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LIKE A DIAMOND:
Shaped Under Pressure
The Man Who Put Gujarat on the Global Diamond Business Map
Dr. Arvind Patel Chairman Sahajanand Laser Technology Ltd
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54 Editorial / Publisher’s Desk Spotlight EMO Hannover 2017 special
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Industry News Cutting Edge-DMG MORI
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Primer Process-Dassault Systèmes
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Industry News Cutting Edge-Marposs
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Case Study Success Story-Mastercam
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Industry News New Launches
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Industry News Events & Promotions
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Case Study Success Story-Carl Zeiss
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Industry News Expansion-CG Tech
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Book Excerpt Dr Mark Goulston
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Case Study Success Story-Hainbuch
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Industry News Expansion-Renishaw
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Company Feature Sahjanand Laser Technology Ltd
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Case Study Success Story-Seco-Hermle
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Industry News Expansion-MOTUL
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Primer Process-Zavenir Daubert
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Imprint / Company / Advertisers Index
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Industry News Expansion-SCHULER
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Primer Technology-Sonderhoff
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Message | EDITOR’S LETTER
We Have A Dream!
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inally, GST is here. It took 18 years to arrive – eighteen arduous, tumultuous, unsure, and speculative years of journey which saw at least four general elections, countless draft revisions, and at least two instances of the opposition stalling the passage of the GST Bill in the Parliament. In short, it’s been a rough ride. To be fair, India started on the road to GST way ahead of any other nation outside Europe. It was in 1999 that GST was given a nod by the then PM Atal Bihari Vajpayee. It is only fitting that it’s only his party that took it to fruition on July 1st, 2017. It’s still early days since the implementation, but I am really enthused by the response of almost everyone I’ve spoken to in the industry about GST. Manufacturers from most sectors, be it FMCG, automobile, or consumer electronics, are excited about huge gains in business efficiency they will get with the reduction of number of warehouses and savings on inventory-carrying costs. I particularly wish to congratulate FMCG manufacturers like HUL, and GCPL and smart-phone manufacturers like Lenovo and Motorola who have announced their plan to pass on the tax savings of 6 to 10 percent to consumers, thanks to GST. There are however, hiccups and gray areas, which you’d expect after a big-bang reform such as this one, and I really hope that they are sorted out soon. Small manufacturers in industrial hubs like Ludhiana have cut down on production as they seek clarity on the new laws that affect them, their customers and suppliers. Similarly, manufacturers in industries where taxes have gone up, such as the textile industry and the renewable energy industry, are worried that that the higher tax will compel Indian producers to source material from China or elsewhere. Overall, the initial landing of GST has been soft and positive – thanks in a big part to the uber-enterprising spirit of people from both the manufacturing and the service sectors who have risen to the occasion. Personally, I have been a big admirer and supporter of the PM’s Make in India initiative, and GST, to me, has given our manufacturing industry just the right fillip in that direction. Fortuitously, the month of July proved momentous to us at MeshMix Media as well. This was the month when we brought a long-held dream of ours to reality: create a transformative business magazine; a magazine that contains compelling and ready-to-use insights for entrepreneurs and professionals of the manufacturing sector. With the launch of the inaugural issue of Dynamic Manufacturing India, we have put our long-cherished dream in your hands, with the hope and belief that you will support and guide us with your continued readership and honest feedback. Do please write to me at editorial@meshmixmedia.com
PREETI MISHRA Editor & Publisher
IN-EM-2017-Win.indd 1
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Spotlight | EMO HANNOVER 2017 SPECIAL
High-ranking experts from India will inform about the growing market at EMO Hannover 2017 on 20th September. India sends the second biggest visitor group from outside Europe to EMO Hannover. Picture: Deutsche Messe AG).
