Modern Machine Tools - May 2012 by Infomedia18

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Editorial

Back To The Grind e it man or metal, the grind brings out the real essence. It is upon the temperament and the tendencies, whether we opt for a rough or smooth finish! Leaving the human aspect alone for the time being, and focussing solely on metals, this finishing operation, with high precision involved, shapes and finishes the metal for extensive and intense performance. Cutting edge gets a new dimension when each cutting grain of the grinding wheel, sharp and irregular, acts as a cutting tool, for the desired finish.

The grinding wheel reflects the needs of the industry as it has adapted and changed as per the requirement of the industry. From resin bonded to the self-sharpening grinding wheel, each phase between these two vast spectrums depicts the changing needs and dynamics of the user industry itself. While the prospects are ripe, Indian manufacturers of grinding machines have to develop and offer some of the advanced features on their machines to catch up with their international counterparts. World renowned manufacturers of grinding machines have put in a lot of R&D efforts to develop machines with these capabilities.

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

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

Shailesh Sheth Media Chairman, IMTMA & Past President, IMTMA

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

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

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

As an expert points out, in India, companies look more into the cost of the product and not into the cost effectiveness of the product. People always compare and relate the grinding wheel by defining the size; they just do not go beyond that and there is much more beyond size comparison. While there is a merit in the logic that companies need to have a holistic approach; in reality, in India, we always use under power machines and then when you put a good quality tool into the machine it goes down. Since grinding is a widely used precision machining method, India seems to be the preferred destination for grinding machines and equipment manufacturers. Driven by domestic demand and the cost efficiency advantage of India, the business outlook for the industry in the country is expected to grow considerably. The growing demand for grinding machines and the need for better product finish have given the push to adopt sophisticated grinding wheels. As the Indian quality norms will increase in future, the need for better grinding wheels will also see a sharp rise. Talking about grinding, we paid a visit to GrindMaster, a homegrown success story. What started in a garage in Aurangabad in 1984 with the making of small super-finishing machines, is today, part of a small elite group of world companies, which have the capacity and expertise to manufacture sophisticated metal finishing machines. Then again, staying with Aurangabad, there is a very interesting news analysis on Aurangabad becoming one of the most promising destinations for machine tools manufacturers housing over 2,000 CNC machines. An interesting thought to ponder over as we leave with a grand content spread, as volleyed by Dr Firodia, the best machine with weak tooling is not as good as a poor machine with excellent tooling. We must strive to get the best tooling solutions for competitive growth in the Indian manufacturing sector. Are we tool and technology ready?

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

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

Archana Tiwari-Nayudu archana.nayudu@infomedia18.in

May 2012 - MODERN MACHINE TOOLS

Contents Insights & Outlook Grinding Industry............................................................... 88 Technology Trends ............................................................. 90 One Q Many Views ........................................................... 92 Eco Pickled Metal Surface ................................................ 99 Grinding Wheel ................................................................. 102

Insights & Outlook Grinding & Finishing

Special Focus Metal Forming

Abrasive Flow Machining................................................... 112 Fibre Laser Technology ..................................................... 116 Simulation Technology ....................................................... 124

Facility Visit GrindMaster, Aurangabad ................................................. 78

Automation Trends - Surface Tuning Special Focus

Finishing Without Manual Laburr ...................................... 128

Indian Metal Forming Industry ......................................... 50 Innovation in Machining ................................................... 54

Energy Management - Eco-conscious Manufacturing Machining With The Environment In Mind .................... 137

Metal Forming Technologies ............................................. 62 Hydroforming .................................................................... 66

Strategy - Social Network Outreach SMEs Click For Global Connect ........................................ 140

Case Study .......................................................................... 74

Event Report Die & Mould India, 2012 .................................................... SIMTOS 2012 ..................................................................... Modern Machine Shop 2012 ............................................... Machines Italia in India .......................................................

In Conversation With

147 149 151 153

Regular Sections Editorial ...................................................................... 15

Ned Librock President (Global), Dynabrade Inc .... 42

News, Views & Analysis .............................................. 26 Technology & Innovation ............................................ 38 Event List .................................................................. 143 Products .................................................................... 156 List of Products ........................................................ 177 List of Advertisers .................................................... 183

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Cover illustration: Sanjay Dalvi

May 2012 - MODERN MACHINE TOOLS

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May 2012 - MODERN MACHINE TOOLS

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NEWS ANALYSIS CNC Market In Aurangabad

Offering Manufacturers A Cutting Edge Housing over 2,000 CNC machines, Aurangabad has become one of the most promising destinations for machine tool manufacturers in India. With the burgeoning growth witnessed in industries like automotive, heavy engineering and FMCG, the growth prospects for machine tools are bound to witness a high in the years to come reports Nishi Rath...

he advent of the automotive industry has created manifold growth prospects for industries in Aurangabad. And the influx of industries, such as heavy engineering and FMCG, are further fuelling the demand for niche segments, such as machine tools, in and around the region. Aurangabad is said to have around 2,000 Computer Numerically Controlled (CNC) machines—the dominant users mainly being players in the automotive industry. Based on the current trends and emerging demands, the CNC machines segment is emerging as a key driver of growth for industries in Aurangabad. According to B Ravindra Naidu, Joint President, Birla Precision Technologies Ltd, “Nowadays, CNC machining has become the most crucial element, considering the high precision involved in the production process and the kind of accuracy desired by the customer. Though in the start, it seemed a little expensive, but going by the returns you get in the long term, it is worth investing in such precision machine tools.” Parvesh Batra, President, Aurangabad Industrial Suppliers Association (AISA), says, “We all agree to the fact that when there are tremendous opportunities waiting to be tapped, innovative methods to enhance productivity are bound to take centre stage. The deployment of CNC machines is among one of those crucial factors for ensuring the same. Notably so, the dominance of diverse kinds of CNC machines has helped companies enhance their productivity, ensure higher precision, increase reliability and attain better finishing & improved aesthetics.”

The Growth Bandwagon Achievement of higher growth and 26

MODERN MACHINE TOOLS - May 2012

increased share of CNC machines in the overall output surmises the commitment to provide competitive manufacturing solutions, and, that too, at cost-effective prices. In terms of key product segments, high growth areas for CNC machining include turning centres, machining centres and grinding machines, among others. Lathe machines, router machines, foam cutting machines and CNC machines, catering to surface finishing and grinding, have been doing the rounds in Aurangabad manufacturing units since the last few years. To this, Milind Umadikar, Owner, Mechatron, adds, “Auto forms a major cluster and every big or small company wants to be at par with its competitors. The CNC machines being used not only add to the productivity, but also ensure accuracy—a must for a business to succeed.” Mukund Kulkarni, President, Chamber of Marathwada Industries and Agriculture (CMIA), opines, “The stupendous growth attained in the past few years has led to the rise of various first generation entrepreneurs in Aurangabad. They are updated with the industry’s scenario and the latest technological advancements. This can also be cited as one of the major reasons for the use of various latest CNC machines in Aurangabad today.”

CNCs In Shop Floors SMEs have also welcomed CNC machines into their shop floors. “You cannot compete with your contemporaries if you are not aware of the latest technology in the business today. Also, CNC users seek to economise on manufacturing cost and time, which is an additional advantage that CNC machines offer,” avers Umadikar. Although CNC machines are difficult to programme, they require less manual intervention to operate—an advantage in

a region that significantly lacks skilled labour that could explain the rise in deployment of these machines. While almost all the industries in Aurangabad have opted for CNC machines, a major chunk of around 70–75% go to automotive players and auto components manufacturers here. With majors players like Bajaj Auto, Skoda and Sanjeev Auto setting up their base in the region, the adoption of CNC machines saw a new light in this growing industrial hub.

Beholding Colossal Potential With the major industries wanting to set up base in the region, machine tools manufacturers can definitely prepare themselves to cater to the burgeoning demands. Substantiating the fact, Mukund Sangvikar, Proprietor, Jyoti Marketing Agency, adds, “Various new businesses will come up in Aurangabad. Also, the auto industry is set to grow further in the next couple of years. Both mean that more and more sophisticated machines & CNC machines will be used. People see them as a one-time investment, which will help them in the long run. Moreover, with technology taking centre stage in manufacturing, this ought to happen.” After all, it is all about making customers happy. By adopting CNC machines, not only reduces cost, but a new level of accuracy is also attained. And as far as the industrial development of Aurangabad is concerned, it has been growing at a rate of 14% per year since the last couple of years…a growth momentum which is likely to continue in the coming years. This trend augurs well for the machine tools industry. In the end, the trend is here to stay and would grow with increasing competition and expansions by existing players. nisi.rath@infomedia18.in

News, Views & Analysis

Adding Value To Engineering

he growth of the Indian industry today is shifting its focus to smart manufacturing. With most companies adopting lean and six sigma practices, IMTMA gauged into the need for ‘Value Engineered Products’ to customers. This practice is gaining more significance due to the liberalised national economic situation, continuing material price increase, cost reduction and increased competition, which is ultimately affecting profitability. A daylong seminar was conducted by G Ananthakrishnan, a mechanical The concept of value engineering and value analysis picked up momentum after people began realising that this is a supporting function and not a replacement. – G Ananthakrishnan

the cost in totality and finds out ways to bring down the cost by removing unnecessary expenses and adding value. Quality, value, delivery and services have become the need of the hour for the Indian industry. This concept picked up momentum after 2003 and people have realised that this is a supporting function and not a replacement,” said Ananthakrishnan. This programme addressed the concepts of handling cost reduction G Ananthakrishnan explains the nuances of value measures and systematic approach to engineering and value analysis investigation of the function and cost. A participant at the seminar Vinay Gandhi, Sr GM, Godrej & Boyce Mfg engineer, with over 40 years of Co Ltd, said, “Cost is the main factor experience with BOSCH, Lucas-TVS which every company is working towards and currently associated with UNIDO. and I feel that proper implementation of “Value engineering and value this concept will be beneficial.” analysis, both look at the product and

IMTMA Seminar calendar for the month of May, 2012 Date 03–04 May 2012 04–05 May 2012 08–09 May 2012 10–11 May 2012 11 May 2012 11 May 2012 15 May 2012 15 May 2012 17–18 May 2012 23 May 2012

24–25 May 2012 24–25 May 2012 25–26 May 2012 28 May 2012 29–30 May 2012

Topic Seminar On Latest Trends In Electrical Discharge Machining Workshop On Design Of Experiments (DoE) In Solving Real-life Problems Seminar On Getting The Best Out Of Coordinate Measuring Machines (CMMs) Training Programme On New Product Development On CNC Machining Centres Seminar On Servo Technology For Industrial Motion Control Seminar On Latest Trends In Gear Manufacturing Seminar On Cleaning Of Machined Components Seminar On Value Engineering And Value Analysis Workshop On Effective Maintenance Of CNC Machines For Productivity Improvement Seminar On Right Selection Of Linear Motion Guideways, Ball Screws & Servo Drives For Industrial Machinery Seminar On Design Of Workholding And Fixturing Seminar On Die & Mould Manufacturing Seminar On Manufacturing Excellence Through TQM Approach Seminar On Idle Time Reduction In Metal Cutting Through Quick Changeover Techniques Training Programme on Practical Solutions for Designing Complex Plastic Injection Moulds

MODERN MACHINE TOOLS - May 2012

Venue IMTMA Technology Centre, BIEC, Bengaluru Gurgaon SKF College Campus, SKF India Ltd, Chinchwad, Pune IMTMA Technology Centre, BIEC, Bengaluru IMTMA Technology Centre, BIEC, Bengaluru Gurgaon IMTMA Technology Centre, BIEC, Bengaluru Gurgaon Gurgaon SKF College Campus, SKF India Ltd, Chinchwad, Pune Chennai Hotel Parkland , New Delhi SKF College Campus, SKF India Ltd, Chinchwad, Pune SKF College Campus, SKF India Ltd, Chinchwad, Pune SKF College Campus, SKF India Ltd., Chinchwad, Pune

News, Views & Analysis

Updates @ Die & Mould India, 2012 Global Presence Veronica Just, Vice President, Millutensil – Italy Over the years, we have been attending different exhibitions in India and this was our second time at DMI. We have been working with Batliboi for 18 years and our business has been growing in India due to this collaboration. Worldwide, our company specialises in manufacturing spotting presses, which are important for die and mould manufacturers. We have sold machines in India to companies like Godrej, JmpTools, L&T and globally, to BMW, Magna Group and so on. Tony Wang, Sales Manager Zheijang Taoshi Group, Huangyan Hualong Co Ltd – China Pavilion. The changing face of the world economy is drawing us to markets like India, as compared to Europe and elsewhere. We are looking to maintain our relations with our existing customers in India, like Videocon, Godrej, etc. In India, we supply tool distributors with technology, management and facilities. There are several facets of the Indian market, which are similar to the Chinese market, especially the growth in the automotive sector. Ravi Sane, Product Manager Dijet Industrial Co Ltd – Japan The style of working between manufacturers and customers in Japan and India is slightly different. Engineers and technical designers in Japan tend to accept in confidence the product and knowledge offered by manufacturers; whereas in India, there is a need to first prove the effectiveness of the product prior to investing confidence or purchasing. This helps customers in India expand their knowledge base and gives them an opportunity to upgrade their technical expertise. Right now we are doing business worth ¥17– 18 million per month in India and our target is to reach ¥35–40 million per month within the next two years. Dijet came to India in 2007, and today 85% of toolmakers for stamping dies, press tool dies and die-mould manufacturers use Dijet cutting tools.

Exhibitors Meet Potential Customers at TAGMA Seminar Tools and Gauge Manufacturers Association of India (TAGMA) brought exhibitors and potential customers, students & visitors face to face in order to engage in an in-depth discussion during the ongoing 8th Die & Mould India International Exhibition. Some of the prominent participants at the seminar include ALD Dynatech Furnaces, Jyoti Machine Tools, Delcam and SAG Materials AG. The presentations at the seminar covered efficiency enhancement, productivity improvement, prototyping and digital manufacturing.

MODERN MACHINE TOOLS - May 2012

News, Views & Analysis

Bombardier Inaugurates Aerospace Engineering Centre

CIMES Poised With Promises

rganised jointly by Reed Exhibitions, China National Machine Tool Corp and China National Machinery Industry Corporation, CIMES, is scheduled during June 12–16, 2012. As China’s largest machine tools event with 1,20,000 sqm in gross area, the international exhibition is a truly global machine tools sourcing and trading platform providing the widest array of innovative products, technologies and solutions showcased by the world’s leading players from overseas as well as from China, to improve the buyers’ manufacturing efficiency and to sharpen their competitive edge. The event will witness 1,300 exhibiting companies with industry experts from 28 countries, displaying nearly 3,000 pieces of machinery & tools at the show, including the latest metal cutting, metal forming & special purpose technologies, tools, accessories & components, automation & NC systems alongside a huge variety of other exhibits onsite.

dding to its current capacity, Bombardier inaugurated its new engineering service centre in Bengaluru to execute aerospace projects, including aircraft design. “The engineering service centre here will support the development and production of aircraft in-house with our software and hardware partners in India,” informed Jean Seguin, VP, Bombardier Aerospace Division. The Canadian major manufactures business jets and turbo-prop regional aircraft global commercial airlines besides designing coaches for metro and mono rail services. “Our aerospace engineers, currently 20, will undertake complex aircraft structural designing, advanced stress analysis and project management services. They will also assist about 400 engineers working on our projects with partners like Tata Consultancy Services (TCS), Mahindra Satyam, Capgemini, Cades and Quest,” Seguin said during the inauguration of the

(From L to R) Jean Seguin, VP – Quality; and Claude Beaudin, VP – Human Resources, Bombardier Aerospace, inaugurate the new engineering service office in Bengaluru

service centre. The new Engineering Service Office will house approximately 50 aerospace engineers by the end of 2013. The company has also projected that India has the potential to buy 1,330 business jets over the next 20 years.

IMTMA Helps Choose The Right Fixture

ven as the level of machining and manufacturing has gone up, workholding devices and fixtures are yet to gain the importance. To encourage the use of the right fixtures while machining, IMTMA hosted a two-day-long seminar coupled with group discussions and demonstrations of a quick change clamping system. “With the development of machines and tools, fixtures need to develop equally. The productivity of manufacturing can go up by around 50% if the right fixture is used,” The productivity of manufacturing can go up by around 50% if the right fixture is used. –Prabhakar J

productivity and eliminate quality defects. The seminar was attended by participants from the mid management of various companies, to discuss the problems related to poor quality and productivity—consequences of poor fixturing in terms of choice and design. “It is true that the Indian industry is yet to understand the importance of proper fixtures Prabhakar J talks about the importance of choosing the right in the machining process. The automotive sector has, however, fixtures started to realise the importance and with such seminars, we are trying to explained Prabhakar J, a Technical reinforce the need for better fixturing,” Expert at Kennametal India Ltd, during explained Gautam Doshi, Advisor, his presentation. IMTMA, who was also one of the The seminar discussed ways to speakers at the seminar. optimally use workholders to improve May 2012 - MODERN MACHINE TOOLS

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TECHNOLOGY & INNOVATION

Technology Galore @ Die & Mould India 2012

Technologies Trends Products Processes @ Die & Mould India 2012

HETO IX 1000 True to its German DNA, this multifunctional mould machine is a one-stop shop and can perform various

has This kind of technology ian Ind at n see never been ng uci red es sid Be . ors flo p sho o als it e, tim production sa uld mo the ing giv in ps hel perfect finish.

tolerance of 0.03–0.05 mm; these units not only protect the core inserts in the moulds, but also ensure high accuracy and service life. These locating units are DLC coated, which is noted for its extremely low coefficients of friction and high level of hardness. In addition, it helps achieve a much higher service life for the moulds.

OR Laser’s EVO Mobile With a compact size, this laser welding machine operates through a touch-

Product Engineer at HETO functions together. It has the capacity to do milling, conventional drilling, tapping, boring and deep hole drilling. Since it is fully automated, the machine eliminates the set-ups between phases in the manufacturing of moulds. With a 3D finish, IX 1000 reduces drilling time by almost 60% as compared to other machines. Also, it decreases the mould delivery time by 20%. The machine is fitted with a drilling capacity diameter of 6–40mm. It is also available in IX 2000 and IX 3000 variants.

Hasco’s DLC Locating Units Hasco has displayed a highprecision locating unit at the exhibition. A combination of precentring with a guide

sta te- of- the -ar t Th is sts of a five litre boa ne machi ich water tank as well, wh rs hou 24 e rat ope it helps a day. Roshan Nair, Product Head, Nickunj Eximp Entp Pvt Ltd screen system. It boasts of an intern video function and auto weld. The machine has an integrated control with a 10” TFT display panel. Weighing 370 kg net, EVO Mobile has a traverse range Zaxis of 570 mm, which is controlled via a solenoid valve. Manufactured by OR Laser, this machine is being distributed by Nickunj Eximp Entp Pvt Ltd in India.

t is costly Even though this produc ventional con er oth to ed par as com d by it ere off s efit fluids, the ben reover, Mo t. cos the for e sat compen ilities fac ing tur with manufac uring ens s ard tow ng rki wo ly active fluid s thi rs, rke wo greater safety of on. uti sol t fec per a be to proves

Shadab Ali, Engineer, Prime Industries

Wikus-Niran’s Fully Automated Band Saws The S-250HA/250HB pivot type is the latest technology being brought to India. With a shuttle type automatic feed, the machine has a PLC control for all electric and hydraulic functions. The saw has a maximum capacity of 250 mm

s The best part about thi machine is that it is not n dependent on huma d intelligence. All you nee set and log the to do is put the functions; the machine n. would operate on its ow , Plus, there is a box below t duc pro ed ish fin where the would be collected.

Prime Industries’ Synthetic Fluid h They are coated wit n rbo Ca e Lik d on Diam be to e saf are (DLC) and d used in the medical, foo ry. ust ind and packaging

Pravesh Padmanabhan, Design Engineer, Hasco India Pvt Ltd.

MODERN MACHINE TOOLS - May 2012

Prime Industries, Italy, has brought to the Indian market a synthetic fluid to be used for electrical discharge machining (EDM) technology. Unlike conventional fluids, the synthetic fluid does not generate fumes, which could be harmful for workers on the shop floor. Besides, the fluid’s evaporation rate is less. While conventional fluids cost around Rs 100 per litre, the synthetic fluid costs close to Rs150 per litre.

A company spokesperson and is equipped with a floating shuttle vise system. The infinitely variable speed control of the machine is controlled by an inverter. The machine is fully automated and is fitted with bar sensors to control work height. The machine has a blade speed of 20m/min. The floor space required for this machine is 2100 x 2200 mm (82.6” x 86.6”).

TECHNOLOGY & INNOVATION

Largest Injection Moulded Plastic Bumper in India

he ubiquitous demand, stringent norms for emissions and a ruthless approach to fuel efficiency has resulted in a proliferation of inventions and technological advances in the manufacture, design and production of automotive components. Of these, the advent of plastic components has been most significant. To illustrate this significance, Mohit Narayan, Deputy Divisional Manager at Force Motors Ltd, highlights, “We have developed an Injection Moulded (IM) front bumper that is the largest injection moulded plastic bumper in India and quite possibly, among the largest in the world.” Why plastic? It is lighter than metal components, reduces vehicle weight, improves fuel economy, is flexible and can easily be used to make complex geometries. The aesthetics are better than those in sheet metal components and the material allows for quick production (lower cycle times than sheet metal fabrication) of complex geometries in fewer steps. Although heavier sheet metal bumpers, used on large vehicles, have a higher impact strength and rigidity, they have formability limitations and add considerable weight to the vehicle. Plastics are cost effective to produce, have low manufacturing cycle times and fixtures for lighting and other components are easily incorporated. As part of a collaborative project with Bright Autoplast Pvt Ltd, engineers at Force Motors designed and manufactured the moulds required to make this

This front bumper is the largest plastic injection moulded bumper manufactured in India

large bumper. Polypropylene is the material used in this uniquely sized IM manufacturing process. Made of the highest grade steels, the mould, core and cavity, weighs over 40 tons and has dimensions of 3m length, 1.6m width and 1.8m. The length of the bumper itself is greater than the length of some automotive vehicles. It has been tested and designed for the large Traveller SUV’s also made by Force Motors.

The Greening of PCB Chemical free CNC milled board

his was an attempt to make printed circuit boards (PCB) for companies and students with CNC milling machines avoiding the use of ferric chloride that is typically used to manufacture PCBs for the electronics industry. “This (ferric chloride) greatly destroys our environment and damages the aquifers,” said Campos. “It’s like chemical logging. By using our procedure, we will do our bit to save our planet and our species.”

generating G-code which drives the computerized milling machine. They use the Gerber file generated by the program for printed circuit design to generate the G-code. The computer program runs to create the tracks, drill holes and cuts them to designated sizes. The program can design a complete and custom printed circuit board fit for specific needs. In addition, besides metal, almost any material can be used, wood, aluminum, plastic, acrylic, etc.

Benefits Process PCBs are used to support and connect electronic components in a circuit using conductive pathways, tracks or signal traces. Campos’ designs of the tracks are made by 40

MODERN MACHINE TOOLS - May 2012

In addition to the environmental benefits, the CNC method is both faster and more accurate than the chemical process. It takes only about 10 minutes compared to 30 minutes using conventional methods.

Products As of now Campos makes two types of PCBs, one is a liquid level control and the other is by control pulse. Printing services are also provided for people if they have any specific design in a Gerber file he can take that design and generate the G-code for the PCB and he can create the design for the circuit if needed. Campos mentioned an initial challenge of first having problems with the G-code and a ground that needed to be connected to the PC and the CNC. Without that ground the entire process didn’t work properly and was not responding to some of the programmed signals. Soon they ironed out all the kinks out and got the program running smoothly. Now they are working on improving their pulse techniques.

IN CONVERSATION WITH Ned Librock

Everything that we touch in our day-to-day lives is touched by an abrasive The potential of this sector is huge. Whether in India or in the international market, we are driven by manufacturing and will follow wherever there is increased manufacturing activityâ&#x20AC;Ś insists Ned Librock, President (Global), Dynabrade Inc, a leading abrasive tool manufacturer, as he shares his key insights with Nishant Kashyap. Excerptsâ&#x20AC;Ś

MODERN MACHINE TOOLS - May 2012

Ned Librock Q How has the field of abrasive

UP CLOSE

power tools evolved over the years?

&personal

Conventionally, manual sanding process was instrumental in driving any finishing process. With India offering the low-cost labour advantage, the manual process has been more prevalent. The need for better finishing has always pressed hard the requirement for improved machinery, bigger machine tools and portable finishing tools. Bigger and more sophisticated machine tools have evolved and replaced the heavy hand-held abrasive power tools. So, in a way, the use of larger machines, to an extent, has reduced the use of power tools. Besides, customers today prefer products that have high finish. So, the opportunities for portable abrasive tools have increased tremendously over the years.

What motivates you to do better? Seeing our young team of professionals satisfying major companies with finishing solutions configured by Dynabrade motivates me. It is always thrilling to see the results of their enthusiastic hard work!

Toughest business decision taken? Tough business decisions for the most part are easy. If you use various filters such as how does this decision affect the overall health of our company, will this decision be good for both the parties, can we perform as per the expectations of our customer, etc., most decisions become easy.

Q In what direction is the grinding

and finishing industry advancing, to be in sync with India’s growth? The automotive industry has a huge consumer base in India, which justifies the massive requirement for steel. On the other hand, owing to the need for huge infrastructure to cater to the growing population bases, there is immense need for cement production. Thus, cement and steel being prime movers in economic growth will drive all the related industries (such as infrastructure, manufacturing, etc.). And with increased industrial and manufacturing activity, grinding and polishing will be key ingredients.

How do you deal with a difficult situation? Probably, the toughest time in the past 20 years was during the global economic slowdown in 2008–09. We had to make some adjustments in staffing which is always very difficult.

Q What are the top five opportunity

areas for the industry?

Q How do you envisage the Indian

market five years down the line? With a lot of global uncertainty, multinational companies always looked for countries providing better growth. India will surely be the growth story for many years into the future. In absolute terms, a growth of 7–7.5% in GDP is very encouraging and we see our company growing at 15–20% yearon-year for next few years. Yes, there is a bit of a slowdown at the moment. But that’s part and parcel of any fast growing economy.

For us, the biggest challenge was converting manual labour to machine sanding, which proved to be the biggest opportunity as well. End users used a 7” heavy tool as the first step in any fabrication or engineering shop. To demonstrate these to end users, the correct tool and correct abrasive turned out to be a big opportunity for us (eight out of 10 demonstrations that we do as a company convert into orders). The other big opportunity for us was to convert end users who understood the benefits of using electrical power tools. As they upgraded themselves from manual to at least using a power tool, they soon realised that although the benefits of using a power tool cannot be disputed, they wanted a more durable option, i.e., using an air

tool. So, end users who were using electric powered tools for professional and heavy duty industrial applications became our next target. Most of the manufacturing that got shifted to India was mainly done to freely utilise the available lowcost labour. Moreover, the jobs that involved huge amounts of manual and repetitive labour also became our target customers. Good examples are small car manufacturing and wind turbines. The biggest opportunity India provides is the huge consumer base and any product that is targeted at a huge consumer base would target the Indian market. Once the demand for these products increases, it needs to be in proximity to the marketplace. Since India was closed as an economy for a long time and is now opening up, the markets will take a long time to mature. It is this transition of the Indian market—from developing to developed—that every company in the world would want to be a part of. When we talk about finishing, most of the components or jobs get painted as the final step, but stainless steel finishing offers a big challenge as it does not get painted and there is no paint to camouflage all the imperfections. With more European companies entering into the Indian market, the requirement for stainless steel finish products on the rise (they use a lot of steel finish in furniture, railings, elevators). This opportunity cannot be ignored. End users or industrial consumers who cater to export markets face a huge challenge when it comes to competing in the global environment. Apart from being competitive in terms of the prices they offer; their finished products also need to match international quality standards.

Q What is being done to overcome

the challenges that the industry is presently facing? Grinding and sanding generate a lot of dust. That is why, people who use applications do not prefer to use May 2012 - MODERN MACHINE TOOLS

IN CONVERSATION WITH Ned Librock machines and instead opt for manual or alternate methods. In some of the developing markets like India, health and safety are still not a major concern, but with multinational companies entering the Indian market, there will be no compromises on this aspect. Being a global company, we will not be allowed to sell our products in the US and Europe, if the safety norms are not followed. Moreover, end users prefer our machines over those of our competitors because of their incorporated design and safety features. In India, it is a challenge to exhibit our products as customers are still not open to these features. Going forward, we expect a big shift in customer preferences in India as health, safety and environmental laws are getting stricter.

Q Your comment on India’s R&D

activity. Being a growing economy, India has a lot of scope. There is also a learning curve and it will build over the next couple of years. In today’s age of Google, distances

MODERN MACHINE TOOLS - May 2012

have reduced and everyone concerned prefers to shorten the trial period. So, import is an easier option. I am sure that with volumes building up here and markets maturing, it is only a matter of time when major investments in R&D will happen and every effort will be made to create an India-specific learning curve. The industry will witness an indigenisation of sophisticated technologies. It is a process and will evolve step by step.

Q What are the emerging avenues in

the grinding industry? The biggest change in trend that is taking place worldwide is an improvement in die and press shops, better castings, forgings, etc. Ironically, this change is taking attention away from the finishing process. We have seen customers requiring very few abrasives to finish their jobs. While this is a matter of concern, to an extent, many new challenges are also coming up. Better technology will reduce grinding and finishing, but these

technologies cannot eliminate finishing requirements. The industry will still need high-quality machines to give products a good finish.

Q Your plans for the Indian market? Almost everything that we touch in our day-to-day lives is touched by an abrasive. So, the potential of this sector is huge. Whether in India or in the international market, we are driven by manufacturing and will follow wherever there is increased manufacturing activity. Our future plans would be to continue solving our customer’s problems by designing and manufacturing highquality machines to carry high-quality abrasives on them. In line with the global standards, we also introduce innovative features in our machines without compromising on the ‘human’ angle. India is our seventh largest market. Currently, we have 70 distributors in India and are planning to increase it by 10 this year. nishant.kashyap@infomedia18.in

MMT May-2012

Ad Name:Kushal Pg No. 45

MMT May-2012

Ad Name: Crane Pg No. 46

MMT May-2012 Ad Name:Jyoti Pg No. 47

MMT May-2012 Ad Name: Birla Pg No.48

SPECIAL FOCUS METAL FORMING 50 54

Indian Metal Forming Industry

Shaping Up For Solid Growth

Innovation in Machining

Forming Possibilities

Metal Forming Technologies

Hydroforming

Case Study

Time To Renew Tech Expiries

Forming The Future From Within Precision Forming Process Reduces Part Costs By 25%

May 2012 - MODERN MACHINE TOOLS

SPECIAL FOCUS Indian Metal Forming Industry

SOLID GROWTH The coming decade belongs to the Indian manufacturing industry. The way the Indian economy is growing, this industry is set to witness manifold growth in the near future. This growth is set to spur the demand for metal forming in the country. But does India have the potential to match the global standards? Nishant Kashyap analyses…

n the last two decades, the metal forming industry has advanced rapidly with the evolution and adaptation of smart technology & automation. Currently, there is a high demand for products having high productivity and flexibility. Manufacturers are veering towards numerical control systems like CNC machines and machining centres for punching & cutting, which are more productive and provide better speed. According to Shailesh Sheth, Media Chairman, IMTMA & Past President, IMTMA, “All Indian manufacturers are busy catering to the demand created by the Indian manufacturing industry. In the last few years, the Indian industry has witnessed a steep growth rate, which is why Indian companies are in their comfort zone. Indian companies can tackle global competition in India itself. And if in India, we can compete with foreign companies; we should be able to compete with global players in their own country as well. It is another 50

MODERN MACHINE TOOLS - May 2012

thing that we have huge domestic demand, which is much more than the domestic capacity. That is the reason why Indian players are not being pushed to pursue opportunities beyond Indian boundaries.”

