipulators can also be used in machine-tending applications to load and unload lightweight objects to and from processing machines or

USPs

small moulding machines. The robots also come with the option of a RC700 robot controller, allowing for versatile and powerful operations. Furthermore, the company also offers Vision Guide 7.0, which is a machine vision option that enables the robots to rapidly and accurately recognise the shape, location and orientation of workpieces.



Speed and accuracy that increase throughput  Compact body and improved design flexibility  Increased maximum payload

High-performance Piston Pumps

rane-Bel has launched highperformance piston pumps, which offer a wide range of flow capacities with higher pressure ratings of up to 420/500 bar, in addition to being DuraForce self regulating. Furthermore, the pumps meet most of the piston pump requirements to replace the wide range

MMT - March 2013

of piston pumps normally available at longer deliveries. These pumps are best

USPs



High suction capacity negates need for booster pump Bearing  Hydrostatic Swash Plate offer a longer performance life with the  Equipped LP-Regulator that prevents prolonged operation of pressure relief valves

suitable for users in the fields of machine tools, pressing applications, moulding, aviation, defence, naval systems, aerospace, test rigs and other industrial & mobile applications. These pumps are suitable for mobile and stationary industrial applications, off-the-shelf, having the following unique features and benefits such as optimum power utilisation capability, quieter pumps with less maintenance and self-priming at high nominal speed. To extend pump life, the pumps are available with a SPU silencer (pulsation dampeners).

In conversation with Carlos M Cardoso Q What are your views about the

current global economy and where is it headed?

Both the machine tool business and the tooling business have endured the challenging times of 2012. This situation was driven by factors such as the fiscal crisis in Europe, the elections in the US and the change in China’s political situation. However, as we look at 2013, we see China coming back stronger and growing in double digits; we also see India coming back in a big way. However, the big question looming over the industry is: ‘How much will the Indian elections affect the economy?’ Thus, we are being cautiously optimistic about India.

Q What role does India play in your

company’s growth?

Both the Indian and Chinese economies have done very well so far and both these countries will continue to play a big role in our company’s growth. For us, India is a platform to enter new developing segments. Hence, we are focusing on expanding our presence here.

Q From automotive to aerospace,

energy and various other new segments—India has been expanding its capabilities. Does this lead to a change in the functioning of the tooling industry as well?

It is a very good strategy that India has adopted. In developing economies, the

We are cautiously optimistic about India …says Carlos M Cardoso, Chairman, President and CEO, Kennametal Inc, who feels that India is on the right track in terms of industrial growth. Debarati Basu Das, in a tête-à-tête with Cardoso, not just finds out about his views on global economy and the growth of the industry but also delves on his philosophy of business, leadership and success quotient.

MMT - March 2013

Carlos M Cardoso automotive industry serves as the base to develop a lot of capacity. So, venturing into all these industries is a good strategy for India to adopt. We are excited to be here and the fact that the industry is changing offers us more opportunities. Kennametal’s tooling capability is globally well positioned to serve all kinds of markets and has been at the forefront in doing so. Since we have the experience required in these segments and know the products well, I think that we are uniquely positioned to help India enter these industries.

Q What are the essential factors

in providing cutting-edge tooling solutions?

The first factor to be considered is innovation because you have to create value. One of our targets is to have around 40% of the sales coming from new products every year. Also, in developing economies, as the standard of living goes up, productivity becomes a bigger issue and we are uniquely positioned with our new products to do well in these areas. The second factor is total solutions. We do not just sell a product; we look into the entire production line/ industry and find out ways in which we can help the customer establish a whole process. We are one of the very few companies to do so. Also, we are well positioned because the majority of our products are produced in India and this allows us to understand the requirements of Indian companies.

Q What are the weaker links in

the Indian industry?

Infrastructure is the most important issue that the industry is facing. However, I think that over the last 10 years, there has been tremendous improvement and it is only getting better. We are optimistic of seeing better infrastructure in future. The second major hurdle is bureaucracy—the way things are done and the time it takes. But it is getting better eventually.

UP CLOSE

& personal

Uniqueness of India that appeals to you I have been coming to India for the last 20 years. This country has a very rich culture with hard-working and committed people. We, as westerners, feel very comfortable here and this is one place in the world where we enjoy and feel safe. Another thing that appeals to me is the country’s high level of education. The country has highly effective technical programmes and I highly appreciate the education level here. The vision of new-age entrepreneurs Nowadays, as I go around the world, there are more similarities among young people today than there were 20 years ago. They are instrumental in bridging the gaps in high-speed information. Another trend I have noticed is that young people are giving more importance to entrepreneurism. In the time to come, there will be very little difference between the way they do business in India and in other parts of the world. The IT revolution here has helped a lot in bringing about this change. Qualities in a leader My personal philosophy is that leadership is a pie that has three pieces—IQ, EQ (the emotional intelligence to understanding and listen) and Experience. A perfect leadership needs an equal balance among these three quotients. What defines success? There are three things that define success: First, a successful company should have a good strategy—a simple and actionable strategy that most people in the company can understand. One should always think about what one wants to be and then walk back to where one is today. This will help in understanding how to go back and take the path. The second element is to have a robust process, which can help realise the dreams that you have. The third element constitutes the people. You have to have the right people who can maintain and improve the processes to grow and achieve. This is part of Kennametal’s DNA. If you enter Kennametal‘s Indian office, you will feel that this is an Indian company and not a branch of a foreign company. But if you go deeper, people in the organisation globally follow one culture. This culture is not Indian, American or European; this is Kennametal’s value system on how to do business. Message to budding entrepreneurs Dream and take calculated risks. If you do not dream, you cannot make it a reality.

Q What are your expansion plans

for India?

Our business has grown twofold in the last 10 years in India. We have had great opportunities to grow. One of the things that we are proud of is that the whole management team

is Indian, which helps us understand the business, culture and pulse of the Indian industry. We are optimistic that we can again double our business here in the next five years. debarati.basu@network18publishing.com

March 2013 - MMT

Special Focus Robotics & Automation 46

Robot Trivia

Did you Know? ...

Leaders Opine

Automation: Productivity Enhancer & More!

50 Well-crafted Solutions

Robots in the Door Production Line

53 Automation Snapshot

PLM: Enabling Smarter Decisions and Better Products

68 Myths & Tips

Fact or Fiction?

68 March 2013 - MMT

special focus Robot Trivia

Did you Know? ...

It is incredibly difficult to define the word ‘Robots’. In the truest sense, it could be called a machine that can be programmed to do tasks automatically. But in the colloquial sense, aren’t clockwork toys also considered robots? Nedra Pereira lists a few interesting facts that you may not have known about this invention—an invention that has enhanced life in every industry. transport die castings from the assembly line and weld these parts on auto bodies.

1. A r c h y t a s of Tarentum, Plato’s friend, built a mechanical bird driven by a jet of steam or compressed a i r — arguably the first robot in history— i n the fifth century B.C. 2.

7. Tanaka Hisashige, known as ‘Japan’s Thomas Edison’ and also one of the founders of Toshiba, built clockwork dolls known as Karakuri ningyo, some of which served tea, fired arrows drawn from a quiver and even painted a Japanese kanji character.

The word ‘robot’ comes from the Czech word ‘robota’, which, when translated, means drudgery. The word first appeared in 1921 in a play named RUR (Rossum’s Universal Robots). In 1739, Jacques de Vaucanson invented the robotic duck. It could not only flap its wings, quack, stir water with its beak but also eat, digest and pass out food as faeces. Elektro, the world’s first humanoid robot, was built in 1939, by Westinghouse. The sevenfoot-tall walking machine ‘spoke’ more than 700 words stored on 78-rpm records to simulate conversation. 5. The first industrial robot Unimate was invented by George Charles Devol. The robot was used in a General Motors assembly line. Its main job was to

6. German robotics company KUKA created Famulus, the first industrial robot with six electromechanically driven axes in 1973.

MMT - March 2013

8. Leonardo da Vinci drew up plans for an armoured humanoid machine in 1495. Engineer Mark Rosheim created a functional miniature version for NASA to help colonise Mars nearly 500 years later. 9.

Takeo Kanade built the direct drive arm in 1981. It is the first to have motors installed directly into the joints of the arm, thus making it faster and much more accurate than previous robotic arms.

10. The world uses more than a million industrial robots—half of these are used in Japan. 11. Mars robots—Spirit and Opportunity—have logged 10.5 miles trudging across the Red Planet for more than three years.

These droids were built to last only 90 days. 12. Chris Melhuish of the Bristol Robotics Laboratory created robots that use bacteria-filled fuel cells to produce electricity from rotten apples and dead flies. The goal: robots that forage for their own food. 13. Australian researchers are trying to build a microrobot that would mimic the swim stroke used by E. coli bacteria. It would be injected into a patient in order to take a biopsy from the inside. 14. Cybernetics professor Kevin Warwick calls himself the world’s first cyborg. Using computer chips implanted in his left arm, he can remotely operate doors, an artificial hand and even an electronic wheelchair. nedra.pereira@network18publishing.com

Special Focus Leaders Opine

Automation: Productivity

Enhancer & More! Automation has already become a norm on the global front. However, this trend is only now becoming popular in India. Nedra Pereira, in a tête-à-tête with K Nandkumar, President, Automation Industry Association, finds out about the major hurdles that SMEs face in adopting this trend, India’s economic dependency on the trend and the future of the machine tools industry. Q Let’s start from the basics. What is

the importance of automation in any industry, apart from it being able to increase productivity? Automation must always be seen in the context of the bigger picture. The way I see it, increased productivity is the by-product of a series of benefits that automation brings to the table or, in this case, the shop floor. Automation is not just the replacement of man by machine to do routine tasks. It is the standardisation of processes and methods, which can be fed into machines unlike humans; of course, not to forget that machines can be put to work in high-risk/hazardous areas wherein human resources cannot be risked. However, the biggest benefit is the possibility of training the staff carrying out repetitive tasks in better, meaningful jobs, which will give them a chance to rise up the social ladder. In other 48

MMT - March 2013

words, it is a holistic processing tool towards sustainability.

Q Where does the automation industry

currently stand in India? And what does the future look like? The growth of the automation industry in India is at an average of 12% pa. The automation industry is a service provider and its growth entirely depends upon the growth of other sectors. If other sectors are stagnant or decelerating, the automation sector will also show similar effects. In the last couple of years, the performance of the automation industry has been less than satisfactory because other than some major ongoing oil & gas projects, there was no major

investment. Hopefully, by the end of this year, large investments in oil & gas, fertiliser, petrochemical and cement sectors are expected. This should drive the growth of the process automation industry. Today, the automation industry in India is worth approximately `12,000 crore and has the potential to grow by 15–20% given the existing capacity addition in infrastructure and energy sectors. As such, automation can be generally classified into three categories: Process, Factory, and Electrical. Electrical automation has so far been in the infancy stage, but has now taken a great leap with the planned automation of transmission & distribution of electrical energy.

Leaders Opine

Q With respect to automation, what

are the repercussions of India not being at par with global adversaries? The repercussions are worrisome to say the least. To put it briefly, Indian products’ competitiveness in terms of price, quality and timely delivery and attaining safe & secure operations will suffer if we do not embrace appropriate automation.

Q What is the major hurdle most

SMEs face in adopting any form of automation? The initial costs of adopting automation as well as developmental costs of customised automation, apart from being expensive, tend to be unpredictable, which is the major hurdle that stops the adoption of automation by SMEs. Apart from this, while the commercial development of human resources is a challenge, the training and retraining of HR to meet the high demands of automation while simultaneously shouldering alternate responsibilities is also essential.

Q What can the big players of the

machine tool sector, associations that support these sectors and the government do to encourage the use of industrial automation within companies? The most basic and easily attainable encouragement initiative would be to develop centres of excellence in various facets of automation, appropriate to each industry sector, develop skills for personnel and certify them, thereby enhancing the social equity of the moderately educated youth.

Q Some may feel that automation is

extremely expensive, but they do not bear in mind the return on investment. What advice would you give them with regards to this? I look at automation as the processing tool for sustainable growth. Brief pointers to the benefits

of automation should help counter the argument of automation being expensive:  Making tasks that are beyond human capabilities possible  Doing tasks in dangerous or hazardous environments  Enlarging Economics of Operations and reducing costs  Increasing quality in manufacturing processes

UP CLOSE

&personal

What are some of your hobbies? I like reading industrial & technical magazines and listening to devotional songs with my wife.

Name a person who inspires you the most? Every hardworking, committed and sincere person I come across in my day-to-day interactions, regardless of his/her job profile (from high profile CEOs to clerical staff), is an inspiration for me.

The biggest benefit is the possibility of training the staff carrying out repetitive tasks, giving them a chance to rise up the social ladder.

What is your personal motto? Nothing succeeds like hard work.

 Enhancing

opportunities in protecting the environment  Quicker response to market volatility  Enhancing energy efficiency

What is your favourite quote? “One must forever strive for excellence in any task, however small, and never be satisfied with the second best” by JRD Tata

Q Automation in the global market is

valued at US$90 billion, but India only contributes to US$2 billion. What are the opportunities/steps that India needs to take in order to increase its global mark? India must undertake a multipronged initiative in order to strengthen her foothold in the global automation market. Corporates, associations and the government must come together to:  Create world-class Infrastructure  Encourage technology leaders to set up manufacturing base in India value-added  E n c o u r a g e manufacturing/service concepts  Enlarge government-industry initiatives  Draw up industry standards to meet future needs  Setting up and getting global accreditation for test laboratories and certifying agencies  Minimise operational hurdles and

eliminate cumbersome procedures industry-institute partnerships  Develop security technologies and best practices  Encourage resource sharing through industry clusters  Establish advanced research & development centres  Promote/mandate the adoption of the risk management framework  Protect intellectual property rights  Encourage developer-user nexus

 Encourage

Q What is your message to the

machine tool sector? Adopt automation global!

and

nedra.pereira@network18publishing.com

March 2013 - MMT

Special Focus Well-crafted solutions

Robots in the door production line In the production shops at Kraft Maschinenbau, there is no doubt about what happened to those boys at kindergarten who were always playing with the construction kits. At the Kraft plant in Rietberg Mastholte, Germany, you will find visionaries and innovators at work creating impressive systems—crammed with know-how and fascinating features. Anyone who is facing seemingly insoluble requirements for production lines would be well advised to pay a visit to Kraft Maschinenbau. In the area of robotic automation, Kraft systems integrate the flexible robots from KUKA Roboter GmbH.

f a m i l y o w n e d company, Kraft was founded in Mastholte in 1816 by Franz Adam Kraft as a forge for carriage construction. Today, with a workforce of 450 based at three locations, the company develops and produces customized solutions for a wide range of production processes in the areas of conveying, warehousing, handling, machining, assembly, automation and packaging. Kraft specializes in machines and lines for furniture and door panels, wood composites and parquet flooring, as well as for insulating materials and construction elements. Kraft’s competencies include the planning, construction, programming and commissioning of complete solutions, automation systems and entire production lines for many industries and markets. Individual, tailored solutions are developed in cooperation with the customers. In addition to Kraft’s own extensive value creation, these solutions use only components and systems from renowned 50

MMT - March 2013

manufacturers. In applications with integrated robotics, these are supplied by KUKA. Before a machine or line leaves the plant, it is completely assembled and commissioned in the large final assembly shops. It is then installed at the customer’s plant by the same technicians, who are highly experienced at assembling extremely complex production lines. A major focus of their work is on automated, interlinked system technology for the manufacture of doors. “We consider one of our particular strengths to lie in the linking of individual system components. We have a highly motivated team dedicated to software development,” says Ferdinand Kraft, MD, Kraft Maschinenbau GmbH, who is the sixth generation to head the company. “The automation of the machines and production systems developed by our engineers is carried out by our Kraft Automation Technology department. We think it important to keep these things in-house.” “The installed electronics, the control technology and the automation today account for 30, 40 or more percent of the performance of a system or machine,” adds Berthold Sudahl, Robotics Manager, Kraft Maschinenbau.

Complexity and Creativity

For a Swedish door manufacturer, Kraft had already supplied a door production line in 2004. Due to the high quality and positive experiences in all aspects of customer service,

Special Focus Well-crafted solutions solutions Well-crafted a second customised and highly complex line has now been designed for manufacturing doors from start to finish. The line measures 100 x 30 metres and is divided into many different production areas and safety zones. It comprises the door loading area, the main machining area, door leaf production, door leaf machining, inlay insertion, various storage locations, removal, feeding, surface finishing of the door leaf, angular transfer conveyors and many other components. Glue is applied, the door mouldings are clamped, the glued cover board is turned back and applied and the finished door leaf is transferred to the press. “A logistically demanding process,” comments Frank Zimmermann, Key Technology Manager, KUKA Roboter. “The KUKA robots in the line form flexible work stations which make it possible to manufacture in a batch size of 1, despite the complexity of the production process.”

Four robots in a Versatile Application

Three KUKA robots of types KR 100 PA and KR 180 PA are employed in the line, each one with a different gripper and tooling. Each of them performs a task that is highly monotonous or difficult for a human worker to execute: a KUKA palletizing robot takes the frame mouldings from a stack and loads them at a slight angle into the infeed of a measuring station. The curvature of the moulding is measured. “We can position the moulding packages on an individual basis—fully automated stack measurement is implemented here with this robot,” explains Berthold Sudahl. With its compact design and streamlined gripper, the robot is not obstructed by other line components, but easily accessible for cleaning and repair work. In the case of the gluing robot, a long reach and flexibility during glue application were of particular importance. “We don’t waste any glue and are totally flexible—each door leaf can be different,” Sudahl explains. All 52

MMT - March 2013

the information about positions, quantities, dimensions, type variants, glue patterns, etc. are specified by the host computer. The KUKA palletizing robot takes care of the monotonous, heavy work of positioning the inlays on the lower face ply and then placing the mouldings on all sides. The products are precisely positioned by the robot and all at a ´ Robot ensuring maximum flexibility rapid pace: one door is produced every minute. production. At the end of the line, the When the door leaf composite finished door is packaged and ordercomes out of the press, it is fed to the picked. The line is to run in two-shift fourth robot; this six-axis KUKA robot operation in Sweden. Berthold Sudahl of type KR 240 L180 grips the door leaf sums up the special features of the door horizontally and stands it upright in production line as follows: “I believe the receiving racks. Here, the door leaf that we have mastered the integration is allowed to cool after the hot pressing of robot systems exceedingly well—we process. After cooling, the same robot chose to integrate robot systems in places the door leaves horizontally order to ensure maximum flexibility. again on the feed conveyor for edge If we had wanted to solve the required application. The door leaf is then tasks with conventional handling transported through an IMA edging systems, this would have been much machine, where edging is applied more complex and costly. Furthermore, one side at a time. This procedure is flexibility with regard to future tasks repeated in as many passes as necessary or modifications is 100% assured here until all the edges have been applied. with the robots.” Finally, the necessary holes The advantage of this line is that it and cutouts are made. The door can be engineered for fully automatic is transferred into the Kraft CNC operation. The robots in the line carry machining centre, where the cutouts out numerous monotonous tasks, thus for the lock case, door handle, key hole easing the workload of the human and other fittings are milled. operators. The speed of the line is not the critical factor in this case. The incredible complexity of the line, batch From Mastholte into the World sizes of 1, and the ability to machine A further highlight of this line is that each individual door leaf differently remote servicing can be carried out and give it a different appearance is at any time. In the event of a fault, what makes the line special. “This the responsible technician can access line will have paid for itself in a very the controller of the door production short time,” Sudahl is convinced. line in Sweden, enabling immediate “And with KUKA robots, we have assistance to be provided. implemented flexible and innovative “Our aim is always to build compact robot technology which will bring the lines,” Sudahl explains. The door leaf customer many advantages.” runs through many individual stations. The raw materials are brought together efficiently in the line in the course of Courtesy: KUKA Robotics (India) Pvt Ltd

Special Focus Automation Snapshot With global economic uncertainties, manufacturers are under a lot of pressure to cut costs and increase revenue. The last time Indian manufacturing faced a similar crisis was in the early 90s, after economic liberalisation in India opened up a previously protected market to global competitors. Many people, including many manufacturers, thought that more efficient foreign manufacturers, providing higher quality products, would completely wipe out manufacturing in India.

PLM: Enabling smarter decisions and better products

hat unfolded over the next 20 years was something very different; Indian manufacturers not only overcame the crisis, but emerged stronger than ever before. They became efficient and high-quality manufacturers. The rapid expansion in manufacturing over the last two decades along with several prestigious quality awards bagged by Indian manufacturers bear testament to this fact. So, what is the next step for Indian manufacturing? Before we answer this question, letâ&#x20AC;&#x2122;s take a look at some of the challenges faced by manufacturers today. We shall start with the need for speed. With shrinking product lifecycles and expanding choices available to consumers, manufacturers have to bring their innovations to the market faster than their competitors to stay in the race. Further, with increasingly complex products, no one manufacturer can possess all the skills and competencies required to bring a product to market.

Manufacturers are increasingly forced to work with suppliers and partners across the world providing key subsystems and competencies. This brings us to our next challengeâ&#x20AC;&#x201D;globalisation.

Challenge Check

Indian manufacturers have to target global markets to achieve economies of scale. They also have to work with global partners who may be providing key competencies that are critical to product success. In this increasingly globalised value chain, one faces the next challenge of optimisation. How can manufacturers get the most out of their resources and competencies that are now spread across the world? How do they achieve this while maintaining flexibility to respond quickly to market demands? And how do they do this while paying close attention to the next major challengeâ&#x20AC;&#x201D; sustainability. With increasing concern for the environment, governments around the world are enacting certain regulations in order to control the use of harmful materials in the product and the production process. Manufacturers

are also being made accountable for the safe disposal of their products at the end of life. In summary, manufacturers today face unprecedented challenges and a complex business environment. Just being an efficient manufacturer is no longer sufficient to achieve long-term success.

Product Lifecycle Management

That brings us back to the question: What is next for Indian manufacturing? The answer lies in the practice of Product Lifecycle Management (PLM). PLM is rapidly emerging as a critical enterprise application for manufacturers. While PLM is a vast domain with several solution sets, one could classify them into three broad areas: digital product development, digital lifecycle management and digital manufacturing. However, please bear in mind that PLM is, first and foremost, a business strategy. Products are the life blood of any manufacturing organisation, and a disciplined approach to decision-making across the product lifecycle can unlock tremendous value for manufacturers. March 2013 - MMT

Automation Snapshot The PLM software has evolved over the years, from simple CAD tools to integrated information systems that contain intelligent product and process information, thus supporting effective decision-making across the lifecycle. Smarter decisions would logically lead to better products, providing long-term growth and profitability to manufacturers. When Maruti Suzuki India Ltd (MSIL) experienced increasing market pressure to introduce new product models in a shorter time frame, it decided to automate its die design process with the help of digital product development tools. This helped MSIL bring down the die design time and costs while enhancing the quality of dies. For Avantha Power & Infrastructure Ltd (Avantha Power), it was a question of reducing project delivery and execution time for commissioning new power plants. With the help of a digital lifecycle management system, Avantha

MMT - March 2013

Power was able to manage and share accurate project information among employees and vendors in a secure environment, thus achieving its overall project objectives. When Mahindra Vehicle Manufacturers Ltd (Mahindra Vehicles) decided to set up a new manufacturing plant at Chakan to cater to the rising demand for medium and heavy commercial vehicles, it turned to digital manufacturing technologies to plan and simulate the entire plant virtually before construction started. This helped Mahindra Vehicles bring down vehicle lead times and costs significantly, as well as eliminate non-value adding activities early in the process, thus supporting its ‘first time right’ philosophy. These examples should not give one the impression that PLM is only suitable for large enterprises. Small and mid-sized manufacturers face the same challenges and are increasingly turning to PLM to deal with the complexity of today’s business environment. In

summary, we are at the cusp of what promises to be an exciting period for manufacturing in India. Challenges abound, but so do opportunities. Innovative manufacturers who make smarter decisions and build better products are sure to achieve success in the years to come.