Crystal-Gazing the Indian economy The India Day at the EMO Hannover 2017 will be exploring opportunities in production technology and capital investment
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rankfurt – Is ‘Modinomics’ fuelling an industrial renaissance in India? This question will be addressed during the India Day hosted by the VDW (German Machine Tool Builders’ Association) at the EMO Hannover 2017 on 20 September, 2017. Investors and rating agencies on the Indian stock exchange, at least, are anticipating good business opportunities in the medium term. Jeremy Leonard, Director of Global Industry Services at the British Research Institute, Oxford Economics, notes that “[There’s] more scope for proactive economic stimuli when it comes to the refinancing costs of the commercial banks. [On its part] the planned tax reform for goods and services, could unleash
some accelerated dynamics.” A view seconded by V. Anbu, Director General & CEO of the Indian Machine Tool Manufacturers’ Association: “Game-changing initiatives such as ‘Make in India’, the opening up of strategic sectors to foreign direct investments, and the implementation of ‘One nation, one tax’ for goods and services have spurred manufacturing growth,” is his firm conviction. India’s economy Is Expanding
In the machine tool industry, India ranks 8th among the world’s largest markets, with a volume of most recently €1.7 bn in 2016. This corresponds to a growth of eleven percent. For 2017/2018 too, a continuingly moderate increase in consumption
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is predicted.India imports around 70 per cent of the machine tools it needs. In 2016, these were worth approximately 1.2 bn euros. EMO’s India Day aims in particular to elucidate the perspectives for the mechanical engineering, automaking and aviation user sectors. Dr. Andreas Wolf from Bosch Ltd., for example, sees potential in the automotive industry. “Triggered by the new legislation in regard to vehicle safety and emissions, we’re going to be seeing rapid implementation of modern-day technologies,” he says. Milind Madhav Shahane, Member of the Board of Directors at Tata Advanced Materials Ltd sees major opportunities in the growing importance of privately owned companies: “Since the turn of the century, India’s aviation industry has been experiencing dynamic growth at privately managed companies, supported by large conglomerates and their engineering expertise.” This is one of the main reasons why United Grinding has opened a subsidiary in Bangalore and set up a technology centre. “This enables us to perform meaningful tests on components and to offer realistic training for machine operators,” says C.R. Sudheendra, President India Operations of United Grinding. India’s keen to attract investors
The EMO’s India Day will also be supported by the Indian government. The event will host Shri N. Sivanand, Joint Secretary of the Department of Heavy Industry in the Ministry of Heavy Industry & Public Enterprises. He will be spotlighting the government’s initiative for boosting the manufacturing sector. The event hosts shall also be welcoming six delegations of high-ranking Indian entrepreneurs, which will be organised and accompanied by various Indian customer associations and the staff of the VDMA’s liaison office in Kolkata. “We are particularly happy to note that it will be almost exclusively Indian speakers or pundits, those who are thoroughly familiar with the country from their own career experience there, who will be presenting their expertise on the India Day,” says Gerhard Hein, the co-organiser of the India Day at the VDW (the hosts of the EMO). “So we’re expecting an exciting event, offering exceptional added value to everyone involved.”