Automotive, Railways… The metal forming industry has been evolving rapidly in recent years. It requires validation of manufacturing processes right from the engineering phase. In order to achieve strict targets to be delivered in a shorter time to market, die manufacturers have to deploy stateof-the-art metal forming technologies. Discussing the demand patterns in India, Sheth elaborates, “The maximum consumption of metal forming is in the automotive & consumer appliance industry, where large amounts of sheet metal are used for forming processes such as forging, stamping, etc. These two industries have started growing rapidly in India over the last few years. Earlier, because the manufacturing

activity in the country was a little dormant, the balance between metal cutting and metal forming was not matching global standards. But now, thanks to the growth of the automobile and appliance industries, this balance has been corrected.” The country is witnessing significant growth with the manufacturing sector clocking exceptional progress. With the country’s automotive, aerospace, energy, consumer durables and electronics & electrical industries, surging forward, and major global players in these segments setting up their facilities in India, the country is establishing itself as a global manufacturing hub. Also, as manufacturers have to meet the requirements of both domestic as well as international markets, machining techniques have undergone a paradigm shift in the industry. The growth of the metal forming industry—mostly related to the automotive sector—has picked up pace in recent time. To overcome the current

Indian Metal Forming Industry situation, the forming industry has started adopting innovative measures in terms of technology. Apart from these industries, Indian Railways has also fuelled the demand for metal forming manufacturing as it is one of the biggest railway networks in the world. Besides, the current Railway Budget and metro projects have created huge opportunities for the metal forming sector.

Import Hurts…Indigenous Works The rising cost of imported machinery has created immense opportunities for Indian manufacturers. Sheth explains how… “Indian consumers are dependent on imports,” he says, adding, “But the rising cost of imported machinery has forced companies to import secondhand equipment, which customers know is not in their long-term interest.” “But, at the moment, companies do not have any option. Once Indian manufacturers begin to provide new technology equipment at reasonable prices, it will open up new market segments, which will offer customers affordable technology. As a result, there would be steep decline in the consumption of second-hand equipment. This, in turn, would not only provide

domestic equipment manufacturers several opportunities, but would also reduce the overall dependence on imports, eventually,” he explains.

Measures To Adopt The Indian metal forming industry has been successfully competing in the global marketplace and registering a high year-on-year growth. However, large sections of the sector still suffer owing to factors such as technology gap and poor infrastructure. The Indian manufacturing industry has all the necessary ingredients, which would enhance its economic development and increase productivity. However, Indian companies are lagging behind when it comes to R&D facilities. Over the last decade, significant technological developments have taken place. Commenting on this situation, Sheth says, “Technology upgradation depends on the demand. If there is no demand, there is no incentive to innovate. Of late, there has been a huge demand—a pull factor in the Indian industry that is forcing companies to innovate and introduce new products in the market. Moreover, Indian manufacturers are successfully producing

machines such as CNC pipe bending machines, hydroforming, servo control presses, friction welding and multi station trans, among others.” To improve product quality and efficiency in production, the metal forming industry would not only need to invest a large amount of time and money into developing and improving the manufacturing process, but would also have to heavily rely on research & technological innovation.

Forming The Future

In the near future, if the demand justifies the economy growth, many foreign companies may start manufacturing in India. In such a scenario, it is likely that not only Indian companies, but even many global players will also set up base in the country. Driven by domestic demand and the advantage of cost efficiency, the metal forming industry in India is expected to grow considerably. As India strengthens its hold on the global metalworking domain, the country’s metal forming industry is set to burgeon. “The metal forming industry in India is extremely bright. Companies should think and plan big. However, at the same time, they should not just depend on the Indian market, but also expose themselves to Production Of Metalworking Machine Tools global competition by exporting Years to different parts of the world. In 2008–09 2009–10 2010–11 the near future, metal forming Machine Tools Value (in Value (in Value (in Qty. Qty. Qty. will witness higher growth than Segments ` million) ` million) ` million) metal cutting. As a result, there Metal Forming will be high demand for metal CNC 201 358.00 208 386.55 544 455.17 forming equipment,” Sheth Conventional 273 1,878.00 378 2,247.35 683 2,628.62 comments. Total Metal 474 2,236.00 586 2,633.90 1,227 3,083.79 This trend has positively Forming affected SMEs and the Metal Cutting component manufacturing CNC 3,437 8,242.00 4,460 10,843.27 7,203 17,043.12 industry. Moreover, enormous Conventional 1,910 3,766.00 2,586 3,084.68 3,016 4,031.40 requirements coupled with a Total Metal Cutting 5,347 12,008.00 7,046 13,927.95 10,219 21,075.52 robust annual economic growth Total Metalworking 5,821 14,244.00 7,632 16,561.85 11,446 24,158.32 rate will be key drivers that will of which: consistently boost demand for CNC 3,638 8,600.00 4,668 11,229.82 7,747 17,498.30 metal forming. All these factors Conventional 2,183 5,644.00 2,964 5,332.03 3,699 6,660.02 are clear indicators of India being on its way to matching Members Reporting 66 79 89 global standards. Data nishant.kashyap@infomedia18.in

MODERN MACHINE TOOLS - May 2012

SPECIAL FOCUS Innovation in Machining Being one of the oldest technologies also brings with it the onus to evolve beyond the obvious. Forming process, over the years, has faced some of the most astounding challenges. However, despite the odds, it rose over them. Here are some such examples of forming excellences, which talk about the magnitude of challenges in forming critical parts. Debarati Basu and Tarun Tampi report...

Metro Train Brake System The brake systems in metro rail cars are one of the most critical parts of the entire operation of the metro rail. Threadaid, a Hyderabad based Indian SME, which has been a pioneer in cold forming technology in India—especially with regard to thread and spline rolling—has taken up one such project to face the challenge. Treading Into New Terrains: The manufacturing of metro rail cars and associated systems has been taken up in a big way in India even though most of the components are still being imported. A key component in one of these systems, the track brake system, uses a special

How Metro Rail Cars Work? Metro rail cars travel at high speeds and require frequent braking within stations present every 3 km. These 640 mm lead screws, made of special steel are cold formed in a single pass. In one revolution, the specialised lead screw moves 44.45 mm—a difficult distance to achieve. The special lead screw engages the brake system, critically and effectively. 54

MODERN MACHINE TOOLS - May 2012

lead screw to provide effective braking in metro rail cars. These brake systems were internationally manufactured and locally assembled. However, in 2010, Threadaid successfully took up the challenge of indigenously manufacturing and supplying these special lead screws. “Although most of the jobs come to us as challenges, this one was of special importance to us. On our thread rolling machine, we have rolled multistart screws with higher pitches like 11.125 mm x 4 starts in a single pass, for the metro train brake system. We have also done 2 roll thread rolling for rolling Scaffolding pipes and solids with 4 TPI, Acme, etc. Besides, we also take the credit for introducing force feeding technology of rolling splines in our country,” says B Subbas Desappa, CEO, Threadaid. Forming Opportunities: Explaining the need for this innovation, Desappa adds,” We did not have the machines. Instead, we only made the dies and tooling to make these screws. Only one government company, HMT, was making thread rolling machines at that time. From 1996 onwards, we started making these machines and

the tools for the cold forming of threads and spline rolling. By cold forming, we made splines, which are used across the automotive and transport industry in axles and specialised shafts.” These lead screws, made of special steel, find a special application in the track-brake system. Metro rail cars travel at high speeds over short distances with stations present every three kilometres. This involves frequent braking, which has to be accurate, immediate and reliable since it is heavily used as the metro rail traverses its The track brake system uses a route. This intensive special lead braking requires screw to provide a special braking effective braking in metro rail cars. system, which

Innovation in Machining uses a uniquely threaded lead screw. The screw, in turn, requires a specially built 60 tonne thread rolling machine with custom tools that Threadaid developed indigenously. Currently, they are the only Indian manufacturers of these tools, machines and specialised lead screws. Desappa enthusiastically explains, “These 640 mm long lead screws are cold formed in a single pass that takes just 55 seconds per screw on our machines. In one revolution, the specialised lead screw moves 44.45 mm—a difficult distance to achieve. Typically, for normal screws, a single revolution traverses only 4–6 mm at the most. This means that the operator would have to repeatedly apply the brake, thereby requiring more revolutions, before it traverses the distance needed to effectively and immediately brake. In one revolution, the special lead screw critically and effectively engages the brake system.” Going Beyond The Defined: Since 2010, Threadaid has been exclusively supplying these lead screws to GM Hi-Tech, who incorporate it into their brake components and then supply these to a German company, based in India, which uses these components to assemble their patented brake systems for Indian Railways. These state-ofthe-art brake systems have been used in all the metro rail cars in India, beginning with the Delhi metro, thus inculcating cutting-edge global technology and unsurpassed reliability for Indian Railways. Spline form varies from customer to customer as per the depth of form, modules and pressure angles, which vary with jobs. “Threadaid has been completely developed in-house without any foreign tie-ups. Our philosophy is that if a part can be rolled anywhere in the world, Threadaid can figure out how to do it. With vast experience in this subject, we feel that if the Japanese can do it, we in India should not settle for any obsolete way of doing things,” avers Desappa. The development of 56

MODERN MACHINE TOOLS - May 2012

The Schuler Group will be making unique press lines for BMW

these lead screws is yet another feather in the cap of Indian innovation and manufacturing, thus proving that Indian SMEs are more than competent in global research.

Servo Press Lines Mass manufacturing technology is progressing rapidly, given the volume of demand and the need for exacting product quality. This progress is exemplified best in Servo press lines developed by The Schuler Group for BMW. What’s New?: These unique press lines have been a revelation in automated press line technology. They are among

How Servo Press Lines Work? The unique press lines have been a revelation in automated press line technology. The systems use 5–6 servo presses linked together, combining to give a huge 9,000 tonne of total press force, that can handle sheet metal up to 2.5 mm and can process upto 600 metric tonne of steel per day. the fastest press lines in existence today and operate at a staggering 20 strokes per minute. This results in 20% more parts produced per minute as compared to conventional press lines. Interestingly, in developing these machines, optimisation of the process and the controls was not done directly, but was simulated using Delmia V5.

Adding Value-Saving Cost & Energy: This led to large cost savings since equipment programming costs were reduced and production capacity was maximised by 5–10%. The press lines are highly integrated and automated, with electronically controlled torque motors, thereby allowing each die highly customisable slide movement. They also have energy recovering cushions, which give the manufacturer unprecedented control over optimisation of the forming process. Also, since it is possible to digitally optimise the working speed, die life is increased. The best of these systems use 5–6 servo presses linked together, combining to give a huge 9,000 tonne of total press force, that can handle sheet metal upto 2.5 mm and can process upto 600 metric tonne of steel per day. This gives the manufacturer unprecedented control over optimisation of the forming process and increases his production capacity. Gearing Ahead: The growing criticalities of manufacturing today have made it imperative for the forming industry to take up new challenges and push its boundaries towards adopting better technologies. The future of the industry will only have more such examples to demonstrate the potential that the industry has to offer. debarati.basu@infomedia18.in tarun.tampi@infomedia18.in

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SPECIAL FOCUS Metal Forming Technologies

lise as to rea ing h e n o , ring orm nufactu tes. Metal f e time a m in r sinc leade ry da To be a e with expi ring processes se of the m u that co f all manufact ountries becau u r o p e a n o E s mother o Afro-Asian c e r i c a a n d t th hand d m o d A b e t h if n it h i w s ay behin rtunity ments r e q u i r e bed the oppo t India is still w b u has gra this sector. B ... in leader nupam reports A Suprita

he development of metal shaping technologies, as the name signifies, revolves around heat and press treatments (temperature and pressure)—greater the heat, lesser the hammering. Based on this heat treatment, we have casting (which involves heating above the melting point, no pressing is required), hot working (above crystallisation temperature with some hammering) and cold working (which involves heating below crystallisation temperature with required hammering). The selection depends on a number of factors. According to MAK Babi, Advanced Trainer, Bharat Forge, “The epithet ‘best’ could be applied most effectively to the products being contemplated and the materials being considered. More specifically, if the products are tubular or hollow, then hydro-forming could score high, while solid cross-section products could use hot pressing and thin sheet forming may respond best to deep drawing. Material wise, most steels can respond very well 62

MODERN MACHINE TOOLS - May 2012

edicines m e k li re he logies a regarded as t e o n h c e t een hav that gy has b methodologies bility lo o n h c a te e sustain orial. Th immem tandards and g with India, rising s s. China, alon established countrie become an pgradation. u s and ha of technology s in term

to the new forming methods mentioned above, but stainless steels are mostly cold formed due to metallurgical constraints.” The US and EU have already adopted these parameters in their selection process. The US auto industry spends more than $600M per year for fixing and tweaking incorrect parts. Some of the reasons causing inaccuracies include the difference between material models and their 3D designing, contraction, ramming, quenching, solidification and floating of mould errors. For the past few years, a couple of new technologies such as rapid prototyping, spray forming and powder metallurgy have been rapidly growing in order to develop a fundamental understanding of the interplay between multi-axial strain behaviour & sheet microstructure. These will soon be adopted by all growth-oriented companies. Metal forming is not a single step, but involves multiple steps and includes processes such as bending, pressing, nibbling, slitting, slotting, texturing, embossing and engraving depending

upon the shape required. Technology has risen in almost all the possible steps depending on the quantity of material required, design, tolerances required, metal specification, tooling cost and economics of machining against the processing cost. Heres a look at some of the technologies that might lift the overall metal shaping industries...

Furnace Technologies In India, basically three types of furnaces, viz., oil furnace, gas furnace and induction furnace, are used. In time, oil furnaces grew obsolete because of factors such as rising oil prices, hazardous flue gases emission and so on and so forth. Even though a gas furnace is comparatively cheaper and emits lower quantities of harmful gases, it is inhibited by gas supply problems. The induction furnace, on the other hand, adds new feathers with tech advancements. Megatherm provides electric arc, ladle refining & coreless steel frame furnace technology solution, which has the ability to perform the best

Metal Forming Technologies in low-to-high power densities, high on shielding magnetic fluxes and has an extremely rugged construction, low on maintenance. The furnace is enhanced by the latest electromagnetic software programmes, which offer higher safety to operators. Its strong Faraday rings & distributed flux guides prevent the intense electromagnetic field from escaping the crucible’s boundaries. Besides, the software also facilitates optimal impedance to go with power source as well as a rapid melting rate undeterred by the loose initial charges. Elaborating further, Abhishek Kumar Singh, Application Engineer, Electrotherm India Pvt Ltd, says, “The induction furnace is the only solution as it is much more energy-efficient, costeffective and safe. With unique software solution developments, it is no more perceived as a dirty field to work in.”

Casting Technologies The process can be best described in the following few steps: Designing and placing a pattern to create a mould Removal of pattern Filling the mould cavity with molten metal through the gate Cooling of the metal to get the desired shape Removal of the sand mould. The moulding process can be done by sand casting, ceramic process, permanent mould process and rapid prototyping. The process again depends on the scale of manufacturing, metal alloy character, tolerances required, etc. Figure 1 shows the comparison of different moulding processes with corresponding tolerances and the scale. Over 70% of the casting is done via green sand moulding. Green sand is a mixture of silica sand (SiO2), or chromite sand (FeCr2O), or zircon and (ZrSiO4), 75–85%, or olivine, or staurolite, or graphite, bentonite (clay), 5–11%, water, 2–4%, inert sludge 3–5%, anthracite (0–1%)—used to make the mould’s shape. Earlier, where four of the above five were manually performed, advances have made, it possible to

mechanise all five. Eighty one percent green sand moulding for high-volume work has been mechanised, where for short runs and prototype work, it is relatively cost effective. Some of the patented technologies introduced in casting by different companies include DISA Flex Technology and DISAMATIC Match Plate, Vibra-Mill, Vibra-Drum and SpiraCool—General Kinematics. These are automated & have enhanced the capacity as well as accuracy of sand casting.

Rapid Prototyping Sand casting is a comparatively complex process. It involves creating a design and then the real pattern, sand preparation, moulding, pouring metal into the cavity via gating system, cooling of metal and surface preparation. Apart from these, it also requires side work, such as flue gas disposal, waste management, and so on, which have nothing to do with the product. Rapid prototyping, also known as incremental sheet dieless numeric control method, is a fast-growing technology, which directly prints the 3D design erasing real pattern formation, sand preparation; thereby minimising the inaccuracy and the surface finishing task. Krunal Ghare, Director, Six Steps, a pioneer company in rapid prototyping in India, says, “Rapid prototyping scores

over conventional forming in many ways. It saves time by 50–60%, which is vital today. Further, it is more accurate than automatic sand casting.” The plus point with rapid prototyping is that it works with plastic, ferrous and non-ferrous and all kinds of materials. The required 3D design once drawn via CATIA gets printed within hours unlike green sand moulds, which takes 1–2 days for the same. “Rapid prototyping enables colour output, which was earlier not possible with the traditional one,” adds Krunal. Although it is still in its nascent age, it is going to revolutionise the way of forming. According to Ghare, “Companies like Tata, Bajaj and other big players have already deployed rapid prototyping machines and are getting orders from all over India. The future of this technology can also be understood by the fact that our growth rate varies from 110–120%.”

Rapid Slurry Forming Rapid Slurry Forming (RSF) is a comparatively new process to manufacture cast components. It is based on enthalpy exchange between alloy systems having different enthalpies, thereby giving semi-solid slurries. Experimental work in this regard has already been done on Al-7Si alloy to form a semi-solid slurry. The beauty of the process is that the slurry’s state

Figure 1: A comparison of different moulding processes with corresponding tolerances and scale

May 2012 - MODERN MACHINE TOOLS

Metal Forming Technologies is controlled by added amounts of the alloy system used. It is a bit difficult to control the heat flux precisely within surrounding media such as crucible or mould. Experiments show that globular microstructures of primary aluminium dendrites can be achieved by this method. RSF technology will thus be most suitable for producing high-quality metal slurries economically, which may be a breakthrough for semi-solid casting processes. Patented in 2011, it is yet to catch the industry’s eye.

Spray Forming Also known as Osprey process, spray casting, spray deposition, in-situ compaction is actually a near net shape casting method. As the name suggests, the method involves use of annular array of gas jets to let the free falling molten metal droplets strike substrate while in semisolid condition. With continuous similar deposition, a billet of metal is formed on the substrate. Spray forming offers many advantages over a conventional process,

MODERN MACHINE TOOLS - May 2012

like sand casting, or specialised one, like powder metallurgy. It is flexible and can be employed on a variety of alloys—be it ferrous or non-ferrous. The strength and quality of the product can vary as per the requirement. In India, they are yet to see the light of day.

India Needs A Jumpstart The Indian forming industry is still struggling to revive/upgrade old tooling. While most are still not aware of these possible upgradations, some either lack the right attitude or do not have the capacity for conversion. Babi explains, “Powder rolling of products and Hot Isostatic Pressing (HIP) of high-purity metal/alloy powders may be workable only in industrially advanced nations where large capital investments are the order of the day due to the easy availability of very low interest longterm loans. The situation in our country is quite the contrary. Our policy is to squeeze maximum out of old machines and older technologies while working

with low grade raw materials. Thus, many forming industries could not boast the highest quality controls, where the entire paradigm of setting up and operating industries is different.” Further, the surface engineering scenario also leaves a lot to be desired, especially since one does not see any impressive progress in the adaption of laser beam-aided surface transformation or cladding, etc.; plasma transferred arc cladding, which is far less expensive and yet very effective has not found any appreciable use; and more advanced surface treatments, like ion implantation, remain confined to strengthening shaving blades... Another less encouraging factor is that some of the older technologies like reverse extrusion for making thin-walled aluminium alloy tubes are defunct now due to replacement by plastic tubes, which are not environment-friendly. A mixed bag of reactions would ensue, if a debate were encouraged. suprita.anupam@infomedia18.in

SPECIAL FOCUS Hydroforming

The Future From Within In the relentless pursuit of efficiency in performance and manufacturing today, materials of the future clamour for processes beyond the conventional, for technology suited more to the material or product rather than to the process. Hydroforming, which questions the traditional approach, marks the evolution in metal forming technologies. Tarun Tampi takes a look at how hydroforming is bringing a renewed sense of economy, opportunity and progress to the manufacturing of high-strength lightweight components across the industry.

ydroforming is a technology with a rich history extending all the way from the early 20th century, when the first patent describing a tube hydroforming technique using molten lead was filed. By the 1970s, hydroforming had already been successfully applied in the manufacturing of artificial limbs, hollow aircraft propellers, cam shafts and bicycle frame tubes. Ever since, it has matured into more than just an alternative to conventional matched die metal forming and has expanded well beyond the manufacturing of frame components. Today, it has gained critical significance in the industrial production of components and designs, particularly in the burgeoning automotive sector.

What Is Hydroforming? Hydroforming essentially applies the principles of fluid dynamics to form metal parts, deforming malleable materials, using pressurised hydraulic 66

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fluid and a contoured die. In terms of industrial production, hydroforming was developed in the early 1950s as a cost-effective method to produce low volumes of drawn parts or parts with irregular geometry that would be difficult to manufacture by stamping. It applies to most metals than can be cold formed; including aluminium, brass, carbon, stainless steel, copper and high-strength alloys. The process initially developed along the lines of similar methods used to manufacture copper plumbing Ts. Hydroforming techniques do away with the need for repeated stamping, joining or spot welding of sections since it directly forms single parts or unibody components. There are fundamentally two types of hydroforming processes, viz., tube hydroforming and sheet hydroforming. The former is further divided into low or high pressure processes wherein cold rolled metal tubing is placed in a closed die set and fluid is introduced via the ends of the tube. Under this

internal fluid pressure, the tube is forced into shaping itself to conform to the cavity. In sheet or panel hydroforming, a bladder may be used to exert pressure on the metal sheet although direct fluid contact forming is more commonly used. To begin the process, low pressure initially forces the sheet against a male punch. Within a hydraulic chamber, pressure is increased until the part forms around the punch. This hydromechanical forming process tends to produce a work hardening effect as the steel forms between the blank and fluid pressure. Springback in hydroforming is also much lower than in conventional forming processes. Few niche processes have also been developed. Explosive hydroforming efficiently forms large parts by exploding a charge around a part, using a mould submerged in water. The shock wave serves as the pressurising medium in this case. Pillow hydroforming is used to form components involving two metal

Hydroforming sheets, joined at the edges, thereby allowing for the hydroforming of variable diameter pillars. Hydroforming has been applied to a diverse range of materials, from aluminium, steel (mild, hard and stainless), copper to inconel, hastelloy and high nickel steels. A hydroforming press opens & closes the die and clamps the load to minimise elastic deflections. Axial force cylinders and pressure intensifiers are also used additionally. These presses are usually very expensive. However, with the complete indigenous development of hydroforming machines, including manufacture, research and technology, these costs should fall with a rise in demand.

Applying The Advantage Hydroforming is capable of economically manufacturing light, complex shapes with high strength-to-weight ratios—a property in huge demand in the automotive and aerospace industries. It has become vital in the manufacturing of structural components of mass produced units. Reji K Daniel, GM – Components Manufacturing Division, Electropnuematics & Hydraulics Pvt Ltd zeroes in on the core benefits: Better productivity: Several mechanical forming stages can be replaced in one stroke by

Reji K Daniel, GM – Components Manufacturing Division, Electropnuematics & Hydraulics Pvt Ltd At Electropneumatics, we have promoted and indigenously pioneered hydroforming technology in India since the early 2000s. There are several segments within the automotive sector that can take advantage of hydroforming and its benefits. The Indian automotive industry can certainly be a big benefactor if it takes the bold step of maximising the use of hydroformed parts in vehicles.

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hydroforming. Hence hydroforming paves the way for high volumes at lower cycle times. Better strength-to-weight ratios: Taking advantage of strain hardening during hydroforming, there is tremendous scope for reducing part thickness, even while improving on strength. The result is reduced weight and obviously, reduced raw material costs as well. Better product integrity: As we can form complex shapes through hydroforming processes, several components, stamped and then joined by welding, can be replaced by one integral part with the desired sections. This will improve the Noise, Vibration, Harshness (NVH) factor as well. In addition to being well suited to easily producing lightweight, complex parts in one step, it also increases the lifetime of these parts since the final shape is inherently optimised to its ‘net shape’ and there are no joints or weld seams. Finishing hydroformed parts is convenient as well since they do not have a grainy texture. Tearing, shock lines and wrinkling, usually found in matched die formed parts, are avoided altogether as well. Also, styling or packaging requirements are incorporated exceptionally well. Daniel observes, “The demand is increasing, given the industry’s priority for weight reduction and value engineering. From chassis members, suspension trailing arms, etc., now even front end components like bumper support, crash box, etc., are being considered for weight reduction as well as improved safety.” For large-scale production, the manufacturing of kitchen spouts was the first application of this technology. Hydroforming has well established itself today as a key forming technology. The automotive industry is one of the largest users of hydroforming technology, ever since energy efficiency and weight reduction have grown in value. Roof panels, side rails, exhaust systems, etc., are some

The Hydroforming Advantage

Consolidation of parts, components, sections Structural strength, stiffness, strain hardening increased Maximises material usage, reduces scrap Overall costs are lower, few secondary operations required Stringent tolerances, low springback Versatile process, vast design freedom.

of the automotive components cost effectively made by hydroforming. It has also found extensive application in the aerospace, health & sanitary, heating and furniture industries.

Promising Future Hydroforming has its set of drawbacks. It has a slow cycle time, the equipment is expensive and there is a lack of in-depth technical knowledge of the process parameters & design factors. Daniel notes, “Now, we find that the phase of early reluctance is getting over. Many OEMs have started considering hydroforming at the early design stage itself, to cash in on its enormous advantages. However, there are still a myriad of unexplored applications for many more stampedwelded parts that can be formed by tubular hydroforming, for better product integrity, higher strength and overall weight reduction.” Material considerations also need to be carefully attended to in order to understand their behaviour under hydroforming pressures. However, the potential benefits of hydroforming are tremendous. The technology requires the industry to reevaluate traditional approaches to design, from concept to production. To realise the elegance of this technology, designers, engineers and technicians, involved in the production process, must be prepared to embrace alternate ways of working and thinking. tarun.tampi@infomedia18.in

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SPECIAL FOCUS Case Study

Global machine shops face a threat from a rising field of small to medium manufacturers who are rapidly developing and ambitiously vying for added business. This is exemplified best in the application of precision forging, a process capable of reducing overall part costs by a remarkable 25%, thus giving manufacturers an alternative to gross forging or screw machining and more importantly, a chance to level the playing field.

aumee, Ohiobased Hammill Manufacturing’s Impact Cutoff Division, uses precision forging, also known as net-shape forging or closeddie forging, to compete with foreign companies for lucrative contracts. The company has converted 36 gross forgings into 36 precision-forged part numbers for a global hydraulics manufacturer.

material loss and parts that are not currently being forged. “Typical parts that can benefit from precision forging include bulk manifolds, side and pinion gears, connecting rods, hydraulic components & other high-machining-content parts,” says Hammill. Impact Cutoff maintains tolerances of ±0.0025 inch on its

precision-forged parts. The company has produced more than 4,50,00,000 total parts over a 17-year period with only three rejections—a 99.99% quality performance. Overall, the company has a 17-year history of 100% on-time delivery for the precisionforging process.

Adding Advantage

Forging Process Impact Cutoff says adapting the traditionally high-volume warm-forging process to small (25,000 parts or less per year) and medium (about 3,00,000 parts per year) lot sizes has been the key to its success. According to John Hammill, President, Hammill Manufacturing, the precision-forging process is ideal for low- to mid-volume part runs that involve high machining content, significant 74

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Impact Cutoff has produced more than 4,50,00,000 parts during the past 17 years.

The precision warm-forging process has reduced the company’s total part costs by as much as 25%. The process reduces material scrap, eliminates or reduces subsequent finishing operations and lengthens perishable tool life. In addition, the process produces a forging blank that is stronger than other conventional forming methods, and the resulting formed parts have lower total part costs than those produced with grossforging processes, the company says. The precision warm-forming process is a viable alternative to screw machining, it adds.