Vivek Marwaha heads the Marketing department of Siemens PLM Software in India. In his capacity as the Marketing head of the erstwhile SDRC, UGS and now Siemens PLM, Vivek has been involved with India’s evolving Engineering-IT/PLM industry for nearly a decade. Vivek has been with Siemens PLM for over 11 years. He has also handled various sales and marketing assignments in his 20-year-long stint with the IT industry, during which he has worked for organisations like HCL, Wipro, Compaq and Computer Associates.

MMT March - 13 Ad Name: Ceratizit Pg No. 59

MMT March - 13 Ad Name:Tungaloy Pg No. 60

MMT March - 13 Ad Name: Tunglogy Pg No. 61

MMT March - 13 Ad Name: Birla Pg No. 62

special focus Myths & Tips The industry, today, seems to be apprehensive of readily adopting automation. There seems to be a fear—be it extensive investment or making the right choice. Nedra Pereira, with insights from Bhaskar Mandal, Executive Vice President and Head of Industry Sector, Siemens Ltd, recognises some common myths, their actual realities and tips to discern which automation is best for you.

r o t c a F Fiction? “Automation equates to expenditure”

Reality: Because the initial investment is high, most may think that automation is expenditure. This is one of the most commonly observed myths, especially in developing markets like India where automation is not viewed as an investment. While it may seem as an expense in the initial stages, automation players need to convey the true value of the offered solution to the customers. From a machine perspective, companies can use an automation system such as Profinet, which monitors the status of a machine and switches off the machine in real time when there is no production scheduled. Such measures can, in turn, enable even smaller manufacturers to benefit from increased productivity and reduced cost.

*Note:

“Automation leads to labour redundancy”

Reality: This is yet another common myth floating in the air. Contrary to what people think, automation enhances the skill sets of labourers and also results in error-free output. Owing to process automation, a worker can invest time in developing his knowledge, which would subsequently add value to the company.

M Y T H S

“There is no requirement for automating a process”

Reality: Automation can help the Indian manufacturing sector to become more competitive by improving productivity, quality consistency and flexibility of the manufacturing process, thereby reducing timeto-market and also helping manufacturers to meet safety & compliance requirements as most automated processes can work in a high-risk and hazardous environments. Automation, in short, is a great enabler to achieve operational excellence.

Today, many pharmaceutical, fine chemical and F&B manufacturers aim to export their produce to the international market. However, compliance to USA’s FDA norms, with complete traceability and tracking, becomes mandatory. Even other manufacturers having discrete or hybrid manufacturing processes need traceability and tracking for their product manufacturing history along with product and production data. Unless one has adequate degree of automation, it is impossible to achieve this compliance and the required traceability & tracking. Hence, for manufacturing processes, irrespective of the type of the processes involved, automation is not only important but essential too!

MMT - March 2013

Myths & Tips

Tips Choose the right partner

In today’s dynamic market scenario, clients demand greater flexibility in production, maximum efficiency from engineering and increased protection for personnel & machinery and protection against unauthorised data access. An efficient automation partner proves to be a vital resource for any manufacturer to meet his demands and have an edge over its competitors. Solutions such as the SIMATIC Solution partner are one way to go. It provides for a reliable automation partner with its comprehensive product portfolio.

Project management

Process industries have to transcend the boundaries between all disciplines and companies involved in a project by facilitating a seamless flow of information without data loss during the handover between various project lifecycle phases. This approach enables to manage projects on an end-to-end basis and deliver project documentation so that all relevant data and information items are available in up-to-date form wherever they are needed.

forms to t a l p n o i t a utom Integrate a tion islands’ a creasing work in in ay m ss ce avoid ‘autom ro cesses, art of a p ancing pro

only p keep enh n Automating te automatio however, to y; ll ia it in ce, incorpora eering and y it en iv H ct . u ry d sa ro p gin neces orm for en tegration is d mmon platf complete in co on easy an ti a ra e g d te vi in ro p ch at su th ss s e proce , ill mak solution aspect of a e , which w n n o io in at ic ly n n u comm is used o automation ely. effective. If used effectiv b will not e d ve sa e m ti the

Understand customers’ processes

It is imperative to understand your customers’ requirements and offer & execute optimum solutions meeting such requirements. Today, a partner is expected to have adequate domain knowledge (about the manufacturing process under automation) so that he can provide value addition to the automated processes. This, in turn, helps the manufacturer to improvise productivity with the requisite flexibility and increase the efficiency of the production plant with excellent repeatable quality of the final output in the shortest possible time-to-market. For example, Siemens follows the vertical market approach extensively, by having market specific products & solutions for focused industries being handled by competent sales and execution teams with extensive application knowledge for that industry. This results in the implementation of optimum solutions, leading to customer satisfaction.

March 2013 - MMT

Insights & Outlook Die & Mould industry 74

Expert Insight

YR Anand, Partner, Unimark & Executive Council Member, TAGMA

Tooling Summit 2013

Changing Dynamics of Tooling Business

Threat Analysis

Dragons vs Tiger: Testing India’s Mettle

MIM Technology

Leapfrogging to Value Engineering

Need Gaps

Enhancing the ‘Made in India’ Trademark

Techno Focus

Technology: Precision and Innovation

One Q Many Views

Additive Manufacturing: Threat or Supplement?

86 March 2013 - MMT

TOOLING SUMMIT 2013 A forum for shaping the future and fortunes of Indian Die & Mould Industry

YR Anand, Partner, Unimark & Executive Council Member, TAGMA

f all the manufacturing processes for producing most items of daily use, toolmaking is the most basic and essential part of the process, albeit an invisible part to the end user, like the reader of this article. Without these â&#x20AC;&#x2DC;toolsâ&#x20AC;&#x2122;, most things that we use everyday from toothpaste, mosquito creams and cell phones to televisions, automobiles and zippers cannot be produced. Tools can be as simple as screwdrivers or more complex like the tools used in metal or plastic cutting operations. Custom-built dies and moulds used in mass production represent a major share in the technology segment and yet remain almost invisible. In most countries, these custom-made dies and moulds are built by either large in-house tool building operations or small and medium operations owned by first-generation entrepreneurs who have built the business from scratch. There are few toolmaking companies that are driven by the purely professional corporate culture prevalent in larger manufacturing operations. This is true for worldwide tool production and India is no exception. The Indian die, mould and allied industry is estimated to be over `13,000 crore in size and growing. Currently, it is also estimated that about 40% of the dies & moulds is imported from several countries, notably China, Taiwan, Thailand, Japan, Germany, France and Italy. Even at the reduced growth rates of this year, the tooling industry is expected to grow to about `23,000 crore by the year 2016. Considering the importance given to increasing the share of the manufacturing segment in the general economy by the state and central governments, the importance and potential of the growth in the tooling industry will be beneficial to everyone including the players in this business. Toolmaking of this type is highly capital intensive and also involves high intellectual and skilled labour. Regardless of the level of automation, it provides many opportunities for Indian die and mould makers to cater to the growing need for quality dies and moulds. The challenge for industry players lies in organising

MMT - March 2013

themselves to meet the needs of imported tools and vast export potential. The larger captive tool rooms tend to concentrate only on their internal requirements. Even those involved in custom tooling focus on supplying parts or complete sub-systems to their customers. So, they are not motivated to go after the businesses that can be obtained from imports or exports. Independent tool rooms are undoubtedly nimble and experienced to handle such work, but they suffer from several handicaps. Major among them are lack of organisation, manpower retention and scaling up to meet large projects. All tool rooms need capital-intensive equipment like production machines, inspection equipment and CAD/CAM/CAE software. The high cost and low Return on Investment (ROI) in this industry makes it very difficult for small and medium companies to manage such expansion. Tool & Gauge Manufacturers Association of India (TAGMA) is an industry association initiated in 1990 to take care of the special needs of this nodal and basic industry. TAGMA has been taking several initiatives to address the concerns of the industry. Since the expansion of the industry is an urgent need, TAGMA and Modern MachineTools (MMT) magazine from the Network18 publishing powerhouse have taken the initiative to have an industry summit for the tool room industry in three major toolmaking centres, namely, NCR, Chennai and Pune. The thought behind this initiative is to bring together industry players like tool makers, end users, policy makers, finance specialists and management gurus in order to lock on practical solutions that will help gear up to new challenges in the coming years. It is being planned as a networking opportunity followed by a daylong practical workshop on new ideas. There will be no technical sessions of any kind and the concentration will be on the business part of the industry. We hope that all the players will respond overwhelminglyâ&#x20AC;Ś

Insights & Outlook Tooling Summit 2013

Changing Dynamics of Tooling Business Dies and moulds are integrated by a form of tacit knowledge-based engineering, and these capital goods are critical in determining the quality and price of products for end use. The Indian industry is facing several challenges in the form of technology gap, skill development and support from the government. With this as the canvas, the die and mould industry is losing its sheen despite its prowess in the value chain. It is time that this industry unifies to achieve the common goal of making a bigger mark. Tool & Gauge Manufacturers Association (TAGMA) & MMT magazine are jointly organising a seminar—Tooling Summit 2013—in three different cities, which will chart out the road map of the industry’s future. Nishant Kashyap elaborates…

ies and moulds are indispensible tools for mass production. They touch our lives in everything we do. We are surrounded by products and services that were made possible because of this industry, its people and their passion! Dies and moulds are clusters of product manufacturing knowhow —a critical element for a country hopeful to develop its industrial sector to acquire manufacturing might. 76

MMT - March 2013

Why Tooling Summit 2013?

While die and moulds provide a tooling edge to manufacturing and thus to mankind, somehow, in its zest to service others, the magic that this sector creates gets ignored and mostly gets pronounced as ‘regular work’… or at best, ‘craftsmanship’ when industry critics are in the mood to use superlatives. Dies and moulds are integrated by a kind of tacit knowledgebased engineering, and they are a critical capital good to determine the quality and price of products for end use.

The country holds several business opportunities for die and mould manufacturers, but has a long way to go to be called a developed market. With huge prosperity come several market challenges such as threat from Eastern countries, technology gap, ever increasing customer requirements, limited government support, skill development, etc. To achieve this goal, a daylong conference in Delhi, Chennai and Pune will have the who’s who of the die and mould industry and most importantly, the user industry will discuss

Tooling Summit 2013 What is it?

A two-day knowledge nexus 1st day evening: Networking dinner 2nd day (9:30 am to 5 pm): Daylong summit

When is it?

Between 10th & 15th June, 2013

Where is it?

Delhi: 10th & 11th June, 2013 Chennai: 12th & 13th June, 2013 Pune: 14th & 15th June, 2013 various aspects of the industry to come to a consensus of making the right mould to reshape the industry’s growth path.

The Format

The two-day seminar in each city will have a networking dinner on the first day followed by a daylong key industryrelated session on the second day. There will be five panel tracks and one workshop discussing various business opportunities, challenges and solutions. The five panel tracks on the present mindset issues of the die and mould industry, threat from Eastern countries, technology gap, skill development and support from the government will discuss pros and cons of the industry. They will highlight the challenges, current demand trends, opportunities, solutions and the road ahead for the industry. The panelists will be mix of die & mould manufacturers; leaders from user industry; government officials from particular regions and officials from educational institutes/ associations such as IIT, AICTE and MHRD. The seminar will be attended by the who’s who of the die & mould industry, user industry and government officials. The interactive workshop on ‘Know what your customer wants’ is designed in a manner wherein representatives from the user industry of dies and moulds and tooling solution providers

What is it about?

1. Confidence & community-building exercise (trust, transparency, team spirit) 2. Identifying trade opportunities by eliminating threats 3. Bridging the expectation gap with the user industry (engaging workshop) 4. Capturing the voice and vision of the industry 5. Charting the road map for action 6. Initiating a regular annual community gathering

will share their pain points and expectation gaps with each other. For the first time in any summit, a live need gap analysis will unfold the discrepancies and perception

SC Kalyanpur, Managing Director, Sridevi Tool Engineers Pvt Ltd & President, TAGMA Events like Tool Talk bring awareness to the people concerned with this industry at the national level as the tooling industry is an important link for the country to excel in manufacturing.

YR Anand, Partner, Unimark & Executive Council Member, TAGMA There is a need to discuss industry related issues to achieve rapid growth with all the stakeholders on one platform – tool makers, large-scale buyers, policy makers, management experts, financing experts, taxation experts, etc. It is essential to discuss the business aspect of the tool rooms rather than the technical issues, for which there are enough industry seminars.

problems between the user and the tooling solutions provider. A representative from a user industry and the tooling solution providers will highlight the top five pain points or need/ expectation gaps.

Why Attend?

The Tooling Summit 2013, a oneof-its-kind event, will have the whole ecosystem of the industry under one roof discussing the expectations, need gaps, business opportunities, challenges and the road ahead. It will be an optimum platform where industry professionals can understand the latest technology solutions available and the user expectations. This event is expected to be attended by decision-makers of the organisation that will further help players enhance their presence in the industry. The industry is a mix of small and big players. Better networking between all companies in the industry is definitely required to fill the gap and work on a common platform. There is also a need for concurrent engineering to take the industry to the next level. In light of this, Tooling Summit 2013 aims to achieve greater success, enhanced confidence and improved camaraderie amongst the community members! nishant.kashyap@network18publishing.com

March 2013 - MMT

Insights & Outlook Threat Analysis India has established itself in the global metalworking industry owing to its lowcost manufacturing certification. The country is now in a very good position to capitalise on the new opportunities coming its way; however, in order to optimise these opportunities, they will have to compete with the Eastern countries that have become aggressive in recent years. Nishant Kashyap analyses the threat from the Eastern countries and ways to survive and compete.

ndia is known for its low-cost manufacturing certification. Many big players in the country have grown rapidly and, now, provide high-end solutions to customers, but a majority of SMEs are still lagging in terms of adopting sophisticated technologies. Also, the demand for die & mould in the Asia n market is on increasing, which was the main reason that many companies in the Eastern countries became technically advanced to meet global standards. Over the years, since they have become strong in the Asian market, they are also acting as a threat to Indian companies.

Competition From East

For generations, the Germans, Swiss and Americans have garnered supremacy, defined quality & precision for the world; painted the aesthetics of mechanics and created certain benchmarks. Subsequently, 78

MMT - March 2013

Dragons vs Tiger Testing Indiaâ&#x20AC;&#x2122;s Mettle

manufacturing moved eastward and then arose the next-generation dragons of manufacturing. While Japan proved that the East can replicate the West in terms of quality, China explained the concept of value for money. India, at the same time, was coming out of its cocoon, but was too young to join the competition. However, now that the country has finally revved up for the run, other players like South Korea, Taiwan, Singapore and Thailand have also joined the race. Although we were late in gaining momentum, we certainly are not underdogs. YR Anand, Partner, Unimark & Executive Council Member, TAGMA, says, â&#x20AC;&#x153;Chinese tool makers supply at great speed and attractive prices. But their quality can be variable. Taiwan and Korea offer higher and more consistent quality and also at rapid lead times. Thailand has a strong presence in the sheetmetal

die making industry and has supplied a number of tools to the Indian automotive industry. Tool making in Singapore is now almost at par with European tools in terms of quality and price. All of them can manage large tooling programmes much better than our Indian tool rooms.â&#x20AC;? In recent times, the competition from these Eastern countries has increased, which is affecting Indian business. These countries not only provide good technology, but they have become highly cost-effective too. For instance, China has, for long, been playing the card of being a low-cost destination for mass manufacturing. Japan is a pioneer of quality in the East, but its self-reliance has partially kept it away from Western trends. Taiwan, Korea and Singapore have made the most efficient sprints of manufacturing a perfect concoction by integrating quality into low-cost manufacturing. Sensing

Threat Analysis the situation, SC Kalyanpur, Managing Director, Sridevi Tool Engineers Pvt Ltd & President, TAGMA, says, “There is competition from Eastern countries such as Korea, Taiwan, Singapore and Malaysia. This is affecting the growth of this industry in our country. The tooling industries in these countries are more competitive because of the availability of raw material and hardware equipment manufactured in their own country.”

What Should India Do?

The attitude of manufacturing needs to change in a big way. Our export items still do not reach the preset global benchmarks. We are still competing with ourselves. There needs to be an aggressiveness in the way we compete. We know how the global market has defined ‘quality’. Hence, we blatantly have to reject whatever does not come under the gyre of that q-u-a-l-i-t-y. Indian companies have to think global, enhance quality and increase their capability. Kalyanpur says, “To enhance

the capability, more investment in state-of-the-art equipment is necessary. Unfortunately, this equipment comes from Europe or Japan and involves heavy capital investment. Indian die and mould manufacturers can attract more customers only by producing quality products and ensuring on-time delivery.” India is not far behind in terms of technology. But when it comes to some niche operations, complex machines, high-precision cutting, etc., global players lead the race. It is high time that India starts focusing on R&D; the country needs to invest more and more in technology upgrades. All companies should devote some share of their revenue to technology upgrades. This warrants not only focusing on product development but also adopting sophisticated technology in the shop floors of innovative product companies. Talking about the Indian condition, Anand adds, “Indian tool makers need to keep adding skills technically (specially in shop floors), manage and deliver

tools for large programmes. There are perhaps just 6–7 Indian companies capable of such work. They also need to add massively to the capacity to meet the eventually growing demand and expectation of users.”

Ensuring Growth: The Indian Way!

The Indian market is very different from other countries, and the country has its own unique way of working. The die & mould industry has undergone a radical shift in its thinking. The Indian die & mould industry is now recognised as the provider of low-cost, high-quality technologies; companies should optimise this and further enhance the quality of products. If we have to compete with countries such as China, Korea, Taiwan, Singapore and Malaysia, we need to look at our own capabilities and optimise the ever growing market. nishant.kashyap@network18publishing.com

March 2013 - MMT

Insights & Outlook MIM Technology technology

Leapfrogging to Value Engineering Innovation in product design is the need of the hour. Designers are looking for a pioneering process that will allow them to work with complex geometries and materials without facing production challenges and restraints. MIM is a technology that has enabled designers to realise their dreams in terms of design complexity, component integration and the use of difficult-to-machine steel alloys.

art geometry and strength play important roles in all the mechanisms and sub-assemblies in the manufacturing world. Be it an engine, a transmission unit of an automobile or a moving component of an aircraft engine, reliability is an important factor to focus on. As a manufacturing technology, Metal Injection Molding (MIM) has been highly successful in meeting the needs of such applications. It has an entire gamut of application ranging from engine parts of an automobile to cosmetic parts of a mobile phone or a tablet. MIM evolved from plastic injection 106 molding & powder metallurgy and is used to manufacture complex-shaped precise metal parts. It combines the design flexibility and production scale of plastic injection molding 105 with the strength and integrity of wrought metals to offer cost-effective solutions to meet these demands. Prod.

Designing for MIM

The ease in designing metal parts, as in plastic injection molding, gives MIM the unique ability to manufacture complex, lightweight shapes that are not economically viable with other metal cutting/forming processes. Minimising part wall thickness through appropriate use of coring and ribs allows the use of less amount of metal 80

MMT - March 2013

without compromising on durability. In addition to superior shape capability, the MIM process provides the designer with a wider choice of high strength ferrous and stainless steel alloys as well as wear-resistant and high-temperature super alloys. MIM has been used primarily in defence parts manufacturing, whereas other important sectors to emerge have been consumer goods, sports, telecommunication devices, medical & dental devices and hand & power tools. In recent times, it has gained popularity in the global automotive sector as well.

Press and Sinter Die Casting

Qty 104

Machining

Investment casting

103 Low

Medium High

Complexity

Fig 1: Production Quantity vs Shape Complexity

MIM technology Production Quantity vs Shape Complexity

Fig 1 shows the appropriate metal forming process for a component with reference to particular shape complexity and production quantity requirements. The diagram shows that ideally, MIM is suitable for high-complexity components with higher production volume requirements.

Unit Cost of Manufacturing vs Shape Complexity

Fig 2 below shows the relative unit cost of manufacturing for a component with particular shape complexity. The diagram shows that ideally, the more complex the part, the more costeffective is MIM.

Testimonials

Machining

Unit Cost

Casting

MIM Press and sinter

Low

Medium

High

Complexity Fig 2: Unit Cost of Manufacturing vs Shape Complexity

Value Engineering Approach

Value Engineering (or Concurrent Engineering) is always at the forefront of MIM application. The problem is designated and the boundaries are fixed, thus enabling an MIM designer to develop innovative solutions tailored to a customer’s specific problems. Over the past 16 years, Indo-MIM has successfully helped its customers migrate from complexshaped steel components in conventional machining and/ or casting technologies to MIM. Indo-MIM’s migration approach to MIM helps customers realise quality and reliability improvements with significant reductions in product cost, all at the same time. To further refine its value engineering approach towards MIM product development, Indo-MIM regularly uses advanced Six Sigma and Shainin Design of Experiments (DOE) techniques in the context of a strong Advanced Product Quality Planning (APQP) process to facilitate a highly robust product development process. The advantages of this approach can be observed in the relatively trouble-free production ramp of many programmes at Indo-MIM. Significant attention is given to process design, FMEA, poka-yoke techniques while developing an optimum MIM production process for all parts under development at Indo-MIM.

MIM Favourites

Parts with weights less than 50 grams are the most likely 82

MMT - March 2013

candidates for migration to MIM. MIM components have a fair amount of design complexity, thus making them unlikely candidates for conventional manufacturing technologies. Greater design complexity increases the likelihood of a successful migration to MIM. The technology is capable of providing cost-effective solutions for annual component volumes as low as 10,000 to as high as 100,000,000. There are some very good examples of parts that Indo-MIM has manufactured for its customers, where existing joining processes like welding, brazing, riveting could be eliminated, thereby leading to integral component design, improved strength, improved yield and lower direct costs. Success stories like these have even helped customers lower their consumables costs. Mr Raghavendra from Tata Motors, Pune, says, “We, at Tata Motors, feel that components such as latch parts and transmission parts like shift levers, detent, etc. could be converted to MIM. Based on the loading and stress levels generated on the parts during the service, the load bearing areas could be strengthened, whereas non-load bearing areas could be optimised or made hollow. This will definitely result in a complex component, which is normally difficult to manufacture with any process. We feel that the competitive advantage of MIM could be realised here. We, at the moment, are studying some similar components for technical feasibility and are working with Indo-MIM. We are confident of getting solutions to all such similar optimisation requirements without sacrificing reliability.” Martin McCaffrey, Technical Director, Camlock Systems Ltd, UK, in his personal capacity, expresses, “MIM is not new, but is still novel to many. This is surprising as it can offer tremendous benefits. Anyone manufacturing small, complex and highly detailed components should be able to make use of this technology. It produces moulded metal components of high dimensional stability, with a density and integrity closely approaching traditionally worked and machined materials. Also, savings are often available by being able to produce a finished part in ‘one shot’, replacing the machining and subsequent assembly of multiple parts. With respect to industrial security with its stringent space constraints, MIM is a technology that I foresee being used with increasing frequency.”