At a glance What: EMO India Day When: Wednesday, 20 September 2017, 10.00 a.m. to 1.00 p.m. Where: Hanover Exhibition Grounds, Convention Centre, Hall 3 B Programme: Shri N.Sivanand, Ministry of Heavy Industry & Public Enterprises Government Initiative for promoting manufacturing industry in India Jeremy Leonard, Oxford Economics Current Situation of the Indian Economy, Outlook on Industrial Production and Investment Activities in Key User-Segments V. Anbu, Indian Machine Tool Manufacturers’ Association Overview of Machine Tool Industry in India including technical requirements Dr. Andreas Wolf, Bosch Ltd. Challenges, Threats and Opportunities from the perspective of an Automotive Supplier in India MilindMadhavShahane, Tata Advance Materials Ltd. Potential of Aerospace Industry in India C.R. Sudheendra, United Grinding Best Practice: Market Activities and Strategical Positioning of United Grinding Seminar Language: German / English Attendance Fee: 185 Euros plus VAT (Early booking: 155 Euros plus VAT) Registration: www.emo-hannover.de/conferences Contact: Bianca Huber, b.huber@vdw.de
EMO Hannover 2017 – the world’s premier trade fair for the metalworking sector From 18 to 23 September 2017, international manufacturers of production technology will be spotlighting “Connecting systems for intelligent production” at the EMO Hannover 2017. The world’s premier trade fair for the metalworking industry will be showcasing the entire bandwidth of today’s most sophisticated metalworking technology, which is the heart of every industrial production process. The fair will be presenting the latest machines, plus efficient technical solutions, product-supportive services, sustainability in the production process, and much, much more. The principal focus of the EMO Hannover is on metal-cutting and forming machine tools, production systems, high-precision tools, automated material flows, computer technology, industrial electronics and accessories. The trade visitors to the EMO come from all major sectors of industry, such as machinery and plant manufacturers, the automotive industry and its component suppliers, the aerospace sector, precision mechanics and optics, shipbuilding, medical technology, tool and die manufacture, steel and lightweight construction. The EMO Hannover is the world’s most important international meeting point for production technology specialists from all over the planet. In 2013, the fair attracted more than 2,130 exhibitors, and around 143,000 trade visitors from more than 100 different countries. EMO is a registered trademark of the European Committee for Cooperation of the Machine Tool Industry CECIMO.
You will find text and images relating to the EMO Hannover 2017 on the internet at:
www.emo-hannover.de/de/presse/pressemitteilungen/pressemitteilungen/pressemitteilungen.xhtml
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Spotlight | EMO HANNOVER 2017 SPECIAL
Germany’s President Frank-Walter Steinmeier will be opening the EMO Hannover 2017 Frank-Walter Steinmeier President of Germany
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MO Hannover 18 to 23 September 2017 – Germany’s President FrankWalter Steinmeier will in September be ceremonially opening the EMO Hannover 2017. “We are absolutely delighted that our head of state will be honouring the EMO Hannover with his presence, and thus unequivocally affirming the high level of perceived importance accorded to the nation’s industrial sector,” says Carl Martin Welcker, General Commissioner of the EMO Hannover, commenting on the EMO Preview 2017. Following a four-year pause, the world’s premier trade fair for the metalworking sector will once again be opening its doors in Hanover, from 18 to 23 September 2017. With its motto of Connecting systems for intelligent production, it will be spotlighting the issues of digitisation and networking for production operations. At the beginning of June 2017, more than 2,050 firms from 45 countries had signed up. There are more than 1,400 exhibitors from Europe alone. The number of Asian participants has increased from 21 to 25 per cent. “This means the current registration status is significantly above the comparable figure for the previous event,” explains Welcker. There are plenty of indications that the EMO Hannover 2017 is heading for a record participation level. The opening ceremony is scheduled to last about an hour on 18 September. Besides FrankWalter Steinmeier, Lower Saxony’s Prime Minister
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Stephan Weil and CECIMO’s President Luigi Galdabini will also be speaking. After this, the President will be taking an exhaustive tour of the fair. “We shall be demonstrating to the President the performative and innovative capabilities of our sector, and the range of solutions we offer in the environment of digitisation,” added Carl Martin Welcker. Intelligent production in a network of possibilities