Case Study One major benefit of the Handling Systems precision forming process results Material handling plays an important from induction-heating the forging role in the manufacturing process. blank prior to forming. According Blanks drop onto an automated to the company, induction heating loading table and individually feed ensures that each formed part has into the heater induction chamber a consistent, uniform hardness via a Dyna-Slide vibrating platform. without hard spots or other material Manufactured by Lipe Automation deviations. Uniform material Equipment of Rochester, New York, hardness can result in predictable and the Dyna-Slide orients the parts for consistent material characteristics, automated loading within the die. which, in turn, can improve The vibrating system allows the part machinability and increase cutting to travel on precise paths without tool life. In addition, the process touching the sides of the loading creates consistent, unidirectional feeder. The controller senses when grain structure in the forged part. Reduced scrap and fewer secondary operations are key process a new blank needs to be fed into advantages. As a result, the precision-formed the queue. part is stronger than conventional The steel blanks are then transferred capabilities for tooling design and forgings, castings or parts machined from onto a feeder through an electric-powered build, prototyping, manufacturing and barstock, the company says. induction heater. The water-cooled prove-out. The company uses “Double electric heater provides temperatures D” 12L14 and 1215 cold-drawn steel, Precision forging has reduced the ranging between 1,100 and 1,400°F. but the process could also work with company’s metal scrap by as much as The blanks are heated to the targeted materials such as stainless steel, brass 30%. The precision-forming process temperature and gravity-fed into a and titanium. uses a closed-die approach in which the staging position perpendicular to the die. Initially, steel barstock is cut off entire forging blank is encapsulated in the to precise gram weight and length die cavity. The forging blank length and The heated steel blank is then tolerances. The company controls weight are tightly controlled, resulting “grabbed” and presented to the die weight closely to ensure a near netin no material waste. The entire forging in a horizontal position by a GEVA shape forging without flash lines. The blank is used in the formation of the cam-operated, pneumatic robot arm. steel blanks’ ODs range in size from part—no material is scrapped because Video cameras verify temperature, part 0.25 inch (6 mm) to 2 inches (50 mm). nothing protrudes from the die, and position and part orientation before the Height ranges from 0.25 inch (6 mm) no part trimming is required. Because press closes. The GEVA then returns to to 3 inches (75 mm), and weight ranges of the closed-die nature of the process, the original staging position. from 0.10 pounds (45 grams) to 3 the parts have no flash lines, material A 400-tonne Verson vertical press pounds (1,400 grams). scaling or parting lines. reshapes the pliable steel blank to the exact dimensions of the die. The The steel blanks are then tumbled and closed-die process leaves no metal scrap, water-washed in preparation for forging. The Cutoff Process flashing or waste by-products because These preliminary operations remove Impact Cutoff has a turnkey all the metal stays contained within burrs and lubricants that can cause carbon manufacturing process with in-house the die cavity. At the end of the press buildup within the die. The cycle, an air blast and ejection pins blanks are then stored in eject the part, which is then dropped bulk bins. onto a slow-moving conveyor for air An Allen Bradley PLC cooling. The formed part is quenched in provides process control to a two-stage water bath and transferred ensure proper temperature, into a completed-parts bin before part positioning, press being prepared for shipping direct to operation and robot arm the customer. movements for automated part loading and “Precision forging has helped unloading. The control Impact Cutoff level the playing field system’s logic provides with low-cost, low-wage foreign increased reliability by producers by lowering production costs,” Efficient material handling is crucial. Blanks are dropped on an preventing crashes and Hammill says. automated loading table and fed into the heater induction chamber. Source: MMS Magazine part jams. 76

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FACILITY VISIT GrindMaster, Aurangabad

STEPPING TOWARDS

EXPONENTIAL SUCCESS It all started in a garage at Aurangabad in 1984, with the making of small super-finishing machines. After years of dedication and hard work from the Kelkars, GrindMaster is today a pioneer in providing speciality products to companies around the globe. With continuous innovations, the company has created its own benchmark for excellence. A recent visit to their facility in MIDC, Aurangabad speaks volume of the hard work put in to take Aurangabad to the global map. Nishi Rath reports...

mall opportunities are often the beginning of great enterprises—famous lines by Greek orator Demosthenes stand true for GrindMaster. What was started 28 years ago by Engineering graduate couple Mohini and Milind Kelkar in Aurangabad is now a world player in grinding, finishing and precision engineering with a proud client list, including TATA, Yamaha, Bharat Forge and Bajaj among others. “Bajaj Auto setting up their facility here was an opportunity for us; we had both just completed our studies and wanted to start something of our own. This is how we formed GrindMaster,” says Mohini Kelkar, Managing Director, GrindMaster. 78

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She explains that the initial years were not smooth, but hard work led them to where they are today. Elaborating further, she adds, “During those years most metal finishing and deburring operations were performed manually. These processes had limitations on productivity, accuracy and consistency of both the result and finish. Thus, we came up with automatic and semi-automatic machines to fill these lacunae.” Their first endeavour was to develop a buffing machine for polishing pots and pans. Then they came up with automatic machines to grind the parting line of forgings, then developing manual machines for grinding and polishing.

Soon after they developed the country’s first indigenously designed fully automatic motor cycle rim polishing machine, which till then had to be imported. Today the company has carved a niche for themselves in the global industry of metal finishing and deburring. The company aims to develop and build machines to suit individual needs and now possess one of the widest range of special purpose machines dedicated to the processes of deburring, grinding, polishing and micro-finishing. With a proven track record of successfully developing new concepts and cutting-edge technological solutions, GrindMaster has earned a

GrindMaster, Aurangabad

reputation of getting it absolutely right the first time.

Continuous Development: Key To Success In the early 90s GrindMaster set up its new manufacturing premises at MIDC,

Mohini Kelkar, Managing Director, GrindMaster GrindMaster is probably the only machine tool company that is supplying machines in such a big way in China. There we are competing with German manufacturers. It is not the pricing that has led us there but our technology, which we provide in collaboration with our partners in US to microfinishing of crankshafts and cam shafts, which are important engine parts and requires advanced technology.

Aurangabad and consolidated its expanding range of machines in terms of components and build-quality. This proved crucial in the successful export of machines starting with South East Asia and expanding to countries all over the world. To explore other opportunities, in late 90s, in order to provide customers with complete solutions GrindMaster ventured into the business of consumables. “We consequently forged a technical collaboration with VSM Germany for a complete range of coated abrasives sold throughout India. A conversion plant set up in 2000 has been successfully manufacturing coated abrasive belts and rolls since then,” says Mohini. It was in 2002-03 that GrindMaster started developing micro-finishing technology for the processing of automotive parts and hard chrome plated rolls. Later upon signing a licensee agreement with IMPCO, USA for GBQ Technology to micro-finish crankshafts and camshafts, GrindMaster joined the small elite group of world companies which have the capacity and expertise to manufacture sophisticated metal finishing machines. “From 2004 onwards, we geared up for future expansion and started by investing in infrastructure and machinery. The systems were smoothened out with the implementation of Axapta – ERP Software,” adds Milind. The company’s current R&D challenges include Robotic Deburring and Finishing Systems.

A Look At The Shop Floor Customised solutions is the name of the game! What makes GrindMaster’s producs and services preferred, is their tailor made solutions. A visit to their well organised shop floor and interactions with their enthusiastic and dedicated team stands testimony to the fact that listening and catering to your customers needs pays handsomely. The manufacturing unit is divided into four parts--the machine shop and G1, G2 and G3. In the machine shop,

Milind Kelkar, CEO, GrindMaster

Innovation is our key. Everyday there is something new innovated in every level. Various deburring techniques are being developed; our latest addition in the category would be robotic deburring. We have also developed some robotic applications in the past one and half years. Robotic deburring, fettling and robotic handling of our machines also forms a part of our innovation process.

after the raw materials are received, roughing operations are initiated. While those that require grinding are sent for surface finishing where both surface grinding and cylindrical grinding are used. The process followed includes --milling, grinding, CNC/ VMC then deburring then goes for quality check. At G1 and G2, fabrication is done for small and medium parts, fabricated structures are polished (automobile parts and utensils among others). It has both semi-automatic and manual machines. On the other hand, G3 caters to assembling of machines for export purpose. The whole area is dedicated to microfinishing of camshafts and Crankshafts. “We are in a good position to cater to the whole of India I would say; only we wish Aurangabad was better connected to the southern part of the country by air. This will definitely help us grow and serve our customers better,” says Mohini.

Realising The Value Chain For GrindMaster, a great team leads to a great future and to ensure the safety of the team, the company has various initiatives in place. “We have safety training in place that is held almost every month. Apart from that, we have safety audits, wherein we keep regular check on the cranes and other machines/ May 2012 - MODERN MACHINE TOOLS

GrindMaster, Aurangabad equipment with consideration to the safety of the employees,” says Milind. The management is also working towards a paperless office and taking all steps to achieve this soon. The Kelkars also believe in continuous upgradation, they organise English classes for employees in the operating level, drivers and clerks. “They are talented people but lack communication skills, so we have regular classes for helping them improve in those areas,” says Mohini. The company that started with only two people, now employees around 200. The duo aspired and achieved what many people had dreamt about in those days in a place like Aurangabad. They understand that being pioneers one has to be on their toes as there are more chances of risks.

The Journey And Future Prospects According to Milind, when they started absolutely nothing was available and for every small thing like even for electric

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motor they had to visit Mumbai. “But now times have changed, Aurangabad has everything starting from vendors and companies with their base here,” he says. Agrees Mohini, “Till 2000, the growth was somewhat sluggish but after that it has grown leaps and bounds. Now, Aurangabad is the place where companies are looking for more sales and business.” In the recent years, after extending the IMPCO license to China, GrindMaster began manufacturing Crankshaft Microfinishing Machines for China. Auto major General Motors, Shanghai, features amongst their list of customers for whom a stateof-the-art High Volume Crankshaft Micro-finisher was commissioned and delivered successfully. Presently, the company boasts of setting up a permanent office in China to provide sales and service support. “GrindMaster is probably the only machine tool company that is

supplying machines in such a big way in China. There we are competing with the German manufacturers. It is not the pricing that has led us there but our technology, which we provide in collaboration with our partners in US for microfinishing of crankshafts and cam shafts, these are important engine parts and requires high technology,” says Mohini. GrindMaster has been consistently growing every year by 15-20% but with this addition in China, the growth has been almost 1.5 times or 2 times since the past two years. With Aurangabad growing as an industrial hub, companies like GrindMaster play a strategic role in the areas growth. With strong technical and innovation skills, the company has already started looking ahead and charted out its growth strategies. GrindMaster as the Kelkars say, is now stepping ahead to witness another era of exponential success. nisi.rath@infomedia18.in

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INSIGHTS & OUTLOOK

GRINDING/ FINISHING 88 90 92 99

Grinding Industry

Supplementing & Complementing MFG.

Technology Trends

Redefining The Scope Of Grinding

One Q Many Views

Hard Turning Vs Grinding Has Grinding Found A Replacement?

Eco Pickled Metal Surface

Green Efforts To Save Rusting

102 Grinding Wheel

Driving The Productivity Movement

112 Abrasive Flow Machining Flowing To A Fine Finish

116 Fibre Laser Technology Cutting To Perfection

124 Simulation Technology

Visualising The Future In Grinding

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INSIGHTS & OUTLOOK Grinding Industry

down to 15–20%. This is mostly due to the changing economic conditions,“ avers NK Dhand, Chairman & MD, Micromatic Grinding Technologies Ltd. Here’s taking a look at the factors, which has changed the dynamics of the industry over the years:

in the changes in the grinding quality as well. For instance, clamping systems itself have undergone a revolution from automatic clampings to hydraulic systems to between the centre clamping. The parameters of how best to hold the component itself has redefined the accuracies of the grinding process.

Setting Up A System Grinding is not an isolated process as it involves a proper amalgamation of various parameters. Right from the grinding tool, dressing tool to coolants and proper clamping, a careful selection of each aspect of the process is what sets up a proper system. The upgradation in these aspects has invariably brought

Redefined Need For Accuracy Parts and components, over the years, have become complicated with intricate designs. This has brought about a complete change in the way the grinding process has evolved. Such geometrically complex parts are well attributed to grinding operations. Component

Courtesy: Pferd India

s grinding technology has evolved over the years, manufacturers have been finding ways to reduce cycle time, increase the quality of grinding, cut down the manufacturing cost and optimise the process itself. Along with the growth of the manufacturing industry, the importance of grinding has only risen with time. Over the years, the Indian grinding industry has seen major changes. While the industry has seen a consistent growth of over 30% last year, the industry experts predict a downturn, going forward. “As the current order books indicate, the growth of this segment may come

Grinding as a process has only perfected its sheen over the decades. With the manufacturing process itself undergoing a dramatic transition in terms of accuracy; grinding and surface finish have invariably kept pace with the industry’s needs and requirements for precision. Debarati Basu takes a look at how grinding and surface finishing have been undergoing a transition to attain perfection. requirements like medical implants, high strength automotive parts and super precision aerospace components, etc., have brought forth the need for grind masters—a shift from conventional grinding process—to give high precision, tight tolerance performance.

Tool Grinding Technology Tools form one of the most important 88

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aspects of the manufacturing process. Hence, the precision of the tool defines the accuracy of the entire process. The close intricacies in machining components have made it crucial for the tool perfection to be beyond expected parameters. “The tool grinding industry has reached a saturation point. Strange enough, but the tool designs as such have not changed rampantly over the last 10

years. Nonetheless, the performance has gone up. The period between 1992 and 2002 had seen a major amount of changes in tool design. But there is hardly a 5% change in the designs of the tools made between 2002 and 2012. However, during this period, the change had come in the raw material used, the coatings applied and the special treatments done. This has completely changed the performance

Grinding Industry of the tools,” explains Santosh Prabhu, Managing Partner, Tool Grinding Technologies Inc.

Change In Materials Be it a micro component in an orthopedic implant or a huge turbine blade, the change in the materials used in the making of new age components has changed the way grinding operations are performed. With a trend veering towards harder materials having tighter tolerances, materials like inconel, titanium, cobalt chromium, etc., are fast becoming a part of every industry’s need. New combination alloys and composites are also becoming popular. But machining or milling such exotic materials comes as a challenge when the surface finish and accuracies for such materials and other coated materials need to be changed. Grinding operations emerge as the only cost-effective operation capable of higher removal rates at relatively low grinding forces, thereby ensuring better dimensional tolerances and fewer burrs. “Today, materials like inconel are not just used for aerospace, but are also used in vehicle engines to sustain the heat, especially in turbo charged vehicles. This material is not easily machinable as it creates an imbalance, which leads to vibrations. We found that grinding was a much effective process for correction operations over milling the material,” explains Prabhu.

Reducing Cycle Time The manufacturing industry operates with a single point focus of reducing the cycle time of the process, which will eventually increase the productivity and bring down the cost of production. Grinding plays a major role in this system. By determining the speed of the grinding process, it would eventually bring down the cycle time. While the use of linear motors have made the axis movement and axis positioning fast, torque motors are being used for indexing of the tool. Use of multiple wheels has also come in as a revolution for multi-point grinding operations,

thereby reducing the operation time. Major grind makers today are pinning their focus on including more than three wheels to perform a single operation. However, this also demands a high-end machine to incorporate grinding technologies & proper simulation technology for prompt, continuous and accurate positioning of the wheels. Putting these technologies together in place, the cycle time has been found to have dramatically gone down by at least 50%. On the other hand, increasing the speed of grinding and performing on hard to machine combination alloys are some of the factors which leads to vibration and chatter marks.

Exploring New Avenues Taking into consideration that grinding

Santosh Prabhu, Managing Partner, Tool Grinding Technologies Inc. The change in grinding has been in terms of raw materials used, the coatings applied & the special treatments done. This has completely changed the performance.

is one of the oldest and tried & tested operations, this process has always generated confidence to cull out the desired accuracies as compared to other operations like milling, etc. This process, in its continuously refined avatar is now being used in new industry applications. Apart from aerospace and defence applications, applications which requires high-precision dies, electronic industries applications, like connectors, are using grinding in a big way. The earth moving industry is also a recent area of application for the Indian industry where grinding operation is widely used in making excavators, bulldozers, etc. Grinding has become a must in any application, which uses hydraulics, like in valves, spools, piston cylinders, etc. Steel mills, especially sheet steel

NK Dhand, Chairman & MD, Micromatic Grinding Technologies Ltd. The Indian manufacturing sector is shifting from manufacturing to blue print to design and manufacturing. The system approach to manufacturing processes should help to push this change along further. This will also pave the way for large-scale improvements in better tolerances, part features & total costs.

mills, need very high-quality roll grinders. With many new steel plants coming up in India over the next decade, the demand for heavy-duty large yet precision grinders would be huge. Others segments like manufacturing of pump parts, textile machinery, hypodermic needles, knives & cutters, instruments and gaging, bearing parts, small tools are avenues where precision grinding can make a mark. “Grinding can be used for high stock removal (rough grinding of gates and risers in castings, flash from forging, side walls of engine blocks, cutting off billets, forgings and bars, etc.) as well as ultraprecision applications (such as honing, super finishing, micro-finishing, microgrinding, etc.),” points out Dhand. However, he adds, “It is the lack of will of the manufacturers to look beyond their immediate zone of activity that limits the future growth of manufacturing in India. Also, a collective will—across the parts suppliers, machine makers, other (tooling) suppliers and the parts manufacturers—to develop the ecosystem is another limiting factor. Finally, there is a desire to indigenise and lower the cost of what is already used (from current suppliers). Anything new, there is a tendency to import or avoid (as imports are too expensive).” The challenges thrown by the manufacturing industry are many, but to continue to remain ahead, the grinding industry has to come up with significant efforts to keep this process an unparalleled operation. debarati.basu@infomedia18.in

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INSIGHTS & OUTLOOK Technology Trends

Redeﬁning the Scope of Grinding Grinding operation has constantly undergone changes keeping pace with the evolving trends of manufacturing. While most processes are getting automated to enhance productivity, other changes are more focussed on the accuracy parameters. Debarati Basu talks to industry experts to find out the new grinding trends, which will define the shifting course of action.

ontinuous transition in the process of grinding has mostly been in terms of refining the technology or amalgamating different methods to create a conducive grinding environment. At times, the traditional turning and milling operations are not enough for the finishing required. It is here that the evolving process of grinding brings in an additional dimension to the operation. Here’s profiling some of the recent changes in the technology, process and machines that the Indian grinding industry has incorporated to better the finishing accuracies...

Combination Technologies With the complexities in the machining process, only grinding as a process is 90

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Sreekanteswar S, President – India Sales & Operations, Korber Schleifring GmbH. Grinding is a process which can never be eliminated. There is no other process which can come close to grinding, in terms of surface finish or accuracies. However, its applications are limited to the innovativeness of the mind.

not sufficient in many applications. The industry today is now leaning towards combining different technologies, which can enhance the effects of grinding. For instance, in the tool grinding category, for carbide or diamond tip tools, grinding alone does not prove to be

adequate. “In such operations, one can get a better output on combining the technologies of laser and grinding for the process. Laser here is used for the final machining of certain critical areas where grinding is not possible,” explains Sreekanteswar S, President – India Sales & Operations, Korber Schleifring GmbH. Such combination technologies also come handy in the finishing operations of micro components. Citing an example, Sreekanteswar adds, “Materials like steel, when milled, comes out in one single roll, which usually gets stuck during evacuation. For this, a small notch, called the breaker is added to the edge of the cutting tip to break the chips for easy removal. This notch, which is as small as 0.5 mm, has certain special

Courtesy: Korber Schleifring GmbH

Technology Trends

angles, which are difficult to obtain with grinding. In such a situation, laser application is used to get these fine accuracies.” With growing intricacies, the industry is trying to bring in new combination of technologies, which will enable them meet the challenges.

Grinding New Geometries Given the changing dynamics of engineering, the shapes of components have undergone a change. From

Nischal Sachdev, MD, Dynabrade Abrasive Power Tools Pvt Ltd. The growth of the grinding industry depends on the growth of the manufacturing industry. However, though grinding cannot be eliminated, there is an effort now to cut down on the grinding and finishing to the extent possible by improving the quality of dies and castings so that perfect finishing can be acquired at the initial stage itself.

perfectly round shapes, the industry is moving to complex geometries. However, non-round objects require a completely different set of expertise in grinding operations. Such geometries are fast becoming a part of the Indian manufacturing gamut. Special software to grind such intricacies are being rampantly adopted by the industry. “This is a relatively new area and India is now looking at technologies to improve grinding of non-round objects,” avers Sreekanteswar. He adds, that pharmaceutical is one of the major industries in need of this technology. “Punches used to make medical tablets of various geometries are in high demand. These punches when manufactured, require high precision and high surface finish without which the material (of the medicine) will stick to the punch itself.” The changing shapes and geometries of tool holders have also brought in equal modulation in grinding technologies.

Handheld Grinders With cost, space is yet another factor, which the industry today seriously needs to take into consideration. Handheld grinders have gained vast popularity in the Indian industry for high-precision surface finishing of components. “As the entire manufacturing operation has undergone a change, the precision of components at every level has gone up dramatically. However, the finished products require finishing at some points, which cannot be achieved by bigger machines. Because of the minimal level of imperfection remaining at very less spots, the industry is moving towards smaller grinding tools, which can provide the remaining accuracy,” explains Nischal Sachdev, MD, Dynabrade Abrasive Power Tools Pvt Ltd.

Tread Grinding The operation has been there for long, but it had never gained much popularity in India until now. The reason was mainly cost centric, but the increasing need for such applications and manufacturing demands have led

the Indian manufacturers to adopt latest simulation technology and software for the operation. Thread grinding is a process of creating screw threads. There are many methods of generating threads and this operation is generally required in shafts & spindles and in many special aerospace bolts, nuts and screws, which require high-quality threads.

Creep Feed Grinding The effectiveness of a grinding process is determined by how fast the process is done maintaining the level of accuracy. Creep feed grinding is a method in which the depth of cut is increased while the feed rate is decreased as compared to the normal grinding practices. This is mainly used in large amount of material removal in a single pass. “With our machines, we have been able to make a slot on a component with 5 mm width and 15 mm depth in a single pass. In the conventional grinding process, multiple traverses are required to remove the material, which leads to an increase in cycle time. However, such high-end creep feed grinding operation would need to be balanced with machines, which are highly stable and powerful,” said Sreekanteswar. The change in technology in grinding industry is experiencing the changing dynamics with the demand for higher precision, better automation, new materials, etc., need to reduce the cycle time, etc. The emphasis today is no longer on individual parts of the process, but on the entire manufacturing system itself. The emphasis on reducing the total cost comes in by focussing on the part quality and consistency (Cpk), cycle time, wheel usage, quicker inspection process, which brings down the level of rejections. Hence, the expansion of the horizon of necessity has led to the continuous creation of new technologies. In time to come and the changing manufacturing practices, this industry is bound to go through many more changes to redefine the parameters of precision and surface finish. debarati.basu@infomedia18.in

May 2012 - MODERN MACHINE TOOLS

HARD TURNING Vs GRINDING Has Grinding Found A Replacement?

ONE MANY VIEWS

With the changing manufacturing parameters, grinding technology has constantly undergone ‘change raising’ debates over various new processes, which can possibly replace grinding. Hard turning is one such method which has gradually gained acceptance in the industry. But can hard turning eliminate the grinding operation? Debarati Basu investigates…

NK Dhand, Chairman & MD, Micromatic Grinding Technologies Ltd

Sreekanteswar S, President, India Sales & Operations, Korber Schleifring GmbH

Santosh Prabhu, Managing Partner, Tool Grinding Technologies Inc

Undoubtedly, hard turning has eliminated grinding in many operations. But where surface integrity is an issue, the threading lines or feed marks created by hard turning are also not acceptable. On the other hand, many turning applications are also being replaced by grinding where solid blanks are converted to net or near net shapes through efficient grinding processes. In the manufacturing process, there are certain areas where hard turning plays a better role and other applications where grinding proves to be better option. Hard turning is mostly applicable in plane reduction of size after the heat treatment of some component. In hard turning, the choice of tool is a very important factor. However, in terms of cost, grinding is an expensive process.

Rather than having an edge over the other, hard turning has more limitations as compared to grinding. Earlier, the industry was not using hard turning for the required purpose. However, with the increase in know-how, this process is now being used in areas where people were unnecessarily using grinding earlier. Like in an automobile shaft, which has just been hardened, earlier the entire shaft used to be ground. But today, only the necessary parts are ground, while the rest is hard turned. Any process needs to be judged by the parameters of accuracies verses the cycle time required. Hard turning at a very low feed rate, and very small depth of cut can probably give high surface finish but the cycle time goes up by around 10-20 times. Grinding, on the other hand, can give much higher accuracies at lower cycle time. Technology is limitless, but it cannot be adopted at the cost of high cycle time.

Hard turning is significantly used in the automotive industry and only volumes can justify hard turning operations. However, grinding, on any given day, is a cost-effective process. The process has, however, not gained immense popularity in India yet, but is used in some specific processes. Machines used in such processes also need to have the strength and rigidity to endure such high cutting speed and tolerances.

Mathew Jacob K, Chief Technical Officer, Pferd India There are many things, which one can do with grinding operation. These two processes are not like competitors. Instead, hard turning is more like a complementing process to grinding. There are some limitations in hard turning process and there are loop holes in grinding process as well. But the fact is that there are certain processes, which can be better done by grinding and certain others where hard turning can play a better role. 92

MODERN MACHINE TOOLS - May 2012

Verdict While hard turning can achieve impressive results, grinding has the additional advantage of being able to achieve higher dimensional roundness and cylindricity accuracies compared to hard turning. On the other hand, since parts can typically be finished in a single chucking, hard turned parts often show superior concentricity and perpendicularity characteristics compared to parts which are ground. Both have carved their set of strengths. So, while replacement might not be a viable option, amalgamation of these two processes—so as to be used in its own area of application—seems to be the answer to achieve better level of surface finish. debarati.basu@infomedia18.in

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INSIGHTS & OUTLOOK Eco Pickled Metal Surface

Eco Pickled Metal Surface

GREEN efforts to save rusting Amid the dire need to make manufacturing processes eco-friendly, Eco Pickled Metal Surface has come up as a replacement for the acid pickling process, which produces lustrous rust-resistant metal surface in hot and cold rolled material.

algro Eco Pickled Metal Surface (EPMS) has come as an innovation in green steel. This is a mechanical brushing system in combination with flexible abrasives steel roller wire brush, and normal hot & cold water that improves hot rolled black strip, making it a better base material for fabrication and OEMs. This is a novel method for removing annealed scale, rust, oxide, mill scale, oil patch, black spot/patch from hot rolled and cold rolled strips. This process creates an ideal surface for paint adhesion, especially on CRC and stainless steel. In addition, it prepares the steel better than any acid chemicals, currently available for wash systems. This method is also used for deburring, cleaning, washing, graining, de-greasing, de-scaling, finishing and surface preparation of different kinds of ferrous and non-ferrous material by wet and dry processing.

stainless steel and other ferrous and nonferrous metals are currently de-scaled by acid pickling process, shot blasting process or slurry blasting process. Each of these three processes may have certain advantages, but also has many distinct disadvantages. The main disadvantage of acid pickling process is the highly corrosive chemical used in this process which damages other equipment, building, land, environment and human assets. Moreover, the hazardous waste is not easily disposable.

Overcoming Limitations Valgro Samarth series Eco Pickled Metal Surface (EPMS) technology is a recent alternative. In this process, surface oxidation is removed using an engineered abrasive and the process leaves the surface resistant to subsequent

oxidation without the need for an oil film or other protective coating. To overcome all acid pickling limitations, surface oxidation is removed using an engineered abrasive and the process leaves the surface resistant to subsequent oxidation without the need for an oil film or other protective coating. EPMS comes as a more direct replacement for acid pickling, shot blasting and slurry blasting. Improperly prepared surfaces can result in reduced coating integrity and service life. Up to 80% of all coatings failures can be directly attributed to inadequate surface preparation, which affects coating adhesion. To ensure adhesion of the coating to the substrate and prolong the service life of the coating system, it is critical to select and implement the proper surface

Process Flow Chart For EPMS Rust And Scale Removal Operation Sheet loading

Scale breaker

Scale dust collector

Strainer / Leveller

Brush scale remover - dust collector

Valgro De-greasing unit/ washer man

Four stage top side valgro brushing unit

Four stage bottom side valgro brushing unit

Four stage top side valgro brushing unit

Four stage bottom side valgro brushing unit

Clean water rinsing zone

Turbine hot air blowing zone

Why EPMS? During the hot rolling process, a layer of oxide forms on the surface of the steel. This layer, commonly called â&#x20AC;&#x2DC;scaleâ&#x20AC;&#x2122; is formed when iron in the steel reacts with oxygen in the air. Thickness and chemical composition of the scale is a function of the hot strip temperature and the availability of oxygen to the strip surface while it is hot. Hot rolled and cold rolled steel,

Oil coating zone

PVC coating

Sheet unloading

The EPMS process is divided into different zones. The said process is either continuous or modular and can be extended to fulfil the customised requirements.

May 2012 - MODERN MACHINE TOOLS

Eco Pickled Metal Surface

Value-added Advantages

Delay rusting process time on mild steel Better surface finish Consistent cleaning effect No disposal restriction for hazardous waste Eco-friendly environment Faster production line Reduced labour and production cost.

preparation. The method of surface preparation depends on the substrate, the environment and the expected life of the coating system. New galvanised metal, a product used to make corrugated sheets, gutters and downspouts, is usually smooth and is coated with a layer of oil to prevent white rust. Paint applied over this oily surface or clear passivator will peel quickly. Alkyd/oil paints that are applied to galvanised metal will adhere initially, but fail quickly. The zinc of the galvanising, chemically reacts with the alkyd binder of the paint, creating a ‘soapy’ film (saponification) on the galvanised metal causing the coating to peel. When unpainted galvanised metal is exposed to the atmosphere and allowed to weather without being painted and is exposed to the atmosphere, the protective zinc coating oxidises into white rust until eventually the zinc metal is depleted. The underlying steel then rusts, which must be removed to ensure good adhesion of the coating. Wire brushing or scrubbing with a stiff brush or cylindrical abrasive roll is recommended to remove the white rust.

How EPMS works? At the core of the patented Valgro EPMS process is a technology called mechanical scrubbing with steel abrasives roller with ordinary water. This technology was invented on the base of shot or slurry blasting process. With the high RPM horizontal axis rotating and oscillating system is propelled onto the strip in a uniform stream that removes surface scale without removing the base steel. The extent of oxide removal is at least as thorough as acid pickling. However, steel abrasives brush also conditions the surface so it is cosmetically uniform and absent of acid pickling’s chloride residues that can accelerate rusting and surface remains rust free. Mechanical scrubbing with steel abrasives wire brush is superior to dry shot blasting for removing oxides from strip—the abrasive brush is typically applied to hot band as it ships from the mill. It also resuscitates coils stored outside accumulated with rust and dirt, and can be turned into prime material. Even a steel tread plate can be Valgro brushed to remove rust and obtain a Before

After

Arvind Patel – Founder & CEO, Bhagwati Sales Corporation (Valgro Group of Companies). At the core of the patented Valgro EPMS process is a technology called mechanical scrubbing with steel abrasives roller with ordinary water. This technology was invented on the base of shot or slurry blasting process.

remarkably clean surface. EPMS prevents removed grit and contaminants getting embedded in the case of a shot blasted surface. Hence, EPMS processing always beats acid pickling, while shot blasting does not. EPMS also gives a smooth, clean, matte surface that is similar to cold rolled. It is the kind of surface needed for glossy paint coatings and defect-free welds. It reduces surface preparation.

Rust Resistance Metal Surface The most amazing property of surface Before

After

Low Carbon Spring Steel Strip

Hot Roll Strip

Cold Rolled Strip

Oil Patch On Cold Roll Coil

Advantages Of EPMS

Improved surface quality Smoother, more resilient paint finish No more rust Reduced paint preparation Smoother paint finish Reduce dimples on painted surface Cleaner work environment Less rework, fewer rejects Faster laser/plasma cutting.

100 MODERN MACHINE TOOLS - May 2012

Figure A: Surface Roughness Distribution, Acid Pickled Process 200X Magnification

Figure B : Surface Roughness Distribution, Valgro EPMS Process 200X Magnification

Eco Pickled Metal Surface

Top view of Valgro-Hyzer Eco Pickle Line

condition steel is its ability to resist rusting without protective oil or coatings. After ordinary hot band has been surface condition processed, existing rust is removed and will not rust again if stored in a dry indoor environment. Such corrosion resistance will extend the ‘shelf life’ of steel and, combined with the absence of an oil coating, offer: Reduced paint preparation Reduced welding fumes No need to grind off rust Cleaner work environment No skin irritation from oil, and No more rejects for rust.