Manoj Kabre, VP – Marketing, Indo-MIM, is responsible for business development in Asia and parts of Europe. With a total experience of 24 years in the industry, he has been instrumental in augmenting the popularity of MIM technology through various brainstorming sessions, exhibitions and seminars. He has been involved in various discussions with some of the key industry players across the globe in Value Engineering initiatives. Email: manoj.k@indo-mim.com

Insights & Outlook Need Gaps

Enhancing the ‘Made in India’ Trademark The progression in industry dynamics and technological upgrade has hiked the graph of quality parameters. However, when it comes to the core of all manufacturing procedures, the Indian die & mould industry is still bearing the weight of dependence on imports. Is it just the cost factor that the industry is trying to evade or has this dependence moulded the entire attitude of industrial growth? Nishant Kashyap looks into the current market scenario and identifies the need gaps between customers and providers.

he manufacturing industry in India is primed to grow at a rapid phase in 2013. For the die & mould sector—an industry fundamental to manufacturing—this growth comes at a crucial time. Rapid technological advancements in global die & mould manufacturing are rising in relevance, particularly in India, where unprecedented growth in demand increases the challenges in production and capacity.

Present Perfect

In an age of tough competition, the Indian industry needs to define its own identity and carve its own niche. Today, if Europe stands for precision, Japan for innovation and China for its mass production, where should India create its domain? We can no longer only be identified as a low-cost outsourcing destination for global OEMs. Getting 84

MMT - March 2013

into a niche market or domain probably may not be a feasible option in terms of return on investment, but the industry needs to look beyond the horizon and calculate the value in it, which would pay back in the longer run. The industry needs to bridge the need gap between customers and providers. Indian companies need to understand the customer requirement and come up with innovative solutions in order to reduce the dependence on import. Muralidhar Lakkanna, Tool, Die & Mould Expert, says, “In the current multinational manufacturing paradigm, the escalating global trends compel the Indian community to radically engineer functionality, efficiently develop and reliably deliver to stand out as a market leader. Indian tool, die and mould manufacturers should equip themselves with the most advanced design, manufacturing and development techniques in terms of machine, material and labour resources; and envision

extreme value addition despite risks rather than envisioning a huge turnover with low value addition and margin cut. Desperate cost cutting can only help in the short term and is catastrophic in the long run. Similarly, the Indian workforce has to inevitably scale its competence for survival in the future.

Ever Changing Customer Demand

The demand from customers is consistently on the rise, and there is extreme pressure on tooling solution providers to deliver on time. This push from the customers has prompted tooling solution providers to continuously upgrade their technology and enhance their solutions. In today’s scenario, only the one who provides cutting-edge solutions to customers will be accepted in the market. According to SC Kalyanpur, Managing Director, Sridevi Tool Engineers Pvt Ltd &

Need Gaps President, TAGMA, “To enhance the capability, more investment on stateof-the-art equipment is necessary. Unfortunately, this equipment has to come from Europe or Japan, which involves heavy capital investment. Indian die & mould manufacturers can attract more customers only by producing quality products with on-time delivery.” “Traditionally, the consolidated tool, die and mould demand has always exceeded the supply in India and this trend will continue for quite some time due to the cognizant foreign trade policies on many consumer goods. Therefore, the Indian tool, die and mould manufacturing community has to radically transform its practices to increase customer satisfaction rather than hawking for new customers at very low satisfaction levels,” avers Lakkanna.

Technology Gap

The development of new machines and applications plays a critical role in the growth of any industry. In the die &

mould sector, various advancements have taken place over the years, be it in cutting, bending, punching or forming. With the customers’ emphasis on quality and quantity increase, companies are bound to shift from conventional systems to automated ones. However, those in the traditional fabrication domain are still utilising the conventional machines. The technology gap between Indian companies and western counterparts is not as much as it used to be. There are still many small players that use conventional machines and do not capitalise modern technology to its full potential. According to Lakkanna, “The competence hiatus between advanced the Indian community and its peers is huge. However, instinctively, India already has the talent needed, which is not leveraged due to negligence and a lazy attitude. The immediate strategy much needed to stir back wealth generation is a strong, intelligent and courageous leadership. Christening revolutionary tactics will ensure quality

with minimum control to explore, for example, better exploitation of polymer material opens up fresh perspectives like human relevance, logical relevance, reality, etc., thus unfolding its thrills and wonders as business progresses.”

The Way Ahead

Despite the impact of the global financial crisis, India’s die & mould industry has maintained its growth momentum in recent times and has managed to maintain its status as one of the world’s top consumers and importers of die & mould equipment. Although, the country has become more proactive in the procurement of foreign and private capital, the future market prospects of the Indian die & mould industry still has room for development. A collective and focused effort needs to be applied to empower the mould makers and the industry as a whole, which, in turn, will reduce the dependence on imports. nishant.kashyap@network18publishing.com

March 2013 - MMT

Insights & Outlook Techno Focus

Technology: Precision and Innovation The Indian die & mould industry has to give consideration to some of the latest technology used globally; however, there is still a long way to cover for such technology to be adopted in India. Nishant Kashyap highlights the advantages of some such technologies such as 5-axis machining, hot runner technology, laser applications and microwelding and their adoptability in the Indian market.

ven as the manufacturing industry has taken a leap towards a higher level of precision, most manufacturers are trying to cut down on the machining costs. To top it all, miniaturisation is a trend that is becoming popular by the day across all industrial verticals in the world. With the rise in micro components, machining parts at the submicron level has always proved to be a great challenge.

5-axis Machining

In recent years, the die and mould industry has been witness to increased usage of 5-axis machining, particularly with respect to larger components such as those seen in the automotive industry. 86

MMT - March 2013

5-axis machining is becoming more and more popular due to the need for reduced time frame for machining, better surface finish and improved lifespan of tools. An increasing number of mouldmakers are investing in equipment engineered specifically for the machining of moulds. Thus, while in the past, a basic vertical machining centre might have been purchased to machine moulds, this is simply not practical in todayâ&#x20AC;&#x2122;s times. To remain competitive in the global marketplace, mouldmakers must invest in technology better suited for mouldmaking. This includes moving away from typical C-frame vertical machining centres accessorised for making moulds to bridge-type VMCs with spindle speeds up to 40,000 rpm,

thru spindle coolant and simultaneous 5-axis capability. Anant Chind, Executive Director, Chind Iron and Steel Industries Ltd, says, â&#x20AC;&#x153;5-axis machining is the need of the hour. To meet customer demand and deliver the products in a short time frame with high productivity, more and more manufacturers are using multi-axis machining.â&#x20AC;? Today, the manufacturing of complex moulds is an absolutely high-tech business. Errors can be extremely expensive and so are most CAD/CAM packages, which are targeted for use in the die & mould industry. Latest design software solutions provide intelligent and powerful 5-axis machining strategies, including swarfing and trimming, for

Techno Focus the machining of complex geometry parts including mould cores and cavities, aerospace parts, cutting tools, cylinder heads, turbine blades and impellers.

Hot Runner Technology

Hot runners are vital in delivering the melt material from the injection nozzle into the cavity and their application helps illustrate the effect of gate quality on the overall part quality. Developments in the hot runner technology have seen vast improvements in thermal uniformity, melt homogeneity, wall thickness, output capacity and automated electric valve gating. Electronically controlled gating systems that use servo control are replacing hydraulic and pneumatic actuation. Electric systems are more precise, cleaner in function and can optimise every parameter in the functioning of up to 64 valves, thus improving melt pressure and flow at each gate. Better process controls allow for easier application and simple maintenance of hot runner systems. These advances have a direct impact on the part quality, cycle times and costs. They reduce resin costs and introduce direct gating where cold runners were used, allowing for more cavities in a single mould.

Culture of Stamping Die

Sheetmetal stamping dies are used to produce high-precision metal components, which are identical in shape and size. Metal stamping dies are now an integral part of any manufacturing industry as they provide high-dimensional accuracy and stability. As the metal stamping component caters to every industry from small electric switches to large automobile and aircraft, the demand for highprecision stamping component is rapidly increasing. Metal stamping dies can be used for various sheetmetal operations such as blanking, bending, shearing, piercing, forming, coining, embossing, extrusion and deep drawing. Tool and die making is one of the most high-precision engineering

branches. It requires precision machinery and highly skilled workforce. Precision metal stamping dies need regular maintenance to ensure the quality of the components that it produces. In normal cases, the maintenance work involves the sharpening of cutting punches, replacing broken and damaged parts and working on dies to ensure that the final stamped product meets all the quality specifications of customers. With systematic processes like preventive maintenance and consistent parts, the life of stamping dies can be increased.

Laser Application

Todayâ&#x20AC;&#x2122;s small precision welding shops, which specialise in plastic injection moulds, dies and tooling repair, have a wide range of new technologies to enhance their ability in order to provide the highest level of quality, craftsmanship and service to their clients. One of the fastest growing technologies is the use of manual laser microwelding laser systems as an alternative to traditional microscope GTA welding. This technology has improved over the years and has come to be widely accepted by manufacturers. Lasers are widely used in manufacturing, for example, for cutting, drilling, welding, cladding, soldering, hardening, ablating, surface treatment, marking, engraving, micromachining, pulsed laser deposition, lithography and alignment. Laser processing methods allow the fabrication of highly fine structures with high quality, thus avoiding mechanical stress such as that caused by mechanical drills and blades. A laser beam with high beam quality can be used to drill very fine and deep holes, e.g. for injection nozzles. â&#x20AC;&#x153;There are some applications wherein laser is a better option for machining, as it can machine highly small parts and complex geometries. Laser also provides speed and is very precise in cutting methods,â&#x20AC;? avers Chind.

Microwelding

Microwelding is a relatively new, highly specialised welding process by

which metals are reformed or joined together using a low amperage power supply, miniature electrode pointing system, small diameter welding wire and customised microwelding microscope. The chief technical advantages of microwelding include low heat production and precision placement of weld material. One of the leading applications of microwelding is in tool, die and mould repair. Tools, dies and moulds are precision products used in close tolerance manufacturing processes. They are constantly subjected to the repeated stress of the manufacturing environment and regularly sustain nicks, gouges, scores and cracks that require maintenance, repair, or, in some cases, complete replacement. Prior to the advent of microwelding, manufacturers were forced to choose between unsatisfactory repairs and costly replacement of moulds. Both choices caused unacceptable levels of production downtime. Microwelding has provided manufacturers with an excellent costsaving alternative. It has proven to be an efficient, cost-effective method to repair and extend the life of tools, dies and moulds without compromising on the manufacturing quality. Additionally, the higher efficiency of microwelding significantly reduces downtime, particularly if the manufacturer has in-house microwelding capability.

The Way Forward

One of the main targets of the die & mould industry is to reduce or eliminate the need of manual polishing and thus improve quality, shorten production costs and lead times. The development of new, more difficult-to-machine materials has underlined the necessity to find new machining solutions. To match this, small and large manufacturers need to increase their production capacities, invest more and more in these sophisticated technologies to match global standards and meet the local demand. nishant.kashyap@network18publishing.com

March 2013 - MMT

INSIGHTS & OUTLOOK One Q Many Views

Additive Manufacturing: Threat or Supplement? Additive Manufacturing technologies have become more and more prominent over the past few years and have now entered the core of manufacturing. The technology has garnered most interest in the manufacturing fraternity and is often referred to as the future of manufacturing. While many believe that it will change the way products are being made and subsequently replace the traditional method, there are others who believe that it will act as a supplement to the industry. With this thought in mind, Nishant Kashyap, along with some industry leaders, finds out the role of Additive Manufacturing in the future. SC Kalyanpur, Managing Director, Sridevi Tool Engineers Pvt Ltd & President, TAGMA Additive manufacturing (AM) is not a threat to the tool room industry for the moment. However, it has been a great enabler for the product development process and low-volume product manufacturers. With rapid development taking place in the last few years, we may see more applications in the future, but as a supplement to production tooling.

Guruprasad K Rao, CEO, Imaginarium India Pvt Ltd I see AM as a paradigm shift from traditional manufacturing. It will envitably capture certain special areas from conventional subtractive processes, particularly where product individualisation is a priority, like in medical applications. In such areas, AM has a comparative advantage over conventional methods. Nonetheless, at present, AM is not really a disruptive

technology but a complement to conventional manufacturing. It will demolish some concepts such as DFMA, DFA, etc. since AM methods are capable of building parts in ways once considered designersâ&#x20AC;&#x2122; sins! With the scale of the ongoing R&D in new materials and technology, AM will surely evolve into a hard-to-ignore, new-age manufacturing technology, which will eventually pose direct competition to conventional methods in production.

YR Anand, Partner, Unimark & Executive Council Member, TAGMA With the current level of development, it only nibbles at low-volume non-precision manufacturing. But various system suppliers are working on improving the repeatability and quality. So, if they can come close to repeating precision and production time, then certain types of tools will become irrelevant. For the moment, it is certainly a minor supplement with the potential to become a major supplement.

The Verdict

AM has significantly improved speed and productivity since its inception. Something that took 50 hours to build in 1985 now takes 10 hours or even less. AM may not be a complete replacement to conventional methods, but it will certainly enhance the manufacturing technology and pose a challenge for traditional manufacturing at some point. The technology will take manufacturing to the next level of speed, precision and quality and hence, it will act as a supplement to the industry. nishant.kashyap@network18publishing.com

MMT - March 2013

Industry Focus Aerospace machining 90

Combating Challenges

Making the giant Leap

Offset Policies

An Opportunity or an Obligation

SME Insights

Creating Opportunities for Smaller Players

104 Facility Visit

Permacel: Pioneering Innovative Excellence

108 New Age Materials

Making Aircraft Feather-light

110 Material Matters

Locking on the Right Ingredients

114 Changing Role of Simulation

Going Beyond NC Programming

108

114 March 2013 - MMT

Industry Focus Combating Challenges

Making the

Giant Leap

Global interest in the growing Indian aerospace industry has rapidly matured over the last five years. The industry, government and investors together have sustained the momentum to create the much required ecosystem, which will build the runway for India’s aero story to spread wings. Debarati Das Basu probes into the ‘Haves’ & ‘Have Nots’ and the ‘Dos’ & ‘Donts’ that the industry is still contemplating on.

or years, the Indian government held monopoly in the aerospace manufacturing circuit, and foreign industries kept prying into the possibilities of finding a vent to enter the huge, unexplored domain. Domestic companies felt that they were way out of the league to enter the elite manufacturing fraternity. But the tables have turned and the country has opened up to exploring the possibilities of exponential growth in the aerospace sector. The state governments are getting their steps in sync with the enthusiasm building up for the investment that is lining up. Assessing the investment opportunity, the Karnataka government recently made the roadmaps for foreign investors clearer with investor friendly policies. Being the much preferred aerospace hub of the country, Karnataka estimates that the expenditure on aerospace and defence equipment in the next 10 years will amount to more than `5 lakh crore. It issued a new policy to 90

MMT - March 2013

Advantage India  Reduction in the global defence spending has increased OEM spending in India  India is an attractive but complex market with fast changing dynamics  Opportunities across value chains attract high-profile domestic entrants  Continuous amendments in policies help understand industry needs  Extensive Transfer of Technology (ToT) has strengthened machining confidence

develop the state as an aero hub; attract investments amounting to `60,000 crore and eventually create employment opportunities for 100,000 people by the end of the second phase. However, are we aero ready yet? Which are the areas we fail in? What are the corrective measures that need to be taken on an urgent basis by the country to reap the benefits of this global enthusiasm?

Overcoming the Pitfalls

Are we creating something new? Gone are the days when India was considered the destination for low-cost

mass manufacturing. The country has climbed the ladder and is growing up from this infancy to become a creator. However, while the country is proving its mettle in aerospace manufacturing, we are yet to attain supremacy in creating indigenous designs and manufacturing technologies. “Indian companies need to understand their strengths and competencies in the value chain and grab the opportunities. Our strengths are clearly in engineering design and IT, but manufacturing presents a huge opportunity,” feels Dhiraj Mathur, Executive Director, PwC.

Combating Challenges

Making the most out of Indian aerospace  To succeed in India, be in India  Build capabilities for long-term haul and global market

Create 

partnerships acquisitions to grow

and

 Explore

opportunities across value chain

 Lead

with engineering design and IT

 Ensure

capabilities are highly skilled and not low-cost

 Become

the fabric of the industry and understand its dynamics

 Explore

the opportunities in R&D, engineering design, manufacturing, assembly testing and Maintenance, Repair & Overhaul (MRO)

Do we have a long-term objective? The country has to put on its glasses and look beyond short-term opportunities. One needs to understand that the Indian aerospace industry is competing with a matured market, which has tried and tested the tides of aerospace revolution globally. While the government is encouraging offset policies, these collaborations will not last forever. Indian companies have to realise that offset policies are just a key to enter into collaborations. RK Mathur, Secretary (DP), Ministry of Defence, explains, “When Indian private sectors negotiate with foreign companies, they need to look at the long term. The offsets will not last forever. The Indian companies need to have a strategy for long-term plans while foreign partners should ensure that the offset partners are willing to cooperate with them.” Are confusing policies creating confusions? It is advisable that any new venture is

considered with cautiousness. Analysing the long-term effects and plugging the loop holes is the right approach to follow. However, have the Indian policies for the aerospace industry become too murky? The lack of clarity in most policies have not just brought in confusion among the investors but has also brought in a sense of distrust and uncertainty among foreign investors. For instance, many clauses in the DPP scheme are still unclear to most investors. This has made investors face various hurdles, delays and complications while finalising a deal. “There are multiple policies that companies have to face. They are often contradictory and different arms of the government interpret the same policies differently. This increases uncertainty and uncertainty is the biggest barrier in investment. We need to align the policies and create synergies to encourage investments,” explains Mathur. Beware of the low-cost syndrome The Indian industry is yet to come out of its low-cost syndrome. Although the country has a huge cost advantage over South East Asian countries such as Taiwan, Thailand, China, Indian companies need to build their skill sets to climb over the value chains. It should be kept in mind that amidst stiff global competition, the low-cost advantage is only temporary. Do foreign investors fear the unknown? It would not be surprising if foreign investors hesitate to partner with an Indian company and invest in India. While competing with aero giants, we are still at the threshold of the learning curve. The primary focus of Indian companies should be to build up on their capabilities and technological know-how and prove to the world that they are capable of handling complex aerospace machining with ease. This will not just build confidence but also help the companies grow.

Flying Forward

The industry is working hard to come out of its tangles and this is being wholeheartedly supported by various

A Didar Singh, Secretary General, FICCI The Karnataka aerospace policy, which intends to attract an overall investment worth `60,000 crore and has the potential to generate employment opportunities for 40,000 people in phase I itself, has come as an encouragement to the industry. The government has already identified the infrastructure and aerospace parks and is encouraging participation with incentives and subsidies. These steps will be the keys to build a platform for aerospace manufacturing.

RK Mathur, Secretary (DP), Ministry of Defence Aerospace is the sunshine sector of Indian manufacturing. The main area of importance for the industry is to focus on modernisation and research. Avionics and electronics constitute almost 50% of an aircraft. These are the areas where you have to continuously develop new things.

Jitendra Singh, Hon’ble Raksha Rajya Mantri, Government of India AThe Indian industry is at the threshold of entering a new era of innovation and many companies in the Indian manufacturing sector are in the process of making global footprints.

government and association initiatives. The country is setting up a stage wherein the entire value chain of Micro, Small and Medium Enterprises (MSMEs), Tier I and Original Equipment Manufacturers (OEMs) are on the same platform of manufacturing avionic wonders from the runway called India. debarati.basu@network18publishing.com

March 2013 - MMT

Industry Focus Offset Policies

An Opportunity or an Obligation? Since the inception of the image of India as the new aerospace hub of the world, the industry has been overflowing with rules, regulations and policies, most of which have remained under the drapes of confusion. While offsets are framed by the government as doors of opportunity, is it instead turning into an unwanted obligation for the players? Debarati Basu Das finds out.

ith an attempt to leverage the buying power of the country and achieve greater self-reliance in defence production, the offset policy, as part of the Defence Procurement Procedure (DPP), has continuously seen revisions since 2005. With the drastically changing dynamics of the industry and the changing requirements of offset partners, the government concerns and the industry demands have been on different pedestals. Hence, constant revisions and amendments are being made to bring all quarters of the aerospace industry on the same page. The recently updated Defense Procurement Policy (DPP) released in January 2013 is expected to be a level above the DPP 2011 so as to encourage efficient procurement. But have the constant upgrades been able to remove the confusion that prevails throughout all strata of the system? 92

MMT - March 2013

The Grievances

One of the major constraints is the fact that amidst various set of policies, each policy is interpreted in a different way by various government departments, thus making the understanding of the policies even more convoluted for the industries in question. There is immediate need to frame policies that are transparent and make the understanding simpler. Following this is the major issue of delayed response. The DPP-2013, which was released after a delay of five or six months, is only the tip of the iceberg. Brigadier SC Sharma, President, Mil Aero, Axis Aerospace Technologies, feels, “Offset policies are like walking on a mine field. Everyone is scared of stepping on one. Hence, one feels safer to go by the book. Issues are being pushed over since years. Every decision in defence procurement is getting delayed because nobody is willing to bell the cat.”

What Offsets Need  Create

a national aerospace commission to address all issues

 Introduce

a national policy on the aerospace sector

 Energising

defence

 Have

the production policy policies

transparency

the

 Create

a single window system for operation

 Invoke the confidence of OEMs and SMEs

The main question that still remains is whether we have been able to achieve the objectives of offset policies? We are probably still a long way from it.

Optimising Offsets

The various government agencies

Industry Focus Offset Policies

Objective of Offsets  The

primary aim of offsets should be self-reliance

 Acquisition of technologies and equipment to increase selfdependence  Build

capacity partnerships

through

 Leverage

capital acquisitions to develop the Indian defence industry

 Foster

development of international competitive enterprises

 Augmenting

capacity for research, design, development in defence products and services

 Encouraging

the development of synergistic sections like civil aerospace and internal security

thronging with new policies are simply stifling the beneficiaries with confusion. The primary step of the government should be to identify the areas of dominance for each segment. As Brigadier Sharma suggests, each segment has its own strengths that should be explored while delegating the policies. The government should focus on MSMEs when it comes to design, testing, specialised software, modeling simulation, maintenance and repair. Large industries should concentrate on building technology for aircraft, ship building, etc. while Public Sector Units (PSUs) should focus on their strengths that involve building technology for weapons, ammunitions, rockets, missiles, etc. On the other hand, Original Equipment Manufacturers (OEMs) should identify PSUs, large industries and MSMEs for transfer of technology for low-cost manufacturing in India. A clear demarcation of responsibilities will help in better understanding and allocation of policies.