Research Results For Surface Finish The EPMS brushing technology proved to be capable of not only producing Ra values in this desired range, it demonstrated that surface roughness can be ‘managed’ by selection of the brush and speed. The nominal Valgro EPMS-processed strip has a uniform surface texture. The surface smoothness, as measured by Ra, is comparable to that of acid-pickled strip

Saving Chemical For Retrofit Pickling Line Through continues research and development efforts in current pickling line through retrofitted cleaning equipment, we are able to remove/reduce the black carbon suits and oil patch which are normally removed with the use of hazardous pickling process. Field trial by the company has proved that saving on pickling chemical cost reduction to the tune of 70-75% can easily be obtained by reducing concentration of chemical. Again the total process becomes environment-friendly due to working with less concentration, which reduces chemical hazards to a considerable extent. The unique machine provides a uniform brushing effect on a wider face area for cleaning, washing and surface finishing operation. This machine is designed to suit individual customer applications and requirements. Arvind Patel, Founder & CEO, Bhagwati Sales Corporation (Valgro Group of Companies). He is responsible for the product and application development of Valgro India Ltd with the technical assistance from Hyzer Technology Inc. Valgro EPMS technology awaits International patent. Email: arvindpatel@valgroabrasives.com

May 2012 - MODERN MACHINE TOOLS 101

INSIGHTS & OUTLOOK Grinding Wheel

The Productivity Movement Grinding wheels used today have come a long way from their ancient sandstone origins. Used in the shaping, finishing and polishing of industrial metals, these wheels are now a select combination of natural and artificial abrasives embedded in specific bonding materials. As the grade of finishing becomes finer, Nishant Kashyap takes a look at how the modern grinding wheel technology is gearing up to roll into the future.

rinding wheels are expendable w h e e l s composed of an abrasive compound. These wheels could either be formed out of an aluminium disc or solid steel by way of attaching the particles to the exterior surface. In general, grinding wheels are normally prepared using the mould of hardpressed coarse particles matrix that are allied together to make a firm circular shape. Based on the planned use of the wheel, various profiles and crosssections are also obtainable. According to Mathew Jacob K, Chief Technical Officer, Pferd India, â&#x20AC;&#x153;Earlier, first generation or hand-held grinding became popular with resin bonded grinding wheel. Gradually, it started moving away from the bonded flat wheels. Today, the latest innovation is the self-sharpening wheel where a lot of cool air is circulated behind the grinding wheel. With this innovation, grinding has become much cooler. As a result, the force or power is more towards grinding rather than 102 MODERN MACHINE TOOLS - May 2012

friction. The emerging sectors are basically nuclear, aerospace & power and grinding wheel and machine manufacturers have a lot of hope from these sectors as the quality norms are always higher than the conventional industries around us.â&#x20AC;?

Role Of Grinding Wheel Manufacturing industries have a growing interest in finding economical ways to improve grinding productivity, part quality and production cost. And grinding wheels are the most common and important types of grinding elements used in this industry. Therefore, having a good understanding of the type of grinding wheel and its proper application is of prudent importance. Grinding wheels come in many different sizes, shapes and abrasives. Their function is to remove materials from the workpiece to smoothen, sharpen or polish it. This happens by the abrasive action of the wheel. Each grain of the wheel acts as a cutting tool. The abrasive grains are the actual cutting tools of a grinding wheel. Each cutting grain is sharp and irregular. It chips off the tiny thin flakes of material while cutting. Abrasive type, abrasive grit size, hardness grade, grain structure

Grinding Wheel and bond type affect wheel performance. By varying the other parameters such as work speed, traverse, feed, and so on, an operator can make a wheel act one grade softer or harder. Grinding, as applicable to the metal cutting industry, is generally a finishing operation on components, especially in industries such as automotive, aerospace, white goods, etc., which call for high precision. Accuracies sometimes reach sub-micron levels that require ultra-high precision machines and special grinding equipment like Cubic Boron Nitride (CBN) wheels, rotary diamond dressers, fine filtration equipment for coolants with controlled temperature, etc. To achieve high accuracies, in-process gauging and dynamic balancing of grinding wheels, among others, is commonly used. High-performance grinding wheels are used for the grinding of auto engine, auto gearbox, auto chassis and auto steering. They also find applications in aerospace for turbine blades, root & tip profiles and so on. The prospects of grinding wheels depend upon the type of manufacturing practices that will be adopted in the future. Wheels made of new forms of synthetic abrasives such as the seeded gel aluminium oxide and CBN are also being used. Further, the use of advanced materials such as ceramics and composites will increase demands for new types of grinding wheels. Research and development in making cutting tools out of polycrystalline super abrasive materials or CBN and aluminium oxide will make the grinding wheel a viable option for shaping hard materials.

Wheel Shape Matters The wheel itself comes in a variety of

Types Of Grinding Wheels

Straight grinding wheels Cylinder or wheel ring Tapered grinding wheels Straight cup Dish cup Saucer grinding wheels Diamond grinding wheels.

104 MODERN MACHINE TOOLS - May 2012

shapes. The grinding face—the part of the wheel that addresses the work—is on the periphery of a straight wheel. A common variation of the straight wheel design is the recessed wheel—since the centre of the wheel is recessed to allow it to fit on a machine spindle flange assembly. On some wheels, the cutting face is on the side of the wheel. These wheels are usually named for their distinctive shapes, such as in cylinder wheels, cup wheels and dish wheels. Sometimes, bonded abrasive sections of various shapes are assembled to form a continuous or intermittent side grinding wheel. These products are called segments. Wheels with cutting faces on their sides are often used to grind the teeth of cutting tools and other hard-toreach surfaces. Mounted wheels are small grinding wheels with special shapes, such as cones or plugs, which are permanently mounted on a steel mandrel. They are used for a variety of off-hand and precision internal grinding jobs.

Selection Of Grinding Wheel As the grinding wheel is a form of cutting tool, the abrasive, grit size, grade and bond type need be correctly selected to fit the particular job. There are various factors which could affect the choice of a grinding wheel specification. These include material to be ground and its hardness, amount of stock removal and finish required, whether the grinding is done wet or dry, wheel speed, area of grinding contact and severity of the grinding operation. Selecting the right grinding wheel for a specific application, if properly understood, is not difficult. In actual practice, where rate of production as well as accuracy and surface finish are important, the grinding wheel must be selected with the utmost care. Sometimes, the first selection of the wheel may not turn out appropriate and modifications in grade or grit size, or both, may be necessary. In such cases, a correct specification could be established after conducting trials in two or three different grits and arriving at the optimum grade. The skill

of the operator also plays an important role in the correct usage of a grinding wheel. A skilled operator can make a wheel act one grade softer or harder by varying the other parameters such as work speed, traverse, feed, etc. Also, proper coolant selection is essential for grinding tools, especially for air-hardened grades. Commenting on India’s approach, Mathew says, “In India, companies look more into the cost of the product and not into the cost-effectiveness of the product. For instance, people always figure out the grinding wheel by defining the size, they simply do not go beyond that when there are many more things beyond size comparison.” “Companies need to have a holistic approach. Most of the time, in India, the problem is that we use under power machines and then when you put a good quality tool in it, the machine goes down. In India, people only talk about the RPM (the speed), but speed is only one part of the story, the other part is power in the machine. When you buy cheaper machine, at end of the day, the machine’s RPM will drop down to 70% in our experience,” he adds.

Set To Witness A Sharp Rise Since grinding is a widely used method of precision machining, India seems to be the preferred destination for grinding machine and equipment manufacturers. “We expect the grinding for high-end applications to grow at a higher rate, since the awareness levels for safer and specialised performance tools are catching up fast in the industry,” avers Mathew. Driven by domestic demand and the cost-efficiency advantage of India, the business outlook for industry in the country is expected to grow considerably. The growing demand for the grinding machines and need for better product finish has given the push to adopt sophisticated grinding wheels. As the Indian quality norms will increase in future, the need for better grinding wheel will also see a sharp rise. nishant.kashyap@infomedia18.in

INSIGHTS & OUTLOOK Tips & Tricks

the right grinding wheel Selecting the right grinding wheel for a specific application, if properly understood, is not difficult. In actual practice, where the rate of production as well as accuracy and surface finish are important, the grinding wheel must be selected with supreme care. Nishant Kashyap suggests some tips... Kind of material to be ground and hardness: This affects the choice of: Abrasive: Aluminium oxide abrasives are well suited for steels & ferrous metals, while silicon carbide abrasives are ideal for grinding non-ferrous & non-metallic materials. Grit size: A relatively fine grit size works best on hard and brittle material. A coarser grit capable of taking heavier cuts can be used perfectly on soft and ductile materials. Grade: The hardness of the material to be ground also affects the choice of the wheel grade or hardness. Amount of stock removal and finish required: These affect the choice of: Grit size: As a rule, coarser grit is selected for fast cutting action, while fine grit is opted for when high finish is required. Bond: Vitrified bonded wheels are generally used for fast cutting action and commercial finish. Resinoid, rubber and shellac bonded wheels produce the highest finish. Wet or dry grinding: Generally, for precision grinding, a coolant is necessary. However, in some cases, such as tool regrinding, the process may be dry. Here, a softer grade wheel may be necessary. But in the case of wet grinding, a one grade harder wheel can be used, as the coolant reduces the heat generated while grinding. Wheel speed: The speed at which the grinding wheel is to be operated often dictates the type of bond. Vitrified bonded wheels should not be used at peripheral speeds of over 33 metre per second, except for specially designed wheels. The speed at which a grinding wheel revolves is important. Too slow a speed means wastage of abrasive, whereas excessive speed may result in hard grinding action and may cause breakage. Area of grinding contact: This affects the choice of: Grit size: A coarser grit is required when the area is relatively large, as in surface grinding, to provide adequate chip clearance between the abrasive grains. As the area of grinding contact becomes smaller and the unit pressure tending to break down the wheel face becomes greater, finer grit wheels should be used. Grade: On large areas of contact, a soft grade wheel provides normal breakdown of the grit, ensuring a continuous free cutting action. On the other hand, a harder grade is needed to withstand the increasingly higher unit pressure, as the area of contact becomes smaller. Severity of the grinding operation: This usually affects: Abrasive: A tougher abrasive is required for severe grinding operations, like snagging. For light grinding operations, intermediate abrasives are used for grinding jobs of average severity. Grade: The severity of the grinding operation also influences the grade. Hard grades provide durable wheels for rough grinding, such as snagging; while medium and soft grade wheels are generally used for less severe precision grinding operations.

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Modern Machine Tools (May 12) IGF Back Pg109 110

INSIGHTS & OUTLOOK Abrasive Flow Machining

brasive Flow Machining (AFM) can be visualised as a grinding process, which generates a selfforming tool that precisely abrades workpiece material at surfaces where imperfections restrict its flow. The purpose of AFM is to smoothen, polish, and remove cracks and burrs from a surface that has ‘hard to reach’ angles and cavities. Patented in 1966 by Extrude Hone, AFM was introduced as a non-traditional method to deburr, polish, radius and remove recast layers of key components—even those with complex geometries— for aerospace, automotive, electronic and diemould industries. Interestingly, it is also used to calibrate fuel injection nozzles to maximise efficiency at specific flow rates. AFM is known to produce surface finishes as fine as 0.05μm (Ra), deburr holes smaller than 0.2mm and radius edges less than 0.025-1.5mm. Due to water’s fluid nature, it is able to reach otherwise inaccessible spots and rid the material of blemishes, particularly when it washes over the surface at high jet speeds. Abrasive media or visco-elastic polymers are made to flow through restrictive passages in the workpiece, thereby grinding internal or external surfaces as needed. This also means that AFM can simultaneously finish multiple cavities, undercuts and surfaces in a part. Unlike most conventional finishing processes, AFM can be fully automated, thereby providing a cost-effective means to finish extruded parts and complex aerospace components. Materials that can be finished using AFM include stainless steel, aluminium, titanium as well as plastics, glass and ceramics. AFM, although expensive, can also be employed as a secondary finishing process, which can easily be integrated and automated within a production line.

Further, by identifying and controlling the process parameters, AFM can be applied in a hugely impressive range of finishing operations that provide uniform, repeatable & predictable results. Anywhere that the media can be forced to flow potentially represents a practical application.

AFM Mechanism And Benefits AFM is solely a mechanical process that is applied in three fundamental ways, ie., one-way

AFM, two-way AFM and orbital AFM. In most applications, typically, twoway flow processes are used wherein the workpiece is clamped hydraulically between two vertically opposed cylinders that contain the media. The process begins by filing the lower cylinder with a specific volume of abrasive laden media. Subsequently, media is drawn through the workpiece into the upper cylinder. The media is then drawn in the reverse direction, fed back through the part and then into the lower cylinder. This combination of a single upstroke and downstroke constitutes a complete AFM cycle. The main parameters that are involved in AFM are the type of abrasive media, the pressure under which it flows and the speed with which it flows over a surface. AFM is unique. It allows for the greatest flexibility in finishing surfaces or edges. The precise location and intensity of grinding can be controlled through appropriate fixture design, media selection and other parameter modifications. This is primarily due to the fact that the finishing in AFM is carried out by a combination of visco-elastic putty and abrasive particles, thereby resulting in a self-deforming medium flowing into or across the surfaces of a component. Extrusion pressures may vary between 100 and 3000 psi. One-way flow systems extrude the abrasive media only in one direction, permitting the media to exit freely from the component or tooling. Orbital AFM oscillates the workpiece by translating it in two or three dimensions, in a ‘pad’ of abrasive media. It is better suited to finishing highly complex geometries uniformly. AFM’s versatility lends itself to an extensive range of applications in finishing operations. It can be applied

fl wing

112 MODERN MACHINE TOOLS - May 2012

to a

Fine Finish

With new materials and highly specific applications emerging, the need for improved finishing processes has become greater than ever. Tarun Tampi portrays Abrasive Flow Machining, a technology growing in stature, as an ideal finishing process for the modern manufacturing era, thus reaffirming an age old Chinese proverb asserting that constant dripping water can pierce through stone.

Abrasive Flow Machining to give reliable and repeatable results practically wherever abrasive media is made to flow through or across a part. Its benefits are as follows: Simultaneously finish multiple components or multiple areas of a single component Complex internal passages and inaccessible areas can be finished economically Automated AFM systems handle thousands of parts a day, saving on cost and labour Cutting forces are low, resulting in minimal surface and residual stresses in the work-piece No foreign particles or impurities embedded Burr removal is clean and accurate.

element of ‘flow retardation’, even those left over post-manufacturing. Similarly, in the automotive industry, it enhances engine performance, torque transfer, flow velocity, volume, fuel economy and component life. For the die-mould industry, it reduces production costs, increases production, improves die performance and extends the life of moulds. Surfaces made by forming can be enhances up to 10 times further. Dies are an ideal workpiece for AFM since they inherently restrict flow. Hence, the uniform and controlled removal of stock material by AFM makes it suitable for the accurate sizing of undersized passages in dies or moulds. In the medical industry, it eliminates surface imperfections that can harbour contaminants and greatly improves the functionality, durability and reliability of prosthetic parts.

An Array Of Applications AFM finds extensive application in medial, automotive, die-mould and aerospace industries. Although it is applied for a variety of components across manufacturing, it brings specific advantages and inherent improvements when applied to each of these industries. In the aerospace industry, it is mostly used to reduce surface friction, thus improving surface quality to a greater degree. It enhances the fatigue strength of high-cycle components, optimises combustion and hydraulic efficiency, improves airflow and extends component life. Ultra-smooth finishes reduce any MR Sankar, Asst Professor, Dept of Mechanical Engineering, IIT Guwahati Presently, there are few big companies and organisations in India, such as Kennametal and ISRO, who use the AFM process for finishing, deburring and radiusing complex surfaces. Currently, due to the high cost of AFM technology (machine, tooling and medium costs are greater than `50,00,000) as well as high abrasive medium cost (2kg costs around `5,00,000), it is not yet possible for small scale industries to have the same.

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Improved Processes AFM has a few disadvantages that are rapidly being overcome by improvements and developments in modern AFM processes. AFM is an expensive technology, currently out of the reach of SMEs in India. More importantly, it has a low finishing rate, a low material removal rate and an inability to correct form geometries. Microflow AFM is a modified application, which is different from standard AFM. It uses abrasive media that have lower viscosity and smaller particle size (less than 50 – 750μm). The low viscosity allows for high velocity flow and the reduced particle size allows for close-tolerance finishing of microsized orifices. Abrasive Jet Machining uses a high-pressure jet that is a mixture of water and hard abrasives such as garnet, diamond or other powders. Parts finished by this process do not require any prior de-burring and have a very fine satin-like finish, similar to sandblasted surfaces. It is particularly used to finish heat-sensitive, brittle and fragile components of any hardness. Magneto AFM applies a magnetic flux across the flow of abrasive particles in AFM thus aligning them as they flow. This application of magnetic abrasives allows

On making AFM more attractive for manufacturers: To overcome the drawbacks of AFM processes, many Indian researchers worked on various advances such as Magnetic Abrasive Flow Machining (MAFM), Centrifugal Assisted AFM (CFAAFM), Drill Bit Guided Abrasive Flow Finishing (DBGAFF) and Rotational Abrasive Flow Finishing (R-AFF) processes. Every development has its own advantages and limitations. But the major aim of Indian research is towards the development of efficient AFM processes at economic prices as compared to commercially available AFM processes (Kennametal Extrude hone, Micro Technica technologies, and so on). On the future of AFM: AFM technology has huge potential in the automobile & medical sectors, which are continuously growing in India. These sectors, instead of purchasing AFM technology from commercial suppliers at high prices, should consider collaborating with top educational/research institutes to develop economical AFM processes. This helps the industry (to sell their products at economic prices) as well as research institutes ( who gain internationally recognition through quality research). Cumulatively, collaboration between the industry and research institutes helps India grow and surge ahead in research and development fields. On the scope of AFM: In the future, AFM has tremendous scope in India as it has the potential to finish complex surfaces at a nano scale. In India, the automobile and medical sectors are growing by the day and AFM processes have huge applications in these sectors. Hence, the scope for this process is expected to widen in the future in our country. - MR Sankar, Asst Professor, Dept of Mechanical Engineering, IIT Guwahati for faster, more accurate finishing along with a high volume of internal deburring. It increases the material removal rate as well as the finishing rate. tarun.tampi@infomedia18.in

INSIGHTS & OUTLOOK

Courtesy: Hypertherm

Fibre Laser Technology

Cutting to Perfection Cutting technologies are continuously evolving, and one of the most significant recent advances in this field is fibre laser, which has marked its presence around 3-5 years back. Most companies are still getting acquainted with laser fibre and are beginning to appreciate the multiple benefits that it has to offer in comparison to the more traditional CO2 laser.

f the key thermal cutting methods involving oxyfuel, plasma and laser technologies, laser cutting offers the best cut quality, especially for fine features and holes that have less than a 1:1 diameterto-thickness ratio. This makes laser the most appropriate method for meeting the stringent precision cutting needs of an industry. Within the laser cutting category, fibre laser is garnering a lot of attention because it offers the speed and cut quality of a CO2 laser. Moreover, it is cheaper and easier to maintain & operate. This makes fibre laser promising as a cutting technology that experts believe it will soon overtake other laser systems.

Fibre Cutting: An Advantage Efficiency In Operations: In CO2 lasers, CO2 gas is involved in the transmission 116 MODERN MACHINE TOOLS - May 2012

of the beam. In fibre laser, however, transmission works through diodes and fibre cables. Instead of relying on mirrors to transfer the light beam, fibre laser systems rely on multiple solid state pump diodes to generate a laser beam, which is then transmitted through a flexible fibre cable to the laser cutting head. This offers a number of benefits, the first being, table size. Unlike gas lasers, where mirrors must be a set distance apart, there is no size restriction for fibre laser. It is even possible to install a fibre laser cone right next to a plasma cutting head on a plasma cutting table, which would not be an option for CO2 lasers. Also, the ability to bend or coil fibre means that the systems are relatively compact when compared with gas systems of comparable power. Energy Efficient: The most important and significant benefit of a fibre laser

is that it is energy efficient. Because of its completely solid state digital & monolithic design, fibre lasers have higher wall-plug efficiency than CO2 lasers. For every unit of power that passes through a CO2 cutting system, it is common that about 8-10% is actually used. Whereas for fibre lasers, users can expect much higher power efficiency figures of between 25% and 30%. In other words, a fibre system consumes about 3â&#x20AC;&#x201C;5 times less energy overall than CO2 versions, thereby making it up to 86% more energy efficient. Increased Output: Fibre lasers also feature positive light properties such as a shorter wavelength, which improves beam absorption into the material being cut, and enables the cutting of nonconductive metals such as brass and copper. A more concentrated light source creates a smaller spot and longer depth

INSIGHTS & OUTLOOK Fibre Laser Technology

of focus. As a result, fibre lasers can cut thin materials fast and medium thickness materials more efficiently. Up to 6 mm (1/4”), a 1.5 kW fibre laser has cut speed equivalent to a 3 kW CO2 laser. This translates into increased output, despite lower business costs because the operating costs for fibre cutting are lower than that of traditional CO2 systems. Minimal Maintenance: Traditional gas laser systems require regular maintenance—mirrors need to be maintained & calibrated, and resonators need to be replaced. But fibre laser solutions hardly require any maintenance. CO2 laser cutting systems require CO2 lasing gas, which can collect impurities that need to be cleaned out regularly. This can cost at least $20,000 annually for a multi-kilowatt CO2 laser system. In addition, many CO2 cutting formats use high-velocity turbines to move around the lasing gas, and these turbines will require maintenance & eventual overhauling. Lastly, because fibre solutions are more compact and have a smaller footprint as compared to CO2 systems, there are less cooling requirements, & energy consumption is significantly reduced. The combination of low maintenance and higher energy efficiency translates to the fact that fibre laser has a smaller carbon footprint, & is therefore more eco-friendly than CO2 laser cutting.

Critical Measures To Consider There are a few important things to take into account while adopting fibre laser: The light from a fibre laser system is at a wavelength that is hazardous to the eye. A good eye protection is a must. Comprehensive training for proper system operation and safety is highly recommended as well, since the technology has only been around for five years or less. Many operators do not have much experience cutting with fibre, so this lack of experience needs to be filled by some good initial training in controlling fibre cutting systems. Another consideration is the material to be cut. While fibre 118 MODERN MACHINE TOOLS - May 2012

Thermal Cutting Processes Advantages Oxyfuel For metal plates thicker than 75 mm (3”) Suitable for carbon steel; not effective on stainless steel or aluminium Plasma Suitable for cutting thickness from between gauge to 75 mm (3”) Preferred over CO2 and fiber laser cutting for materials >1/4” (6 mm) Able to cut a wide range of material thicknesses and metal types, including ferrous and nonferrous material, and can be used on rusted, painted or grated metal CO2 Laser Excellent cut quality and productivity on material ranging from gauge to 12 mm (1/2”) thickness Cuts well for fine features on thin plate of around 6 mm (1/4”) High-powered systems enable cutting a broad thickness range with good tolerance Fibre Laser Best cut quality with highest energy efficiency on material less than 6 mm (1/4”) Good for fine features on thin plate < 6 mm (1/4”) Better cut quality than plasma on holes with less than a 1:1 diameter to thickness ratio Lower operating & maintenance costs compared to CO2 laser; 86% more energy efficient than CO2 lasers

laser is excellent at cutting most materials, it cannot be used to cut acrylic or polycarbonate, and can only cut wood or fabric in limited applications. The thickness of the material to be cut is also an important factor in deciding when to use fibre laser. Thicker materials will require more power to cut, and in those instances, laser cutting may be a less attractive option. This is where the ability to install fibre laser

right next to a plasma cutting head may be well utilised. Operators can cut thinner material requiring tight tolerances with fibre laser, before quickly and easily switching to plasma. It is even possible to cut the same part with two different cutting methods. For example, an operator can choose to cut the outside of a part with plasma, and then any inside shapes with fibre laser. One final consideration is to assess which components are necessary for a comprehensive laser cutting setup, and how to acquire each part. A system that comes complete with the laser power source, gas console, laser cutting head and height control, the Computer-Numeric Control (CNC) and cutting control programmes will offer the valuable benefit of an allin-one off-the-shelf solution. With a comprehensive solution, the process of purchasing and integrating the fibre laser is much less complicated. Consider shortlisting a system that was optimised specifically for cutting, where cut parameters have been identified in advance so that cutting can begin as soon as power is supplied.

Offering Multiple Benefits Fibre laser offers many unique benefits over the traditional CO2 laser cutting systems such as higher energy efficiency, lower maintenance costs, and a more compact solution—but it may not be right for everybody. As much as lasers cutting offers multiple benefits to companies today, it is still a relatively new technology that is rapidly evolving. This only means that lasers are likely to witness continued improvements to meet its true potential in the years to come. Companies can, therefore, look forward to cutting even faster and better with the fibre laser technology of tomorrow. Doug Shuda, Product Marketing Manager – Fibre Laser Team, Hypertherm. The New Hampshire-based company’s reputation for metal cutting innovation dates back to more than 40 years. E-mail: technology.hypertherm@hypertherm.com

MMT May-2012

Ad Name: Samkrish Pg No. 119

MMT May-2012

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MMT May-2012 Ad Name:Hyundai Pg No. 121

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INSIGHTS & OUTLOOK Simulation Technology

eing the final operation in metalworking, grinding is often the most demanding and precise technique that is increasingly facing several challenges. Grinding machines not only have to guarantee high degrees of accuracy in individual cases, but also have to ensure reproducible results at sufficiently high rates of productivity. Since all the manufacturing processes are automated nowadays, grinding—a traditional finishing operation—can no longer be an exception to this trend. Improvements in its performance have allowed for the use of grinding in bulk removal of metal, while, at the same time, maintaining its characteristic of being able to perform precision processing, thus opening new areas of application in today’s industrial practice. Commenting on the scope of automation in the grinding industry, Mathew Jacob K, Chief Technical Officer, Pferd India, avers, “Automation is widely used in the grinding industry. But then, there are several areas where automation is not an economically viable option to programme a machine for grinding operation. Nonetheless, wherever implemented, automation has definitely increased the productivity levels by way of minimising human interference and consistency in part manufacturing—a major issue in countries like India and China. Automation has really taken over in areas related to consistency in output

124 MODERN MACHINE TOOLS - May 2012

and offered excellent dimension as well as surface quality.”

Simulation In Grinding Grinding is one of the most important machining methods for finishing, which is performed by using a large number of abrasive grains with irregular shapes and random distribution. While this feature enables accurate and high quality machining, it makes it difficult to analyse the grinding process. In order to solve this problem, several computer simulations have been developed, which help users to statistically calculate geometric interference between a grain

and a workpiece. It gives users the flexibility to visualise the result as an animated image using a threedimensional (3D) graphics technique. New generation CNC control system uses software and 3D simulation to work out the programme offline, which increases the productivity. Acoustic sensors reduce the idle time while dressing and approaching for the part, thereby increasing productivity. Most of the grinding process works on closed loop measurement system, which helps achieve a high rate of consistent production. The simulation makes it easy to understand the microscopic g r i n d i n g phenomena and makes it possible to analyse the surface generation p r o c e s s quantitatively.

VISUALISING The Future In

GRINDING Industrial and academic interest pertaining to the role of technology in manufacturing is increasing, since modelling and simulation lead to optimisation of processes and, at the same time, reduce expensive and time-consuming experimental work. Nishant Kashyap analyses the advantages & reasons to take up simulations and the future of this technology in the grinding industry.

Simulation Technology Simulation can be used as a practical tool for predicting the grinding results, such as surface roughness, and for optimising grinding parameters such as infeed rate. The key advantage to tool grinding simulation software is that users can design and perfect a complete tool grinding process offline and prior to actual production. There are new products coming up in the market, which use exotic materials. There are superalloys, hard-to-grind materials, composite materials, which can only be dealt with grinding. As a result, there is a growing demand for simulation in this segment.

Why Simulate? Grinding is a complex material removal process with a large number of parameters influencing each other. In the process, the grinding wheel surface contacts the workpiece at a high speed and under high pressure. The complexity of the process lies in the multiple microscopic interaction modes in the wheel-workpiece contact zone, including cutting, plowing, sliding, chip/workpiece friction, chip/bond friction and bond/workpiece friction. Any subtle changes of the microscopic modes could result in a dramatic variation in the process. To determine the engagement condition for all micro-modes quantitatively, many virtual grinding

Mathew Jacob K, Chief Technical Officer, Pferd India

Automation is widely used in the grinding industry. But then, there are several areas where automation is not an economically viable option to programme a machine for grinding operation.

Nonetheless, wherever implemented, automation has definitely increased the productivity levels by way of minimising human interference and consistency in part manufacturing—a major issue in countries like India and China.

126 MODERN MACHINE TOOLS - May 2012

Advantages Of Simulation In Grinding Process

Amplification of process knowledge Optimise cast of process stability Forecast of component characteristics Reduction of planning and development steps Cost reduction.

wheel models have been developed based on the wheel fabrication procedure analysis. Also, a kinematics simulation has been developed according to the operational parameters of the grinding process. A Finite Element Analysis (FEA), which has become a ‘must have’ technology, studies the single grain cutting under different conditions to characterise and quantify the grain-workpiece interface. Given the engagement condition on each individual grain with the workpiece from the physics-based simulation, the force, chip generation and material plastic flow can be determined through the simulation results. From the perspective of process prediction and optimisation, the simulation can analyse and provide the output value, including the tangential force and surface texture. In terms of the microscopic analysis for mechanism study, simulation is able to estimate the number of cutting and plowing grains, cutting & plowing force and probability of loading occurrence, which can be used as evidence for process diagnosis & improvement.

Advantages Of Simulation The biggest advantage of tool grinding simulation software is that toolmaking shops can design and perfect a complete tool grinding process offline and prior to actual production. Such software typically uses any tool grinding programme that is written in standard software, and then fully simulates tool grinding. The tool grinding simulation includes the complete machine and its axes movements, workholding and

accurate wheel data. With all of these, users can predict whether they would be able to achieve specified tool geometry. The tool grinding software simulates either tapered or stepped cylindrical tool blanks and includes features that provide quick displays of finish-ground tools that do not entail the whole tool grinding process. Through the use of colour coding, shops can distinguish & highlight different operations and measure & inspect tool features in minute detail, correct operational problems or easily edit troublesome NC sentences.

Future Prospects In this growth phase, manufacturers are aiming towards automating their processes wherever possible. But till now, unlike other machining operations, the grinding industry has not found many software solutions to simulate its processes. According to Mathew, “Worldwide, everyone aims to automate all manufacturing processes, but unfortunately nothing major has happened in the grinding industry, so far, because this is a typical hand held job. The industry always needs human intelligence for this job. Hence, heavy influence of automation is unlikely in the future as well. In fact, this is one of our big advantages as we expect a lot grinding process to come to India and China in future.” The current scenario and demand for the sector clearly indicates that the need for automation is ever increasing and will continue to grow till manufacturing activities exist. In future, the industry will witness many new software solutions to simulate the grinding process. Unlike other shortspan activities, grinding is heading towards consistent growth in terms of business opportunities & application areas, such as product design & development, reverse engineering, etc., which will pressurise simulation technology providers to innovate automated solutions. nishant.kashyap@infomedia18.in

AUTOMATION TRENDS Surface Tuning

Finishing without Manual

Laburr

pplying automation to finishing is a quandary for most Indian manufacturers. Apart from the fact that finishing was considered a secondary process till modern demands forced brutal quality standards on products, introducing automated finishing systems simply cost too much and seemed to return little. This argument weighs high cost, low flexibility and downtime vulnerability against a plethora of benefits such as more goods produced per manufacturing floor area, reduced rework and wastage, high volume production, greater customer satisfaction, reduced inventory levels and a reduced dependence on highly skilled workforce. As far as the costs are concerned, most do not see how the sharp increase in quality and productivity result in a quicker payback time to offset the costs of investing in automation. In the everprogressing world of manufacturing, nothing stays the same. If you are not 128 MODERN MACHINE TOOLS - May 2012

improving continuously, you cannot stay in the game for long. In this context, here are several instances where automation can and has been applied profitably.

CNC-based Grinding Grinding is a less controllable process than other areas of manufacturing because of the use of a grinding wheel for metal removal. The grinding wheel is a cutting media that is constantly breaking down and changing. It actually changes its grinding characteristics as it grinds. When you can control your grinding wheel through automation, there is rarely an operation that is done faster on a manual grinder. The technology brings the much required conveniences and core advantages like position repeatability for unattended product lines, controlled processing, high-speed stroke grinding for maximum productivity, control of multiple grinding wheels, multiple process automation as well as slot and step automation.

Courtesy: GMN Paul MĂźller Industrie GmbH & Co. KG

Finishing technology has evolved and progressed over the past 20 years. It has resulted in thousands of different surface treatment options. But the most important development has been the application of automation and robotics in finishing processes. The driving demand for precision products, aesthetics and performance has transformed finishing from a manufacturing afterthought into a critical part of production. Tarun Tampi takes a look into how automation is taking this transformation one step further. Robotic Deburring Robots prove advantageous for the deburring of machined parts because they are more repeatable than humans and suffer no fatigue. Deburring is the removal of rough or thin ridges formed during the machining process. Typically done manually, deburring is accomplished by applying tools such as brushes or files to the edges of the part to be deburred. Manufacturers are continually plagued by high job turnover, broad variation in quality, and low employee esteem associated with the tedious process of manually deburring job shop quantities of machined parts. Robotic deburring has slowly found its way into commercial applications involving the production of large quantities of single part types, and where there exist stringent requirements for reproducible results. Commenting on the application of these technologies, Mohini Kelkar, MD, Grindmaster Machines Pvt Ltd, says, â&#x20AC;&#x153;We have adopted robotic finishing

AUTOMATION TRENDS Surface Tuning for felting (parting line removal) of front axle beams, forging, felting and deburring of aluminium die casts. Apart from this, robotics and automation can also help during the process of finishing, as it brings a consistency to the result. These days robotics and automation is majorly used in sectors like critical engineering and aerospace, among others.”

Mohini Kelkar, MD, Grindmaster Machines Pvt Ltd Automation brings consistency, irrespective of the operator and when we say consistency, it is with respect to both the result and the productivity.

Controlled-force Honing Controlled-force honing, one of the features in multi-feed honing, works like cruise control to ensure the optimum cutting load on the honing abrasive throughout a cycle, regardless of the incoming part’s hardness, geometry or size variation. Depending on the application, controlled-force honing can cut cycle times by as much as 50%, lengthen abrasive life for lower consumable cost and allow finer control of surface finish parameters. Controlledforce technology eliminates glazing of the abrasives because of too little force, and maintains a steady, free-cutting, self-dressing condition for maximum metal removal in the shortest possible cycle time. The technology is especially suited for applications using segmented diamond or super abrasive honing tools or involving workpieces with slight variations in hole diameters, hardness and geometry. It maintains optimum feed force on the honing abrasive and keeps the entire process in balance.

Automated Process Lines Although systems for automating surface finishing process lines are commercially available and have been proven in a wide range of applications, a majority of surface finishing process lines remain manually controlled. Significant process improvements for surface finishing manufacturers include: Automating manual process lines Software systems for lab analyses for scheduling, automatic-calculations, statistical tacking and output controls or actions based on analytical results Production software will be used to track product quality and defects Continuous process improvement 130 MODERN MACHINE TOOLS - May 2012

programmes, like Six Sigma, can be integrated to identify and implement specific process monitoring and control improvements.

Automation Systems Automatic Timers, Pumps And Switches There are still mass finishing departments crammed with vibratory bowls and tubs that shake and shimmy endlessly. Timers on machines and automatic mixing pumps delivering chemical solutions to the process helps to completely monitor and control the process without depending on manual expertise. Programmable Logic Controller Finishing equipment that do not run on Programmable Logic Controllers (PLCs), will prove difficult to upgrade to the next level of process control. PLCs are sort of a ‘central dispatcher’ for automated machinery, tying together materials handling components, timers, proximity switches and more. It can also store entire processing programmes or multiple programmes. So, operators need to only load a batch of parts and press start. The system can even be programmed to accept automatic parts loading, monitored by time, part count or weight, from upstream production machinery like automated stamping, fine blanking and powdered metal presses or automated conveying systems. At its best, an intelligently programmed PLC can even handle mid-process changes. Graphical User Interface This is a mixed issue for many manufacturers since on the one hand operators are not qualified programmers while on the other, the operator must

be able to adjust the required settings at any given moment. Guided by the philosophy that a picture is worth a thousand words, Graphical User Interfaces (GUIs) take programming a notch up, displaying information in intuitive, graphic displays. Local Area Network Tying PLCs together and letting machines ‘talk’ to one another or to a central monitoring station is the next step toward true, full automation. Doing this requires the creation of a Local Area Network (LAN). Much like the ones that allow office workers to share files and send e-mails, LAN allows a department full of machinery (or a complete manufacturing cell) to carry on a sort of ‘binary conversation’. Central Process Monitoring Central Process Monitoring (CPM) might be described as the absolute peak of process technology. CPM has been applied to CNC machines, stamping presses, injection moulders and warehousing pick/place systems for more than a decade. Adding networked LAN to automated finishing machines can get those answers with the click of a mouse, even from offsite locations.

Rounding Off The Future Manufacturing has never been an easy way to make a living. And, metal finishing departments are the final operation in many plants. Still, customer demands continue trickling down to every operation, every department and every process. Adding headcount is rarely the most efficient and sustainable solution. By adding automation and monitoring systems, these obstacles are better managed, keeping productivity high and profit margins safe. But, there is more to it than just numbers. Today’s quality standards are simply unforgiving. Absolute uniform consistency is no longer a dream; it is a demand. With the technology becoming cheaper and better, automation and tight process monitoring is going to be the only way to meet it. tarun.tampi@infomedia18.in

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Modern Machine Tools (May-2012) Insert 11-Pg136

ENERGY MANAGEMENT Eco-conscious Manufacturing

Machining with the

Environment in

Mind

o shops feel that becoming more environmentally responsible is beneficial for their business as well as the planet? To find out, a benchmarking survey was devoted to learning more about shops’ environmental attitudes as well as practices they have put in place to recycle and conserve energy. While this may not be a comprehensive guide to become a more environmentally responsible machine shop, it does indicate where leading shops are focussing their efforts. Here’s sharing the learnings’ & trends from the survey conducted by Modern Machine Shop.

It is safe to assume that most shops recognise the importance of being environmentally responsible. However, benchmarking data suggests that the effort shops put into both recycling and reducing energy consumption varies.

perspective, recycling can also bring in money. Many surveyed shops recycle the chips created during machining. Some even integrate equipment to maximise the return on their recycling efforts, which can range from briquetters to centralised, facility-wide systems for chip handling and processing. Fewer shops reported that they recycle used cutting tools. However, shops can realise a good return, especially when selling back used carbide inserts and solid carbide tools. Many cutting tool suppliers offer carbide recycling programmes that make

it easy to sell back spent tools. With carbide scrap ranging from $11 to $13 per pound, it makes sense to have such a formal recycling programme in place to recover this valuable material, notes Jeff Solomon, Owner, Globe Metal Recycling Services Inc. Solomon says a good carbide recycling programme begins with effective inventory control of both new and used tooling. One reason why a formal programme is important is because it prevents theft. Because carbide is small and dense, employees can easily pocket a few pounds of it and walk out the door. Effectively tracking tooling assigned to each employee and securely storing both new and used tools

Table 1: How important is environmental responsibility to the success of your business? All Shops Total responses

Top Shops

Other Shops

169

122

Not important

13.8%

16.2%

13.1%

What The Survey Revealed...

Minor importance

24.5%

24.3%

24.6%

Recycling Programmes Most respondents cited the importance of recycling. In addition to being conscientious from an environmental

Somewhat important

26.4%

16.2%

29.5%

Important

27.0%

40.5%

23.0%

8.2%

2.7%

9.8%

Highly important

May 2012 - MODERN MACHINE TOOLS 137

Eco-conscious Manufacturing helps prevent this from happening. Solomon notes that there is also value in recycling high speed steel tools. Some scrap dealers are not familiar with the tool steel grades and may pay just $0.15 or so per pound for it, as they would for regular steel scrap. However, scrap tool steel is currently worth more than $1.25 per pound, so it makes sense to separate and collect those tools as part of a shopâ&#x20AC;&#x2122;s recycling programme in addition to carbide. Coolant Management When a coolant is properly maintained, its effective life can be indefinite and disposal costs can be eliminated. Some of the surveyed shops have such coolant management procedures in place. Other advantages to maintaining coolant versus disposal/replacement include reducing the amount of coolant concentrate to be purchased, achieving longer cutting tool life, improving part quality and minimising machine downtime. Some coolant management companies even offer a mobile service in which they come directly to a shopâ&#x20AC;&#x2122;s location to recycle spent coolants or cutting oils. A few surveyed shops have also switched to biodegradable and vegetable-based cutting oils. These oils provide an added level of safety because of their very high flash point, and their low mist formation means less product is consumed compared to similar mineral oils. Minimum Quantity Lubrication Approximately 10% of all surveyed shops perform some machining using Minimum Quantity Lubrication (MQL). MQL delivers a very small amount of coolant to a cutterâ&#x20AC;&#x2122;s edge in the form of an oil mist or aerosol, as opposed to traditional techniques of flooding the workpiece and tool with a substantial volume of liquid coolant. It permits dramatic cuts in coolant costs, while protecting workers and the environment. And for the right applications, it can deliver improved tool life and surface finish for machined components. More Efficient Machines Simply put, modern machine tools 138 MODERN MACHINE TOOLS - May 2012

Table 2: Which of these environmental programmes/practices occur at your shop? All Shops

Top Shops

Other Shops

157

120

Energy Management

39.5%

54.1%

35%

Recycling/reuse programmes

75.8%

91.9%

70.8%

3.8%

2.7%

4.2%

2.7%

8.3%

3.8%

2.7%

4.2%

19.1%

6.4%

23.3%

Total responses

Use of renewable energies Corporate environmental programme Carbon footprinting None of these

are more energy efficient than their predecessors. In fact, one surveyed shop noted that the total amount of power it consumed at its facility decreased each time it replaced an old machine with a newer, more efficient model.

Integrating Energy-Efficient Design Elements Shops that throw scrap chips and remnants in the garbage instead of recycling them...

...are throwing away money...

...because carbide scrap currently can yield as much as $13 per pound, it makes sense to have a formal recycling programme in place to recover spent tools made of this valuable material.

Machine tool builders continue to integrate design elements to minimise energy consumption. Some models stop the spindle motor, servo motors and fans inside the control panel during standby. In addition, more efficient LED lighting is increasingly common. Improved efficiency is being built into elements such as guideways, hydraulics and drive systems, too. In fact, some drive systems offer power source regeneration capability that transforms kinetic energy from decelerating servo and spindle motors into electrical power. Real-time monitoring of energy usage is also becoming more popular as managers seek to identify the prime drivers of energy costs during machining operations. Right-sized Machines Lean operations focus on eliminating waste. As some surveyed shops noted, one way to do this is to purchase machines that are properly sized for the types of parts the shop will produce. Rightsizing equipment makes maximum use of floor space and consumes less energy than equipment that are too big for the application. Facility Considerations HVAC systems can represent a significant portion of facility operational

Eco-conscious Manufacturing

VTD Systems upgraded its lighting system for increased energy efficiency and to provide a better work environment. Robert Vilagi Jr, the companyâ&#x20AC;&#x2122;s president, replaced his shopâ&#x20AC;&#x2122;s existing bulbs and magnetic ballasts with a 320-watt, high-intensity discharge metal halide system with electrical ballasts. This system is noticeably brighter and is said to save approximately 30% on energy costs.

costs. While some surveyed shops have changed to more efficient, controllable systems, others have benefitted by a simpler changeâ&#x20AC;&#x201D;raising or lowering (depending on the season) the thermostat temperature slightly during operating hours and more so during off-hours to reduce electricity used for heating and cooling. Similar steps can be taken for lighting systems. Surveyed shops noted

that savings can be realised by simply turning off lights when an area is not in use or by using timers or motion detecting devices. Other surveyed shops have completely revamped their lighting system. Old fluorescent systems that use T12 lamps can be upgraded by using the existing fixtures and replacing the T12 lamps and magnetic ballasts with T8 lamps and electronic ballasts. In addition, some surveyed shops have found that high-intensity fluorescent lighting is more efficient than the conventional metal halide systems they replaced. Compressed Air A number of surveyed shops examined their compressed air systems and optimised them for reduced energy consumption and operational costs. Also, control technology for new compressed air systems has improved to enable compressors to draw power only when needed. One surveyed shop says state energy credits allowed it to upgrade its HVAC and air compressor systems and

Ten percent of surveyed shops perform some machining using minimum quantity lubrication (MQL), which delivers a fine oil mist to the cutter.

realise a three-year investment payback. Four-day Work Week Something as basic as changing from a five-day work week to a four day week with 10-hour days can be beneficial. Since doing that in late 2009, one surveyed shop has experienced close to a 2% increase in productivity as well as a 5% reduction in energy costs. Courtesy: MMS Magazine

May 2012 - MODERN MACHINE TOOLS 139

STRATEGY Social Network Outreach

The countryâ&#x20AC;&#x2122;s industrial growth is shouldered by the small-scale industries; companies, which have the potential, but not the finance to advertise their abilities; companies, which are still trapped in their own ghetto and are yet to explore the outside world. Stepping in to pull SMEs to the fore, the Federation of Indian Chamber of Commerce and Industry (FICCI) has recently collaborated with Facebook to enable Indian SMEs to utilise the power of social media. Will this move take positive strides towards bringing the spotlight over the achievements of SMEs? Debarati Basu finds out...

FOR GLOBAL CONNECT

ccording to recent statistics, India has over 6,400 industrial clusters across the country. But how many of these companies have a proper official website? Say, half of them. How many of those websites are updated on a regular basis? Well, not many. And how many of them have networked themselves actively on social media sites to project their business potential globally? Barely a handful!! 140 MODERN MACHINE TOOLS - May 2012

In an age when the Internet and its possibilities have been explored to its optimum, Indian SMEs are still far off from upgrading their computer skills and utilising the outreach opportunities that the social media sites offer today. SMEs in India have a huge opportunity for growth, given the perfect strategy chosen for the global outreach. Finding potential opportunities to elaborate their services, major search engines and social networking sites are

now targeting the small-scale industries to strike a win-win dealâ&#x20AC;&#x201D;Facebook and Google have taken the lead.

Building The Bridge FICCIâ&#x20AC;&#x2122;s recent collaboration with Facebook aims to fill in this gap and harness the power of the Internet and social networking sites. The initiative aims to make global business networking easy and effective for SMEs to help them attract more customers online. The

Social Network Outreach initiative will also provide tutorials on ways to use Facebook optimally to build & engage in branding the company and also use free advertising credit on the social networking platform. “The major problem that this segment faces today is on ways to reach out to the global market. Facebook, which has over 800 million users globally has come up with the ‘Add Boost Programme’. This was already launched in Germany and the US. In this, companies put up their advertisements, which are automatically displayed in the profiles of Facebook users who have mentioned similar line of interest in their profile,” explains Hemant Seth, Joint Director & Head – MSME, FICCI, Delhi. The initiative will begin with training programmes, which will start this year. FICCI, along with local chambers and associations, will initiate pan India training programmes wherein SMEs will be trained to use Facebook and understand the applications for using the online medium optimally. Initially, cities like Indore, Ahmedabad, Hyderabad, Coimbatore, etc., will be targeted. Taking into consideration the lack of online presence of most Indian companies, a similar initiative was previously launched by Google, which started the ‘India Get Your Business Online’ campaign. The initiative offered free website, domain & hosting services and technical support for SMEs. The search engine had aimed to open over one lakh new websites and they have been reported to have already reached mid way through this target. Narrating his experience of consistently using networking sites,

Rajni Patel, GM, Uniexcel Agencies & Services Pvt Ltd SMEs of India have been underestimated for long. This industry is educated and mature enough. They only need to change their mindset and use the Internet to their advantage.

142 MODERN MACHINE TOOLS - May 2012

like Linkedin, Ashutosh Singh, GM, Hind Tools Pvt Ltd, says, “Such social networking sites have helped me not just to develop industry contacts, but also to know about the latest technologies in the market, enhance my customer base and generate product enquiries. With various industry groups and discussion forums, we can also assess the change in the customers’ needs. I have been able to generate business links with many good customers through these sites.” However, there are a few necessary measures which SMEs need to incorporate to make their presence felt in the market. These include: Take The Initial Step A website is the face of the company. Most Indian companies, especially the small and mid-sized ones, do not give adequate importance to creating its online presence. However, most foreign companies, when they do not find an online presence of an organsation, find it difficult to entrust business decisions on them. When the world is standing on the same e-platform, you cannot miss any step. So, create a company website using professional help. Share Comprehensive Information Most company websites do not provide adequate information or are loaded with outdated details. Apart from being aesthetically appealing, the content uploaded on the websites should be a reflection of the company with relevant details and information. The information on the website should be properly categorised in different pages with easy to understand navigation. Go Beyond Getting a website in place is not enough. The website should be noticed and attract potential customers. One needs to go beyond. Networking sites like Facebook, Linkedin and Twitter are being optimally used to connect to the world outside. Create a company’s profile page on social networking sites. Link your company website to it. Be active on the links. The entire world is out there. Join and be a part of the various industry associations. Send out product and company details frequently

Hemant Seth, Joint Director & Head – MSME, FICCI, Delhi The report by the Ministry of Micro, Small & Medium Enterprises (MSMEs) on the Working Group on MSME for the 12th Five Year Plan, and also the Prime Minister’s Task Force has identified this segment as a low-tech enterprise. In this age, technology has become a critical area for SMEs to come up.

to keep those interested in the product line updated. Optimal utility These social portals have today become the point of contact. While it can be a medium for SMEs to advertise their potential, it can also be a learning ground for them to know and understand the shop floor transitions going on around the world. Such networking sites also open up discussion forums for likeminded people. For instance, Facebook, along with Natural Resources Defense Council and an energy information software specialty firm, has launched a programme to make energy saving an online community affair. This application will tap into the smart grid capabilities at public utility companies, monitor and compare energy saving and also share conservation tips. Rajni Patel, GM, Uniexcel Agencies & Services Pvt Ltd, feels, “SMEs of India have been underestimated for long. This industry is educated and mature enough. Taking help of such tools like Facebook will only help them expand their reach. However, it is not correct to say that they are not tech-savvy. They instead they need to change their mindset and use the Internet to their advantage.”

Time To Become E-wise The resources are many, but the inclination to adopt the new age technology will determine how well the Indian SMEs become e-wise!! “The whole idea is about adopting new technology and creating awareness about the usage of new technology,” said Seth. debarati.basu@infomedia18.in

Event List - National

AHMEDABAD Gujarat Oct 5-8, 2012

PUNE

CHENNAI LUDHIANA INDORE

Madhya Pradesh Punjab Maharastra Tamil Nadu Nov 2-5, 2012 Nov 22-25, 2012 Dec 21-24, 2012 Jan 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 Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. Mob: 09819552270 Fax: 022 3003 4499 • Email: engexpo@infomedia18.in • Web: www.engg-expo.com

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

IMEX 2012

ACMEE 2012

The premier event is designed to facilitate effective interaction among several fraternities of the machine tool, automation, cutting tool and user industry; May 4-6, 2012; Chennai Trade Centre, Chennai

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

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

For details contact ACMEE 2012- AIEMA Technology Centre, 1st Cross Road, Ambattur Industrial Estate, Chennai 600 058 Tel: +91 44 2625 8619 Fax: +91 44 2652 0814 Email: info@acmee.in Website: www.acmee.in

IMTEX 2013

For details contact: Address Conventions & Fairs (India) Pvt Ltd E-519, Floral Deck Plaza, Central MIDC Road, Opp Seepz, Andheri (E), Mumbai 400 093 Tel: +91 22 2839 8000 Fax: +91 22 2839 0502 Email: conventions@mtnl.net.in Web: www.confairs.com

AMTEX 2012 India Machine Tool and Automation Expo The expo would provide a unique gateway for manufacturers/suppliers of machine tools & automation products/services providers; May 18-20, 2012; Codissia Intec Technology Centre Coimbatore. For details contact: Paramount Exhibitors C-84, Industrial Area Phase 7 Mohali (Chandigarh) Punjab Tel:+91-172-2274801-02, 4699301-2 Fax: +91-172-2274803, 4699303 Email: contact@paramountexhibitors.com Web: www.imtexindia.com

AMTEX (Asian Machine Tools Exhibition) has constantly strengthened its position as one of the largest shows of machine tools, machineries and manufacturing technologies in the Asian region. The event will showcase the latest advances in machine tools and manufacturing solutions; July 27-30, 2012; Pragati Maidan, New Delhi. For details contact Triune Exhibitors Pvt Ltd 25, 3rd Floor, 8th Main Road Vasanthnagar, Bangalore 560 052 Tel: +91 80 4330 7474 Fax: +91 80 2235 2772 Email: info@triuneexhibitors.com Web: www.triuneexhibitors.com

The 16th Indian Metal-cutting Machine Tool Exhibition, with international participation, will showcase the exhaustive range of innovations and technological refinements in the complete product segment of metal-cutting machine tools and manufacturing solutions. The concurrent event - Tooltech 2011 - the international exhibition of cutting tools, tooling systems, machine tool accessories, metrology and CAD/ CAM, will feature the latest trends in cutting tools and tooling systems from across the globe; January 24-30, 2013; at Bangalore International Exhibition Centre (BIEC), Bengaluru. For details contact: Indian Machine Tool Manufacturers’ Association Bangalore International Exhibition Centre, 10th Mile, Tumkur Road Madavara Post, Bengaluru Tel: 080 6624 6600 Fax: 080 6624 6661 Email: info@imtex.in Web: www.imtex.in

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Event List - International AUSTECH 2012 The show exhibits with new manufacturing technologies and techniques to cut costs. More than 10,000 decision-makers regularly attend Austech and National Manufacturing Week to get ideas, find innovative ways of making things and solve manufacturing problems; May 8 - 11 2012, Sydney Showground Sydney Olympic Park, Australia. For details contact AMTIL Suite 1, 673 Boronia Road Wantirna, 3152, Victoria, Australia Tel: +61 3 9800 3666 Fax: +61 3 9800 3436 Email: kwarren@amtil.com.au Web: www.amtil.com.au

INTERMACH 2012 The show focuses exclusively on industrial machinery and aims at introducing the latest high-tech machinery and cutting edge technology from around the world; May 17-20, 2012; at Bangkok International Trade & Exhibition Centre (BITEC), Thailand. For details contact: UBM Asia (Thailand) Co Ltd 503/23 K S L Tower 14th Floor Sri Ayuthaya Road, Kwaeng Thanon Phayathai, Khet Rajathewee, Bangkok 10400 Thailand Tel: +66 0 2642 6911 Fax: +66 0 2642 6919 E-mail: info-th@ubm.com Web: www.ubmthailand.com

Fax: 34 94 40 40 001 Email: bec@bec.eu Web: www.biemh.com

CIMES The largest machine tool event in China will witness 1,300 exhibiting companies with industry experts from 28 countries/ regions will display nearly 3,000 pieces or sets of machineries & tools in the show; June 12-16, 2012; New China International Exhibition Center (NCIEC), Beijing, China For details contact: Reed Exhibitions (Shanghai) Co Xinyuan South Road, Chaoyang District, Beijing, China Tel: +86 10 59339072 Fax: +86 10 59339099 Email: cimes@reedhuayin.com.cn Web: www.cimes.net.cn

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

IMTS 2012

The 27th edition of the event will showcase latest developments and technologies from leading companies in their specialty; May 28 – June 2, 2012; Bilbao Exhibition Centre, Bilbao, Spain. For details contact: Bilbao Exhibition Centre Ronda de Azkue 1, 48902 AnsioBarakaldo Tel: 34 94 40 40 000

For details contact: The Association for Manufacturing Technology John Krisko, AMT Director - Exhibitions 7901 Westpark Drive, McLean,

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

MTA VIETNAM 2012

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

BIEMH

VA 22102-4206 USA. Tel: 703-827-5252 Fax: 703-827-5250 Email: jkrisko@amtonline.org Web: www.imts.com

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

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

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MMT MAY-2012 AD NAME: FULTON

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REPORT Die Die && Mould Mould India, India 2012

Behind the Indian Manufacturing Blitzkrieg With humble beginnings in the setting up of railway workshops in the 1860s, Indian manufacturing today contributes over 20% to the national economy with tooling demands expected to surpass `23,620 crore by 2015. In the backdrop of this mercurial rise, the die & mould industry, the mother of all manufacturing, presented itself at the 8th biennial Die & Mould India 2012, in Mumbai. Covering the event, Tarun Tampi, turns the spotlight on this gathering of movers and shakers propelling this growth.

ith the intention to aid progress as well as to discuss the challenges faced by the Indian tooling industry, the 8th Biennial Die & Mould India (DMI) International Exhibition—a four-day event—began on April 19, 2012, drawing participation of local and global players in the manufacturing sector. Held at the Bombay Exhibition Centre, Goregaon, Mumbai, the event was inaugurated by Dr Abhay Firodia, Chairman, Force Motors and PG Deshmukh, MiG Complex, Hindustan Aeronautics Ltd (HAL). The event was organised by TAGMA India, under the guidance of SC Kalyanpur, President, TAGMA. Encapsulating the importance of an evolving tooling industry, Dr Firodia said, “The best machine with weak tooling is not as good as a poor machine with excellent tooling. We need to strive to get the best tooling solutions for competitive growth in the Indian manufacturing sector.” He added that most factors,

such as availability of quality manpower, technical solutions and a growing market for tooling solutions, are in the country’s favour, and it is up to the industry players to seize this opportunity.

A Widening Platform Over 400 exhibitors participated in the event, setting up a variety of stalls in an exhibition area spread over 20,000 sqmt. International participants from Italy, Korea, China, the US, Japan and many other countries were present and shared their valuable insights, knowledge and technology with those from the tooling industry in India. The exhibition had a large influx of visitors, in the form of prospective clients, existing customers, OEM delegates, students and researchers. The 8th Die & Mould exhibition also held seminars, workshops and live demonstrations to address contemporary issues and to develop a consolidated approach towards a stronger future. Taking advantage of the connectivity and logistics Mumbai offers, this edition of

DMI well surpassed the 7th Die & Mould India Exhibition, which had seen in 2010, a 21% growth in the number of exhibitors, 15% growth in the number of visitors and 17% in the size of the exhibition area. In this regard, TAGMA has to be commended for striving to promote the die & mould sector through initiatives, such as organising conferences, seminars and exhibitions on an international scale for the promotion of the Indian machine & tools industry. Stressing upon the crucial needs of the tooling industry, Kalyanpur said, “The 8th Die Mould India show is an important event that enables decision makers to see live demos, meet all suppliers of this industry and display their latest products and technologies to finalise their expansions plans. Organised since 1998, the B2B show is the only trade fair in the Indian industry with a global platform.” The range of products exhibited at the event included press tools, mould bases, standard parts, hot runner systems, tool steels, heat treatment systems, texturing gauges, CAD/ CAM, die spotting, machine tools and

May 2012 - MODERN MACHINE TOOLS 147

Die & Mould India, 2012 accessories/consumables for machine tools & moulds. The solutions were aimed at improving productivity and quality as well as reducing costs for customers.

Vacuum Heat Treatment of Dies &

Tooling Frontiers

Horizontal Cast Plates: Enhanced

It is currently estimated that the tooling demand in India will reach `23,620 crore by the end of 2015 and will see a growth of 16% over the next five years. Plastic mould & die and casting dies are expected to grow at a CAGR of 17%, whereas sheet metal and forging dies anticipate a growth of 14% CAGR. As of now, the global tooling industry is moving steadily towards high-end technology and applications in their mainstream operations. Beginning with product designing, prototype development, pricing & delivery, Indian tool makers are keeping pace with global standards of technical competence and innovation. Some of the many developments showcased at DMI included HETO IX 1000, a multifunctional mould machine, Hasco’s DLC Locating Units, a highprecision loading unit, WikusNiran’s fully automated bandsaws and Prime Industries’ Synthetic Fluid, a wire EDM fluid that does not produce fumes. This shift has led to many mould makers now looking at low volume, high-precision moulds as compared to high-volume and low-precision moulds. The recent spurt in the automotive industry has aided the growth of toolmakers and machine tool sales alike. This has resulted in need creation, which is the basic requirement for the continued growth of any sector. Visiting DMI, Saket Dharkar, Director, Pragati Forge, said, “The industry is developing at a rapid pace and there is a push towards cutting-edge technology. However, we have not been able to develop such technology indigenously and acquiring highly sophisticated automated technology is highly cost prohibitive. Since the volumes in the Indian market do not exist, it becomes a difficult proposition for cost sustainability. Only OEMs can manage to do well in such a scenario. There are various segments in the market and if 148 MODERN MACHINE TOOLS - May 2012

Seminars Held On Tools

Properties For High Quality Applications Universal 3D Metrology: Inspection And Reverse Engineering For Today’s Die & Mould Industry Usage of CNC Controllers And Machines For Die - Mould Tools, Die & First Article Inspection By ATOS 3D Scanning Concept to Component: Delcam’s Advanced Manufacturing Solutions Transfer Press Dies: From Concept To Prototyping.

you cater to a specialised segment, only then can acquiring high-end technology be much easier.”

Experiencing The Event Die & Mould India is a large and renowned platform for toolmakers to interact with their counterparts, suppliers and customers from India as well as those from foreign shores. Many international companies have direct operations in India and prefer to source from local companies. One of the first places they look at is TAGMA and the DMI Exhibition. Initiatives such as the annual market report on Indian tooling industry, newsletters and member directory, are worth mentioning, as most purchasers abroad, before taking their next step. would look at these first. Another fact is that DMI is perceived—by most toolmakers and customers—as an industry gathering to witness all innovations happening from time to time. There were several exhibitors from various backgrounds, some new to the experience and some veterans of DMI. Highlighting what the event means for an exhibitor, Vijay Menon, AGM – Sales & Marketing, Godrej Tooling, said, “This unique exhibition gave tool rooms and those involved in the die & mould industry a platform to showcase

their capabilities at a critical time where growth in the automotive sector is expected to be 15% CAGR over the next few years. The tooling industry must match this growth. We invited and encouraged our customers to visit the exhibition. It also gave automotive OEMs a great opportunity to meet suppliers and establish relationships. Besides, it helped them learn about various tooling solutions that Indian manufacturers, like us, have to offer.”