Opportunities in Store

It would be unfair not to recognise 94

MMT - March 2013

the fact that there has been substantial improvement in the way defence acquisitions have been happening over the years. However, much more is needed. The country today stands at the threshold of enormous opportunities. Various reports suggest that the military sector alone is looking at US$230 billion of business in the next 10 to 12 years. Helicopter manufacturing is one of the major areas brimming with business. While the world market for helicopters is US$160 billion, the Indian business is worth US$16 billion. Hence, India accounts for over 10% of the helicopter market. There is a requirement of 1,300 aircraft in the next two decades, which amounts to about US$150 billion. Much of this business is in the 70–100 seater segment. Further, the private jet market in India constitutes 12% of the global market. The Indian High Network Individuals (HNI) own maximum number of private jets in Asia, thereby giving a clear push to the demand. Apart from manufacturing, the industry also has huge opportunities in IT products, final assembly, integration & delivery and services like Engineering Services Outsourcing (ESO) and Maintenance, Repair and Overhaul (MRO). “This is the time. If you do not use this opportunity now, you will never get another one. We should have our rationale in place and aspire to make 7th-generation fighter aircraft. Let us stop being the tail lights and let others chase our tail lights instead,” says Cmde Sujeet Samaddar, CEO, Shinmaywa Aerospace. Rajinder Bhatia, EVP & CEO, Bharat Forge Ltd, points out, “Over the ages, offsets have proved beneficial. For instance, countries like Saudi Arabia, Israel, Japan, Korea and Spain have used it to their benefit to stimulate the industry. Defence offsets have been successful worldwide when the primary purpose was not general economic development but the development of the indigenous arms industry.” Hence, to make this a smooth ride, the focus

Jitendra Singh, Hon’ble Raksha Rajya Mantri, Government of India

DPP is reviewed periodically to encourage private participation and create an environment of growth for the public and private sectors. The government is trying to be a catalyst towards the involvement of the private sector and foreign companies investing in India.

Rajinder Bhatia, EVP & CEO, Bharat Forge Ltd Defence offsets have been successful worldwide when the primary purpose was not general economic development but the development of the indigenous arms industry.

Cmde Sujeet Samaddar, CEO, Shinmaywa Aerospace This is the time. If you do not use this opportunity now, you will never get another one. If we do not ensure growth in the transport aircraft industry and helicopter business in India today, we will have written off these markets for the next 25 years.

Brigadier SC Sharma, President, Mil Aero, Axis Aerospace Technologies Offset policies are like walking on a mine field. Everyone is scared of stepping on one. Hence, it is safer to go by the book. Every decision in the defence procurement is getting delayed because nobody is willing to bell the cat.

of the industry should be on just one question: “What do we want out of offset policies?” debarati.basu@network18publishing.com

Industry Focus SME Insights

Creating Opportunities

for Smaller Players

t has been said time and again that SMEs form the backbone of any industry’s growth. But when we talk of a high-precision, high-end industry like aerospace, are Indian SMEs ready to take up the challenge? Today, there are over 6,000 small and medium enterprises that work for the Indian aerospace and defence industry. Are the right efforts in place to support and strengthen SMEs who can, in turn, toughen the links of the Indian aerospace industry? With the pace at which aerospace is expanding its base, the efforts to strengthen SMEs need to be calibrated faster.

Are you Partnering with the Right SME?

Even as 70% of the industry is dominated by SMEs and the MSMEs, this segment has always fallen short of technological upgrade in manufacturing. Most major players—foreign and domestic—are trying to deal with one of the most pertinent dilemmas that strike 96

MMT - March 2013

any major player: How to choose the right SME to partner with? To begin with, there needs to be a strong generation of an aerospace ecosystem of which the SMEs need to be a significant section. While consistent efforts are necessary to upgrade the overall outlook of SMEs in general, small high-tech companies will form the backbone of the future of the Indian aerospace industry. There are many opportunities waiting to open up for MSMEs if the right effort is invested at the right time. In the current course of action, MSMEs need focused interventions and attention from the manufacturing industry, the government and the ecosystem. Support from all quarters towards the development phase in terms of creating clusters and common infrastructures, tax incentives and cost of capital is highly essential. Most countries across the globe have realised the value of supporting a strong SME base. India needs to understand the same.

The growth of any sector needs to be the result of a cumulative effort from all quarters of the industry. As the Indian aerospace heads towards the runway of global recognition, the sector has invariably attracted a huge response from global Original Equipment Manufacturers (OEMs) and domestic Tier 1s. However, are we missing out on the smallest yet the strongest link in this whole value chain? Debarati Basu Das delves upon the role played by the Small and Medium Enterprise in the growth story of the Indian aerospace industry. While partnering with an Indian SME, every OEM has certain issues pertaining to the availability of technological know-how, on-time delivery and a responsive supply chain.

SMEs’ Take on Reliability

Should an SME rely only on gaining support from OEMs and the government to carve its growth path? This may be the old school approach. Indian SMEs today are well aware of their strengths and weaknesses. While being low-cost is their strength, new-age entrepreneurs are fighting the financial setback to make their way towards being self-sustainable. They are in sync with global technological advancements and are working towards strengthening their multiple domain manufacturing abilities. While the handholding approach by

Industry Focus SME Insights OEMs and Tier 1s only leverages the knowledge sharing process, SMEs are building on their own capabilities.

Evolution Phase of Aerospace Industry

Every industry is defined by three milestones: The Entry phase of an industry is compensated with enormous government support, entry of big players and heavy dependence on import. This is followed by the Growth phase, which is defined by dramatic evolution in government policies, encouragement of technology transfers by OEMs and rise in domestic production. This leads to the Maturity phase, which is recognised by focus on complete indigenisation, R&D and rise of domestic competition. Unfortunately, despite talks of growth in the aerospace industry, we are still in the Entry phase. The government has to start giving importance to the needs of the industry and act upon them. As various aero reports suggest, the focus should drastically shift from ‘Buy’ to ‘Make & Buy Indian’ to ‘Make Indian’. SMEs play an important role in

- Have expertise in multiple technologies: This is an era where a single skill would not last but a broader understanding and competence will - Quick adaptors: You may not have all the capabilities required. But the quicker you understand the ropes of the trade, the better - Make big investments: Aerospace is not for the weakhearted (in terms of money). 98

MMT - March 2013

Air Marshal M Matheswaran, DCIDS (PP&FD), Ministry of Defence In the decades to come, if the country aspires to be an important player in the global system, it has to have significant control over critical technologies that need a significantly large and vibrant aerospace ecosystem. This not only includes government bodies and OEMs but also small and medium industries.

each of these three stages. Most SMEs are still at the component level, sub-contracting from government organisations and Tier 1s. They have to effectively move up the value chain and show their competence in production.

The Indian aerospace industry is in the take-off phase and this gives a lot of opportunities to stakeholders, foreign OEMs, the industry and the SMEs.

Bejoy George, Chief Executive Officer, Axis Aerospace and Technologies Pvt Ltd Foreign OEMs look for companies who already has the capabilities and be long-term partners; companies that can invest in developing technologies; companies that are willing to wait for return on investment on manufactured items.

Think Small, Grow Big

Indian SMEs have constantly demonstrated their ability to absorb and

OEMs track into India: Steps to be taken in creating an ecosystem for SMEs Strengths of an SME:

Cmde Mukesh Bhargava, Vice President, Flight Systems Business Unit & International Business (Defence & Aerospace), Larsen & Toubro Ltd

Reestablishing faith in the government

- Exploit business opportunities: OEMs need to explore the various links of the value chain for business opportunities - Handhold new entrants: Handholding is required not just in technological transfer but also in various other processes. - Be in India: OEMs need to be in India and understand the nuances of this market.

- Formulate SME facilitating policies: Take consideration of the various SME constrains and create policies that would leverage this sector - Build an ecosystem: No industry can grow in isolation. Make persistent efforts to create a functional ecosystem that would leverage the industry - Put policies in action: The biggest challenge today is that various policies never see the light of the day.

Ashok Kanodia, Chairman, FICCI Defence Sub-Committee on Indian Defence SME and CMD, Precision Electronics Ltd SMEs are technocrats who have entrepreneurship skills. Engineering and technology are their forte and they have risktaking ability, which is way ahead of Tier 1s. They are defined by their flexible thinking and nimble approach.

adapt new technologies. They have the ability to mould themselves according to the need of the hour. Their quick decision-making, risk-taking ability, hunger and passion to grow makes them an appropriate choice. An OEM can easily get the desired results in the most cost-effective manner. And in this whole process, there is nothing to lose in thinking small and acting big. debarati.basu@network18publishing.com

MMT March - 13 Ad Name:Ptc Creo Pg No. 99

MMT March - 13 Ad Name: Tyrolit Pg No. 100

MMT March - 13 Ad Name: Blaser Pg No. 101

MMT March - 13 Ad Name: Gifu Pg No.102

Industry Focus Facility Visit

Permacel: Pioneering

Innovative Excellence

For over 60 years, PRS Permacel Pvt Ltd has been a pioneer of innovation in industrial tapes. Located in the industrial area of Ambernath, Thane, the company’s production facility focuses on three core business segments—automotive, industrial, railway. Their business division of Kavach Brand Protection, along with aerospace, is one of the key growing sectors. With about 3–5% of its sales being invested in R&D, the company has churned out several industry-pertinent processes in India. During a visit to the company’s shop floor, Nishant Kashyap gets to know various manufacturing processes and developments taking place at the plant.

ermacel Permacel has been in the industrial tapes business for over five decades, offering a comprehensive range of products to the automobile, aerospace, railway and public sectors as well as all kinds of engineering sectors in India & across the globe. Known for its expertise and innovation, today, the company receives enormous appreciation for the quality and performance of its products across domestic & international markets. This new plant is certified for ISO9001:2008, 14001:2004 and IS18001:2007 quality assurance standards. The product range includes self adhesive LT/HT tapes, 104 MMT - March 2013

laminates, B-stage insulation products, self-amalgamating tapes, thermal insulation products, speciality tapes and labels for different applications.

Journey So Far

Permacel was originally founded in 1927 as the industrial products division of the health-care giant Johnson & Johnson to produce and market masking tape. Over the years, Permacel has grown to be one of the world’s leading companies in tapes, with a large range of innovations to its credit. It is believed that the name ‘Permacel’ was derived from ‘Permanent Cellulose Tapes’. The ubiquitous cellotape, which is used even today,

was originally made by Permacel. In addition, Permacel ‘Duct Tape’ was the only tape selected by Fortune magazine in its ‘Products of the Century’ series. Talking about the journey, NS Shenoy, President & MD, PRS Permacel Pvt Ltd, says, “We were the first company in India to make self adhesive tapes. Anyone dealing in industrial tapes has been associated with us in our 50 years of existence in some form or the other. With respect to labels, we are one of the first flexo-graphic printers in India and one of the first screen printers in India on self adhesive materials.” In India, Permacel started its operations in the late 1950s as a division

Facility Visit of Johnson & Johnson (India). The initial years saw Permacel establishing itself as the Indian leader in the manufacturing of tapes. In the late 1960s, Permacel entered the label-making business, pioneering specialty-printing technology in India. By the late 1970s, being at the forefront of innovation and technology, Permacel became the market leader in labels, insulation and specialty tapes in India. “We were the first organised player to enter the self adhesive screen printing business in India. We are the pioneer in self adhesive tapes and label manufacturing in India. In terms of size, we may not be the largest, but in terms of bringing new technology to India, we consider ourselves to be among the best,” avers Shenoy. In the global restructuring process, the worldwide business of Permacel was sold by Johnson & Johnson in the early 1980s. Permacel India was an exception and continued as part of Johnson & Johnson (India) till it was taken over in August 1999 by the Premchand Group [now called PRS Group]. The new company was named PRS Permacel Pvt Ltd.

The Facility

In order to provide world-class service to its esteemed customers, in 2010–11, PRS Permacel set up a state-of-theart, green field manufacturing facility based at Ambernath, approximately 60 km north of Mumbai, which covers a constructed area of over 100,000 sq ft. This facility encompasses the entire value chain, from adhesive manufacturing and adhesive stock & tape coating to printing and finishing operations—all under one roof. This new plant is certified for ISO9001:2008, 14001:2004 and IS18001:2007 quality assurance standards. The automotive manufacturing operations are certified for TS 16949:2002. This makes PRS Permacel the only manufacturer of its kind in India, giving it the flexibility to be a ‘one-stop shop’ for its valued customers. PRS Permacel’s constant endeavor to improve efficiency ensures

that its customers receive the most costeffective solutions. The facility follows all the environment safety norms and parameters for the safety of workers. If you walk through the company’s shop floor, you will realise that there are many safety equipment and rules in place. Shenoy says, “We have had visitors from all over the world and have a huge customer base of multinational companies. When these customers visit us for audit, they understand that the facility is as good as those in the European and US continents.” Talking about the safety features in the facility, Shenoy continues, “We have adopted many environment-friendly and safety norms in our facility. Even the nearest fire station sends its new firemen to our facility for training purposes. Our roof, known as ‘blow off roof’, is designed in such a manner that in the event of explosion, the roof will blow off and nothing else will happen to the plant.”

R&D Facility

As suggested by the company’s tagline ‘Innovate & Excel’, innovation has been a key growth propeller for the company over the years. This has been achieved because of the ultra-modern R&D unit at the facility. The R&D

Awards Received  SGIA

(Speciality Graphic Imaging Association - Golden Image Award Winner.

 IHMA

(International Hologram Manufacturers Association) for “Best Applied Security Product”  ISQA Awards (Instituted by IEEMA): Every year awardee since the inception of the award. The last one was in the stage “Sustainable Quality Systems”.  SPIA (Screen Print India Awards): Gold and Silver award in different categories.

unit is equipped with sophisticated machines and highly technical people. It has been awarded recognition by the Department of Scientific and Industrial Research (DSIR), which operates under the Government of India Ministry of Science and Technology. Shenoy says, “Whatever we manufacture in our plant today is based on the technology created by our R&D. We are the only DSIR-approved R&D lab in our line of business in India. Strong R&D support is our forte that drives our business and sets us in a different league. Many of our

Product Range The current product range of products covers the following:

 Self Adhesive LT/HT Tapes  Laminates  B-Stage Insulation Products  Self-Amalgamating tapes  Thermal Insulation Products  Speciality Tapes Labels for different  applications

internal technologies have been granted several domestic and international patents.”

Skill Development

It is rightly said that the company’s success lies in its people, and Permacel follows this to the hilt. The company has a highly knowledgeable research team, enthusiastic sales and marketing teams and skilled workers. The company also has many training and development programmes in place with proper training for all the departments. In our yearly review programme, we identify every individual’s skill set and improvement areas. “If we find a certain number of people lagging in particular skills, we call in experts to conduct training sessions with them. Apart from this, 80% of our sales team comprises highly qualified engineers so that they can understand customer requirements and provide proper March 2013 - MMT 105

Industry Focus Facility Visit solutions,” says Shenoy.

Entering Aerospace

Sensing the huge requirement from the aerospace sector, Permacel started focusing on this industry. Starting with small orders from the aerospace industry, the company now supplies its products to many public sector units. The company has been supplying various indigenously developed products to defence & aerospace establishments for almost two decades, with the customer base comprising of ISRO, VSSC, SDSC, SHAR, DRDO, DRDL, HAL, Indian Navy & many other Tier 1 suppliers to the industry. “We are associated with many aerospace companies for specialised tapes and currently, about 7–8% of our revenue comes from the aerospace sector. We aim to increase this share to around 30–40% in the near future,” says Shenoy.

Expansion Plan

Permacel is one of the few companies

106 MMT - March 2013

´ This facility encompasses the entire value chain, from adhesive manufacturing and adhesive stock & tape coating to printing and finishing operations—all under one roof.

that believe in innovation and customer satisfaction. With a vision to provide the best technology solutions and optimize the opportunities in India & abroad, Permacel is in an expansion mode. Considering its growth potential in the Indian market, the company is planning to continuously invest in R&D to further improve the productivity of

customers. Shenoy says, “We have the entire infrastructure ready for the nearfuture expansion. We have kept some space in our facility for the expansion and extra machinery, which means that we do not need to look for extra space for the next 3–4 years.” nishant.kashyap@network18publishing.com

Industry Focus New Age Materials

Making Aircraft

Feather-Light The soaring demand for increasing aircraft fleets today is facing a roadblock in the form of rising costs of jet fuel and raw materials. Considering this, one of the prime focus areas in the avionics industry today is finding ways to make aircraft lighter. This has led to various experiments with composite materials, machining techniques and extensive research on the laws of physics. Debarati Basu Das finds out some of the tried and tested methods applied by the aerospace industry to make aircraft lighter than air.

as the rise in airfare hit your pocket again? The blame can be directed to the price hike in Aviation Turbine Fuel (ATF)— the aviation industry is no stranger to constant hike in fuel prices. According to a report, every pound on an airplane— from passengers, luggage to aircraft parts—equates to about US$10,000 in fuel costs every year. Hence, reduction in the weight of the airplane can lower the requirement for fuel and, in turn, lower the operating costs. Since jet fuel constitutes over 40% of an airline’s operating costs, the aerospace industry has been constantly finding ways to compensate the cost by making aircraft lighter. Innovation has become the need of the hour to 108 MMT - March 2013

combat the challenges that this industry faces. Innovations in this area have, in a major way, come in terms of using new materials. While composites have been widely preferred by the industry, research is underway to lock on the right combination for composites.

Optimising Composites

Composites have always been preferred for their outstanding mechanical properties and low densities. The physical properties of these composites, such as higher thermal conductivities than copper, low coefficients of thermal expansion and densities, are what make them an ideal choice. When it comes to composites carbon-reinforced epoxy and glass fibre, reinforced polymers are the most favoured. Composites are of four

main types: Polymer Matrix Composites (PMC), Metal-Matrix Composites (MMCs), Carbon Matrix Composites (CAMCs) and Ceramic-Matrix Composites (CMCs). Each category includes a wide range of materials. PMCs are one of the most important categories and they consist of polymer matrices like an epoxy reinforced with fibres. On the other hand, carbon fibres have been successfully tried and tested over the years with remarkable progress in the machining parameters. Carbonepoxy composites have outstanding properties and have become the baseline materials in aerospace machining. Composite airframes have been found to weigh less but are stronger than conventional airframes, thus giving the

New Age Materials requisite efficiency and performance. The other advantages of this material are its anti-corroding properties and its ability to resist fatigue and refrain metal structures from weakening and cracking. Carbon-Fibre-Reinforced Polymer (CFRP) has found extensive use in aerospace and defence applications including aircraft, spacecraft and launchvehicle structures; aircraft engines; helicopter rotor blades and weapon systems. Carbon composites are also widely used in high-temperature aerospace applications such as rocket nozzles and aircraft brakes. Silicon carbide fibre reinforced carbon composites have been used in aircraft engines. On the other hand, graphite composites have exceptional mechanical properties as compared to other materials. The material is strong, stiff and lightweight. Graphite composite is the material of choice for applications where lightweight & superior performance is of utmost importance, such as components for spacecrafts, aircraft structures and fighter aircraft. Graphite fibres (sometimes called carbon fibres) are made from organic polymer such as polyacrylonitrile. The material is drawn into fibres and kept under tension while it is heated under high temperature (more than 1000°C). Graphite composites are ideally suitable for applications that require more stiffness and less weight.

Crafting Ceramics

Ceramics have proved to be lightweight, strong and can resist heat. But they have a reputation of being brittle materials that shatter on impact, making them a less likely choice for engine design. However, researchers have come up with a material called Ceramic Matrix Composite (CMC). This ceramic composite is made from a silicon carbide matrix toughened with a proprietary coating of silicon carbide fibers. The durable new material withstands temperatures as high as 2,400°F and weighs one-third of nickel superalloys. The fibres have been found to be less than one-sixth the diameter of a human hair. Research also shows that if airlines substitute CMC parts in gas

turbines, engines will become 15% more efficient due to their reduced weight.

Structural Materials

NASA labs are working on structural materials that are lightweight. One such material in this category is Fibre Reinforced Foam (FRF). FRF is a foam, sandwiched between glass or carbon structural fibre composite sheets. It is said to act as a better alternative to metal and sandwich materials. It is 30 to 40% lighter than metal parts and absorbs the same amount of energy as metallic structures. As per NASA reports, the

Graphite composite is the material of choice for applications where lightweight & superior performance is of utmost importance, such as components for spacecrafts, aircraft structures and fighter aircraft.

material can withstand severe impact and can be used for dynamic loads. FRF can be made into continuous sheet rolls or into continuous snake-like rolls for cylindrical components. The sheets can be moulded using resin-infusion processes.

Silicon Seals

When it comes to aerospace, no material is left behind to explore the possibilities of reducing weight. Extensive research is being conducted on the sealants of aircrafts in order to make them lighter. The industrial sealing products division of the Freudenberg Group of companies has been developing a low-density silicone material that reduces the weight of sealants by 15–20% as compared to other sealants. The material has shown to have the same physical properties of traditional

silicone materials while weighing less. These low-density silicones operate at temperatures anywhere from –65°C to 205°C. Like most silicones, they resist common aircraft fluids and work in fireproof constructions.

Titanium for Lighter Engines

While the focus is on strong yet light materials to have an impact on the overall weight of an aircraft, significant weight saving can be done in the manufacturing of turbine engines. While nickel is strong, stable and not easily corrosive, Titanium Aluminide (TiAi) is emerging as a lighter alternative. TiAi is not just resistant to corrosion and heat but is also lighter than nickel superalloys by 45%. The only restraint while using TiAi is in successfully moulding it into the required shapes. However, a research by the European Space Agency solved this problem by using hyper gravity and creating a gravitational force greater than that on the surface of the earth. This can be achieved by using a centrifuge to rotate an object around a fixed point. Experiments by ESA proved that TiAi can become the compound of choice for creating jet turbine blades, thus increasing the efficiency of both existing and new engines.

From Light to Lighter

Research and studies in the area of newage materials have been targeting materials that would reduce weight of the aircraft, which, in turn, will lead to significant fuel savings. However, considering the pace of the research to find the perfect composite, which will prove to be lighter than the lightest, future composite materials may have a completely different constitution. Today, scientists are also trying to find inspirations from nature, for instance, bionic structures that mimic the bone structure of birds, which is light and strong with porous interior cavities. Such experimentations with biomimicry helps find ways to amalgamate new materials that will work towards reducing weight, bring down fuel consumption as well as add new features in aircraft. debarati.basu@network18publishing.com

March 2013 - MMT 109

Industry Focus Material Matters

Locking on the Right Ingredients

Two is company, but threeâ&#x20AC;&#x2122;s a crowd. However, thatâ&#x20AC;&#x2122;s certainly not the case when we talk about aerospace machining. While the requirement for super precision machining has given rise to the deft use of two alloys in making the perfect composite, the rise in the complexities of machining has brought in the concept of sandwich materials or a combination of three materials to redefine aerospace machining. Debarati Basu Das finds out how these sandwich materials are changing the course of machining.

he increasing complexity of aerospace machining has led to a wide range of research in terms of finding the right amalgamation of materials for the right operation. While combination alloys and composites solved most of the machining problems, new machining complexities made way for sandwich materials. Although sandwich materials have been used in aerospace machining for quite some time, the industry is coming up with new combinations of materials to make the perfect sandwich materials for various machining operations. These combination materials have been proved to maximise the structural performance while significantly reducing the superstructure weight of the aircraft.