Marching Forward The Indian mould making industry is growing at a steady pace, largely on an SME backbone, but technological development is possible only when end applications of moulding technologies broaden beyond their existing horizons. In India, SMEs contribute around 45% of industrial output, 40% of exports and offer 42 million employment opportunities. The sector creates one million jobs every year and produces over 8,000 quality products for the Indian & international markets. SMEs are expected to contribute 22% to India’s GDP by 2012. As India progressively moves towards becoming a ‘knowledge economy’, it becomes increasingly important for the tooling industry to focus on advancement of skills, which have to be relevant to the emerging business environment. Taking a fine view of the event and the industry, Kalyanpur said, “Tool makers should be given incentives to enable double-digit growth, through timely support from the government in the form of soft loans for expanding capacity, along with upgrades and modernisation. They should be given higher rates of depreciation for faster ROI to tide over obsolescence and to remain competitive, thereby making the procurement of technology and equipment attractive and affordable. Involving new players and scaling up investments to expand production is vital to boost the die and mould sector if India is to become a leading ‘manufacturing hub’. tarun.tampi@infomedia18.in

REPORT SIMTOS 2012

Expanding The Convergent Field Around Machine Tool

Upgraded from the Machine Tool show to Manufacturing Technology Show, SIMTOS, the international exhibition, perfectly justified the changed name and showcased the latest in manufacturing technology. Nishant Kashyap shares the impressions and energy that this trend-setter event generated and its impact on the world machine tools industry. SIMTOS @ A GLANCE

he sprawling 108,165 sqmt of KINTEX was home to the 15th edition of the Seoul International Manufacturing Technology Show (SIMTOS 2012). The event, over the years, has strengthened its position to become one of the largest shows of machine tools, machinery and manufacturing technologies in the world. Organised by Korean Machine Tools Manufacturers Association (KOMMA), the event flagged off the supremacy of the Korean machine tools industry. Sharing his thoughts on this trendsetting show, Jong-Hyeon Shon, Chairman, KOMMA, said, “SIMTOS 2012 is an ideal place that provides opportunity for Korean as well as foreign

No of Exhibitors: 700 No of countries participating: 35 Exhibit space: 108,165 m2 No of visitors: 100,000 (95,000 domestic and 5,000 international) companies to promote their technologies and products in Asian and especially in Korean market. As most of the wellknown machine tools manufacturers participate in this event, it would be a good opportunity to understand the current trend of manufacturing technologies.” The exhibition was demarcated into five brand pavilions depending on exhibit product; metal cutting & diemould working, press & metal forming; cutting-off & welding; tools & related

equipment; CAD/CAM, measuring system & robotics; parts materials & motion controls. “The demand for machine tools has dramatically increased in recent time, which makes SIMTOS a platform to showcase your technical capabilities. This year, the impression of this show is fantastic. Korean companies are known for their technology and production capacity. We are receiving enough number of enquiries, and expect to convert around 1/3rd into orders,” said Charles Kim, Machine Tool Overseas Sales & Marketing, HYUNDAIKIA Corp.

Machine Tools And More... Going by the motto of ‘United Manufacturing Technology with Machine Tool’ the six-day premier May 2012 - MODERN MACHINE TOOLS 149

SIMTOS 2012 event showcased a wide array of latest machinery, solutions and services for the metalworking industry by nearly 800 exhibitors from 35 different countries. The exhibit range included metal cutting & die-mould working, metal forming, cutting-off & welding, tools & related equipment, CAD/CAM, CNC system, measuring system & robotics, and parts materials, motion controls, other related machinery & parts and machine tool accessories. KOMMA also organised many technical seminars on various topics in the field of CAD/CAM/CAE, robotics, welding, metal cutting, metal forming, die & mould among others, which attracted many enthusiastic technocrats. The main agenda of these technical seminars were to contribute to the development & promotion of the industry and trade through increased international transaction and technical exchange in the areas of machine tools and their related equipment.

Hee-Chul PARK, Director General, KOMMA

India @ SIMTOS Since SIMTOS is the biggest event in Korea, many Indian associations, exhibitors and buyers were present at the show to grab the growing Korean opportunity. Indian Machine Tool Manufacturers’ Association (IMTMA), Ambattur Industrial Estate Manufacturers Association (AIEMA) and Engineering Export Promotion Council (EEPC India) had supported many exhibitors and brought many buyers as well, which was the reason why a number of Indians was significantly higher than last edition. MV Robert, Chairman, AIEMA said, “We have delegates from 32 companies and are looking for new technologies here. Indian companies are very competitive in component manufacturing and have been accepted worldwide, we are looking for customers who can buy our components for their machines. We are very optimistic about the trade between India and Korea.” Most Indian exhibitors and buyers were component manufacturers and looking for some customers as well as dealers in Korea. When asked about future of trade between India 150 MODERN MACHINE TOOLS - May 2012

Industry Dynamics: Recently, Asia’s machine tools production has increased its share from 41% to 62% as compared to Europe, whose share has decreased significantly. The Korean machine tools industry has developed tremendously. It has ranked 5th in terms of production ($5.6 bn), 7th in terms of export ($2.3 bn), 5th in terms of import and 5th in terms of consumption. Benefits of SIMTOS: Participating in SIMTOS offered exhibitors the chance to demonstrate their technical capabilities. For Korean companies, it provided a platform to meet global customers. Since Korea ranks 5th in terms of consumption, it would provide a good opportunity for overseas companies to set up base in Korea. This year, many technical seminars were conducted during SIMTOS, which helped the industry communicate with each other, enhance knowledge and increase contact base. We also arranged for a purchase consulting team to redress the queries of buyers from abroad & domestic companies. India and Korea: India is the 4th country we export to, next to China, the US and Germany. In 2011, we exported machinery worth $168 million, with an increment of 39%. India has huge potential, especially since it has recently set up its strong position in machine tools industry. We have a good relationship with Indian companies. It is all about synergic growth prospects, as Indian companies have shown interest in Korean products and the Korean companies are also willing to invest in India. This will enhance the trade prospects between the two countries.

and Korea, more than 90% exhibitors were optimistic about it. Around 40% exhibitors said currently Korea has not shown much interest in Indian products, but very soon we will find space in the country. Mustafa Gandhi, GM, Precision Machinekraft (P) Ltd, said, “We came here with no expectation, but found many buyers coming in to enquire about our products. Our main focus was to meet the small and medium sized enterprises, who could be our potential customers.” Talking about new product development, he said, “We have developed a new product, which is used for turning, drilling, milling, and grinding operations. We have applied for a patent for the same. In future, Indian components will be accepted by Korean companies, which will lead to enhanced trade between India and Korea.”

Unique Platform SIMTOS 2012 was not only about the exhibition. The event also provided a place to exchange ideas, offers scope for business transaction as well as a meeting place for the world’s machine tool industry. Many visitors were pleased as the event provided them knowledge about the Korean machine tools industry and kept them abreast with the current scenario. For the exhibitors, it was the best place to launch products and get immediate response. According to Yountae Park, VP, DMG/MORI SEIKI Korea, “In this edition of SIMTOS, we launched a five axis machine and are getting a good number of responses. Our main aim to exhibit in this edition of SIMTOS was to meet our existing Korean customers and get some overseas customers. Currently, the demand from Asian countries, such as China, India, Indonesia and Korea has increased, which makes this event a best place to grab the market.” As Korea has become one of the biggest producers and consumers of machine tools. Hopefully, the exhibition will lead to commensurate developments in the global machine tool industry till SIMTOS 2014. nishant.kashyap@infomedia18.in

Modern Machine Shop 2012

Maximising Metalworking Scope A nation’s industrial growth depends on many factors, including market demands & dynamics, newer technologies and companies, products & service offerings, exchanging ideas and inspirations, forging ties…the list is an exhaustive one! The second edition of Modern Machine Shop (MMS) delivered all this and more under one roof. Going by industry sentiments, the four-day trade show, held during April 5–8, 2012, enhanced the prospects of maximising metalworking scope and opportunities for one & all. A report by Tarun Tampi and Arindam Ghosh...

s this decade unleashes the exponential growth of the Indian machine tools industry—as expected and witnessed in the global market—the second edition of Modern Machine Shop (MMS 2012) was successful in bringing to the fore the significant role played by small-scale industries in this ever-evolving journey. Held during April 5–8, 2012, the event was inaugurated by Arvind Kapur, President, ACMA; Vikram Sirur, President, IMTMA; RD Madan, Chairman – Regional Council (North), IMTMA and V Anbu, Executive Director, IMTMA. Speaking on the occasion, Kapur said, “This event is vital for the machine tools industry. It reaches out to all the regions of the country where manufacturing activities actually take place.” MMS 2012 displayed a variety of technologies, including metalworking machinery, low-cost automation, material handling, quality control systems & equipment, software and consultancy & off-the-shelf production aids, which facilitate modernisation in manufacturing organisations. Explaining the reasons for organising MMS 2012 in the northern region, Anbu informed, “The region generates about 40% of the total machine tools demand in India.” In addition to this, Sirur said, “We want to make companies aware of all the latest machine technologies and capabilities available in the market. Our goal is to maximise the productivity levels of all manufacturing companies and we are

IMTMA President Vikram Sirur sets the tone for MMS 2012 with his inaugural speech

content with the response generated in this edition.” The event also witnessed various high-level delegations from companies such as North Central Railway, COFMOW, ACMA, Ordnance Factory Board, BHEL and Hero Motors, among others.

USPs The second edition of MMS 2012 was special in more ways than one. Discussing the uniqueness of MMS 2012, VS Goindi, Past President, IMTMA, said, “We made special arrangements for engineering students so that they could attend our show and gain exposure to the machine tools industry. This initiative played a key role in further improving their technical capabilities.” Anbu added, “In addition to machine tools, there were several innovative solutions on display that would enable the whole manufacturing process achieve higher levels of productivity.” Highlighting

another unique feature of this year’s edition, Sirur stated, “This MMS show made young professionals aware of the latest developments, machine capabilities and quality controls, which can help them serve their customers better. Further, the show bridged the expectation gap between OEMs and their vendors.”

Visitors’ Voice This business-to-business exhibition provided a new platform in terms of forging new partnerships between engineering professionals, system integrators and customers. Visitors were impressed with the state-ofthe-art technology & equipment on display. Ajay Bhanot, GM – Operations (Lighting Fixtures), Havells India, opined, “Havells always aims at expanding the production areas by implementing newer & innovative technologies and platforms like Modern May 2012 - MODERN MACHINE TOOLS 151

REPORT Modern Machine Shop 2012 Machine Shop give us scope to look out for such technologies. We came here to look for systems like turret punch presses and press brake tools, which we can easily procure locally from Northern India. More exhibitions like Modern Machine Shop should take place in this region, as it will play a key role in giving more exposure to manufacturers based here. However, I believe that more awareness-related initiatives are required towards popularising such industrial shows and demos should be incorporated on the shop floor itself.” Adding to Bhanot’s perspective, Parvez Alam Gaur, Regional Manager – North, Magnaflux, Division of ITW India, informed, “Presently, the show is in a nascent stage. However, over a period of time, it will become a major show for the manufacturing industry. Here, one gets to learn about the latest technologies available in the market, on one platform. I came here to primarily look for material handling systems like automated conveyors.”

Beholding Tremendous Potential

Objectives Achieved

Special focus on technology and innovation to drive competitiveness, especially for SMEs Improve quality and productivity at every stage of manufacturing Upgrade machine and job shops Provide manufacturing flexibility to accommodate shorter product lifecycles Educate and encourage SMEs to move up the value chain.

our share from 16% to 25% by 2025. Such events witness better partnerships, advanced technologies and increased business, thus building momentum & business confidence.”

Expanding Reach IMTMA plans to take the exhibition to other parts of the country and expand its reach on a regular basis. “The event is a one-stop shop for engineering SMEs. It aims to bring together an entire array of machines, equipment, products and services,” informed Sirur, adding, “We propose to organise such exhibitions every year, particularly in those centres where industries are setting up their manufacturing base.” Commenting on the expansion plans, Anbu said, “This year, we focussed on Delhi and the National Capital Region. We have already made plans to expand the presence of our show. In the coming year, we intend to hold two more editions of the show in Mumbai and Chennai along with Delhi.”

Competing With China It has been an established fact that China is making efforts to grab a major share of the pie by bringing in low-priced solutions. In such a scenario, India needs to strengthen its machine tools base such that it is not only able to compete in terms of quality, but also in terms of price. Goindi explained that a country should have a strong machine tools industry to support the growth and expansion of the country’s manufacturing demands. The Chinese Government strongly supports the growth of the machine tools industry, where manufacturing contributes nearly 50% of the GDP; unlike in India, where manufacturing contributes just 15–17%. On similar lines, Sirur opined that an Indian machine tools builder holds an advantage in India, as the company can immediately attend to the problems of customers within India, as compared to their international manufacturers in India. Elaborating on tough competition from Chinese companies, Anbu stated that, presently, in terms of technology, reliability and customer service, Indian companies have an edge over their Chinese competitors. However, he also cautioned that Chinese companies are improving their quality and their technology offerings and that too, at competitive prices. In order to tackle this situation, Indian companies need to work harder, he suggested.

India is set to become one of the Top 5 global machine tools markets over the next five years and events, like MMS 2012, with global participation, will play a critical role in helping India move forward in this direction. The event featured about 100 stalls with several live demonstrations, as well as overseas exhibitors representing six nations, including Austria, China, Japan, Netherlands and the US. The four-day event also witnessed an influx of about Connecting The Dots 5,000 visitors representing local and The show not only bridged the national businesses, educational expectation gap between OEMs and & research institutes as well as their vendors, but also helped SMEs government organisations. gauge the magnitude of competition Presently, two-thirds of the coming from neighbouring entire machine tools demand in countries. All in all, the event was India is met through imports. To a resounding success. With greater lower this fraction, exhibitions like national awareness and an expansion MMS will play a crucial role. Sirur of coverage of MMS, SMEs can said, “2012 is a significant year for successfully forge together a future us as it marks the beginning of for the Indian manufacturing the 12th Five Year Plan for the industry from the grassroot level in manufacturing industry. This ACMA President Arvind Kapur and IMTMA Past President NK the years to come. Dhand review the products displayed lays down the vision to increase tarun.tampi@infomedia18.in arindam.ghosh@infomedia18.in 152 MODERN MACHINE TOOLS - May 2012

Machines Italia in India

Adding Italian Advantage to Indian Capabilities With an objective to promote the implementation of the Italian machine tools technologies in the Indian manufacturing sector, the Italian Ministry of Economic Development in association with Federmacchinne and UCIMU - Sistemi Per Produrre along with the support of Indian Machine Tool Manufacturers Association (IMTMA) organised ‘Machines Italia in India.’ A report by Arindam Ghosh...

oday, one of the primary concerns of most manufacturing companies in India is that of achieving manufacturing excellence along with maximising productivity levels at competitive prices. To tackle this issue, Italian machine tools companies are bringing to India, highly advanced European-stamped products at competitive prices. To discuss the scope for Italian machine tools’ manufacturers in India, a forum, ‘Machines Italia in India’, was held on March 20 and March 22, 2012 in New Delhi. Italian companies, including Prima Electro SpA, Cerin SpA, Losma S.p.A and Automator International Srl and Gasparini S.p.A, among others, participated in ‘Machines Italia in India’.

Why India? Presently, improving the competitiveness of the Indian manufacturing sector is one of the major focus areas of the Indian Government. Commenting on the opportunities that the Italian machine tools solutions provide in India, Giancarlo Losma, President, Federmacchine (National Federation of Association of Manufacturers of Capital Goods intended for Industrial and Handicrafts Manufacturing Processes), said, “With 1.2 billion inhabitants, an expected GDP equal to 9% in 2013–14 and with the Indian Government planning to increase the share of manufacturing in India’s GDP to 25% by 2025; India is a country of great interest for Italian firms. The

goal of the country is to speed up the development of the manufacturing sector, which is necessary for India to rise in the international economic framework. This is a good opportunity for Italian companies to create partnerships and collaboration with Indian companies.” “If we are looking at modernising the manufacturing industry, we need better equipped and state-of-the-art machines to support the development,” said Sandeep Chadha, Director, Rare Tech Projects (the coordinating office for ‘Federmacchine’ for Project Machines Italia in India 2012), adding, “Like all the machine tools solutions from European countries, Italian tool technologies are also stamped with European class and quality. However, one of the biggest advantages Italian companies hold over its European

Italian Offerings For India

Improving competitiveness of the Indian manufacturing sector Modernising the Indian manufacturing industry by offering better equipped and state-of-the-art machines to support the development. Italian tool technologies are stamped with European class and quality. One of the biggest advantages Italian companies hold over its European counterparts is that they offer the same quality of products & technology, but at competitive prices.

counterparts is that they offer the same quality of products & technology, but at competitive prices.” Giving a perspective of UCIMU-Sistemi Per Produrre on the opportunities, Alberto Nicolai, Marketing Manager, UCIMU-Sistemi Per Produrre, commented, “The Indian manufacturing sector has been booming since the last few years and according to our projections, it will continue to boom in future. The sector needs innovative and advanced solutions to meet their requirements and Italian machine tools manufacturers have the capability to cater to this sector’s needs.”

Gateway To India So, what are the key steps an Italian company needs to take to enter into India and remain competitive? Roberto Pinton, Manager – Sales, Prima Electro SpA, replied, “India is a big market. However, for a company to be successful in any country, one has to find a reliable partner, who will not only help us gain a good customer base, but will also help us provide technological support based on local needs & demands.” Igor Colombo, Export Manager – Asia, Losma SpA, on the other hand, said, “The Indian market is one of the most dynamic markets. The rapidly growing technological needs are pushing the demand for quality machines. This opens up huge scope for Italian machine tools systems. But I think our ability to customise solutions according to the needs of the customer will help us gain major share and enable us to remain competitive in the Indian market.” May 2012 - MODERN MACHINE TOOLS 153

REPORT Machines Italia in India Alberto Nicolai, Marketing Manager, UCIMU-Sistemi Per Produrre Italian technologies are highly appreciated in the automotive sector. We have competitive offerings in aerospace, home appliances, development of energy equipment. Besides this, we produce a lot of mechanical equipment.

Agreeing with Igor’s views Matteo Ramico, Marketing, Cerin S.p.A, said that India is a very important market and the company will be looking at offering customised solutions at competitive prices.

Benefits Of Implementing Italian Solutions Implementing Italian solutions in Indian manufacturing processes brings with it several benefits. Elaborating on the same, Losma averred, “Italian machinery is well acknowledged all over the world for its extremely high technological advancement, customisation of solutions offered and capability to meet customers’ specific needs.” But how do Italian machine tools’ manufacturers manage to have an edge? Nicolai said, “The strong emphasis of Italian machine tools’ manufacturers on R&D makes our technology offering highly innovative and state-of-the-art. We also keenly listen to our customers’ requirements so that we can develop standardised and as well as customised products for them.” Losma said, “We also offer an extensive after sales support to them.” Commenting on the after sales services offered by Italian companies in India, Chadha informs that in order to serve their customers better in India, a conglomerate of Italian companies is going to set up a platform by mid2012. They will offer spare parts, components and after sales service for their machinery on the same platform. “This step will boost the confidence of the Indian buyers in going for the Italian technologies,” Chadha added.

Italy’s Global Standing Italy ranks fourth in terms of contributing to EU’s GDP and holds the second spot in terms of contribution to the industry turnover, which is equivalent to that of France. With respect to contribution of machinery, Italy ranks second after Germany, far ahead of France and Great Britain. Presently, Italy ranks third in the exportation of machinery to India, after Japan & Germany. According to industry body, FICCI, Indo-Italian bilateral trade is expected to double to €12 billion ($17.5 billion) in the next five years. And with initiatives such as ‘Machines Italia in India’ taking place, over a period of time, the figures may exceed the estimated ones easily. arindam.ghosh@infomedia18.in

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

Gears/gear components and assemblies A wide range of high-precision gears, gear components and gear assemblies, both standard and custom-built is available. The manufacturing range includes: spiral bevel gear sets: up to dia 457 mm and module 12.7, hobbed gear: dia 500 mm x 8 m, hardened and profile ground spur and helical gears: dia 330 mm x 5 m, internal gears: dia 152 mm x 3 m, and custom built/non-standard gears and gear assemblies. Salient features include intelligent design, superior raw materials and very high degree of process discipline and lazor sharp quality assurance measures. Applications are in machine tools, railways, textiles, automation, automotive, engineering, pumps, compressors, printing machines, etc. Eppinger Tooling Asia Pvt Ltd Coimbatore - Tamil Nadu Tel: 0425-304000, Mob: 08870013053 Email: eppinger@dataone.in

Surface grinding machine A wide range of precision hydraulic and manual surface grinding machine is offered. The design makes easy movement of reciprocation table provided with V and flat guideway lining with Turciteâ&#x20AC;&#x201C;B for easy movement and hand scraped to fine tolerance. The manual surface grinding machine has working surface with manual oil dip of 225 mm x 450 mm / 300 mm x 6oo mm and also hydraulic. Wheel head spindle is hardened and ground, runs on precision angular contact bearings

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

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Products - National with imported greece and driven by flange mounted motor through flexible couplings. Wheel head micro feed is 0.002 mm. Atul Machine Tools Rajkot - Gujarat Tel: 0281-6542034 Email: info@atulmachine.com Website: www.atulmachine.com

Racks and pinions The TCG Runner non-backlash racks and pinions have distinct advantage of nonbacklash, high-precision, low noise, less vibration, low dust generation, extended length and smooth running. The trochoidal profiled tooth enables to make a plurality of mutual teeth mesh at one time. The teeth always mesh via two or three portions and eliminate backlash when rotated in one or another direction. Rollers smoothly mesh with the optimised trochoidal tooth surface so as to avoid rattling noise, tooth striking noise and rotating noise being induced together with least amount of vibration. Applications are in gantry loader, robot transfer in cleanroom, transfer equipment, plurality of heads, robotic run at long stroke, etc. Rotolinear Systems Bengaluru, Karnataka Tel: 080-23572855, Mob: 09845196751 Email: rotolinearindia@vsnl.net Website: www.rotolinearindia.com

Precision bearings The super precision bearing is used for machine tools spindle. Machine tool application require superb performance in terms of running, rigidity, stability, noise level, speed and temperature stability. Running accuracy class P4 and angular contact ball bearing with phenolic cage. The high-precision angular contact bearings, double row cylindrical roller bearings and axial ball bearings are designed to satisfy these demanding requirements by machine tools. Angular contact ball bearings come in series of metric 71800, 71900, 7000, 7200 and 7300; and double row cylindrical roller ball bearings come in series of metric NN 3000 and NNU 4900. Austin Engineering Company Ltd Jabalpur - Gujarat Tel: 02873-252223 Email: sales@aecbearings.com Website: www.aec-bearings.com

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Products - National Plastic packing boxes These plastic boxes for cutting tools are used for industrial packaging. These are also used for packing carbide tools, end mills, reamers, tips, insert, tap set, tool holder, etc. Also offered are foam, stickers, screen printing, emboss and designing of logo of company on the boxes. Om Manufacturer Dist Rajkot - Gujarat Tel: 0281-2384444, Mob: 09978500100 Email: ommanufacturers@gmail.com

Indexable center drill Nine9â&#x20AC;&#x2122;s i-center indexable center drill has new replaceable super-hardened chip with high pressure coolant supply through center drill that enables high-efficiency, shortens setup and center drilling time and increases tool life which reduces tooling cost. The tool holder is suitable for both stationary and rotating tools for VMC and turning centers. Stitch Overseas Pvt Ltd Gurgaon - Haryana Tel: 0124-4755400, Mob: 09313361202 Email: stitch@vsnl.com Website: www.stitchtools.com

Self-opening die heads Taco self-opening die-heads (model SDH and SDG) are thread cutting tools of a single design to achieve mass production with a uniform and high accuracy. These die heads are suitable for cutting both right and lefthand threads. Model SDH die head is suitable for taking coventry chasers, while model SDG die head is suitable to taking geometric style-D chasers, having threading capacity from 2 mm to 30 mm in different sizes. These die heads are used on automatic and semiautomatic lathe machines, turrets, capstans and screw machines. Tools & Appliances Corporation Ahmedabad - Gujarat Tel: 079-22740375 Email: taco@imitoolsindia.com Website: www.imitoolsindia.com

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Products - National Non-reversible tapping heads The model QCSFL non-reversible tapping heads are specially developed for radial drilling machine and reversible drilling and tapping machines. These are also suitable for large boring machines. The chucks have an extensive tapping range from M3â&#x20AC;&#x201C;M42 comprising of 4 sizes. Very easy in operation, these heads are versatile in their usage. Equipped with radial parallel float, quick set torque mechanism, compression + expansion enable the operator to maximise productive without breakage of tap. Thread profile precision is as guaranteed on these chucks. The tapping heads are appropriate for LH and RH threads. Indmech Industrial Corporation Dist Gandhinagar - Gujarat Tel: 02764-233983, Mob: 09825146659 Email: sms@imitoolsindia.com Website: www.imitoolsindia.com

Quick change chucks and adapters The quick change chucks (model TF, KD, KF and KT) are designed for all types of drilling, lathes and boring machines.

Due to the nature of the simplistic design, operators can easily perform multiple operations, like drilling, reaming and tapping with efficiency and accuracy, not compromising on quality of work. Tool change is made while the spindle is in rotation and can be used for horizontal and vertical spindle machines. These chucks are appropriate for LH and RH threads. IMI Machine Tools Pvt Ltd Ahmedabad - Gujarat Tel: 02764-233983 Email: imi@imitoolsindia.com Website: www.imitoolsindia.com

Hand cleanser Microcream is a creamy hand cleanser with unique detergent and softening properties. The washing base is a combination of ingredients, free of solvents and of other substances harmful to the skin, but effective against dirt of any kind. Macrocream also contains fine micro-spheres of vegetable

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Products - National origin that strengthen the cleansing action. Thanks to its pH it can be used as many times as needed, without causing any reddening of the skin. Macrocream is effective against both greasy dirt and dry dirt. The Macrocream is suggested for repair shops, mechanics, tyre dealers, coach builders, plumbers, blacksmiths, building and allied trading, metallurgical, mechanical, mining, marine industries and petrochemical refineries. Arizona Company Ahmedabad - Gujarat Tel: 079-27700989, Mob: 09913607364 Email: arizona.company11@gmail.com

with hydrostatic bearings for smooth glide, rotatory table clamped securely by a hydraulic system, ensures superior accuracy and stability in heavy-duty machining, and automatic head changer C-axis functions with 30째/90째 milling head that can adjust the best angle in mould machining. Femco India Pune - Maharashtra Tel: 020-40147870, Mob: 09822310454 Email: sales@femcoindia.com Website: www.femcoindia.com

CNC crankshaft pin milling machine CNC boring and milling machine The T-type column moving BMC-250 T is a high-speed CNC boring and milling machine specialised for deep-slot die and mould manufacturing. Machining in vertical mounting condition of die-block helps to fall the chips down by gravity, no need of chip removal during operation. Special features are spindle with ZF transmission to improve the torque at low speed, ram diameter 250 mm with 700 mm stroke and provided

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The CNC crankshaft pin milling machine has length of 700 mm, swing diameter of 220 mm, clamping diameter of 120 mm and pin diameter ranging from 40-60 mm. The work range include longitudinal stroke X-axis (positioning) at 600 mm, transverse stroke U-axis (feed) at 300 mm, transverse stroke Z-axis (RH) at 400 mm, steady rest slide (manual adjustment) at 150 mm, and rotary index tables (A-LH & B-RH) at 360 degrees. Bharat Fritz Werner Ltd Bengaluru - Karnataka

Products - National Tel: 080-28394816 Email: bfwmarketing@bfw.co.in Website: www.bfwindia.com

existing die casting machines by installing auto ladlers for transferring molten metal to the shot sleeve.

Roll forming machines

Emtex Machinery Pvt Ltd

These r o l l forming machines h a v e features inbuilt to provide roll forming solutions for simple to critical jobs. The machines are built from prime material. Body and structure is stress relieved. These have robust design of heavy-duty steel plate body. Easy replacement of parts are also possible.

New Delhi Tel: 011-23710693 Email: emtexmachinery@gmail.com Website: www.emtexmachinerylimited.com

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

Coolant recirculators

The model CRH1400 coolant recirculator has capacity of 1400 W, delivery height at maximum 32 m, flow of maximum 20 litre per minute, tank capacity at 10 litre and total weight of 35 kg. The stainless steel tank construction eliminates coolant contamination due to electrolyte. No external plumbing is required because of the closed loop water system. Abicor Binzel Technoweld Pvt Ltd Pune - Maharashtra Tel: 020-66743904 Email: pune@abicor-india.com Website: www.binzel-abicor.com

Cold chamber die-casting machines The cold chamber die casting machines have 150 ton capacity and are available with up to 650 ton locking force. Also offered areservices to automate the

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Products - National Geared lathe machine The model ETM 660 geared lathe machine has center height of 330 mm, swing over bed at 660 mm, swing over cross slide at 440 mm, distance between center at 2000/3000; swing in gap at 900 mm, length of gap at 250 mm, width of bed at 400 mm, and power of main motor at 7.5 kW.

1,250 kg in weight. This HMC answers the demands of the market for reduced manufacturing and door-to-door-times. It is consistently driven towards the reduction of nonproductive idle and setup times and an optimum price/performance ratio. Starragheckert Machine Tools Pvt Ltd Bengaluru - India Tel: 080-40977186 Email: india@starragheckert.com Website: www.starragheckert.com

S&T Engineers Pvt Ltd

Boring tool system

Coimbatore - Tamil Nadu Tel: 0422-2590810, Mob: 09489079060 Email: advt@stengineers.com Website: www.stengineers.com

The large diameter boring tool system combines various technical feature like super light execution, which ensures minor stress for operators and presetter spindles. With full HSC capability, it renders highest precision and performance. The system is based on aluminium extension slides of different lengths, which supports variety of aluminium and steel components for roughing and finishing tool assemblies. The mounting component is pinned to fit specific locations on the slides and is secured with steel bolts. The precise location of the components on the slide along with incremental adjustment scales for insert holders permit diameter and lengths setting without a tool presetter.