Understanding Sandwich

A sandwich material is essentially a 110 MMT - March 2013

special form of laminated composite comprising a combination of different materials that are bonded to each other. This way, it utilises the properties of each component to the structural advantage of the whole assembly. A sandwich composite consists of three main partsâ&#x20AC;&#x201D;two thin, stiff and strong faces separated by a thick, light and weaker core. The faces are adhesively bonded to the core to obtain a load transfer between the components. Open- and closed-cell structured foams such as polyvinylchloride, polyurethane, polyethylene or polystyrene foams, balsa wood, syntactic foams and honeycombs are the commonly used core materials. The core is bonded to the skins with an adhesive or to metal components by brazing them together. The adhesive that bonds the faces to the core is of critical importance.

Why use a Sandwich?

Sandwich composites prove to be advantageous because they possess properties such as high levels of stiffness-to-weight and high bending strength-to-weight ratio. These composites enhance the flexural rigidity of the structure without adding weight. Extensive research has shown such structures to have fatigue strength, acoustical insulation and additional thermal insulation. The key properties of a sandwich material are high level of stiffness, which gives it a high flexural rigidity; high tensile and compressive strength; impact resistance; surface finish; environmental resistance and wear resistance.

Application Areas of Sandwich Materials

Sandwich materials have been used in various applications across different

segments. GRP terrain vehicles use these materials in their structures to obtain higher levels of stiffness, strength and integrated thermal insulation. It is also favoured for its low structural weight. In aerospace, sandwich construction has been used in applications like wings, doors, control surfaces, radomes, tail planes, stabilisers, space structures, antennas and solar panels for both military and civil aircraft. Other applications include landing gear doors, interiors like overhead stowage compartments, partition walls, ceiling panels and galley structures.

Making of a Sandwich

The selection of the right materials for the two faces and the core is extremely critical in making a sandwich material.

Face materials

The face or the outer skin of a sandwich material can be both metallic and non-metallic materials. Metallic materials include steel, stainless steel and aluminum alloys while nonmetallic materials comprise plywood, cement, veneer, reinforced plastic and fibre composites.

Composing Core

The cores used in sandwich constructions are of four main types—corrugated, honeycomb, balsa wood and foam. The main property of the core material should be its low density so that it adds as little as possible to the total weight of the sandwich construction. The core is mainly subjected to shear, and the core shear strains produce global deformations and core shear stresses. Thus, a chosen core should not fail under the applied transverse load and with a shear modulus, it is high enough to give the required shear stiffness. Other functions of the sandwich such as thermal and acoustical insulation also depend mainly on the core material and its thickness. The properties of the core should centre on its density, shear modulus, shear strength, stiffness perpendicular to the faces, thermal and 112 MMT - March 2013

acoustical insulation. The most commonly used cores are the honeycombs that are made of aluminum or impregnated glass or aramid fibre mats. In most honeycombs, the out-of-plane properties and in-plane properties are different from each other. The three main principals of the material properties of most honeycombs are width, length and transverse directions. Honeycombs have excellent properties such as high levels of stiffness perpendicular to the faces and the highest shear stiffness and strengthto-weight ratios of all available core materials. However, the main drawbacks are the high cost and handling difficulty during the layup of sandwich elements. Honeycomb sandwich panels have been extensively used in aircraft flooring, aircraft interiors, tooling industry, automotive industry, ship & train interiors and construction industry.

Advancements in Core Materials

Foam is one of the most preferred types of core materials in a sandwich. It has been found to dramatically reduce the weight of the material. Some of the common forms of foam used are:  Cellular Foam: High-density and high-quality cellular foams have had a major impact on the sandwich concept. Cellular foams do not offer the same levels of stiffness and strength-to-weight ratios as honeycombs. However, cellular foams are less expensive than honeycombs and are solid on a macroscopic level, thus making the manufacturing of sandwich elements much easier. The foam surface is easy to bond to and surface preparation and shaping is simpler. Also, the foam offers high thermal insulation and acoustical damping.  Polyurethane Foam: The urethane polymer is formed as a result of the reaction between isocyanate & polyol and trichlorofluoromethane or carbondioxide, which is used as a blowing agent and is vaporised by the heat released by the exothermic reaction.



Polystyrene Foam: It is produced either by expansion or by extrusion in closed moulds. In both cases, the plastic is mixed with the blowing agent, which then expands at a higher temperature. This foam has good mechanical and thermal insulation properties and is cheaper; however, its sensitivity to solvents is a drawback.  Polyvinylchloride Foam (PVC): PVC exists in two different forms: purely thermoplastic (also known as linear PVC foam) and cross-linked, isocyanate-modified. The linear PVC has high ductility and good mechanical properties but softens at elevated temperatures. The crosslinked PVC is more rigid, has higher levels of strength and stiffness, is less heat sensitive, but more brittle.

Binding the Sandwich

Choosing the right material is not enough. One also needs to choose the right adhesive to bind the sandwich materials to enhance effectiveness. Today, there are a variety of adhesives for such bonding. However, there are a few key properties that need to be checked during the selection process. The adhesive should fulfil the mechanical requirements of the structure of providing a good bond between the material components in the environment in which the structure will work. One also needs to take factors such as fatigue, heat resistance, strength, aging, etc. into consideration. The various adhesives used today include epoxy resins, modified epoxies, phenolics, polyurethanes, urethane acrylates, polyester and vinylester resins.

Aiming for Perfection

With the aim to make lighter and stronger materials, the aerospace industry has been continuously evolving in terms of advancement in sandwich materials and soon, a day will come when these materials will be lighter than air. debarati.basu@network18publishing.com

Industry Focus Changing Role of Simulation

Going Beyond NC Programming Most NC programmers are aware of the importance of accurate workpiece verification and many now consider CNC machine simulation to be a necessity as well. However, what some NC programmers do not realise is that information gathered during the simulation step can be used throughout the enterprise for a variety of other purposes outside the NC programming department.

he benefits of simulation have moved beyond the NC programming department—process planners, set-up, production and quality control can all save a significant amount of time by using the data created by CNC machine simulation technology.

Getting Started with NC Verification Software

This ‘virtual machining’ process is quite similar to setting up and running an actual prove-out on the machine tool. First, the user specifies the stock from which the part will be cut, either by entering dimensions into the software or importing a CAD model. Then, after importing the NC programme file (either G-code data or native CAM output), the software simulates the NC programme. The programmer can watch the material removal process and see how each cut changes the 114 MMT - March 2013

shape of the part. During cutting simulation, the NC programme is verified to detect problems such as fast feed errors, gouges and collisions that could potentially scrap the part, break the cutter or crash the machine. If an error is discovered, the programmer immediately identifies the offending NC programme record by mouseclicking on the error. The problem can then be fixed during the programming phase so that the NC programme is error-free by the time it reaches the shop floor. Analysis of the ‘as-cut’ part delves deeper into the verification process. Is it dimensionally accurate? Does it match the design intent? The AUTO-Diff module of VERICUT, a leading CNC simulation software, can embed the CAD design model inside the raw stock in order to reveal any discrepancies such as gouges or material left behind by the cutter.

Simulating the Entire Machining Process

In addition to simulating and verifying the NC programme at the workpiece level, the simulation software enables manufacturers to build and simulate all their CNC machines in order to eliminate the potential for disaster in a machine crash. A machine crash can be very expensive, potentially ruin the machine and delay the entire manufacturing schedule. But by simulating the machining process beforehand, the chance for error is dramatically reduced. Proving-out new programmes on the machine becomes an unnecessary step saving valuable production time. The creation of the machine tool model is either a user function or it can be supplied by the software provider as part of the initial package. A range of sample machines are supplied with each system and these can act as a starting point. Most importantly,

Changing Role of Simulation CNC controller models are supplied. These controls include Fanuc, Siemens and Heidenhain. Canned cycles, subroutines, macros, loops, etc. for all popular CNC controllers are also supported.

Getting the Most from the CNC Machine

The final step in the verification process ensures that the NC programmes sent to the shop are both accurate and efficient. To create the most efficient machining environment possible, optimisation software can determine the best feed rates for each segment of the tool path. Finding the right feed rates has always been a goal for NC programmers, but has traditionally been a guessing game plagued by a number of problems. An incorrect estimate can break the cutting tool, damage the fixture or scrap the part. So, usually a few conservative feed rates are used. These feed rates are generally fine for cuts that remove the largest amount of material or encounter the worst cutting conditions. Unfortunately, these typically slow, poorly controlled speeds waste time, increase costs and create poor cutting conditions elsewhere on the part. Even if the optimal feed rates are known, inserting them into the NC programme is time-consuming and error-prone. OptiPath, an intelligent module in VERICUT, determines the best feed rate for each cutting condition encountered, taking into account the volume of material removed, chip load, and accel/decel control. The software can also divide cuts into smaller segments and vary the feed rates accordingly in order to maintain a consistent chip load or volume removal rate. It then creates a new tool path with the same trajectory as the original, but with improved feed rates.

Simulation for Product Designers

Manufacturing engineers often need a method to get a model of the part cut on the machine back into the CAD

system for a variety of reasons such as legacy NC programme data exists but a CAD model does not; reverse engineering or simply for more efficient process planning. Traditionally, getting a model of the part cut back into the CAD programme has been a major challenge and it is difficult to create NC programmes for subsequent operations without an accurate representation of the initial material. The accuracy, efficiency and ‘correctness’ depend on the material’s initial geometric shape. Access to the correct geometric workpiece shape in the CAD/CAM environment at each manufacturing stage helps avoid problems when creating subsequent cuts. Until now, the only way to create an in-process CAD model has been by using expensive, labour-intensive, errorprone and inaccurate methods. However, through simulation, the in-process state of material is created as a by-product of the verification step, making it possible to export a cut model as an in-process CAD model.

Simulation for Set-Up and Production

Simulation software includes powerful tools for creating custom reports tailored for a specific user/department/ company’s needs, containing useful process information generated during the simulation. The automatically generated highly customisable documents can be used for set-up and production. The software has a reviewer tool, which can generate ‘interactive videos’ that show the actual machining process that has been simulated. Users can zoom in and out, rotate and step forward & backward. This serves as a visual aid on shop floors to know the actual and entire machining process.

Simulation for Process Planning, Scheduling & Quality Assurance

In order for process planners to do their job effectively, it is crucial to know the accurate machine times. This can be easily obtained by simulating the NC programme. Times are calculated for every step in the machining process,

right down to the amount of time it takes to change a tool. This information can be essential to keep the production floor operating to its full capacity. Additionally, process planners can use simulation to create robust inspection sequence reports in very little time. Typically, a manufacturing engineer, NC programmer or process planner manually creates these instructions to tell the machine operator what to measure and how to document the results. Without an in-process model of the part, manual methods are very tedious and prone to mistakes. The highly customisable inspection instructions can be created automatically. This feature works by using the software’s built-in measurement features. The software outputs the inspection instructions based on the dimensions of the simulated cut stock. The accurate in-process geometry knowledge required to automatically generate this type of document is only available by simulating the NC programme. Simulating CAM output to view basic workpiece material removal is no longer enough in today’s incredibly competitive global marketplace. Modern simulation and optimisation software has become a key tool to minimise the cost and time of production while maintaining or increasing product quality. It has evolved into an important process that protects and frees up CNC machines, helps eliminate scrapped parts and creates in-process information. debarati.basu@network18publishing.com

Indudhar C is the Marketing Communications Specialist for CGTech India Software Solutions Pvt Ltd. CG Tech specialises in NC/CNC simulation, verification, optimisation and analysis software technology for manufacturing. Today, CGTech has a global footprint with offices in the UK, France, China, Brazil, Germany, Italy, Japan, Singapore and India.

March 2013 - MMT 115

Industry Focus SME Insights

Frances Moore Lappe, Author, once said, “Individuality doesn’t just mean individualism— standing alone. It means developing one’s unique gifts and being able to share them for the enjoyment of oneself and others.” Although, at first, it might seem irrelevant to sectors such as machine tools, plastics or foundry, but the truth is far from it. For any section of a community to survive and flourish, it needs the support of its community.

he presence of community is often underestimated. In addition, it is a well known fact that without keeping an open mind to experiences, we, as humans, tend to be narrow minded and limit ourselves in what we can achieve. We sometimes need an awakening to help us come out of the ego-centric attitude of “I know it all”. To help us move forward and be the best we can be and also help others be the best they can be, we need to communicate with our fellow members. United Nations Industrial Development Organization (UNIDO), in joint association with Indian Machine Tool Manufacturers’ Association (IMTMA) and MMT (Modern Machine Tools), is holding an event to do just that. LEAP—Lead, Educate, Apply, Prosper—is an event that will identify common misconceptions, promote correct thinking and help build stronger ties within the cluster members of UNIDO. To achieve these aspirations, a twoand-half-day-long event will be held in 116 MMT - March 2013

Goa and will cater to 150–175 delegates from the industry. The event will feature an exciting Treasure Hunt, which will help in gauging your understanding of how you make decisions. Furthermore, there will be a session on how to break the barriers of your mind, on inculcating habits for growth, managing risks and technology upgrade. The overall essence will be one of rejuvenation. The reason behind this is to help open doors and create a stronger community within the clusters, so that the community as a whole continues to prosper.

Why LEAP?

There is a need for concurrent engineering between cluster members, across sectors and size. UNIDO LEAP aims to bridge the communication gap and increase support between the small and big players of the industry.

Top three reasons you should attend:

• It will help identify key barriers in

industry growth & pave the path to success • It will help open doors and create a stronger community within the clusters • It will provide opportunities to interact with industry leaders

Who is eligible to attend this event?

If you are part of the machine tool sector, the foundry sector or the plastics industry, then this event is for you. It will help you forge beneficial long-term business relationships, give you access to the latest technology know-how and also help you break the barriers of conventional thinking. The event aims to bridge the gaps in throughout the industry and make it more inter reliable. The event will be held from the April 12–14, 2013 in Goa. For any further queries or to register for the event, please contact Shubhangi Kitchloo via email: shubhangikitchloo@gmail.com or mobile: +91 9717297678.

Industry Focus Energy Management

Machining the Green Way! There have been many forums and debates on green manufacturing. The need for efficient use of energy has become incessantly necessary in many sectors of industry. In addition to being environmentally concerned, going green for the machine tool sector also equates to savings, efficiency and quality, says Nedra Pereira. accuracy starting from the very first part can therefore become a decisive factor for energy efficiency.

Machine Design and Testing

lot has been spoken about the use of alternate or renewable energy for the machine tool sector. However, energy management is often neglected in a machine tool plant’s production objectives. Nevertheless, in recent years, this perspective has changed. In emerging economies, where the prices of the fossil fuels typically used to generate this electricity will continue to rise, it is essential to become energy efficient. With increasing energy prices, tough competition in the marketplace and dramatic climate changes experienced, manufacturing sectors worldwide have started to value energy as an important resource to be handled strategically. And it is high time we too join this bandwagon. In the machine tool industry, the energy consumption of motors and components vary during the machining processes. Moreover, scrap or waste inevitably increases energy consumption per good part. Manufacturing with 118 MMT - March 2013

The need of the hour is to design machines such that they are energy efficient. Software like ESTOMAD help machine designers analyse energy simulation and optimisation of the integration of subsystems. Using such a tool helps in the following ways: • Better understand the interplay between subsystems • Asess different system architectures • Customise control strategies • Explore many scenarios in a quick and cost-effective way Companies like Renishaw and Aimil have testing tools that check the performance of the machine before the actual machining begins. This helps eliminate waste and ensure that the machine is optimally aligned in every aspect. Also, the set-up time and machine downtime is reduced.

Energy Consumption Monitors

Apart from using energy efficient auxiliary components, you can reduce the base load. Also, unnecessary running of machines in their non-productive phases can be specifically switched off through automation or a machine controlling unit. There are many energy consumption measuring tools available in the market. These programmes run directly on the machines interface, can provide a fast evaluation of the machine tool’s energy consumption and manage energy consumption during machine downtime. In addition, such tools support

the operator during set-up and increase energy efficiency because they shorten non-productive phases and reduce the influence of the base load. Furthermore, other functions of energy monitoring programmes are providing a configuration platform for the management of the machine’s energy saving modes, thus helping to selectively shut down specific power loads during downtimes.

Check Component Specifications

A study conducted on the feed drives of a machining process suggests that feed drives only consume a small share of the total power usage. However, spindle selection can significantly affect energy consumption. If a spindle drive operates far below its rated power, the drive’s intrinsic losses increase in proportion with the negative effects on the energy balance. If the spindle limits the maximum possible metal removal rate, the milling process inevitably takes longer. Therefore, energy efficiency decreases due to the base load generated by the auxiliary components. Milling processes can be made more efficient through consideration of spindle-motor efficiency. In conclusion, potential energy savings can be found even in the production process. With the relatively high base load of machine tools, a reduction of non-productive phases is essential. Whatever the process, one thing is for certain ... energy management will not only help you gain a manufacturing edge but also protect the environment while you are at it. nedra.pereira@network18publishing.com

Event Report Engineering EngineeringExpo ExpoAurangabad Aurangabad2013 2013

Aurangabad February 22-25, 2013 Ayodhya Nagari Grounds

Exhibiting Aurangabad’s Unparalleled Potential Since the last few years, Aurangabad has been boasting of being one of the fastest growing industrial hubs. The region already has a huge industrial presence with a large number of engineering services, auto ancillary and pharmaceutical research companies setting up facilities here. The ever-evolving industrial scenario and the entrepreneurial spirit of its entrepreneurs have helped Aurangabad grow into an industrial area of repute. Taking it further, Engineering Expo Aurangabad 2013 proved to be the right ‘growth tonic’ for boosting the region’s industrial might.

t was in 1960 that the region of Marathwada was merged with Maharashtra. This was the time when the industrial development of Marathwada began. Over time, the Maharashtra Industrial Development Corporation (MIDC) acquired land and set up industrial estates, which provided a boost to the region’s tremendous growth. Aurangabad is now one of the classic examples of efforts towards balanced industrialisation with factors such as availability of labour, comparatively lower cost for setting up base and a developing market attracting an array of industries to the city. Additionally, the presence of renowned MNCs and domestic giants in Aurangabad has further catalysed the city’s industrial growth by offering SMEs a boost. Reflecting the city’s industrial growth was the second edition of Engineering Expo Aurangabad. Held during February 22–25, 2013, at Ayodhya Nagari Grounds, the fourday Expo was inaugurated in the presence of an esteemed set of Guests of Honour including Kala Ojha, Mayor, Aurangabad; Sanjay Shirsat, MLA, Aurangabad West; Pradeep Jaiswal, MLA, Aurangabad Assembly Constituency; GM Ambhore, Director, MSME Development Institute; P Udayakumar, Director, The National Small Industries 120 MMT - March 2013

´ Dignitaries unveil the Exhibitors’ Directory at the inauguration of Engineering Expo Aurangabad 2013

Corporation; Sudhanva Jategaonkar, Associate Vice President, Network 18 Publishing and Vijay N Jaiswal, President, Aurangabad Industrial Suppliers Association (AISA). The inauguration also witnessed the presence of Sunil Raithatha, President, Chamber of Marathwada Industries and Agriculture (CMIA); Dr Uday Girdhari, President, Marathwada Association Of Small Scale Industries and Agriculture (MASSIA); Adesh Palsingh Chabda, President, Aurangabad Zilla Vyapari Mahasang and Mansingh Pawar, Past President, MASSIA, among others.

Officially Approved

Organised by Network18 Publishing with AISA as supporting partners, the Expo played host to various industry giants and market leaders who showcased their best products and services during the trade show.

Shri Balasaheb Thorat, Hon’ble Minister of Revenue, Government of Maharashtra, also graced the Expo. He said, “Engineering Expo Aurangabad has become a platform for new industries developing in the region. It has also proved to be the best platform for students as it gives them exposure to the real industrial world. I feel more events on similar should be organised in the near future.” Shri Rajendra Darda, MLA & Minister of School Education, Government of Maharashtra, also marked his presence in Engineering Expo Aurangabad. “The whole experience here was worth the visit. The Expo was well organised and provided a platform for local entrepreneurs. We look forward to more such events,” he said.

Bright Future for SMEs

According to experts, the historical background of the place helps attract

Engineering Expo Aurangabad 2013 Speaking at the event, GM Ambhore, Director MSME Development Institute, informed, “Our main objective is to identify and explore the business opportunities in the highly competitive area. We also encourage benchmarking for meeting the challenges in the best way.” Engineering Expo Aurangabad was not all about exhibitors but it also offered a lot to the visitors. ´ Shri Balasaheb Thorat, Minister of Revenue, Government of Maharashtra, being felicitated with a momento by Network18 Publishing & AISA team

foreign investors. Aurangabad also boasts of a very strong brigade of young and enthusiastic first-generation entrepreneurs, who not only implement new ideas but also steer the growth. “Aurangabad has a lot of potential when it comes to the industries. The small scale industries here have a great future. They are keen to grow and play a key role in the growth of any particular region,” said Udayakumar. Engineering Expo Aurangabad focused on providing SMEs an opportunity to demonstrate their capabilities, to offer a platform to industries across the country and enable exhibitors to formalise business alliances for mutual growth. “The trade show truly opened up a new world of opportunities for the small and medium scale industries here. The enthusiasm among exhibitors was very encouraging. It was a good experience to be a part of this grand show,” said Shirshat.

Upbeat Exhibitors

The exhibitors were overwhelmed by the positive response they received from the visitors. They are looking forward to generating more business gauging from the enquiries that they received at the Expo. Manoj Kumar, Director, Apex Group, who exhibited at the trade show, said, “We have had a lot of enquiries; I cannot gauge how many will turn out to be good business leads, but yes, I am pleased with all the enquiries. It proves that we have managed to attract the target customers

and create our brand visibility.” Another exhibitor, Nitin Bagul, Director, Technovision Instrumentation Solution Pvt Ltd, expressed, “We have participated in Engineering Expo Aurangabad last year as well; it has helped us build good contacts. Aurangabad is an industrial hub and the number of industries is increasing by the day. This is a good place for such an event; only awareness among the masses has to be increased.” Anand Pahade, Proprietor, Chintamani Electricals, who also exhibited at the trade show, said, “We participated in this trade show as we wanted to create our brand image on which customers can bank on. The response we have received has been mixed. Expos such as these should work towards creating awareness among the masses in Aurangabad.”

Initiatives in Action…

Engineering Expo Aurangabad saw some great initiatives in action. The ‘National Vendor Development Programme’ acted as a crowd puller both in terms of exhibitors and visitors. Organised by the MSME Development Institute, Government of India, Ministry of MSME, the event became an instant hit. It saw participation from organisations like Western Railways, State Transport, Hindustan Petroleum Corporation Ltd, Indo German Tool Room and Central Institute of Plastics Engineering and Technology.

Visitors Make the Most @Expo

Commenting on how an Expo of this stature acts as a growth catalyst, Mayur Parikh, Senior Manager Marketing, Sah Petroleum Ltd, explained, “Exhibiting companies fully utilised this platform at the Expo. Such trade shows always help the industrial circuit of a particular region. Though we are not exhibiting this year, it was great to be part of the Expo as a visitor.” Another visitor opined that the turnout despite of the recession was commendable. “Taking into consideration the recession, the turnout was good. Engineering Expo is a great platform for small and medium scale industries to connect and understand the market requirements,” averred Abhay Sharma, Director, Extreme Ro System Pvt Ltd. Students too had a great chance to gets hands on experience at the Expo. Starting from market trends to new technology, the Expo turned out to be a helpful lesson for them. “Students can learn a lot here; where else can they find the latest technologies and machines at one place?” asked Ojha.

Marking a New Beginning

Adding another feather to its cap, Engineering Expo came to an end with a promise to come back with more enthusiasm and better opportunities for Aurangabad. The next edition of Engineering Expo will be will be held in Hyderabad, Andhra Pradesh, during May 31 to June 3, 2013. nisi.rath@network18publishing.com

March 2013 - MMT 121

Engineering Expo Aurangabad 2013

Event Report Panel Discussion

Gauging Aurangabad on Critical Parameters A panel discussion was organised on the sidelines of the Engineering Expo Aurangabad 2013. Held on February 22, 2013, the panel discussion focused on the topic, ‘Trade, Trends and Technologies: Gauging Aurangabad on the Critical Parameters’. A report…

urangabad has carved a niche for itself among the industrial leaders in the country. In the era of liberalisation and intensive competitive environment, Aurangabad is resolutely addressing the challenge of moving to a higher growth trajectory in the industry. Taking a peek into this growth story, Network18 Publishing with support from Aurangabad Industrial Suppliers Association (AISA) organised a panel discussion on the sidelines of Engineering Expo Aurangabad 2013. Held at Taj Presidency on February 22, 2013, the panel discussion served as food for thought for more than 150 industry leaders and professionals. Some of leading industry experts like Ram Bhogale, Director, Umasons Auto Compo Pvt Ltd; SG Rajput, GM, District Industries Center (DIC) & Superintendent Industries Officer, Aurangabad; Mukund Kulkarni, Director, Expert Global Solutions and Ex-President Chamber of Marathwada Industries and Agriculture (CMIA); Udayakumar, Director, The National Small Industries Corporation (NSIC) and Maithilee Tambolkar, Director, Sanjeev Auto Parts Manufacturers Pvt Ltd, enlightened the audience on the opportunities Aurangabad can provide. The panel discussion was moderated by Archana Tiwari-Nayudu, Editor, 122 MMT - March 2013

´ Voicing Their Views: (L-R) Sushree Maithilee Tambolkar, Director, Sanjeev Auto Parts Manufacturers Pvt Ltd; Shri SG Rajput, GM, DIC & Superintendent Industries Officer, Aurangabad; Sushree Archana Tiwari-Nayudu, Editor, Network18 Publishing; Shri Ram Bhogale, Director, Umasons Auto Compo Pvt Ltd; Shri P Udayakumar, Director, NSIC and Shri Mukund Kulkarni, Director, Expert Global Solutions & Ex-President, CMIA, express their views at the panel discussion

Network18 Publishing.

Is Aurangabad Underrated?

The first non-stick pan came from Aurangabad, one of the best white goods brands and electronics is offered by this city, it also supplies the best microfinishing machines, which also compete with the world’s best. However, it seems to lack visibility. “We export to 72 countries and in the last two years, Aurangabad-based organisations have done acquisitions overseas. But we are still understated because we have been underestimating ourselves. It is high time we move ahead,” said Kulkarni. “We have created brands, but were never given that status. This is because we were overshadowed by major industrial hubs like Mumbai and Pune. But I think it is time for us to come out of that shadow and prove our calibre,” observed Bhogale. Taking the discussion ahead, Tambolkar added, “There is no denying that Aurangabad is underrated as a manufacturing hub, one of the reasons being the presence of various first-generation entrepreneurs. Every business has to go through a cycle and most of them are completing the cycle now. So, this is the time.” Giving the discussion a twist, Udayakumar said, “I look at it in a very positive way. In the age of competition, it can be seen as an opportunity.

Entrepreneurs can focus on their resources and future plans, when no one looks at you as a threat.”

Technology Takes the Lead

According to the panelists, investing in technology and innovation will take Aurangabad to a new level. “What we have focussed on is right investment and right technology; investing in the latest technology will always pay back in the long term. This strategy has helped us too,” added Tambolkar. Speaking up for technology, Bhogale added, “Investing in technology is one of the reasons why we have witnessed growth. In non-stick cookware, we have adopted one of the latest technologies in Aurangabad that involves a highdegree of automation and deliver world-class quality. Aurangabad is a good mix of innovation and tradition. There are people who have innovatively managed their traditional ways. That has given them a competitive edge,” said Bhogale. Kulkarni added, “Investing in the best technology is key; the shortterm costs may be higher, but the long term gain is what people should be looking at.” The panel discussion received an overwhelming response from the industry, who actively participated as the audience. The insightful discussion was followed by a lively question and answer session.

Event List - National

chennai Ludhiana Indore

Tamil Nadu Punjab Madhya Pradesh Nov 22-25, 2012 Dec 21-24, 2012 Jan 11-14, 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. For details

Infomedia18 Ltd, Ruby House, 1st Floor, JK Sawant Marg, Dadar (W), Mumbai 400 028. Mob: 09819552270 • Fax: 022 3003 4499 • Email: engexpo@infomedia18.in • Web: www.engg-expo.com

BLECH India 2013

The event is focussed on sheet metal forming related sheet metal, tube, sections, finished products, components, assemblies handling; April 17–20, 2013; Bombay Exhibition Centre, Mumbai For details, contact: Brooks Exhibitions (India) Pvt Ltd Plot No 859, Phase-V, Udyog Vihar, Gurgaon - 122 016 Haryana, India Tel: 124 452 4207 Fax: 124 452 4234 Email: blech.india@interads.in Web: www.blechindia.com

IMEX - 2013

INTERNATIONAL MACHINE TOOLS EXPO (IMEX), an exclusive showcase of Machine Tools and allied products is a gateway for international and domestic manufacturers / suppliers of machine tools & automation products; May 3-5, 2013; Chennai Trade Centre, Chennai, For Details, contact : International Trade and Exhibitions India Pvt Ltd E-519, Floral Deck Plaza, Central MIDC Road, Opp SEEPZ, Andheri (E), Mumbai 400 093 India. Tel: 91 22 2839 8000 Fax: 91 22 2839 0502 Email: nikhil.behl@itei.in 124

MMT - March 2013

Web: www.imexonline.com

International Industrial Trade Fair INTEC 2013

The 14th edition of the event will showcase latest in Machine Tools and Accessories, Hydraulics and Pneumatics, Material Handling Equip & Machinery Foundry Equipment’s, Precision Tools, Cutting Tools and Instrumentation and Automation; June 06–10, 2013; Codissia Trade fair Complex, Coimbatore, India For details, contact: CODISSIA GD Nadiu Towers, Post Bag No-3827, Huzur Road, Coimbatore - 641 018, India Tel: 0422 2222396 Fax: 0422 2222397 Email: intec@codissia.com Web: www.intec.codissia.com

IMTOS 2013

IMTOS covers 40 sectors of the machine tools industry and more than 20 countries have participated in the last 4 series since 2007; July 4 - 7, 2013; Pragati Maidan, New Delhi For details, contact: K & D Communication Limited. 4th Floor, Chinubhai House, 7-B, Amrutbaug Society, Opp. Hindu colony, Nr. Sardar Patel Stadium, Navrangpura, Ahmedabad - 380 014 Gujarat, India. Tel: + 91 - 79 - 26469725, 26460624,

26460453 Fax: + 91 - 79 - 26403087 Email:info@imtos.com

AM 2013

Apart from expert talks by leading International domain experts on 3rd International Conference on ‘Additive Manufacturing Technology’, the event will also highlight parallel technology exhibition supported by leading vendors of additive manufacturing technology systems as well as 3D Scanning Devices, CAD/ CAE solutions and additive manufacturing technology materials; October 07-08, 2013; NIMHANS Convention Centre, Bangalore. For details contact: Additive Manufacturing Society of IndiaAMSI #42, BSK 3rd Stage, 3rd Phase, 3rd Block 9th Cross, Bangalore- 560 085 Tel: 9901033712 Fax: 80 26729437 / 32422663 Email : contact@amsi.org.in Web: www.amsi.org.in

Productivity Buzz 2012

The two-day event is a first-of-its-kind event to display productivity solutions and innovations. The event promises to be a complete platform to share, learn and network with productivity gurus, practitioners, productivity solution providers (exhibitors) and productivity solution seekers (visitors); December 07–08, 2013; Bangalore International Exhibition Centre (BIEC), Bangalore For details, contact: Bangalore International Exhibition Centre (BIEC) 10th Mile, Tumkur Road, Madavara post Bangalore - 562 123, India Tel: 80 6624 6600 Fax: 80 6624 6661 Email: imtma@imtma.in

Event List - International TIMTOS 2013

The 16th international exhibition will showcase the latest in metal working machinery, metal cutting machinery, machine parts & accessories, industrial automatic equipment/machinery, tools, cutting tools, molds and other related equipment; March 5–10, 2013; Nangang Exhibition Hall, Taipei For details, contact: Taiwan External Trade Development Council (TAITRA) 5-7 Fl., 333 Keelung Rd Section 1, Taipei 11012, Taiwan ROC Tel: 886 (2) 2725-5200 Fax: 886 (2) 2757-6245 Email: taitra@taitra.org.tw

MTA 2013

The event will focus on the technology and quality required to machine parts and components in metals and composites; April 09–12, 2013; Singapore Expo, Singapore For details, contact: Singapore Exhibition Services Pte Ltd 1 Jalan Kilang Timor 09-02 Pacific Tech Centre Singapore Tel: +65 6233 6638 Fax: +65 6233 6633 Email: mta@sesallworld.com Web: www.mta-asia.com

CIMT 2013

Email: cmtba@cmtba.org.cn

Austech 2013

Australia’s premier advanced precision manufacturing and machine tool exhibition. The event specifically target at the metalworking, machine tool and ancillary market.; May 07-10, 2013; Melbourne Convention and Exhibition Centre, Melbourne, Australia. For details contact: Exhibition Manager Ms. Kim Warren Tel: +61 3 9800 3666 Fax: +61 3 9800 3436 Email: kwarren@amtil.com.au Web: www.amtil.com.au

EASTPO – 2013

The 15th international exhibition on metal cutting will focus on forming machines, cutting tools, manufacturing systems, automation device, precision tools, industrial electronics and accessories; July 02-05, 2013; Shanghai New International Expo Centre, Shanghai, China. For details contact: Mark Excellence Business Management Contact: Mr. Avneet Singh Tel: 22 32074604/05 Fax: 22 26396204 Email: avneet@markexcellence.com Web: en.eastpo.net/

CIMT is a truly global machine tool sourcing and trading platform for the global advanced manufacturing industry at the world’s largest machine tool market; April, 22–27, 2013; New China International Exhibition Center, Beijing

China International Industry Fair

For details, contact: China Machine Tool & Tool Builders Association (CMTBA) No 88 Yuxiang Road, Tianzhu Airport Industrial Zone Shunyi District, Beijing Tel: +86-10-6334 5694 Fax: +86-10-6334 5699

For details, contact: Shanghai Eastbest International (Group) Co,Ltd CIIF Breach, Add No - 837 Yan’an Road (C) Shanghai, China, 200040 Tel: 86-21-62892666 Fax: 86-21-62895703, 62790302

Machine Tool Indonesia

The international exhibition on metal cutting machine tools, metal forming machine tools, presses (mechanical, hydraulic, pneumatic), sheet and plate metalworking tools, machinery and accessories, surface treatment, wire and tube forming equipment, precision measurement and testing technology; December 4–7, 2013; Jakarta, Indonesia For details, contact: PT Pamerindo Buana Abadi Deutsche Bank Building 13th Floor Jl Imam Bonjol No 80 Jakarta 10310, Indonesia Tel: +62 (021) 316 2001 Fax: +62 (021) 316 1981 Email: info@pamerindo.com Web: www.pamerindo.com

MTA Vietnam 2013

Since 2005, the exhibition has showcased latest in manufacturing technologies and provides a platform for professional interested in Vietnam’s manufacturing market; July 02-05, 2013; Saigon Exhibition and Convention Center (SECC), Ho Chi Minh City For details contact William Lim & Jeffrey Au Tel: +65 6233 1206 Fax: +65 6233 6633 Email: mta@sesallworld.com Web: www.mtavietnam.com

The event will focus on the latest in manufacturing technology; November 05–09, 2013; Shanghai New International Expo, Shanghai, China

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

March 2013 - MMT 125

Tenders & Projects

Latest Popular Tenders brought to you by www.tendersinfo.com Projects

Tenders High Precision Centre Lathe

Project - 1

TRN : 14810325

Project Type: New Facility

Org

: Ordnance Factory Board

Desc : Supply, erection, installation, testing & commissioning of 1 no. of high precision centre lathe BOD : 22 Mar, 2013

Loc

: Tiruchirapalli, Tamil Nadu

: Domestic (NCB)

Forging

Org : Ordnance Factory Board TRN : 14808833

Desc : Supply of forging to gear sector elevating BOD : 26 Mar, 2013

Loc : Ambarnath, Maharashtra

: Domestic (NCB)

CNC centreless grinding

Org : Ordnance Factory Khamaria TRN : 14790279

Desc : Supply of CNC centreless grinding m/c BOD : 28 Mar, 2013

Org: SKH Sheet Metals Components Ltd

Project News: SKH Sheet Metals Components Ltd is planning to set up a new industrial products project at Pune, Maharashtra. The project involves the manufacturing of pressed sheet metals components (MV Parts)/Fuel Tank Axle Housing Heat Shield Oil Pump. As of 2/3/2012, the company received an industrial license from the Secretariat of Industrial Assistance (SIA), Department of Industrial Policy and Promotion, Government of India, for setting up the project. The closing Date will be 28 Feb, 2014. Loc: Pune, Maharashtra Project Cost: NA

Implementation Stage: Planning

Contact: SKH Sheet Metals Components Ltd B-5, Vrindavan Apartments

Vrindavan Vihar, King Road Jaipur, Rajasthan - 302016 India

ProjecT- 2 Org: Jyoti Structures Ltd

Project Type: New Facility

Surface Grinding Machine

Project News: Jyoti Structures Lt. is planning to set up a new industrial products project at Nashik (Nasik) in Maharashtra. The project involves the manufacture of fabricated structural products of metals other than or iron or steel. The closing date will be 28 Feb, 2014.

TRN : 14769590

Project Cost: NA

Loc : Jabalpur, Madhya Pradesh

: Domestic (NCB)

Org : Ordance Factory Board

Loc: Nashik, Maharashtra

Desc : Supply of surface grinding machine

Implementation Stage: Planning

Loc : Kolkata, West Bengal

6th Floor, New Link Road

BOD : 02 Apr, 2013

: Domestic (NCB)

Contact: Jyoti Structures Ltd

Plot No. B06, Valecha Chambers Oshiwara, Andheri (West)

Mumbai, Maharashtra - 400053

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

Information courtesy: Tendersinfo.com 1, Arch Gold, Next to MTNL Exchange, Poisar, S.V. Road, Kandivali (W), Mumbai - 400067, Maharashtra, India Tel: +91-22-28666134 • Fax: +91-22-28013817 • Email: parmeet.d@tendersinfo.com 126

MMT - March 2013

Launch Pad

A New Multipurpose Line of Milling Cutters

he KSRM™ line of cutters from Kennametal is a new, multipurpose milling solution from Kennametal specifically engineered for titanium and stainless steel applications. Their design enables pocketing, profiling, ramping, and plunging with up to 1mm fz. KSRM milling cutters deliver consistent performance and excellent metal removal rates with the lowest cutting forces for roughing applications. All KSRM inserts offer up to eight index able positions for fast and accurate insert changes. These inserts were designed with a high positive rake angle and stronger cutting edges for lower cutting forces when machining titanium. They are available in 12mm and 16mm diameters for KSRM face mills and screw-on, Weldon®, and cylindrical KSRM end mills. These diameters are

offered in SGE and ELE insert styles, which are the first choice for titanium applications. SGE inserts are designed for medium and heavy milling tasks, whereas ELE inserts should be used at low cutting forces and to avoid edge build-up. A 20mm diameter insert is also available for compatible KSRM face mill models. These inserts are offered in three styles. ELF inserts are designed for low cutting forces to avoid edge build-up. SGF and SHF inserts are for general purpose and heavy-duty roughing applications, respectively. KSRM tool bodies are offered in a range of internally cooled face mill and end mill styles with pocketing, ramping, plunging, and helical interpolation capabilities. All are designed with a high clearance for superior plunging, ramping, and chip load capacities. An anti-rotation screw delivers excellent stability with higher feed rates and cutting forces. The anti-rotation components also provide eight indexable positions for 12mm and 16mm inserts. Face mills utilizing 20mm inserts are engineered for roughing titanium with large depths of cut through positive geometry inserts. These mills allow six indexable rotations and are used for diameters from 60–200mm.

Disc milling cutters 335.25 Disc Mills

eco recently showcased a wide variety of innovative cutting tools at IMTEX 2013, including versatile solutions for milling, turning and hole making applications. In addition to the cutting tools featured in Seco’s booth, many of the machine tool builders in attendance used Seco tools for cutting demonstrations in their own machines. Solutions were shown for components related to cylinder heads, turbine blades, helicopter engines, crankshafts and composites materials. Seco introduces a new generation of disc milling cutters, named 335.25, for large slot widths (which will progressively replace the existing 335.18). 335.25 Disc

Mills are available for slot widths of up to 25 mm (1.0”), these disc milling cutters feature free cutting geometries, wiper flats and optimised chip flow. With a broad range of corner radii and both fixed-pocket and adjustable options, 335.25 disc mills can be applied to a wide variety of applications. The milling insert features a V-shape concept that creates an optimum cutting geometry, reducing cutting forces and noise. Thus, cutting data can be increased for maximum productivity even in unstable conditions. The V-shape also creates a strong and reliable connection between the insert and the cutter body. Insert corner radii are available from 0.8 to 6 millimetres,

with four cutting edges to reduce the cost per part. Insert geometries and grades are available for all materials, and a built-in wiper flat produces fine surface finish, eliminating secondary operations. The cutters are available with fixed pockets with central coolant or adjustable pockets for maximum flexibility.

EPLAN Software Solutions for coiling and winding equipment projects

PLAN speeds up the completion of coiling and winding equipment projects by 30%. Advanced Machine & Tool, AMT, of Fort Wayne, Indiana, saw considerable productivity improvements by using EPLAN solutions and has switched from AutoCAD 130

MMT - March 2013

Electrical to EPLAN. Time-consuming product development steps, like device tagging, wire numbering, and machine design standardization, including archiving and re-using recurrent content, have been simplified and accelerated.“I thought we were comfortable with our

Launch Pad old CAD system, but I sure would not go back to it now,” says electrical engineer Mark Lohrman. For an assignment that might have taken two weeks working in AutoCAD, that can be completed with EPLAN in about 23 to 28 work hours. Device tagging and wire numbering used to be a manual task. Now it has been automated along with the generation of the actual device tags, wire numbers and terminal tags. Engineers use the internal functionality of EPLAN to set up the printers by transmitting an Excel spreadsheet with all the data and 4-5 hours are saved. Error-free terminal diagrams and BOMs are automatically generated with five hours saved. Standard circuitry is archived and re-used from project to project saving 8-12 hours. Fluid schematics have been integrated into the overall project, eliminating errors with device naming and missed components and another six hours are saved. For larger projects, the savings are proportionately greater.

Hypertherm introduces new 3.0 kW HyIntensity Fiber Laser cutting system Mills

ypertherm, a US based manufacturer of advanced cutting systems, today announced the release of a new 3 kW fiber laser system—the HyIntensity® Fiber Laser HFL030 with a recommended cut capacity of 3/4 inch (20mm) for mild steel, a 1/2 inch (12mm) for stainless steel, and 3/8 inch (10mm) for aluminum. Like all Hypertherm HyIntensity Fiber Laser systems, the HFL030 is specifically optimized for cutting applications. It comes complete with pre-developed cutting processes, and all the needed components for significantly simplified table integration and operation. As a result, the system can cut thicker materials in some cases much faster than many higher powered competitive systems. In other words, Hypertherm’s 3 kW systems have the cut capacity of other 4 kW fiber laser systems without sacrificing cut quality. When compared with CO2 laser systems, the fiber laser cutting process significantly simplifies table design requirements and integration. Operating costs, thanks in part to the high energy efficiency of the fiber laser, and maintenance requirements which are virtually nonexistent are also much lower than with CO2 laser for lower total cost of ownership. “HyIntensity Fiber Laser system are easily integrated into a wide range of cutting machine types, allowing service centers and fabricators to expand their business by adding high precision fine feature cutting to their operations,” said Doug Shuda, product marketing manager for Hypertherm’s fiber laser products. All

Statement about ownership and other particulars about newspaper/periodical, namely MODERN MACHINE TOOLS, as required to be published in the first issue of every year after the last day of February. Form IV (See Rule 8) (Press and Reg. of Books Act, 1867)

1 Place of Publication: Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (West), Mumbai - 400 028 2. Periodicity of Publication: Monthly 3. Printer’s Name: Mr Mohan Gajria Nationality: Indian Address: Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (West), Mumbai - 400 028 4. Publisher’s Name: Mr Lakshmi Narasimhan Nationality: Indian Address: Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (West), Mumbai - 400 028 5. Editor’s Name: Ms. Archana Tiwari-Nayudu Nationality: Indian Address: Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (West), Mumbai - 400 028 6. Names and addresses of individuals who own the newspaper & partners or shareholders holding more than 1% of the total capital: Network18 Media & Investments Limited** is the owner of the publication, namely MODERN MACHINE TOOLS, having its registered office at 503, 504 & 507, 5th Floor, Mercantile House, 15, K G Marg, New Delhi - 110 001. Details of the shareholders of Network18 Media & Investments Limited who hold more than 1% of the paid up equity capital of the Company as on 20-02-2013 are given below: a. Rrb Mediasoft Private Limited, 403, Prabhat Kiran, 17, Rajendra Place, New Delhi - 110 008 b. RB Mediasoft Private Limited, 403, Prabhat Kiran, 17, Rajendra Place, New Delhi - 110 008 c. RB Media Holdings Private Limited, 403, Prabhat Kiran, 17, Rajendra Place, New Delhi - 110 008 d. Watermark Infratech Private Limited, 403, Prabhat Kiran, 17, Rajendra Place, New Delhi - 110 008 e. Colorful Media Private Limited, 403, Prabhat Kiran, 17, Rajendra Place, New Delhi - 110 008 f. Adventure Marketing Private Limited, 403, Prabhat Kiran, 17, Rajendra Place, New Delhi - 110 008 g. Shinano Retail Private Limited, 4th Floor, Court House, Lokmanya Tilak Marg, Dhobitalao, Mumbai - 400 002 h. Nexg Ventures India Private Limited, C-157, Industrial Area, Phase - Vii, Mohali, Punjab - 160 055 i. Arizona Global Services Private Limited, 1204, 12th Floor, Hemkunt Chambers, 89, Nehru Place, New Delhi - 110 019 j. Acacia Banyan Partners, Citibank N A, Custody Services, 3rd Floor, Trent House, G Block, Plot No. 60, Bkc, Bandra (East), Mumbai - 400 051 k. Independent Media Trust (held in the name of its trustee), Empire Complex 1st Floor, 414, Senapati, Bapat Marg, Lower Parel, Mumbai - 400 013 l. Network18 Media Trust (held in the name of its trustee), 503, 504 & 507, 5th Floor Mercantile House, 15 Kasturba Gandhi Marg, Delhi - 110 001

m. Network18 Group Senior Professional Welfare Trust (held in the name of its trustee), 503, 504 & 507, 5th Floor Mercantile House, 15 Kasturba Gandhi Marg, Delhi - 110 001

I, Lakshmi Narasimhan, hereby declare that all particulars given above are true to the best of my knowledge and belief. Dated: 20th February 2013

Lakshmi Narasimhan Signature of the publisher ** ownership of this magazine stands transferred from Infomedia Press Limited (formerly known as Infomedia18 Limited) (hereinafter “Infomedia”) to Network18 Media & Investments Limited (Network18) in pursuance of the scheme of arrangement between Network18 and Infomedia and their respective shareholders and creditors, as approved by the Hon’ble High Court of Delhi and the necessary approval of Ministry of Information and Broadcasting is being obtained.