Horizontal machining centre The model CWK 630 horizontal machining centre (HMC) features a compact design, highly productive tool and workpiece handling. It is ideally suited for a broad spectrum of production applications, the complex machining of the varied work-pieces in steel, cast or light metals with edge lengths to 1,000 mm and

Quattro Engineering India Ltd Coimbatore - Tamil Nadu Tel: 0422-2571606, Mob: 098947 88663 Email: coimbatore@quattroengg.com

CNC rotary surface grinder The WRS series CNC rotary surface grinder is a 3-axis grinding machine driven by Siemens 810DE/840DE/802D SL controls. The WRS 300H/V and WRS 600H/V surface grinders are available in both horizontal and vertical spindle arrangement. These machines are used for grinding of precision parts for the automobile and engineering industry. The special feature of these machines is the massive, multi-piece gray cast iron column, housing all the assembly units with the exception of the hydraulic and coolant lubricant system and the switch cabinet. Solid construction of all the assembly units provides rigidity for the entire structure during grinding. Wendt India Ltd Hosur - Tamil Nadu Tel: 04334-276851 Email: vijayvernekar@wendtindia.com Website: www.wendtgroup.com

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Products - National 2D laser machines The 2D laser machines, builtin control panel, window into the workpiece area and a barcode reader all make for easy operation. These deliver low running costs and eco-friendly features for power and gas consumption, and stable operation for up to 1.4 times greater productivity. MC Craftsman Machinery Pvt Ltd Coimbatore - Tamil Nadu Tel: 0422-6615200 Email: mccm@mccm.in Website: www.mccm.in

Machine mount The machine mount is especially suitable for mounting workshop machinery without being anchored to the ground. The height adjustment feature allows precise leveling of machinery. The machine mount provides good mobility of machinery layout in the workshop. Mounts are made with high strength materials and high quality production processes; zero or minimal maintenance required; lifelong service, wide range of solutions for both anchored & free standing machines and of varied weight

carrying capacities; suits almost all applications. Dynemech Systems Pvt Ltd Delhi Tel: 011-27347982, Mob: 09810760131 Email: sales@dynemech.com Website: www.dynemech.com

Cylinder block boring machine The cylinder block boringmachine has bore diameter (without stand) ranging from 80 mm to 100 mm, bore length of 275 mm, spindle speed at 1, and motor of 0.5 hp. Bhavya Machine Tools Ahmedabad - Gujarat Tel: +91-079-40087900 Email: info@bhavyamachinetools.com Website: www.bhavyamachinetools.com

Laser-sintering systems The EOS laser-sintering systems distinguish themselves by ergonomic peripheral devices and a high degree of automation. Thus, these ensure maximum user friendliness, optimal utilisation of machine capacity, and excellent integration into any industrial environment. EOS India Chennai - Tamil Nadu Tel: 044-28158794, Email: p.anand@eos.info, Website: www.eos.info

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Products - National Smart logic controller Crouzet new Millenium3 smart logic controller has additional function and feature compared to the earlier version of Millenium3 essential. This has both ladder and function block diagram (FBD) programming methods. Millenium3 Smart comes with improved blue coloured screen for improved legibility. Models are available with and without display. A model comes with 2 types called compact and expandable range. It can expand up to 50 I/Os. A wide range of accessories can be directly connected to this Smart version. These are remote display, touch panels, temperature sensors, light sensors, bluetooth interface and STN & GSM modems. CST Sensors India Pvt Ltd Bengaluru - Karnataka Tel: 080-41132204 Email: india@cstsensors.com Website: www.cstsensors.com

thereby increasing the blade life, reducing power consumption, better value for chip realisation and good housekeeping. The machine is specially designed and manufactured for cutting larger diameters, RCS and rail section of heavy engineering industries. ITL Industries Ltd Indore - Madhya Pradesh Tel: 0731-3044400 Email: itlindia@sancharnet.in Website: www.itl.co.in

Hydraulic swing beam shearing machines Cutting size is 12x 4000 mm, shear angle is 1Â°54â&#x20AC;&#x2122;, strokes is 8 min-1 , adjusting range of back gauge is 20-800 mm, throat depth is 300 mm, outline dimensions is 4800 x 2270 x 2000 mm and main motor capacity is 18.5 kW.

Circular sawing machines These large size circular sawing machines are available with cutting capacity that has 200 mm diameter. Broad gauge rail can cut on in just 40 sec using a cutter of diameter 630 with a thickness of 6 mm. The cutting is dry-type by using Micromist cooling arrangement (made in USA)

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Production Aids & Consultants (P) Ltd Faridabad - Haryana Tel: 0129-4001625 Email: info@pacindia.net Website: www.pacindia.net

Products - National Multi-functional tool The new Dremel Trio multifunctional tool offers unparalleled style and technology. Poised for nearly any application, ie, cutting, sanding or routing, the Trio brings precise 360-degree cutting technology to usersâ&#x20AC;&#x2122; fingertips. With the help of Trio, users can tackle multiple planes and materials including wood, plastic, drywall, metal and wall tile without switching tools. Dremel Trio is a new addition to the existing Dremel portfolio. Bosch Ltd Bengaluru - Karnataka Tel: 080-22999118 Email: boschindiafoundation@in.bosch.com Website: www.boschindia.com

Digital laser scanner Nikonâ&#x20AC;&#x2122;s superior optics is combined with innovative 3D laser scanning technology as digital laser scanner LC15Dx, which is a new milestone, and brings laser scanning in the accuracy range of tactile inspection. The LC15Dx 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. The application extends to pilot plant metrology, automotive components inspection, aircraft component inspection, surface analysis, sheet metal inspection, die and mould applications, power train components, flush and gap inspection, etc. Nikon India Pvt Ltd Gurgaon - Haryana Tel: 0124-4688500 Email: ateet.kaushik@nikonoa.net

Blasting unit Nederman suction blaster (model 750) provides a cleaner and healthier working environment. Blasting is a highly effective way of removing rust, old paint, welding scale, etc, and can often replace mechanical or chemical grinding/cleaning. Blasting offers a perfectly clean surface providing an outstanding grip for surface treatment. Blasting has a superior accessibility irrespective of the shape of the surface and different accessory nozzles keep the process closed and dust-free. Welding Technologies India Pune - Maharashtra Tel: 020-65101340 Email: wti@weldingtechindia.com Website: www.weldingtechindia.com

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Products - National Vertical machining centre The newly designed Premier PVM 40, a high-speed vertical machining centre is cost-effective, and suitable for toolroom, automobile component and engineering industries. Its advanced technology makes it one of the most superior models available in the current Indian market, suitable for die mould application. Technical specifications include: work area of 460 mm x 900 mm, maximum distance between table top to spindle face is 610 mm, and maximum spindle speed is 10000 mm.

MT4 taper and 250 mm spindle travel. The machine also has threading on the outer side to hold the collets holder. It is made available with MT4 E40 collets holder. The milling-cum-drilling machine has cross table travel of 228 mm and longitudinal travel of 765 mm. Prakash Engineers Bhavnagar - Gujarat Tel: 0278-2438241, Mob: 09852356226 Email: sales@prakashmachines.co.in Website: www.prakashmachines.co.in

Premier Ltd

Drilling machine

Mumbai - Maharashtra Tel: 022-61179024, Mob: 09833866265 Email: valerievaz@premier.co.in Website: www.premier.co.in

The all-geared, auto-feed radial-type drilling machine has 40 mm capacity. The machine design is prepared with the latest technology in which 9-spindle speed gets in a single speed motor. All-geared are made of special gear steel, harden gears (50-55 HRC) fully oil bath gearbox and lifting gearbox is also made of fully oil bath. One can gain 260 mm spindle which travels with heavy-duty MT4 forged spindle in internal & external for ground finish. Box table is provided

Milling-cum-drilling machine The milling-cum-drilling machine comes with autofeed and finefeed facility. This machine has 38 mm drilling capacity and 20 mm end milling capacity. It also has one autofeed to enable the user for boring, and reaming along with auto stop facility. To give depth of cut in the job the machines have fine-feed facility. Spindle is made up of EN8 material with internally ground

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Products - National for full machinable facing in right angle. Heavy-duty base plate design is provided inside the moulded coolant tank. Ribs are easily levelled at the foundation clamping feet. Satya Prakash Machine Tools Bhavnagar - Gujarat Tel: 0278-3012407, Mob: 09825071161 Email: info@spdrills.com Website: www.spdrills.com

Cylindrical grinding machine The model SWIFT500 CNC cylindrical grinding machine is designed to cater to customersâ&#x20AC;&#x2122; requirements of high accuracy, productivity and reliability of performance. This machine is suitable for production as well as toolroom applications. The machine comes with Siemens 802D CNC system and is 2-axis and single spindle controlled. It has specially designed heavy-duty machine bed made of single-piece close grained graded casting. The machine also incorporates digital AC servo motors for X-Z axes, and linear motion guideways for cross slide and better response, universal workhead with CNC controlled constant surface speed of workpiece, etc.

Hi-Life Machine Tools Ltd Ahmedabad - Gujarat Tel: 079-22821615 Email: info@hilifegroup.com Website: www.hilifegroup.com

Hydraulic cylinder grinder The model PUI-500 hydraulic cylindrical grinder comes with base made of close-grained and heavily ribbed casting for high rigidity in one-piece body. All guideways are carefully handscraped to ensure high accuracy and V-flat table guideways have continuous lubrication. Longitudinal hand travel of the table is by rack & pinion arrangement and automatic travel is by hydraulic mechanism. The hydraulic system consists of hydraulic pump, valves, levers, piping, etc; and all conveniently housed in the base as well as separate powerpack. Rapid approach can be provided hydraulically with separate slide. Drive to the wheel head is transmitted by two V-belts. Pitroda Utility Industries Wadhwan - Gujarat Tel: 02752-243795 Email: response@pitrodautilityindia.com Website: www.pitrodautilityindia.com

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Products - National Coolant pump The Alto coolant pump is available in various types for use in machine tools. This pump comes in 25, 40, 63 and 100 LPM capacity in 120, 170, 220 and 270 steam lengths, respectively. Performance of all pumps and motors is as per IS:2161 and IS:325 respectively. Appropriate protection is provided to prevent coolant entry into the motor.

size is Ă&#x2DC;500/400 mm x 400 mm, spindle nose face to table/pallet top 140-590 mm, spindle power 11/7.5 kW, rapid traverse X/Y/Z is 40/40/32 kW, LM guideways, chip-to-chip time 5.3 sec, basic machine weight 5400 kgf, and power supply (basic machine) 40 kVA.

Mototechnika

Ace Manufacturing Systems Ltd

Wadhwan - Gujarat Tel: 02752-243351, Mob: 09825223593 Email: alto_ad1@sancharnet.in Website: www.altopumps.com

Bengaluru - Karnataka Tel: 080-28360508, Mob: 09880493879 Email: helpdesk@amslindia.co.in Website: www.acemicromatic.net

Cylindrical photoelectric sensors

Pillar drilling machine

The CY series of cylindrical photoelectric sensors have an M18 thread size for most convenient mounting in industries. These sensors have long sensing range up to 12 meter, thru-beam type, 3 meter, retro-reflective type, and 120 mm, and diffuse-reflective type. The CY series also has a wide product range with DC supply type 10 to 30 V DC and AC supply type 24 to 240 V AC.

The model AP-40 all-geared pillar drilling machine has spindle gearbox with eight mechanical speeds ranging from 90 to 885 rpm. Gears are made from steel. The totally enclosed 2 HP motor is direct coupled with gearbox. Levers for changing the speed are avoided by means of providing special gear system. Speed is changed in the running. The feed gearbox has 2 feed for vertical movement of the Ram. As the usual hand feed is with the machine, the automatic feed arrangement is provided. As the feed engagement handles are pulled out automatic feed is engaged.

Lubi Electronics Ahmedabad - Gujarat Tel: 079-22205471, Mob: 09327497006 Email: info@lubielectronics.com Website: www.lubielectronics.com

Cut-off machine The model BU-14 is a 355 mm cutoff machine having 2,000 W dynamically balanced motor. This machine has large applications in cutting off, round bars, pipes, shaped steel tubing, conduct and channels, etc. The cutoff machine is extensively used in any heavy-duty industrial construction. It is portable, continuous-type and 100 per cent indigenous, so that all parts are locally available. Nippon Electrical Industries Ahmedabad - Gujarat Tel: 079-22822750 Email: marketing@nipponpowertools.com Website: www.nipponpowertools.com

Horizontal machining centre The model HMC- 400XL is a basic model in horizontal machining centre with 10 index table. The 400 mm x 400 mm rotary type pallet changer is an optional feature. It has higher rapid traverse of 40 m/min on X & Y axes and 32 m/min on Z axis. Strokes available are 600/450/415 mm. Key specifications include stroke (X, Y & Z axes) 600/450/415 mm, table/pallet

168 MODERN MACHINE TOOLS - May 2012

Poly Kraft Machines Ahmedabad - Gujarat Tel: 079-22743639, Mob: 09898003625 Email: pkmdrill@gmail.com Website: www.polykraftmachines.com

Hydraulic cylinders A variety of standard and custom-built cylinders are offered. These hydraulic cylinder are used in various critical applications. Specialpurpose adjustable stroke cylinder with 30 to 35 per cent adjustment in stroke with cushioning is available. The hydraulic cylinders find application in plastic injection moulding machines, where moulded goods are picked up by robots. This helps in exact positioning of moulds with respect to robot pick up device to ensure trouble free functioning of system as well as reducing the cycle time by adjusting of travel. Shashwat Systems Pvt Ltd Ahmedabad - Gujarat Tel: 079-65214825 Email: sales@shashwatsystems.com

Products - National Mop wheels Valgro-Fynex combi and interleaved mop wheels are manufactured from closely packed strips of Valgro materials with an additional flap of coated abrasive between each layer. The interleaved flaps are radially bonded to a resin core and mounted on a spindle. Specific applications are removing paint & conditioning surface on aircrafts, boats, garage doors, windows, deburring and satin finishing hard metals, weld removal and blending-in, removing heavy dirt and oxide before plating and painting, heavy-duty cleaning inside cooling coils, pipes and tubing, light sanding of wood before lacquer, cleaning stainless steel, deburring stamped and routed aluminium parts, etc. Valgro Engineers Pvt Ltd Ahmedabad - Gujarat Tel: 079-22972603 Email: arvindpatel@valgroabrasives.com Website: www.valgroabrasives.com

Radial drilling machine The model SMT 40/1000 DC double-column radial drilling machine is used for drilling, tapping, lapping, screwing and counter boring operations. This machine is also used for screwing in cast iron, steel, plastics and other materials. Its drilling capacity is about 40 mm and spindle nose is of MT-4. Double column is ground by Germanmake cylindrical grinder. Headstock is bored on imported boring machine (TOSS). The accuracy conforms to IS-2425 standards. The drilling machine is useful for every toolroom and maintenance purpose. Siddhapura Machine Tools Bhavnagar - Gujarat Tel: 0278-2445077 Email: bipin@siddpuradrills.com Website: www.siddhapuradrills.com

Surface grinding machines These surface grinding machines (model GSH8040) comes with table size 800 x 400 mm, (model GSH-10050) is available with table size 1000 x 500 mm, (model GSH 15050) has table size of 1500 x 500 mm and (model GSH 15060) comes with table size of 1500 x 600 mm. These machines are available in hydraulic as well as NC/CNC version. The machines have rigid construction

May 2012 - MODERN MACHINE TOOLS 169

Products - National and sufficient motor power for higher metal removal rate. The longitudinal table drive of the machines is hydraulic with separate hydraulic power pack and solenoid operated valves. Pinnacle Engineering Enterprise Surendranagar - Gujarat Tel: 02752-230552 Email: mail@pinnaclegrinder.com Website: www.pinnaclegrinder.com

Force-feed lubricator The range of the force-feed lubricator includes highpressure and low pressure up to 24 feed pumps. Each feed pump produces discharge up to 0.30 CC/stroke, and have working pressure up to 1000 kg/cm^ with different type gear reduction from 1:2 to 1:400 and with ratchet drive, handle drive, etc. The lubricator is ideal for air and gas compressor, reciprocating plunger pumps, rubber & plastic machinery, and similar other industries. Also offered are hydraulic cylinder, hydraulic power pack, pallet pump, grease pump, auto bike lifter, double-plunger hydraulic hand pump, etc.

provided ribs and appropriate wall thickness for base-plate, arm, inner column & column sleeve and is rigidly built to withstand static as well as severe dynamic loads. The machine finds application in engineering workshops, fabrication shops, die, mould & machinery manufacturing, automobile & shipbuilding industries, railways, defense industry. Arsun Engineers Bhavnagar - Gujarat Tel: 0278-2514076, Mob: 09426816961 Email: sales@arsun.com Website: www.arsun.com

High-pressure cleaner

Ahmedabad - Gujarat Tel: 079-22812945, Mob: 09426326091 Email: zenith_amrut@yahoo.com Website: www.hydraulicsystemsindia.com

The HDS 558 C Eco hot-water compact class high-pressure cleaner is simple in operation. The impressive features of the compact class include single-button control, chassis with integrated tank and the integrated high-pressure hose reel. It is very user-friendly and is a single-phase comfort unit of the compact class with one-button operation. The high-pressure cleaner has chassis with integrated tanks, hose and accessory stowage. Easy press trigger gun with servo control is also provided.

CAM followers

Karcher Cleaning System Pvt Ltd

These stud-type cam followers are available with standard as well as eccentric stud cage/needles guided cylindrical/crowned outer race, grease-filled readyto-use. Holes for grease nipples and plug fittings are provided. These are used as full complement bearings and can take heavier loads but at lower speeds. Applications are in all medium and heavy industries. Key attributes include grease lubricated, maintenance-free, slight gap adjustment by eccentric.

Noida - Uttar Pradesh Tel: 0120-4661800 Email: info@karcher.in Website: www.karcher.in

Zenith Hydromatic

NMTG Mechtrans Techniques Pvt Ltd Ahmedabad - Gujarat Tel: 079-22821527, Mob: 09328271660 Email: nmtg@nmtgindia.com Website: www.nmtgindia.com

Hydraulic shearing machines The NC/CNC hydraulic shearing machines are offered from 4 mm to 25 mm thickness capacity in shearing lengths of 3100 mm and 4100 mm. These machines are offered with very accurate and quick blade setting mechanism. The machines offer shearing accuracies at par or better than the latest DIN standards. These machines are offered with the NC/ CNC controls and powered with the precise and accurate back gauge. The horizontal shearing machines are provided with the proven and reliable hydraulic system.

Radial drilling machine The AR series radial drilling machine is designed to offer rigidity, precision and easiness in operation. Model AR50 has a drilling capacity of 50 mm in steel and 60 mm in cast iron. Its drilling motor power is 3.7 kW (5 hp) and arm lifting motor power is 1.1 kW (2 hp). This machine has a robust structure with generously

170 MODERN MACHINE TOOLS - May 2012

Hindustan Hydraulics Pvt Ltd Jalandhar - Punjab Tel: 0181-2670054 Email: hhpl_sales@vsnl.net Website: www.hindustanhydraulics.com

Products - National Lathe machine The Max series medium-duty type lathe machine is compact and offers better value for money. This machine features simplicity, robustness and longer working life. It is rotates the workpiece on its axis to perform a variety of operations, like cutting, sanding, knurling, drilling, etc. The machine is sturdy and easy-touse and assures optimum return on investment. It is highly versatile and durable. The medium-duty lathe machine is built using modern technology to assure enhanced functioning. This lathe machine is useful for precisely machining relatively hard objects. Bhavya Machine Tools Ahmedabad - Gujarat Tel: 079-40087900 Email: info@bhavyamachinetools.com Website: www.bhavyamachinetools.com

Coolant separators These coolant separators are of high quality made by using finest raw materials. The mechanism of the coolant separators is that the coolant fluid with iron dust particles falling by gravity to the inlet of the separators from the precision machine tools like the grinders, milling machines, automats, etc. Coolants with iron impurities come into contact with the magnetic drum and remove all iron particles. The magnetic drum is kept clean at all times by a scrapper blade along the circumference. Champion Industries Surendranagar - Gujarat Tel: 02752-231741, Mob: 09898166908 Email: champion_ind@yahoo.com Website: www.championindustries.co.in

Roll turning lathe machine The roll turning lathe machine is rigidly designed and suitable for heavy jobs. This lathe machine combines all the features which is expected in roll turning lathe machine with great efficiency and is ideal for all sliding, surfacing and screw cutting operation. Important features include: hardened & ground bedways, plano type one-piece solid bed, raw material used is selected and first grade quality. Main spindle is hardened and ground with double grinding. All screw is made from bright steel with gunmetal screw nut, Turcite-B coated in saddle & surface guideways, Full Norton gearbox fitted. Premier Lathe Manufacturing Co Rajkot - Gujarat Tel: 0281-2387556 Email: info@premierlathe.co.in Website: www.premierlathe.co.in

May 2012 - MODERN MACHINE TOOLS 171

Products - National Cylindrical grinding machine

Solid carbide drills

The model UC-450 universal cylindrical grinder machine has castings closely grained and well ribbed to minimise vibration and distortion. The wheel head spindle runs in bush bearings and the work head spindle runs in taper roller bearing. Wheel head and workhead spindles are heattreated to achieve dimensional stability and the performance roundness of <0.005 mm. Optional accessories are: mechanical/ hydraulic/self-feeding & internal grinding attachment, two-point steady rest, three-point steady rest, wheel balancing stand, balancing arbour & wheel flange, rapid approach, etc.

Blood solid carbide drills, like Stub and Jobber series for general application and high-performance drills with 3D & 5D for mass production of drill holes in steels, cast iron, titanium alloys and non-ferrous metals with excellent self-centering geometry are offered. Combination of point angle and helix angle parameters is designed to produce holes to obtain superior smooth operation and accurate result. The axial-radial campoint geometry with through coolant holes is responsible for better performance in high speed drilling, thereby reducing the cycle time.

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

Timing belts and pulleys These timing belts and pulleys come with unique features. Positive grip of the belts with pulley grooves eliminates slippage and speed variation. There is no variation and no elongation because of cable tension member. Features include: positive slip-proof engagement, wide range of load and speed capacities, freedom from high tension, compact design, constant angular velocity, minimum backlash, high mechanical efficiency, lightweight and quiet operation, economical, etc. The timing belts and pulleys conform to ISO:5294 quality standards.

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

Super-rigid press The super-rigid series power press is available the capacity rating of 10, 16, 25, 40, 63, 80, 100, 125, 200 and 250 ton. This machine incorporates features of variable speed drive, manual or motorised slide adjustment, pneumatic clutch, pneumatic counter balance, slide tool die holder, stroke counter, electropneumatic safety control, manual or automatic centralised lubrication systems, hydraulic overload safety device, pneumatic die cushion die lifters, hydraulic die clamping etc. Applications include sheet metal components for automotive/furniture/electronic and wide range of consumer goods industries. Kawa Press Systems Pvt Ltd

Kwedos Belt Drives Pvt Ltd Ahmedabad - Gujarat Tel: 079-25507367, Mob: 09925111749 Email: www.kwedospulleys.com

Rajkot - Gujarat Tel: 0281-2461102, Mob: 09825389169 Email: info@shaileshmachines.com Website: www.shaileshmachines.com

Shearing machine

Independent chuck

This hydraulic shearing machine HGL has welded all steel frames which provide maximum rigidity and cutting accuracy. Top beam and has work table of box type construction with rapid blade gap adjustment mechanism. Back gauge retract function and is compact, low-maintenance hydraulic unit located underneath work table. Hydraulic overload protection, fine-adjustment system for blades, adjustable stroke length is available to increase number of strokes on shorter cuts. It has work table with filler plates, ball transfers and hand slots.

The heavy-duty independent chuck is designed to achieve higher grip with reasonable torque, thus giving pleasure to the operator. This chuck is smooth and rugged, manufactured in 160, 200, 250, 315, 400, 500 and 600 mm sizes. The body of the chuck is of high strength cast iron alloyed with manganese and chrome. Jaw is case-hardened and precision ground at gripping faces and jaw ways. Operating screw is of case hardened alloy steel for strength and wear resistance. Thrust bearing is case-hardened alloy steel designed to provide maximum strength and life to working parts.

Metfab Machines (India) Pvt Ltd

State Engineering Corporation

Mumbai - Maharashtra Tel: 022-26719788 Email: metfab@vsnl.net Website: www.metfabindia.com

Phagwara - Punjab Tel: 01824-261677 Email: contact@secochuck.com Website: www.metfabindia.com

May 2012 - MODERN MACHINE TOOLS 173

Products - International Power vice

Diamond compound

The MC power vice has pressure constant. The clamping force is presetting-type. The same clamping force is repeatedly used. The vice body is made of ductile iron FCD-60. Vise bed is hardened to HRC45-degrees and maintains accuracy for long. The vise bed height-size and the guide block sides are all made with full control, with 2, 3, 4 vices to perform a fob at a time. The length of the vice body is very short, but the clamping range is very big. It works with every kind of milling machine, CNC machine centre.

Five-Star diamond compound is known the world over as the professionalâ&#x20AC;&#x2122;s choice in mould and die polishing. It is graded to closer tolerances than normal industry standards which results in faster and more consistent cut rates. It is used with Hyprez OS type IV (oil-soluble) or type W (water-soluble) lubricants, which offers maximum versatility. Features include faster cut rates, better finishes grit size to grit size, excellent surface tension, very consistent viscosity, will not evaporate, excellent adhesion to tools & surfaces, easily cleaned with either water or oil-based products, and offered in medium, standard & strong concentrations.

Jin Year Precision Co, Ltd

Engis Corporation

Taichung City - Taiwan Tel: +886-4-25232817 Email: liu0930@ms58.hinet.net Website: www.jinyear.com.tw

Illinois - USA Tel: +1-847-8089400 Email: info@engis.com Website: www.engis.com

Grease manual lubricator

Link clamp

These are CLHP grease manual lubricator and KSC electric grease lubricator for plastic extrusion machines, press and woodworking machines. These are easy to operate by hand and can be easily installed. Capacity ranges are 300 cc, 600 cc, 800 cc, 1,000 cc, and 2,000 cc. A level switch can be added on request. Also offered are various types of lubricators, oil systems, fluid grease system, distributors, oil pumps, motors, accessories and fittings. All products are tested and verified by TĂ&#x153;V and have CE of machinery safety directive certificate.

The link clamp arm arcs up and out of the way to accommodate hard-to-reach or hardto-hit clamping points. It contains the beam mechanism often preferred by fixture builders. This self-contained beam eliminates the need to build or design a clamp mechanism as part of the fixture. The unique single-piece body and pivot design provides the least sideto-side axial deflection and the most rigid product in the market today. It is available in five sizes ranging from 450 lb to 6,800 lb capacities at 5,000 psi. Pivot pins are made up of stainless steel and are corrosion resistant.

Changhua Chen Ying Oil Machine Co Ltd Taichung Hsien - Taiwan Tel: +886-4-26393751 Email: inquiry@chenying.com.tw Website: www.chenying.com.tw

Vektek Inc Kansas - USA Tel: +1-800-9920236 Email: sales@vektek.com Website: www.vektek.com

HSS drill

The cold forming machines has unique linear feeding system and high speed cut-off system which assures accuracy. This mid-sized machine is suitable for wire-diameters from 5 to 28 mm and products lengths up to 260 mm. integral pointing and threading station for bolt forming is also available.

The high-speed steel (HSS) drill has quick change adapter and threaded adapter. This drill is generally used for low tolerance holes for the fuselage. Also offered are single-margin and double-margin drill, HSS M2, M7 and cobalt with 5 and 8per cent. Each drill has a serial number for tracing any problem that may occur, along with an inspection report.

Nedschroef Herentals NV

Apache Aerospace Inc

Herentals - Belgium Tel: +32-14-257100 Email: info@nedschroef.be Website: www.nedschroef.be

Washington - USA Tel: +1-425-3495800 Email: aa@apacheaerospace.com Website: www.apacheaerospace.com

Cold forming machine

174 MODERN MACHINE TOOLS - May 2012

Products - International Belt-driven spindle The Sentry series belt-driven spindle comes with a patented Setco AirShield providing the good sealing system. This is a computeraided designed 100 per cent inch spindle having minimum number of components. Incorporating the Setco AirShield technology on most models, the Sentry precision spindle provides high protection to the spindle against coolant and condensation contamination of any spindle in the market. Standard bearing construction makes the spindle ideal for combined radial and thrust loads associated with single and multiple point boring tools, milling cutters, and grinding wheels. Setco Sales Company Ohio - USA Tel: +1-513-9415110 Email: sales@setco.com Website: www.setcousa.com

Box distribution solution The use of a Burland box with a DB 2000 installation avoids the expense of blanket distribution of services in the office space. With fewer connections and considerably less cabling, the net effect is much lower installation costs, plus the additional benefit of substantially reduced costs when replanning and modifying workstation clusters. In addition, it is easily accessible above the floor for maintenance and reconfiguring furniture and hence, there is no need to install new raised floors. The Burland box also connects to DB 2000 units, which offer socket outlets for all major international standards. Burland Technology Solutions Suffolk - UK Tel: +44-1473-858214

Mob: moc.dnalrubn Email: sales@burland.com Website: www.burland.com

Machining centre The FZ-12W series machining centre is based on the vertical moving column principle. Highest accuracy can be achieved for all kinds of workpieces since the machine accuracy does not depend on the weight of the workpiece. The machine bed distinguishes itself by its high rigidity. The strength of the FZ-12W series lies in the

stable and powerful machine tool construction. Consequently, this machining centre has such a high capacity that it can tackle even the most demanding cutting operations very efficiently. With chip-to-chip time of 1.9 s (FZ-12W), the machining centre of the FZ-12 series is amongst the fastest in this machine category. Chiron-Werke GmbH & Co KG Tuttlingen - Germany Tel: +49-7461-9400 Email: info@chrion.de Website: www.chrion.de

Vertical turning machine The VL series of standard vertical turning machine is used for chucked components, automation and turning on a single machine with the smallest footprint. Distinguishing features of this turning machine are high productivity levels, accuracy, process integrity and a high degree of operator friendliness. The principle of short traverses has been consistently realised. Pick-up spindle forms part of the overhead slide and serves to collect the raw-parts from and deposit the finishmachined components on the conveyor belt. This results in extremely short loading times. EMAG Gruppen-Vertriebs- und Service GmbH Salach - Germany Tel: +49-7162-170 Email: info@emag.com Website: www.emag.com

Pull-back chuck The Spanntop chuck works on the pull-back principle. The clamping head is inserted into the coupling and is drawn into the taper of the chuck body via the drawtube and clamping cylinder. While the spindle flange and the drawtube adapter are made to fit a specific machine, the clamping head is made to fit a specific part. The clamping head is precision ground in its solid state in one set-up. It is made of extremely wear resistant case hardened chrome/nickel steel and very rigid. After finish machining, it is separated into segments and re-joint to its intended diameter through the vulcanisation process. Hainbuch GmbH Marbach - Germany Tel: +49-7144-9070 Email: sales@hainbuch.de Website: www.hainbuch.de

May 2012 - MODERN MACHINE TOOLS 175

Products - International Cemented carbide tool and tungsten product The tungsten products and cemented carbides and cemented carbides tools are available in fives series, such as power products, cemented carbide, special cemented carbide, microdrills & routers of PCB and cemented carbide tools. Power products include APT, tungsten trioxide, blue tungsten oxide, tungsten metal powder, tungsten carbide powder, etc. Cemented carbide is offered for mining and geological prospecting tools, while special cemented carbide consists of rods, tubes and strips. Also offered are cemented carbide tools, such as end mills, ballnose end mills, conical end mills, carbide tap, drills, step drills and special applications tools, etc. Nanchang Cemented Carbide LLC Jiangxi - China Tel: +86-791-3878647 Email: nccp603@21cn.com

Precision press The HD series straight-side two-plunger type high-speed precision press has frame of cast iron with excellent design structure. Three sets of massive frame resist deflection and reduce vibration. Hydraulic locking device of screw rods eliminates the clearance to keep reciprocating accuracy. Colorful TFT-LCD screen is applied to operate simply by a variety colours of screen and letters display. Oil temperature is controlled stably and cooling system is separated from circulation to prevent from condensing water inwardly. Dual plungers isolate slide from angular front-to-back movement of connections and bear up more upward eccentric load during stamping to keep reciprocating accuracy. Colorful TFT-LCD screen is applied to operate simply by variety color of screen and letters display.

and above. Filling the high-efficiency environmental refrigerant is without pollution. Wexten Precise Industries Co, Ltd Taichung County - Taiwan Tel: +886-4-24180799 Email: service@wexten.com.tw Website: www.wexten.com.tw

Tool grinding machine The GT series tool grinding machine is used for grinding drills, end mills and all kinds of tools. Maximum tool diameter reaches 120 mm and 150 mm. This machine is the solution to regrinding and manufacturing of all kinds of tools. Main features are as follows worldwidepatented 5-axis design, B-axis rotary column are supported by high-rigidity bearings, can stabilise the free movement of the grinding wheel spindle & ensure compact grinding procedures, can complete measuring, multi-process shape processing and radius grinding in one clamping, use pneumatic grinding wheel arbour HSK clamping system can keep the concentricity of grinding wheel in 3 ?m. Paragon Machinery Co Ltd Taichung - Taiwan Tel: +886-4-25395678 Email: info@paragoncnc.com Website: www.paragoncnc.com

Resist and piston lubricator

Taichung Hsien - Taiwan Tel: +886-4-26358569 Email: info@ingyu.com Website: www.ingyu.com

The resist and piston lubricator is easy-tooperate and has multi-purpose applications. It is suitable for milling press, grinder and planer. Running-lubricating function helps maintain machines. The lubricator’s timememory function helps continue its time recording after the power is on. Special counting function helps operators to set up the unit of the intermittent time as the number of operations. While the lubricator’s oil-level switch detects the oil-shortage of oil tank (standard equipment), its pressure switch detects the damage of pipes. Its wireless equipment is suitable for the future in view of a factory working automatically without any body.