March 2013 - MMT 131

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

CNC Turning and Grinding Compound Machine

Owing to excessive deformation after heat treatment or too much tolerance left to be ground, the workpiece requires more time for grinding. With the new developed CNC grinding machine BMT-D320GT with turning function, the complicated machining can be accomplished in one setup of workpiece, including internal turning, internal grinding, external turning, external grinding, tapered surface turning and grinding. The turning spindle can be mounted on Y axis or Z axis to cut the excessive tolerance before performing fine grinding. Then the grinding spindles on the Y, Z axis can perform coarse and fine grinding. Workpiece concentricity and accuracy can be assured on the turning and grinding operations done by this machine. Moreover, both spindles can do grinding processes, one for internal grinding and one for external grinding or any combination, so many more complex grinding procedures can all be completed on this same machine to speed up the process and to be more accurate. Benign enterprise co ltd

Taichung, Taiwan Tel: 886-4-2323-3016 Fax: 886-4-2323-2826 / 886-4-2323-8341 Email: bematoco@ms11.hinet.net Website: www.e-bemato.com

Servo Type Drilling/ Tapping Spindle Head

The material of body of the machine is FC30, it was stress relieved for the steady application. The spindle shaft is made of alloy steel and after heat treatment & grinding procedure it delivers high accuracy Precision with 0.002mm. All bearings used are with brands NSK or SKF for high precision & longer life. The machine Propel via Ball screws & Servo motor and is

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

eg. MMT EDM and send it to 51818

132

MMT - March 2013

positioned, to improve the drilling efficiency and also prolong the cutting toolsâ&#x20AC;&#x2122; life. The spindle head with servo motor can do tapping function, and then one unit can be multi-function for drilling/ tapping/ milling. Hann Kuen Machinery & Hardware Co Ltd Taichung city, Taiwan Tel: +8864-24860602 Fax: +8864-24860605 Email: hann.kuen@hardy.com.tw Website: www.hardy.com.tw

RF-300R/300RV

The machine 300R is a semiautomatic and high-productivity for tubes, profiles, solid bars, ferrous and non-ferrous materials. Table and saw bow swivel, but the work piece stays still when turning the angle. Blade guides at both sides are supported by carbide/bearings. One piece chip tray with stand, integrated cooling tank underneath. The machine includes heavy duty transmission gear box with longer life. Heavy duty drive and idle wheels provide stable cutting. Rong Fu Industrial Co Ltd

Taichung, Taiwan Tel: 886-4-22771199 Fax: 886-4-22790033 Email: rongfu@rongfumfg.com Website: www.rongfu.com

Laser Welding

The PSM 400 BladeWelder is a special laser beam machine for demanding materials. It can be used for crack-free, fast and cost effective processing even on hightemperature nickel or cobalt base alloys. With a maximum pulse power of 8 kW, the Lasag laser achieves pulse energy of 110 J. Freely scalable pulse formation and modulation enable adaptation of the laser parameters to the specific characteristics of the materials. The pulse duration can be extended to a very impressive value of 200 ms. Adaptive closed-loop controller ensures precise and stable operation of the lamp-pumped solid state laser. To prevent damage to the fibers by a reflected laser beam when used on highly reflective materials, the BladeWelder is equipped with high-performance fibers that absorb such reflections.. Schunk Intec India Private Limited Bengaluru, Karnataka Tel: 080-40538999 Email: Info@in.schunk.com Website: www.schunk.com

Products - General Fast reacting collision protection device

The OPS 063-M collision and overload protection device has a lightning fast reaction time and is simple to operate. With a response time of 1 ms, the OPR-063-M is setting new standards for robot applications. The rapid lightweight consists of a housing which is made of hard-anodised aluminium alloy, weighs 290 g and has been particularly designed for applications on small robots. The monitoring is not carried out with internal proximity switches, but is carried out by an exchangeable magnetic switch from outside. After a collision, the unit only has to be returned to its original position, disassembly is not necessary. This makes operation simpler, minimises malfunctions, and reduces the need for spare parts. The triggering force and moment can be adjusted via the operating pressure. With the help of a standardised adapter plate, the module can be quickly and simply integrated into the system.. Schunk Intec India Pvt Ltd Bengaluru, Karnataka Tel: 080-40538999 Email: info@in.schunk.com Website: www.schunk.com

Cylindrical Grinding Machine

This machine base is manufactured from high quality cast iron FC30, tempered and stress relieved for maximum stability of material and assures maximum rigidity. The base permits fast coolant exhaust, preventing thermal deformation from influencing machine accuracy. The forced lubrication system of the grinding wheel spindle features vibration absorbing function. The oil film pressure created by the hydrodynamic bearings automatically absorbs vibration according to the current working condition. The grinding wheel spindle is supported by two special hydrodynamic bearings on the ends with five-point support, providing maximum rigidity and stability of spindle running. In case insufficient lubrication oil occurs, the spindle stops automatically to avoid wearing on the spindle and bearings. Cylindrical grinding machine can be applied several different controller as customer request and it combines various grinding functions in one machine, effective improve grinding precision and operational convenience, such as, tapered grinding, curve and end face grinding and forming grinding etc. It is suitable for manufacture and process components such as machine spindle, roller shafts, large or small motor spindles, module accessories, etc. Jainnher Machine co ltd

Taichung, Taiwan Tel: +886-4-23585299 Fax: +886-4-23594803 E-mail: saledep@jainnher.com

Website: www.jainnher.com March 2013 - MMT 133

Products - General Geared Head Light Duty Lathe Machine

Geared head light duty lathe machine series has height of centre 165mm, length of bed ranging up to 1820 mm, admit between centres up to 1135 mm. main spindle hollow is 38 mm. main spindle nose is A2- 4 or threaded type. Dynamically balanced spindle enable the spindle run at vibration free motion at 1200 rpm. All gears are made of 20MN CR5 material and fully induction hardened and teeth grinding. At the Norton gear box is able to cut the any of metric, modules and pitch (D.P). the bed is made from graded cast iron and flam hardened up to 400 BHN diametric. Also offered are face plate, carrier plate, steady rest, and follow rest, motorized coolant pump with tank and fittings, rear tool post, quick change tool post. The machine is maintenance free and easy to use. The parts of the machine are interchangeable and stock in regional dealer office Vinit Engimech Pvt Ltd

Rajkot, Gujarat Tel: (0281) 2312091 / 2311734 Fax: (0281) 2311935 Website: www.balajilathe.com Email: vinit@balajilathe.com

134

MMT - March 2013

Products - General Machining Unit

The machining unit provides new speed options, reliably up to the maximum speed limit. With an increase of 25% up to a permissible maximum spindle speed of 23,000 rpm, operations requiring higher spindle speeds can be accomplished more easily. This improvement is the result of a complete redesign of drive and spindle bearing components. A new style timing belt drive multiplies the motor speed up to 13,050 rpm spindle speed. An AC drive is used to increase the spindle speed up to 23â&#x20AC;&#x2122;000 rpm at 87 Hz. The machining unit can be applied in axial and radial orientation, directly mounted to a slide assembly type UA15PH or UA15-CNC. In this combination numerous machining operations like milling or demanding drilling cycles including jump or peck feed can be accomplished very easy. Suhner India Pvt Ltd

Bengaluru, Karnataka Tel: +91 80 27831108 Fax: +91 80 278311092 Email: automation.in@suhner.com Website: www.suhner.com

March 2013 - MMT 135

Products - General the accuracy range of tactile inspection. It is a viable alternative to a tactile probe for an increasing number of high precision CMM applications; including moulds, small turbine blades, medical devices and other complex geometry. A wider variety of parts, geometry and materials can be measured more effectively, including many parts too small or fragile for a touch probe. The application extends to pilot plant metrology, automotive components inspection, aircraft component inspection, surface analysis, sheet metal inspection etc. Nikon India Pvt Ltd

Gurgaon, Haryana Tel: 0124-468 8500 Email: ateet.kaushik@nikonoa.net Website: www.nikonmetrology.com

Drill Re-Sharpening Machine

Mini Arc Welding Transformers

Regulator type mini welder medium duty machines are available in 150, 200 & 250 Amps. They are compact, light weight arc welders used for repair and maintenance jobs in medium duty cycles, light fabrication works, light production jobs in farms and small workshops, automobile garage and repair workshops. Yielding quite higher performance to cost ratio compared to any other machine in the market. Built with latest trends in design and manufacturing and tested to most stringent standards to offer years of trouble free service. Canary Electriclas Ltd

Morbi, Gujarat Phone: +91-2822-250431 Fax: 91-2822-250433 Email: info@vulcanwelding.com, vulcanwelding@gmail.com Website: www.vulcanwelding.net

Digital laser scanner

Nikon’s superior optics is combined with innovative 3D laser scanning technology as digital laser scanner LC15Dx, and brings laser scanning in 136

MMT - March 2013

This machine has the “CE safety authentication”, which originated with up to down way of grind drill. This new research and develop about swing the drill from up to down made the finished of drill more sharpen and more durable than the traditional swing way. Easy to operate, easy to understand and the point angles are from 90°~135°. Chisel edge grinding can adjusting by your demand. Jin year precision Co Ltd

Taiwan Tel: +886-4-25232817 Fax: +886-4-25151230 Email: Liu0930@ms58.hinet.net Website: www.jinyear.com.tw

Taper pins

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

Mumbai, Maharashtra Tel: +91-022-22671141 Email: rkeng@vsnl.net Website: www.rkengineeringco.com

Products - General Chipformer

Chipformer under the designation of M3M was designed especially for machining stainless and low carbon steel.In addition, it was designed with geometric features that improve the toolâ&#x20AC;&#x2122;s life due to a reinforced cutting edge at the area where VG (notch wear) wear tends to occur when machining stainless steel, causing poor surface finish and risk of edge breakage.Additional geometric elements such as optimal positive rake angle feature a smooth cutting process and reduced cutting forces (by 5 to 10%), thus reducing the wear and dramatically increasing tool life.The M3M has a wide chipbreaking range, making it the first choice in most stainless steel applications.The combination of the new advanced SUMO TEC grades IC6015 and IC6025, together with the unique and innovative M3M chipformer, ensures higher productivity over any other insert existing in the market for machining stainless steel. Larsen & Toubro Limited â&#x20AC;&#x201C;ISCAR

Mumbai, Maharashtra Tel: 022 6705 4015, 9833215872 Email: Shriharsh.Chandak@larsentoubro.com Website: www.larsentoubro.com

138

MMT - March 2013

Products - General Portable Welders

The welding machines are strictly manufactured & are confirming to IS, incorporating latest technological developments and controls with highest order of quality & performance. The machine also has modern looks, novel design concepts, Light weight and compact. Real Portability for one person to do welding at odd places like civial work sites etc. Sturdy belt provided for carrying and hanging. It is made from high-grade materials, with protection against overload by thermal cut-out. Works even on domestic power line, Reliable and durable, Epoxy powder coated body for long life, Coil varnishing by vacuum pressurised impregnating varnishing system. Canary Electricals Ltd

Gujarat Phone: +91-2822-250431 Fax: 91-2822-250433 Email: info@vulcanwelding.com, vulcanwelding@gmail.com

Synthetic High Speed Grease

Premium synthetic high speed grease is made with technology from UK for high speed CNC machine spindles which operate upto 12 lacs DmN value.The product is trusted by the major auto component manufacturers. The major content mixed in the grease are PAO base oils so that the grease provides excellent performance at low operating and start up temperatures. The product is a blend of synthetic oils and additive package that offers excellent lubricity even at high speeds. It offers Lower friction when operating therefore lower running temperatures and also,quiet in running and suitable for silent running electric motors.The synthetic base oils offer longer grease life. Compatabile with bearing seal materials like NBR, FKM, PTFE etc.The High Speed grease is recommended for high speed applications in machine tools, textile Industries: small electric motors in medical & dental equipment etc. It is available in 1, 3 & 18 Kg packs. Raj Petro Specialities Pvt Ltd Chennai, Tamilnadu Tel: (O44) - 42288900 Fax: (044) - 42288912 Email: onwo@rajgrp.com Website: www.rajgrp.com

March 2013 - MMT 139

Products - General Plate Bending Machine

Hydraulic / mechanical 4 rolls / 3 rolls standard prepinch type and pyramid type plate bending machines are available in wide range from 1,000 mm to 6,000 mm length and 1 mm to 100 mm thickness. The machine features movable control panel, gear box / hydraulic motor, MS plates, fabricated main frame, housing with forged steel rolls and hydraulic and electrical balancing system. Moreover, it has the advantage of easy maintenance, simple mechanism enable, suitable for medium and heavy plates and pipes in full circle or various radius can be done easily. The machine also comes with the accessories like conical bending, section bending and plate feeding table etc. Weldor Engineering Pvt Ltd

Rajkot, Gujarat Tel: 0281 - 2360242, 2360243, 44 Fax: 0281 - 2360466 Email: weldor@weldor.com Website: www.weldor.com

140

MMT - March 2013

Products - General Super Rigid Press

Super rigid series power presses in the capacity rating of 10 / 16 / 25 / 40 / 63 / 80 /100 / 125 / 200 and 250 tonnes conform to the press standard both in terms of dimensions and geometrical accuracies. The machine incorporates modern design features and latest manufacturing practices. The press provides various features such as variable speed drive, manual or motorised slide adjustment, pneumatic clutch, pneumatic counter balance, slide tool die holder, stroke counter, electro pneumatic safety control, manual or automatic centralised lubrication systems, hydraulics overload safety device, pneumatic die cushion die lifters, hydraulic die clamping etc. Application areas include sheet metal components for automotive / furniture / electronic and wide range of consumer goods industries. Kawa Press Systems Pvt Ltd

Rajkot, Gujarat Tel: 0281-2461102, 2461162 Fax: 0281-2461665 Email: info@shaileshmachines.com

Diamond Disc

Diamond discs use a process by which diamond abrasives are chemically fused on top of a metal base. The construction provides highly exposed, ready to cut diamond edges at the contact surface to either grind or hack. With reduced friction at the cutting edge and a well balanced construction, the power tool mounted breaks down very less and completes the work much faster. It can be fitted on any brand of portable grinder. It is available in 100 mm (4”) diameter with 20 mm bore, 115 mm (4 ½”) and 125 mm (5”) with 22.3 mm bore. The same discs can be used both for grinding and hacking applications. Wendt (India) Ltd

Hosur, Tamil Nadu Tel: 04344 - 276851, 276852 Fax: 04344- 405620 Email: deepaks@wendtindia.com Website: www.wendtindia.com March 2013 - MMT 141

Products - General Boring Tool

Boring tools comes in different ranges ranging from 0.4mm to 3,255mm hole diameters. The complete range is available in analog & digital types with 2 micron diametrical adjustment. The size adjustment is easy and ISO inserts can be used, the connection of tools is modular type and the clamping is done on serrated slides to ensure strong mounting. When the tool size increases the tool body is provided in aluminium alloy to reduce the weight. We also provide tools which can do roughing & finishing in a single go thus reducing the cycle time. We also offer a range of tool holders, turn mill machine tools, boring & facing heads, customized tools etc to cater to your machining requirements. The tools can be easily serviced in India. Wohlhaupter India Pvt Ltd. New Delhi Tel: 011-32227044 Fax: 011-26131690 E-mail: info.in@wohlhaupter.com; keshav.khurana@wohlhaupter.com

Plastic Packing Boxes For Cutting Tools The boxes are used made to be used for industrial packaging. It can be use full for packing the carbide tools, end mills, reamers, tips, insert, tap set, tool holder etc. Foam, stickers, screen printing, embosses & design the logo of company on the boxes can also be provided. Om manufacturers

Rajkot, Gujarat Tel: 0281-2384444, 09978500100 Email: - ommanufacturers@gmail.com ; info@ommanufacturers.com Website: www.ommanufacturers.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 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 Email: blroffice.in@suhner.com Website: www.suhner.com 142

MMT - March 2013

Thermometer

This infrared thermometer has an IR range between 50 to 2200 deg C 2.2’’ TFT 320 x 240 pixels color LCD display & camera resolution of 640 x 480 pixels. It supports images in JPEG & video in 3GP format. It has provision for micro SD memory card (upto 8 GB), dual laser targeting & USB interface, language selection (English/French/ German/Spanish). Other features include date/ time setup controls; max, min, DIF, AVG record & dew-point & wet bulb temperature. Specifications include response time: less than 300ms, optical resolution is 50:1 Distance to spot size etc. India Tools & Instruments Co

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

Vertical Machining Center

The 3-axis machining center from Pittler represents an economically attractive version for small and medium size production shops. Parts with diameters up to 800 mm can be processed on a set-up area of only 6 m². The benefits of this product are high quality parts at low per-part costs, excellent accessibility to the parts and tools, quick programming and short conversion times. Large door openings and a short control distance allow work pieces and tools to be changed quickly. The Siemens 828 D control offers simple and rapid programming in work steps. Pittler T & S GmbH

Gutenberg-Dietzenbach Tel.: +49 (0) 6074 4873 0 Fax: +49 (0) 6074 4873 291 E-Mail: vertrieb@pittler.de Website: www.pittler.de

Portable circular saw

Portable circular saw can effortlessly saw at high speed through all kinds of material such as steel, stainless steel, aluminum and copper. It faces no problems sawing wood and plastic. Showers of sparks belong almost to the collector and therefore the surroundings remain clean. The Blade Runners are lightweight and ergonomically designed. Besides, they are easily manageable, extremely precise and accurate in working. All Blade Runners are equipped with a variable angle setting. They are useful for fast and burr-free working and no greasing or cooling is required. Consortech Tools (India) Ltd

Pune, Maharashtra Tel: 020-24445576, 65002414.

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

eg. MMT EDM and send it to 51818

Product

Pg No

Product

Pg No

Product

Pg No

2d and 3d CAD software............................ 99, 155

Carboloy............................................................41

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

5 axes high speed machining center................ 9, 93

CE marked CNC vertical machining center........47

Coolant...........................................................101

3 axes high speed machining center................ 9, 93

5 faces double coulmn milling machine.............144 Adaptor.............................................................54 Advance cutting material....................................33 Aerosol multispray.............................................67 Aerospace machine..........................................153 AGV (automated guided vehicle)......................103 Air operated hydraulic pump............................133 Airline fluid.......................................................67 Analog timer......................................................22 Angel head........................................................66 Angle encoder.................................................BIC

As-interface system............................................44 Assembly & high temperature grease..................67 Assembly technology & transfer system..............66 Auto-diffmachine simulation multi-axis.............97 Automation.....................................................107 Automation product.........................................117 Automotion controller.......................................95

Casting..............................................................47 CE marked milling machine...............................47 Centre drill........................................................54 Chain hoist......................................................136 Chain oil...........................................................67 Chains................................................................ 8 Chillers...........................................................138 Chipformer......................................................138 Chrome bars/ shaft..........................................133 Chuck...............................................................54 Chuck jaw........................................................107

Clamping tool.................................................. BC Clyindrical grinding machine .........................133 CNC.....................................................9,32,83,93 CNC double column machining centre................ 6 CNC engraving machines..................................79 CNC equipments...............................................39 CNC horizontal boring & milling machine......... 6 CNC horizontal machining centers................ 6, 47

Balancing systems for grinding.......................BGF

CNC horizontal turning centre........................... 6

Bar ........................................................... 133

CNC machine simulation...................................97

Ball- lock systems zero point system.................133

Bearing............................................................... 8 Bed mill...........................................................111

CNC machine probing.......................................97 CNC machine tools...........................................21 CNC machines.............................................. 9, 93

Bed type/travelling column milling machines/boring........15

CNC machining center............................. 9,24, 93

Boring machine.................................................66

CNC multi-tasking centre................................... 6

Boring bar.........................................................63 Boring mill......................................................106 Boring tool......................................................142

CNC milling machines......................................47 CNC small machining center.............................24 CNC toolings....................................................54

BTA / ejector counter boring.............................18

CNC turning and grinding compound machine ..... 132

Buffing powder..................................................63

CNC turn-mill centre......................................... 6

BTA / ejector drilling........................................18 Cable & hose carrier........................................113 Cable carriers...................................................... 8 Cable conduits...................................................37 Cable connectors................................................ 8 Cables for bus system.........................................44 Cad/cam software..............................................30 Cam follower...................................................134 Camwork.........................................................135 Capacitive and magnetic sensor..........................44 Carbide.............................................................54 Carbide endmill tool........................................ BC

Carbide rod.......................................................59 Carbide tool.......................................................54

CNC turning center....................................... 9, 93 CNC vertical machining center...................... 9, 93 CNC vertical machining centre........................... 6 CNC vertical turning lathe.................................. 6 Collet................................................................54 Collet chuck......................................................54

Conventional phase failure relay.........................22 Counter.............................................................22 Counters & power supply...................................57 Countersink........................................................ 3 Crane drive......................................................136 Crush blade.......................................................60 Custom & turnkey...........................................123

Customised tooling solution..............................62 Custom-made cable...........................................44 Cutting oil................................................. 63, 101

Cutting speed optimisation................................97

Cutting tools........................... 19,41,59,60, 81,154 Cylindrical & internal grinding..........................65 Data cable.........................................................44 Deep hole drilling..............................................66 Deep hole drilling machine................................18 Deep hole drilling subcontract...........................18 Demo. & refurb...............................................123 Design software......................................... 99, 155

Dfmpro...........................................................135 Diamond disc..................................................141 Diamond lapping & polishing system.............BGF Diamond tools.................................................... 3 Didactic equipmetns for training........................75 Die coater..........................................................60 Die/mould machine.........................................144

Digital laser scanner........................................136 Drill chuck arbor...............................................54 Drill mill...........................................................54 Drill resharpening machine.............................136 Drill tap center..................................................47

Drill tool......................................................... BC Drilling machine........................................ 66, 123 Drilling tool.................................................. 3, 19 Drilling unit......................................................13 Drive.................................................................95

Drive technology...................................... 58, BIC

Composite application.......................................97

Dynamic information delivery software....... 99, 155

Connectors.................................................... 8, 75

Edrawings publisher........................................135

Compressor oil..................................................67 Content and process management software..... 99, 155 Control cabinet..................................................75 Control panel....................................................75 Control systems.................................................75 Control technology............................................58