Air-conditioner

Ishan Precision Industry Co Ltd

The air-conditioner is applied for electrical control panel of CNC vertical and horizontal machine center CNC lathes, CNC doublecolumn grinding milling machines and CNC EDM machines. This air-conditioner prevents dust, humidity and moisture from entering into the electrical control panel. It has digital control panel with precision ±1?. Components of electrical control panel are maintained dry by the dehumidification. It withstands high ambient temperature of 38?

Taichung Hsien - Taiwan Tel: +886-4-263028813 Email: ishan@ishan.com.cn Website: www.ishan.com.tw

Ing Yu Precision Industries Co, Ltd

176 MODERN MACHINE TOOLS - May 2012

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

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Pg No

Product

Pg No

Product

Pg No

2D laser machine ..............................................163

Centreless grinding machine ........113, 127, 162, 163

Coating machine ............................................................... 32

3-axes high-speed machining centre ...............47

Ceramic ...............................................................................185

Coating plant ...................................................................... 32

3D printing system ........................................................... 70

Cermet.................................................................................185

Coating system .................................................................. 32

5-axes high-speed machining centre ...............47

C-frame power press ....................................................... 18

Cold chamber die-casting machines .......................161

5-axes machining centre ......................................... 85, 93

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

Collet chuck......................................................................... 58

5-face double-column milling machine ............... COC

Chain ....................................................................................120

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

Abrasive belt grinder .......................................158

Chemlok coating machines .......................................... 32

Connector ...................................................................39, 120

Abrasives ............................................................................101

Chiller...................................................................................156

Control cabinet .................................................................. 39

AC gear motor.................................................................... 24

Chrome bars and shafts ...............................................171

Control panel accessories .............................................. 27

AC servo motor .................................................................. 24

Chuck jaw...........................................................................111

Control panel ...................................................................... 39

Aerosol multi-spray .......................................................... 55

Chuck ...................................................................................135

Control system ................................................................... 39

Air ejector pin ..................................................................... 36

Circular sawing machines ............................................164

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

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

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

Conventional precision lathe .....................................132

All-geared drilling-cum-milling machine ................. 64

Cleaner ............................................................................83-84

Coolant pump ........................................................ 158, 168

All-geared head ................................................................. 64

CMMs ...................................................................................181

Coolant recirculators......................................................161

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

CNC angular cylindrical grinding machine ...........127

Coolant separators ............................................... 160, 171

Appliance switch ............................................................... 27

CNC boring and milling machine .............................160

Coolants ................................................................................ 69

Assembly and high temperature grease ................. 55

CNC controller ..................................................................141

Cooling plug ....................................................................... 36

Auto power feed ............................................................... 64

CNC crankshaft pin milling machine .......................160

Coro mill .............................................................................FGF

Automation .....................................32, 53, 101, 111, 141

CNC cutting machines .................................................... 32

Coro thread .......................................................................FGF

Ball bearing .........................................................73

CNC cylindrical external grinding machine ..........113

Corrosion preventives ...............................................83-84

Ball screw support shaft and unit.............................166

CNC cylindrical grinding machine ............................127

Countersink .......................................................... FIC, 10-11

Ball screw ...........................................................................166

CNC double-column machining centre ................... 12

Cut-off machine ...............................................................168

Bar feeder ...........................................................................135

CNC equipment ................................................................. 29

Cutting fluid ..................................................................83-84

Bar ......................................................................................171

CNC external grinding machine ................................113

Cutting machine................................................................ 32

Bearing ................................................................................120

CNC horizontal borer ....................................................... 93

Cutting oil ..................................................................... 57, 69

Bench grinder ...................................................................158

CNC horizontal boring and milling machine .. 12, 85

Cutting tap ........................................................................134

Bench grinder-cum-polisher .......................................158

CNC horizontal machining centre .............................. 12

Cutting tool ..........21, 37, 71-72, 95, 97, 107-110, 129

Bench polisher .................................................................158

CNC horizontal turning centre..................................... 12

Cutting tools carbide metal working tool .............185

Billet shearing machine .................................................. 18

CNC internal grinding machine.................................113

Cycle time reduction and programming software for

Blasting unit ......................................................................165

CNC laser cutting machine............................................ 32

CNC for milling/turning ................................................131

Boring bar ............................................................................ 57

CNC lathe ........................................... 35, 86, 115, 93, 132

Cylinder block boring machine .................................163

Boring tool system .........................................................162

CNC machine tool ...........................................................121

Cylindrical and internal grinding machine ............. 59

Brass and aluminium ball cage.................................... 36

CNC machine ....................................................8-9, 47, 145

Cylindrical grinding machine ............................................

Broaching machine .......................................................... 46

CNC machining centre ............................................. 16, 47

..............................35, 113, 127, 162, 163, 167, 173

Buffing powder .................................................................. 57

CNC mill ..............................................................................115

Cylindrical photoelectric sensors ..............................168

Building automation ........................................................ 32

CNC milling machine .....................................................115

Demagnetiser ...................................................160

Cabinet ................................................................82

CNC multi-tasking centre............................................... 12

Desktop printer .................................................................. 70

Cable and hose carrier ..................................................157

CNC oxyfuel cutting machine ...................................... 32

Diagnostic system...........................................................103

Cable carrier ......................................................................120

CNC plasma cutting machine ...................................... 32

Diamond tool ...................................................... FIC, 10-11

Cable conduit ..................................................................... 27

CNC precision lathe.......................................................... 58

Didactic equipment for training ................................. 39

Cable connector ..............................................................120

CNC rotary surface grinder..........................................162

Die and mould machine............................................. COC

CAD/CAM software........................................................... 14

CNC small machining centre ........................................ 16

Dies and mould polishing & finishing tools ........... 36

CAM followers ........................................................ 169, 170

CNC tools.............................................................................. 53

Digital laser scanner.......................................................165

Carbide end-mill tool.......................................................BC

CNC turning centre .................................................47, 145

Dip spin coating machines............................................ 32

Carbide rod.......................................................................... 95

CNC turning technology ..............................................131

DNC system for networking CNC machine...........131

Carbide tool......................................................... 71-72, 129

CNC turn-mill centre ........................................................ 12

Drawing and forming compound ........................83-84

CED coating machine ...................................................... 32

CNC vertical machining centre ............................. 12, 47

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

Centers through tooling ................................................ 13

CNCs ........................................................................... 7, 34, 47

Drilling machine ......................................44, 64, 117, 166

May 2012 - MODERN MACHINE TOOLS 177

List of Products Product

Pg No

Product

Pg No

Product

Pg No

Drilling tool......................FIC, 10-11, 37, 71-72, 97, 129

High-performance milling ............................................. 13

Linear rods .........................................................................171

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

High-precision tool holders .......................................... 23

LM shafts ............................................................................171

Ejector pin ...........................................................36

High-pressure cleaner ...................................................170

Load break switch............................................................. 27

Ejector sleeves .................................................................... 36

High-speed drill tap centre ........................................... 93

Lube ....................................................................................... 69

Electric discharge machines ......................................... 13

High-speed milling ........................................................... 13

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

Electromagnetic chuck .................................................160

Hold back ...........................................................................169

Machine mount ...............................................................163

Element shrink disc ........................................................169

Holder .................................................................................... 57

Machine tap ........................................................................ 57

Exhibition - EngineeringExpo.....................................122

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

Machine tool ................................................................ 20, 53

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

Horizontal boring/drilling and facing machine...167

Machining and grinding fluid ................................83-84

External grinding machine ..........................................158

Horizontal machining centre... 7, 47, 93, 117, 162, 168

Magnescale technology ...............................................119

Factory automation............................................32

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

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

Flexible coolant pipe .....................................................169

Horizontal spindle rotary table surface grinder ..113

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

Flexible coolant pipes and accessories ..................169

Hydraulic and gear oil ..................................................... 55

Metal cutting tool ............................................................. 81

Flexible shaft grinder.....................................................158

Hydraulic centerless grinding machine..................163

Metrology instrument & solutions ...........................181

Fluidised bed coating machine ................................... 32

Hydraulic cylinder grinder ...........................................167

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

Force-feed lubricator .....................................................170

Hydraulic cylinders ..................................................46, 168

Milling cutter ................................................ FIC, 10-11, 95

Forging press ...................................................................... 18

Hydraulic cylindrical grinding machine ..113, 127, 163

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

Forming tap ......................................................................134

Hydraulic equipment....................................................... 46

Milling machine .................... 37, 97, 115, 117, 167, BIC

Freewheel-oneway-clutch ...........................................169

Hydraulic internal grinding machine ......................163

Milling tool ...................................................71-72, 129, BC

Friction drop hammer ..................................................... 18

Hydraulic machine..........................................................135

Milling-cum-drilling machine .....................................166

Friction screw press.......................................................... 18

Hydraulic power pack ..................................................... 46

Modular tooling system .................................. FIC, 10-11

Gamet bearings ..................................................73

Hydraulic press................................................................... 46

Mop wheels .......................................................................169

Gantry and NC boring & milling machine ............... 86

Hydraulic shearing machines .....................................170

Motor protection circuit breaker ................................ 27

Gauges ................................................................................123

Hydraulic swing beam shearing machines ...........164

Motors and control........................................................... 46

Gear box .............................................................................166

Hydraulic universal cylindrical grinder ...................158

Mould base .......................................................................... 36

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

Hypercad .............................................................................. 14

Multi-functional tool ...............................................95, 165

Gear milling solution for CNC milling & turn-mill

Imaging and vision systems ..............................32

Multi-functional turret...................................................135

machine ..............................................................................105

IMTMA - AMTTF ...............................................................178

Multimedia software for learning CNC milling

Geared drilling machine ................................................. 64

IMTMA - Finishing School Summit ...........................172

technology.........................................................................131

Geared lathe machine ...................................................162

IMTMA - Productivity Summit...................................... 94

Needle roller bearing .........................................73

Gears/gear components and assemblies ..............156

Independent chuck ........................................................173

Non-reversible tapping heads ...................................159

Glass ....................................................................................... 67

Indexable center drill.....................................................158

Oil cooler ...........................................................156

Glide coating machine .................................................... 32

Indexable cutting tools................................................... 57

Paint shop equipment .......................................32

Grease .................................................................................... 55

Inductive proximity switch............................................ 27

Paint shop machine ......................................................... 32

Grinding machine ......67, 77, 113, 127, 158, 162, 163

Industrial cleaning ............................................................ 75

Panel cooler.......................................................................156

Grinding tool for hard material ............................ 67, 77

Interface electronics........................................................BIC

Parting lock ......................................................................... 36

Grinding wheel .................................................................. 57

Internal grinder ................................................................163

PCD and CBN tool ...........................................................185

Grooving and parting tool ............................................ 95

Internal grinding machine................................. 127, 163

Pedestal grinder and buffer ........................................158

Guide rod ...........................................................................171

Jewellery polisher ............................................158

Permanent magnetic chuck........................................160

Gun drill ................................................................. FIC, 10-11

Keyless transmission element.........................169

Pillar drilling machine ............................................44, 168

Hammer ...............................................................18

Large part drilling and milling machine ........117

Pillar drilling-cum-milling machine ............................ 64

Hand cleanser ...................................................................159

Large-size machining centre .................................... COC

Pilot light .............................................................................. 27

Handling system module............................................... 39

Laser shaping machine ............................................ 67, 77

Piston bar ...........................................................................171

Hard chrome plating bar .............................................171

Laser-sintering systems ................................................163

Planning machines .........................................................171

Heat exchanger machine .............................................117

Lathe chuck .......................................................................111

Plano-milling machine ..................................................171

Heat pipe .............................................................................. 36

Lathe machine................................................... 7, 167, 171

Plastic packing boxes ....................................................158

Heavy-duty bearing ......................................................... 73

LEDs ........................................................................................ 27

Plugs and socket ............................................................... 27

Heavy-duty CNC machine............................................171

Length gauges ..................................................................BIC

Pneumatic ..........................................................................135

Heavy-duty drill machine............................................... 44

Linear bearings and shafts ..........................................166

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

Heavy-duty radial drill machine .................................. 44

Linear guideways ............................................................166

Post processor .................................................................... 14

H-frame power press ....................................................... 18

Linear motion system....................................................166

Power chucking cylinder................................................ 35

May 2012 - MODERN MACHINE TOOLS 179

List of Products Product

Pg No

Product

Pg No

Product

Pg No

Power source ...................................................................... 61

Smart logic controller....................................................164

Vertical and horizontal machining centres ............. 86

Power tool .........................................................................101

Solid carbide drill and mill ............................................ 81

Vertical lathe machine .................................................... 85

Preci chuck .......................................................................... 80

Solid carbide drills ..........................................................173

Vertical machining centre.......... 7, 12, 35, 47, 93, 166

Precision bearings...........................................................157

Solid carbide reamer........................................................ 81

Vertical turning lathe .....................................................171

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

Solid carbide special drill and mill ............................. 81

Vertical turret lathe ........................................................146

Precision locknut .............................................................166

Solid carbide special reamer ........................................ 81

Wear parts and consumables to

Precision measuring instrument ...............................123

Solid rotating tool............................................................. 57

automation solutions.........................................13

Precision steel.............................................................. 67, 77

Spare parts........................................................................... 13

Wear parts............................................................................ 95

Precision switch ................................................................. 27

Special hydraulic expansion technology ...............111

Website service .................................................................. 41

Precision universal cylindrical machine .................163

Special induction hardening machine...................... 61

Wire cut EDM ....................................................................185

Pre-treatment system ...................................................... 32

Speciality oil ........................................................................ 57

Process automation and control equipment ......... 39

Special-purpose machine ............................................171

Productivity tracking system for CNC machine ..131

Spindle nose tooling........................................................ 95

Air-conditioner .................................................176

Pump...................................................................................... 46

Spindle .................................................................................. 33

Belt-driven spindle ...........................................174

Push-button ........................................................................ 27

Spring plunger ................................................................... 36

Box distribution solution..............................................174

Quick change chucks and adapters ................159

Spruce bush ........................................................................ 36

Carbide ball end mills ........................................98

Rack and pinion ................................................166

Standard induction hardening machine.................. 61

Carbide drills ....................................................................... 98

Rack ........................................................................................ 82

Stationary work holding...............................................111

Carbide end mills .............................................................. 98

Racks and pinions ...........................................................157

Super precision bearing ................................................. 73

Carbide reamer .................................................................. 98

Radial drilling machine ...............44, 64, 167, 169, 170

Super-rigid press .............................................................173

Carbide spotting drills..................................................... 98

Reamer ................................................................... FIC, 10-11

Surface and profile grinding machine ...................... 59

Cemented carbide tool and tungsten product ...175

Resharpening solutions .................................................. 60

Surface grinder................................................................... 93

Centerless grinding machine ................................ 25, 30

Reversible jaw..................................................................... 80

Surface grinding machines ............................... 156, 169

Clamping series ...............................................................154

Ring groove gaskets cutter ........................................... 20

Tap ...................................................10-11, FIC, 96

CNC angular cylindrical grinding machine ............. 25

Roll forming machines ..................................................161

Taper interlock ................................................................... 36

CNC lathe ...........................................................................125

Roll turning lathe machine..........................................171

Tensioner nut ...................................................................169

Cold forming machine ..................................................174

Rolling oil .......................................................................83-84

Thread gauge ..................................................................... 80

Diamond compound ........................................174

Rotary encoder..................................................................BIC

Thread mill cutter ............................................................. 57

Grease manual lubricator ................................174

Rotary switch ...................................................................... 27

Thread mill .........................................................................105

Grinding machine ............................................................. 30

Rotary........................................................................................7

Thread whirling tool ......................................................FGF

High-speed centerless grinding machine ........25

Runner lock pin.................................................................. 36

Threading tool....................................................................BC

HSS drills .............................................................................174

Rust preventive ............................................................83-84

Thrush ball bearing .......................................................... 73

IMTS 2012-International Manufacturing

Safety protection devices ..................................27

Timing belts and pulleys ..............................................173

Technology Show ...........................................................139

Saw blade............................................................................. 60

Tool grinding machine ................................................... 59

Internal grinding machine...................................... 25, 30

SCADA and DCS implementation............................... 32

Tool holding system ...............................................57, 111

Link clamp .........................................................174

Screw machine .................................................................115

Tool path simulator for CNC milling and turning .....131

Machining centre..............................................174

Sealed linear encoder.....................................................BIC

Tooling system ......................................................... 165, BC

Mould changing system ...............................................161

Self-opening die heads .................................................158

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

Power chuck......................................................154

Sensor ..................................................................................103

Track roller .........................................................................169

Power vice .........................................................................174

Services ................................................................................. 13

Transmission ...................................................................a101

Precision press .................................................................175

Shaft .....................................................................................171

Transparent gel .................................................................. 55

Pull-back chuck ................................................................174

Shearing machine ...........................................................173

Tubing accessory............................................................... 39

Quick die change system .................................161

Sheet metal working machine..................................... 65

Turn mill centre ................................................................. 85

Quick mould change system ......................................161

Shrink-fit technology ....................................................... 57

Turning holder ................................................................... 95

Resist and piston lubricator ............................176

Single and double column vertical

Turning machine solutions ........................................... 51

Rotary cylinder .................................................................154

machining centre - ........................................................... 93

Turning machine ............................................... 37, 97, BIC

Special form cutting tools .................................98

Single and multiple precision switch ........................ 27

Turning tool ........................................................................BC

Tool grinding machine ....................................176

Single limit switch............................................................. 27

Turret ..................................................................................... 35

Twin-spindle compound grinding machine........... 25

Sinking EDM ......................................................................185

Universal cylindrical grinder ...........................158

Universal cylindrical grinding machine ...........25

Slant and flat bed.............................................................. 93

Vacuum chuck...................................................135

Universal grinding machine.......................................... 30

Sleeve bearing.................................................................... 73

Valve terminal .................................................................... 39

Vertical turning machine .................................174

Small size ball bearing .................................................... 73

Valve....................................................................................... 39

INTERNATIONAL PRODUCTS

COC - Cover on Cover FGF - Front Gate Fold FIC - Front Inside Cover BIC - Back Inside Cover BGF - Back Gate Fold BC - Back Cover

180 MODERN MACHINE TOOLS - May 2012

List of Advertisers Advertiser’s Name & Contact Details Agie Charmilles (South East Asia) Pvt Ltd

Pg No

Advertiser’s Name & Contact Details

Pg No

Champkraft Machine Tools T: +91-2752-241881 E: champ1@sancharnet.in W: www.solcogrinder.com

113

Ask Me T: +91-22-35555555

182

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

139

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

Autogrip Machinery Co Ltd T: +886-4-822-8719 E: sales@autogrip.com.tw W: www.autogrip.com.tw

154

Crane-Bel Hydraulics T: +91-120-3263281 E: office@crane-bel.com W: www.crane-bel.com

Autotech Machine Tools Sales & Service

8-9

T: +91-80-40798019 E: info@in.gfac.com W: www.gfac.com/sg

T: +91-20-25690044 E: autocnc@vsnl.com W: www.autotechcnc.com Baker Gauges T: +91-20-66093800 E: bakerbmi@bakergauges.com W: www.bakergauges.com

123

Bharat Machine Tools T: +91-288-2757329 E: info@nagmatilathe.com W: www.nagmatilathe.com

167

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

Birla Precision Technologies Ltd T: +91-22-67933000 E: itmth@idiantool.com W: www.indiantool.com

Blaser Swisslube India Pvt Ltd T: +91-124-4994000 E: india@blaser.com W: www.blaser.com

Cadem Technologies Pvt Ltd T: +91-80-26634767 E: sales@cadem.com W: www.cadem.com

131

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

Champion Industries T: +91-2752-231741 E: champion_ind@yahoo.com

160

Advertiser’s Name & Contact Details

Pg No

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

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

Finechrome Shafts Pvt Ltd T: +91-22-29204209 E: finechromespl@yahoo.co.uk

171

Forging Machinery Manufacturing Co T: +91-161-5011755 E: info@nkhammers.com W: www.nkhhammers.com

162

161

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

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

156

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

Freeze Tech Equipments Pvt Ltd T: +91-44-42152387 E: info@freezetechequip.com W: www.freezetechequip.com

146

Durr Ecoclean-A Division Of Schenck T: +91-20-30585001 E: info.india@ecoclean.durr.com W: www.durr-ecoclean.com

Fullton Machinery Co Ltd T: +86-411-82767678 E: fullton@fulltontech.com W: www.fulltontech.com

EFD Induction Ltd T: +91-80-7820404 E: sales@efdgroup.net. W: www.efd-induction.com

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

115

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

Ganesh Techmachinery Pvt Ltd T: +91-11-41612203 E: rajesh@ganeshmachinery.com W: www.ganeshmachinery.com

Devco Engineers T: +91-2752-241995 E: lion.grinders@gmail.com W: www.liongrinders.com

Engineering Expo T: +91-9819552270 E: engexpo@infomedia18.in W: www.engg-expo.com Ermaksan Machinery T: +90-224-2947500 E: emre.ozkaya@ermaksan.com.tr

122

Google India Pvt Ltd T: +18002663000 W: www.indiagetonline.in

GSK Cnc Equipment Co. Ltd T: +91-9886835186 E: gskwang@hotmail.com W: www.gsk.com.cn

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

165

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

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

164

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

FIC

May 2012 - MODERN MACHINE TOOLS 183

List of Advertisers Advertiser’s Name & Contact Details Hangsterfer’S Laboratories Inc T: +856-468-0216 W: www.hangsterfers.com Heidenhain Optics & Electronics (I) T: +91-44-30234000 E: info@heidenhain.in W: www.heidenhain.in

Pg No 159

Kanefusa India Pvt Ltd

BIC

W: www.kanefusa.net Korber Schleifring Gmbh

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

121

Korloy India Tooling Pvt Ltd

P Parmar Mechanical Works T: +91-278-2447409 E: info@parmardrill.com W: www.parmardrill.com

P R Sales Corporation Pvt Ltd T: +91-20-25437591 E: info@prsales.in W: www.prsales.in

T: +91-124-4930080 E: sales.kip@korloy.com W: www.korloy.com Kushal Udyog T: +91-291-2764040 E: kushaludyog@sancharnet.in W: www.kushaludhyog.com

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

103

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

120

Indiam Machine Tools Manf - Amttf T: +91-80-22731625 E: director@amttf.in W: www.amttf.in

178

71-72, 129

T: +91-22-67051093 E: sm.haridas@larsentoubro.com W: www.larsentoubro.com Meiban Engineering Technologies Pvt Ltd

T: +91-80-26491229 E: sales-turning@meibanengg.com Metrol Corporation India Branch Off

T: +91-80-42105031 E: sales@metrolindia.com W: www.toolsensor.com Micromatic Machine Tools

Indiam Machine Tools Manf - Finishing School 172 T: +91-80-66246600 E: augustin@imtma.in W: www.imtma.in Indiam Machine Tools Manf - Productivity Summit 94 T: +91-80-66246600 E: augustin@imtma.in W: www.imtma.in ISGEC Heavy Engineering Ltd T: +91-120-3301 001 E: trading@isgec.com W: www.isgec.com

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

T: +91-80-41492285 E: mmtblr@acemicromatic.com W: www.acemicromatic.com Mitsubishi Heavy Industries India Pvt Ltd

COC

T: +91-11-41021234 E: mtdsales@mhiindia.com W: www.mhiindia.com Neway Cnc Equipment (Suzhou)Co.,Ltd

T: +91-281-276-7100 E: newaycnc@gmail.com W: www.newaycnc.com Nikon India Pvt Ltd

W: www.schleifring.in

Larsen & Toubro Ltd

Objet Ap Ltd

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

E: sales@schleifring.in

158

Pg No

T: +91-80-41554601

Hitesh Engineering Works T: +91-2752-241926 E: contact@hiteshengineering.com W: www.hiteshengineering.com

Advertiser’s Name & Contact Details

T: +852-2174 0111 E: info@objet.com W: www.objet.com

E: info@kanefusa.co.in

127

184 MODERN MACHINE TOOLS - May 2012

Pg No

T: +91-124-4208440

Hi - Life Machine Tools Pvt Ltd T: +91-79-22821615 E: info@hilifegroup.com W: www.hilifegroup.com

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

Advertiser’s Name & Contact Details

181

T: +91-124-4688 500 E: nind.Inst@nikonoa.net

134

Palmary Machinery Co Ltd T: +886-4-2492-9799 E: roger@grinding.com.tw W: www.grinding.com.tw

Paragon Machinery Co Ltd T: +886-4-2539-5678 E: info@paragoncnc.com W: www.paragoncnc.com

Pitroda Utility Industries T: +91-2752-243795 E: response@pitrodautilityindia.com W: www.pitrodautilityindia.com

163

Praj Industries T: +91-281-2373399 E: prajgroup9@gmail.com

169

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

Precihole Machine Tools Pvt Ltd T: +886-3-329-9968 E: pshtech@gmail.com W: www.peei.com.tw

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

W: www.nikon-instruments.jp/eng/ 157

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

169

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

83-84

List of Advertisers Quattro Engineering India Ltd

Pg No 53

T: +91-80-25585439 E: bangalore@quattroengg.com W: www.quattroengg.com Quickmill Inc. T: +705-745-2961 E: info@quickmill.com W: www.quickmill.com

117

S B S Precision Systems (India) Ltd T: +91-33-3292 0078 E: enquiries@sbsindia.in W: www.sbsindia.in

S&T Engineers T: +91-422-2590810 E: sales@stengineers.com W: www.stengineers.com

Samkrish T: +91-44-23612310 E: info@samkrish.com W: www.samkrish.com

119

Samkrish Machine Tools T: +91-44-23612310 E: info@samkrishmachinetools.com W: www.samkrishmachinetools.com

145

Sandvik Coromant India FGF T: +91-20-27104725 E: coromantindia.communications@sandvik.com W: www.sandvik.coromant.com/in Sarabsukh Machine Tools T: +91-1871-223893 E: sarabsukhbatala@yahoo.co.in W: www.sarabsukhmachines.com

171

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

111

Shuter Enterprises India Pvt Ltd T: +91-44-32407116 E: 32407116@shuter.in W: www.shuter.in

Siddhapura Industries

Pg No

Advertiser’s Name & Contact Details

Pg No

Tyrolit India Superabrasive Pvt Ltd

T: +91-278-2445048 E: mitul@siddhapura.co.in

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

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

Advertiser’s Name & Contact Details

21, 107-110

Siemens Ltd W: www.siemens.com/sinumerik Sigma Engineers T: +91-240-6600606 E: info@sigmatoolings.com W: www.sigmatoolings.com

141

SME Mentor W: www.moneycontrol.com/smementor

155

Suhner India Pvt Ltd T: +91-80-27831108 E: automation.in@suhner.com W: www.suhner.com

101

Superslides & Bushes Corporation T: +91-22-61567567 E: sales@superslides.in/sbcslides@vsnl.net W: www.superslides.in

166

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

Taiwan Takisawa Technology Co.Ltd T: +886-3-464-3166 E: bryan@takisawa.com.tw W: www.takisawa.com.tw

125

Takamatsu Machinery Co Ltd T: +81-76-2741403 E: h.nakagawa@takamaz.co.jp W: www.takamaz.co.jp

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

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

Trigon Tooling Solutions Pvt Ltd T: +91-124-2370250 E: info@trigontools.com W: www.trigontools.com

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

132

T: +91-80-40953259 E: subrahmanya.kumar@tyrolit.com W: www.tylolit.com Vargus Ltd T: +91-9730028248 E: vishal@vargusindia.com W: www.vargus.com

105

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

158

Vijaydeep Mould Accessories Pvt Ltd T: +91-22-66949677 E: sales@vijaydeep.in W: www.vijaydeep.in Weizmann Engineering Ltd T: +91-44-22280595 E: weizmann_engg@yahoo.com W: www.weizmann.in

135

Wendt India Ltd T: +91-4344-405500 E: vijayvernekar@wendtindia.com W: www.wendtgroup.com Wexper India Ltd T: +91-124-2210020 E: rajan.vaid@wexper.com W: www.wexper.com YG Cutting Tools Corporation Pvt Ltd T: +91-80-43543636 E: admin@yg1india.com W: www.yg1.co.kr

185

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Zen Wu Zheng Sun Tool Co Ltd T: +886-7-352-5743 E: first@jsk-tools.com.tw W: www.jsk-tools.com.tw

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