Edm sinker machine..........................................79

Element shrink disc.........................................134 Encoder.............................................................57 End mills...........................................................54 Engine shafts work holding devices....................62 Exhibition- Blechindia 2013......................127, 129

March 2013 - MMT 147

List of Products Product

Pg No

Exhibition- Engineering Expo............................72

Product

Pg No

Hydrolic press break..........................................51

Product

Pg No

Milling head......................................................66 Milling machine........................................ 66, 123

Exhibition- Intec 2013.......................................26

Hypercad...........................................................30

Fast reacting collision protection device...........133

Indexable cutting tool........................................63

Mini arc welding transformer...........................136

Inductive...........................................................44

Modmachine simulation multi-axis....................97

Exposed linear encoder...................................BIC Fibre laser cutting machine................................51 Financial solution..............................................11 Five axis workholding......................................133 Fluid connector...............................................136 Fork head..........................................................66 Freewheel-oneway-clutch.................................134 Fule injection system parts collet........................62 Gantry machining center..................................106 Gas spring.........................................................64 Gauge..............................................................137 Gear cutting machine.......................................144 Geared head light duty lathe machine...............134 Geomcaliper....................................................135 Glass linear encoder.........................................139 Grease...............................................................67 Grinding...........................................................13 Grinding machine...................................... 66, 100 Grinding tool for hard material........................100 Grinding wheel..................................................63 Grooving & parting tool....................................59 Guide rod........................................................133 Gun drill............................................................ 3 Gun reaming.....................................................18 Gundrilling.......................................................18 Hanlding system module....................................75 Hannover messe-2013......................................143 Hard chrome plating bar..................................133

Identification system..........................................44 Inductin motor..................................................95 Inductive proximity switche................................37 Industrial control & sensing device....................57 Industrial exhibition........................................143

Industrial robot...............................................119

Large size machining centre.............................144 Laser cutting......................................................13 Laser marked logo plate...................................139 Laser shaping...................................................100

Laser welding..................................................132 Lathe.................................................................32 Lathe chuck.....................................................107 LED..................................................................37 Len ..................................................................60

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

Level controller.................................................57

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

Machine vise.................................................BGF

Machining center......................................... 20, 66 Magnetic linear encoder...................................139 Maintenance lubricant.......................................85

Honing machine................................................66

Measured value acqusition and dis...................BIC

Horizontal CNC lathe.....................................111

Measuring instruments......................................66

Horizontal milling machine.............................144

Metal injection moulding.................................135

148

MMT - March 2013

Panel bending machine......................................51 Panel cooler.....................................................138 Panel meter.......................................................22 pcb drill.............................................................60

Penta iq grip for grooving and parting.............FIC Phase failure relay..............................................22 Photo electric sensor.................................... 44, 57 Piston bar........................................................133 Plasma 3d..........................................................13 Plasma cutting machine.....................................51

PLC.................................................................117

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

Hydraulic valve housing shrinkfit adaptor...........62

Optipath...........................................................97

Machine tool protection system......................BGF

Holemaking.......................................................33

Hydraulic cylinder....................................136, 138

Oil cooler........................................................138

Plastic packing boxes for cutting tool................142

Machining unit................................................135

Hydraulic chuck.................................................62

Networks...........................................................58

Machine simulation multi-axis...........................97

Hold back........................................................134

Hydraulic & gear oil..........................................67

NC lathe............................................................20

Piston rod........................................................136

Lube................................................................101

Machinery loans................................................11

Hoses..............................................................136

Multimedia union..............................................64

Load break switch..............................................37

Lm shaft..........................................................133

Hmi 95

Horizontal machining center..................... 9,32, 93

Multi functional tool.........................................59

Pilot light..........................................................37

Machined casting...............................................62

Horizontal boring mill.....................................144

Monitoring of grinding system.......................BGF

Linear rod........................................................133

High speed precision centre lathe.....................111

holemaking tool.................................................60

Mold iron & steel part.......................................60

Multi spindle head...........................................142

Kwik lock pin..................................................133

Machine tools & spares....................................141

Holder...............................................................63

Mold component...............................................60

Keyless transmisson element............................134

IS ..................................................................51

High precision wire cut edm machine.................79

Hoist ring........................................................133

Modular tooling system...................................... 3

Motor protection circuit breaker........................37

Machine tap......................................................63

High pressure hydraulic clamping system.......BGF

Model export interface.......................................97

Instrumentation made cab..................................44

High precision machining service.......................62 High precision tool holder.................................17

Milling tools...............................................60, BC

Measuring & monitoring relay for 1ph/3ph........57

Metal cutting tool..............................................55 Metal working fluid...........................................85 micron drill........................................................60

Milling................................................19, 33, BIC Milling centre....................................................32 Milling cutter................................................ 3, 59

Plate bending machine.....................................140 Plugs and socket................................................37 Portable circular saw........................................142

Portable welders..............................................139 Post processor....................................................30 Power sources....................................................56 Preci chuck......................................................134 Precision gear cutting tool................................144 Precision measuring instrument.......................137 Precision steel..................................................100 Precision switches single & multiple..................37 Pressure sensor for wet packaging application.....12 Process automation and cntrol equipmetn..........75 Production vise................................................133 Program verification..........................................97 Programmable logic comtroller........................117 Proximity sensor................................................57 Pull stud............................................................54 Punching...........................................................13 Punching laser cutting.......................................51

List of Products Product

Pg No

Product

Pg No

Product

Pg No

Punching shering machine.................................51

Spirac cable.......................................................44

Vertical turret milling machine.........................139

Raciprocated oil free compressor......................111

Stacking system.................................................51

Wear part..........................................................59

Push button.......................................................37 Raciprocating lubricated compressor................111 Reamer.......................................................... 3, 54 Relay.................................................................22 Reversible jaw..................................................134 RF 300R..........................................................132 Roatry...............................................................32 Robot..............................................................119 Roll forming machine........................................51 Rotary damper...................................................64

Spms.................................................................18 Standard induction hardening machine..............56 Stationary work holding...................................107 Steel tube........................................................136 Super rigid press..............................................141 Surface & profile grinding.................................65 Switching relay..................................................57 Synthetic high speed grease .............................139

Tap .............................................................. 3, 14 Taper pin.........................................................136

Rotary encoder......................................... 44, BIC

Technology event............................................143

Rotary joint & union.........................................64

Temperature indicator.......................................22

Rotary indexing table.....................................BGF

Rotary switches..................................................37 Rotating union..................................................64

Safety lig...........................................................57 Safety protection devices....................................37 Scroll type oil free compressor..........................111 Sealed linear encoder......................................BIC Sealing system.................................................136

Temperature controller......................................22 Tempurature controller......................................57 Tensioner nut..................................................134 Thermometer..................................................142 Thread gauge...................................................134 Thread milling cutters & taps holder..................14 Threaded inserts..............................................133 Threading tools............................................... BC

Vision sensor.....................................................57 wear resistant tool..............................................60 Workholding solution....................................BGF

INTERNATIONAL Automatic lathe.................................................70 Bench grinder....................................................70 Cemented carbide rod........................................16 Cemented carbide roll........................................16 Center lathe.......................................................70 Centerless grinding machine..............................35 CNC angular cylindrical grinding machine.........35 CNC deep hole drilling machine for shaft...........28 CNC lathe.........................................................70 CNC milling machine................................. 70,141 Cobalt...............................................................16

Coordinate advance milling and drilling machine.28 Die spotting machine.........................................28 Electric discharge machine.................................70 End mill cutter................................................140

Sensor...............................................................44

Threadmill cutter...............................................63

Sero drive........................................................117

Tool..................................................................54

Floor type horizontal CNC milling machine.......28

Tool holding system.................................. 63, 107

Grinding machine..............................................70

Toolholders turbo charger part...........................62

Hard alloy turning cutter..................................140

Toolings for EDM / WEDM / VMC-S / HMC-S.51

Horizontal CNC milling machine......................28

Track roller.....................................................134

Machine center..................................................70

Timer................................................................57

Engraving machine............................................70

Tool grinding....................................................65

Forming milling cutter.....................................140

Tool monitoring system.................................BGF

Hand tool..........................................................70

Shock absorbers.................................................64

Tooling system...........................................33, BC

High-speed centerless grinding machine.............35

Side lock adaptor...............................................54

Touch probe...................................................BIC

Internal grinding machine..................................35

Sensor technology..............................................58 Servo motor.......................................................95 Servo type drilling / tapping spindle head.........132 Shaft...............................................................133 Sheet metal working machinery..........................10 Shrink fit technology.........................................63 Single limit switch.............................................37 Siphon systems..................................................64

Trade show......................................................143

Smart turn electronic lathe...............................111

Tubing accessories.............................................75

Slotting machine..............................................141 Solid carbide drill...............................................55

Solid carbide drills with IC................................55

Transparent gels................................................67 Turning................................................19,33, BIC Turning centre.................................................111

Solid carbide mill...............................................55

Turning holder..................................................59

Solid carbide reamers with IC............................55

Turning tool...............................................60, BC

Solid carbide reamer..........................................55 Solid carbide special drill...................................55 Solid carbide special mill....................................55 Solid carbide special reamer...............................55 Solid carbite tool..............................................154 Solid rotating tool..............................................63 Special hydraulic expansion technology............107 Special induction hardening machine.................56 Special purpose machine....................................47 Special tools......................................................54 Speciality oils.....................................................63 Specialty lubricant.............................................85 Spindle nose tooling..........................................59

Turning mill......................................................66 Turnmill centre...............................................111 Turret mill.......................................................111 Turret punching machine...................................51 Twist drill..........................................................54 Ultra high pressur apparatus...............................60 Ultrasonic sensor...............................................44 Valve.................................................................75 Valve terminal...................................................75 Velocity & feed controller..................................64 Vertical machining center............................... 7, 32

Vertical machining center.................................142 Vertical turning lathe.......................................106

Machinery tool..................................................16 Milling cutter..................................................140 Milling machine................................................70 Mining inserts button........................................16 Multifunction horizontal CNC deep hole drilling

machine.............................................................28 Niobium............................................................16 Oil fields prospecting tool..................................16

Radial drilling machines....................................70 Rolling machine..............................................140 Sawing machine.................................................70 Shaft...............................................................140 Slotting machine................................................70 Tantalum..........................................................16 Thread............................................................140 Tools magazine & tool changer........................102 Tungsten molybdenum......................................16 Twin-spindle compound grinding machine.........35 Universal cylindrical grinding machine...............35

March 2013 - MMT 149

List of Advertisers Advertiser’s Name & Contact Details

Accut Machinery Co. Ltd.

Pg No

106

Advertiser’s Name & Contact Details

Ceratizit India Pvt Ltd

Pg No

Advertiser’s Name & Contact Details

Farmax Machines Private Limited 51

T: +86-411-84804589

T: +91-33-24947146

T: +91-80-28435034

E: info@accutmachinetools.com

E: info@ceratizitindia.co.in

E: skr@farmax.in

W: www.accutmachinetools.com

W: www.ceratizit.com

W: www.farmax.in

Ace Micromatic Group

Cgtech India Software Solutions (P) Ltd 97 T: +91-9845212147

T: +91-80-22894100

E: customercare@acemicromatic.com

E: Info.India@cgtech.com

E: info_in@festo.com

W: www.acemicromatic.net

W: www.cgtech.com

W: www.festo.com

137

Danobat Group

Finechrome Shafts Pvt Ltd

133

T: +91-20-66093800

T: +91-20-66094531

T: +91-22-29204209

E: bakerbmi@bakergauges.com

E: nmehta@danobatgroup.com

E: finechromespl@yahoo.co.uk

W: www.bakergauges.com

W: www.danobat.com

Benign Enterprise Co. Ltd.

Dongguan Minglee Steel Mould Products Co.,Ltd 28

Freeze Tech Equipments Pvt Ltd

138

T: +886-4-2323-3016

T: +86-769-8331-6878

T: +91-44-42152387

E: bematoco@ms11.hinet.net

E: info@minglee.com

E: info@freezetechequip.com

W: www.bemato.com.tw

W: www.minglee.com

W: www.freezetechequip.com

Bharat Bijlee Ltd

Doosan Infracore India Pvt Ltd

G W Precision Tools India Pvt Ltd 55

T: +91-22-24306237

T: +91-80-42660122

T: +91-80-40431252

E: vishwajyoti.vengurlekar@bharatbijlee.com

E: sandesh.kumar@doosan.com

E: info@gwindia.in

W: www.doosaninfracore.com

W: www.bharatbijlee.com

Bharat Fritz Werner Ltd

Dormer Tools India Private Limited 41

W: www.gwindia.in

Gelco Electronics Pvt Ltd

T: +91-80-28395745

T: +91-124-4703825

T: +91-79-22200902

E: bfwmarketing@bfw.co.in

W: www.carboloy.com

E: info@gelco-world.com

W: www.gelco-world.com

W: www.bfwindia.com

Big Daishowa Seiki Co. Ltd

EFD Induction Limited

Geometric Ltd

135

T: +81-729-828277

T: +91-80-7820404

T: +91-22-67056880

W: www.big-daishowa.com

E: sales@efdgroup.net.

E: inquires@camworks.com

W: www.efd-induction.com

W: www.camworks.com

Birla Precision Technologies Ltd (B

Emuge India Pvt Ltd

Gifu Enterprise Co., Ltd.

102

T: +91-240-2554301

T: +91-20-39310000

T: +886-4-2533-4244

E: info@birlaprecision.com

E: marketing@emugeindia.com

E: overseasdept@atcgifu.com.tw

W: www.birlaprecision.in

W: www.emugeindia.com

W: www.atcgifu.com

Blaser Swisslube India Pvt. Ltd.

101

Engineering Expo

GSK CNC Equipment Co. Ltd

T: +91-124-4994000

T: +91-9819552270

T: +91-9886835186

E: india@blaser.com

E: engexpo@infomedia18.in

E: gskwang@hotmail.com

W: www.blaser.com

W: www.engg-expo.com

W: www.gsk.com.cn

Brisloy Tools India Private Limited 153

150

Festo Controls Ltd

T: +91-80-41492285

Baker Gauges India Ltd

Pg No

Ermaksan Sheet Metal Working Machinery 10

Haas Automation India Pvt Ltd

T: +91-124-4283106

T: +90-224-2947500

T: +91-22-61392800

E: info@brisloy.com

E: hakan.ceki@ermaksan.com.tr

E: indiasales@haascnc.com

W: www.brisloy.com

W: www.ermaksan.com.tr

W: www.haascnc.com

MMT - March 2013

List of Advertisers Advertiser’s Name & Contact Details

Pg No

Hannover Milano Fairs India Pvt Ltd 143

Advertiser’s Name & Contact Details

Pg No

Jyoti CNC Automation Pvt. Ltd. 9,93

Advertiser’s Name & Contact Details

Metrol Corporation India Branch Off 24

T: +91-22-42369719

T: +91-2827-287081

T: +91-80-42105031

E: geeta.bisht@hmf-india.com

E: info@jyoti.co.in

E: sales@metrolindia.com

W: www.hannovermesse.com

W: www.jyoti.co.in

W: www.toolsensor.com

Heidenhain Optics & Electronics (I) BIC

Kabel Schlepp India Pvt. Ltd.,

113

Mitsubishi Heavy Industries India P 144

T: +91-44-30234000

T: +91-80-41158997

T: +91-11-41021234

E: info@heidenhain.in

E: gm@kabelschlepp.in

E: mtdsales@mhiindia.com

W: www.heidenhain.in

W: www.kabelschlepp.com

W: www.mhiindia.com

Hi-Tech Robotic Systemz Ltd

103

Kim Union Industrial Co., Ltd.

140

MJK Manufacturing

139

T: +91-124-4715100

T: +886-4-2533-1131

T: +91-9557469320

E: marketing@hitechroboticsystemz.com

E: kimunion@kimunion.com

E: india@mjkmail.in

W: www.hitechroboticsystemz.com

W: www.threadrolling.com.tw

W: www.mjkmail.in

Hyundai Wia India Pvt. Ltd.

Korber Schleifring Gmbh

Pg No

MMC Hardmetal India Pvt Ltd

154

T: +91-9940653703

T: +91-80-41554601

T: +91-80-23516083

E: sales@hyundaikiamachine.net

E: sales@schleifring.in

E: mmcindia@mmc.co.jp

W: www.hyundai-wia.com

W: www.schleifring.in

W: www.mitsubishicarbide.com

IFM Electronics India Pvt Ltd

Korloy India Tooling Pvt. Ltd.

Moonlight Industries

141

T: +91-2312672770

T: +91-124-4930080

T: +91-281-2364836

E: info@ifm-electronic.in

E: sales.kip@korloy.com

E: info@moonlightindustrie.com W: www.moonlightindustrie.com

W: www.korloy.com

W: www.ifm-electronic.in

Igus India Pvt Ltd

Kuka Robotics (India) Pvt. Ltd.

T: +91-80-39127800

T: +91-124-4635774

E: info@igus.in

E: pradeep@kuka.in

W: www.igus.in

W: www.kuka.in

Intec 2013

Larsen & Toubro Limited

119

Motul 85 T: +33-148117030 W: www.motul.com

FIC

Nicolas Correa S.A.

T: +91 422 2222396

T: +91-22-67051093

T: +91-20-25654891

E: intec@codissia.com

E: sm.haridas@larsentoubro.com

E: u.medha@correaanayak.es

W: www.intec.codissia.com

W: www.larsentoubro.com

W: www.correanayak.es

Intec Capital Ltd

Larsen & Toubro Ltd

117

Nmtg Mechtrans Techniques Pvt Ltd. 134

T: +91-8860612707

T: +1800-2335858

T: +91-79-22821527

E: marketing@inteccapital.com

E: cic@lntebg.com

E: nmtg@nmtgindia.com

W: www.inteccapital.com

W: www.larsentoubro.com

W: www.nmtgindia.com

Inter Ads - Brooks Exhibitions Pvt 129

Maco Corporation India Pvt Ltd

NN Combined Engineering Agencies Pvt BGF

T: +91-33-24758371

T: +91-40-27844279

E: blech.india@interads.in

E: rdutta@macocorporation.com

E: mail@nncea.com

W: www.blechindia.com

W: www.macocorporation.com

W: www.nncea.com

T: +91-124-4524207

Jergens India Pvt Ltd

133

Marox Tools Industrial Co. Ltd.

140

Octahedron Superbrasive Co Pvt Ltd 135

T: +91-22-41238039

T: +886-4-2278-0167

T: +91-141 -2570495

E: joseph.killukan@jergensinc.com

E: service@marox.com.tw

E: jb.roytalukdar@gmail.com

W: www.jergensindia.com

W: www.marox.com.tw

March 2013 - MMT 151

List of Advertisers Advertiser’s Name & Contact Details

Pg No

Omron Automation Pvt. Ltd.

Advertiser’s Name & Contact Details

Pg No

Raj Petro Specialities Private Limited 67 T: +91-44-42288900

T: +91-22-26592392

E: in_enquiry@ap.omron.com

E: francis@rajgrp.com

E: teknic@vsnl.com

W: www.omron-ap.com

W: www.rajgrp.com

W: www.tecknic.co.in

Robin Precision Products Pvt Ltd. 54

The Jaws Mfg Co

T: +91-80-30504647

T: +91-2827-287631

T: +91-20-26877842

E: Info.India@openmind-tech.com

E: info@bloodtools.com

E: jaws@jaswindia.com

W: www.openmind-tech.com

W: www.bloodtools.com

W: www.jawsindia.com

Para Mill Precision Machinery Co., Ltd 141

S&T Engineers

T: +886-4-2680-0678

T: +91-422-2590810

E: para.mill@msa.hinet.net

E: sales@stengineers.com

W: www.paramill.com

W: www.stengineers.com

Paragon Machinery Co., Ltd.

T: +886-4-2539-5678

Samchully Machinery Co Ltd

E: makeitdream@samchully.com

W: www.paragoncnc.com

W: www.samchully.com

T: +91-80-28378030 E: info@in.pepperl-fuchs.com W: www.pepperl-fuchs.com

Pilz India Pvt Ltd

T: +91-20-24213994

T: +91-80-41277361

T: +91-22-25836780

Seco Tools India Pvt Ltd

139

Quickmill Inc.

123

SHW Machine Tools (India) Pvt. Ltd.

R S Electro Alloys Pvt Ltd T: +91-11-25280488 E: info@rselectro.com W: www.rselectro.com

MMT - March 2013

E: adeshmukh@shw-wm.de W: www.shw-wm.de

Sri Yantra Engineering Agencies (P) 111 E: info@yantraengineers.com

W: www.quickmill.com

W: www.yantraengineers.com

Taegutec India Ltd

T: +91-124-2370250

Tungaloy India Pvt Ltd

T: +91-22-61248888

Tyrolit India Superabrasive Pvt. Ltd 100 T: +91-80-40953259 W: www.tylolit.com

T: +91-80-40710555

E: phil-g@quickmill.com

Trigon Tooling Solutions Pvt. Ltd. 63

E: subrahmanya.kumar@tyrolit.com

T: +91-22-32222491 W: www.ptc.com/go/Aristides

W: www.hydrauliccylinder.co.in

W: www.tungaloy.co.jp.in

W: www.secotools.com/in

E: ssentp2009@gmail.com

W: www.precihole.co.in

E: trident.sales@tridenthydraulics.com

E: info@tungaloyindia.com

T: +91-9316056942

E: info@precihole.co.in

138

T: +91-124-4300626

W: www.trigontools.com

W: www.schunk.com

Shri Shyam Enterprises

Trident Products Pvt Ltd

E: info@trigontools.com

E: info@in.schunk.com

E: seco.india@secotools.com

W: www.pilz.in

PTC Creo

107

T: +91-2137- 667300

E: info@pilz.in

Precihole Machine Tools Pvt Ltd

Schunk Intec India Pvt Ltd

136

T: +91-11-41425326 W: www.trident-precision.com

E: info@paragoncnc.com

Trident Precision International

134

E: trident.sales@tridenthydraulics.com

T: +82-32-822-4811

Pepperl & Fuchs(India) Pvt. Ltd.

Pg No

Teknic 37

T: +91-80-40726400

Openmind Cadcam Technologies (I) Pvt 30

152

Advertiser’s Name & Contact Details

T: +91-80-27839111 E: sales@taegutec-india.com W: www.taegutec-india.com

Wohlhaupter India Pvt Ltd

T: +91-9810405242 E: keshav.khurana@wohlhaupter.com W: www.wohlhaupter.com

YG Cutting Tools Corporation Pvt Ltd 3 T: +91-80-43543636 E: admin@yg1india.com W: www.yg1.co.kr

Zhuzhou Cemented Carbide Works Imp.&Exp.Co 16 T: +86-731-2826-1443 E: zccc@chinacarbide.com W: www.chinacarbide.com

March 2013

Reg No: MH / MR / WEST / 235 / 2012 â&#x20AC;&#x201C; 2014 RNI No: MAHENG / 2008 / 24347 Licence to Post at Mumbai Patrika Channel Sorting Office, Mumbai GPO., Mumbai 400 001 Date Of Posting 5th & 6th Of Every Month / English & Monthly. Date Of Publication: 28th of Every Month

160