The paramount topics of discussion in the international world of production technology are digitalisation and networking, as the EMO’s motto communicates. The EMO’s organisers are confident that the EMO Hannover 2017 will generate important impetus for implementing the much-discussed concept of Industry 4.0 or the Internet of Things (IoT). A foretaste will be provided by the EMO Hannover 2017 Preview in Hanover on 21 June, at which 36 EMO exhibitors will three months before the actual event be unveiling their innovations to the media on an exclusive basis. “In the machine tool, we have long since implemented digitalisation,” says Carl Martin Welcker. “Digital images, for example, for simulations have likewise been possible for quite a long time now.” Under the keyword of Industry 4.0, the task now is to network the entire production operation, and indeed the complete added-value chain. In a consistently networked manufacturing line, flexible production is possible with optimised sequences, so that even rush orders in small batch sizes can be handled. Complete networking of the entire production line with real-time communication and control will create maximised added value for companies when it implements horizontal communication from receipt of the order all the way through to dispatch. Within the added-value chain, moreover, it’s important to network not only the component suppliers, but also the logistical partners and the customers involved, so as to achieve maximised productivity, flexibility and efficiency. “If all this succeeds, this signifies a quantum leap forwards in terms of productivity, and will catapult those
who can do it to the leading edge of international competition,” is the succinct verdict of the EMO’s General Commissioner Carl Martin Welcker. As an innovation forum and trendsetter, the EMO Hannover 2017 will in addition be presenting a broad supporting programme themed around commercial and technical issues. Keywords here include Industry 4.0, the production operations of tomorrow, additive manufacturing processes, metal-cutting in the aerospace industry, the safety of machine tools, the development of the markets in the USA, Mexico, and India, start-ups for intelligent production, youth recruitment, etc. EMO Hannover 2017 – the world’s premier trade fair for the metalworking sector
From 18 to 23 September 2017, international manufacturers of production technology will be spotlighting “Connecting systems for intelligent production” at the EMO Hannover 2017. The world’s premier trade fair for the metalworking industry will be showcasing the entire bandwidth of today’s most sophisticated metalworking technology, which is the heart of every industrial production process. The fair will be presenting the latest machines, plus efficient technical solutions, product-supportive services, sustainability in the production process, and much, much more. The principal focus of the EMO Hannover is on metalcutting and forming machine tools, production systems, high-precision tools, automated material flows, computer technology, industrial electronics and accessories. The trade visitors to the EMO come from all major sectors of industry, such as machinery and plant manufacturers, the automotive industry and its component suppliers, the aerospace sector, precision mechanics and optics, shipbuilding, medical technology, tool and die manufacture, steel and lightweight construction. The EMO Hannover is the world’s most important international meeting point for production technology specialists from all over the planet. In 2013, the fair attracted more than 2,130 exhibitors, and around 143,000 trade visitors from more than 100 different countries. EMO is a registered trademark of the European Committee for Cooperation of the Machine Tool Industry CECIMO.
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Spotlight | EMO HANNOVER 2017 SPECIAL
Tool and metrological technology indispensable for Industry 4.0 VDMA to put spotlight on “Innovative Solutions for Industry 4.0” at the EMO Hannover 2017
I Markus Heseding, Executive Director of The German Mechanical Engineering Industry Association’s (VDMA) Metrological and Testing Technology and High-Precision Tools. Picture: VDMA
ndustry 4.0 is progressively emerging as the crucial factor in the race for leading-edge technology and market shares in the future. And time is running out for the German machinery and plant manufacturers. On one side of the world is the USA, with its exceptional software competence and not least its digital entrepreneurship when it comes to new business models. On the other side of the globe is China, which with its “Made in China 2025” and “Internet Plus” programmes is channelling substantial resources into digital transfor-mation. So despite the good starting position that German companies have created for themselves, they would be well advised not to rest on their laurels.. The German Mechanical Engineering Industry Association’s (VDMA) Metrolog-ical and Testing Technology and High-Precision Tools will
The German Mechanical Engineering Industry Association’s (VDMA) Metrolog-ical and Testing Technology and High-Precision Tools invite during EMO Han-nover from 19 to 21 September to the event “Innovative Solutions for Industry 4.0” in hall 4, booth D44 Picture: Wenzel
accordingly be spot-lighting ideas and products from the Industry 4.0 environment. At the VDMA’s stand (Hall 4 / D44), member companies and partners from the research community will from 19 to 21 September be contributing 30 brief presentations, focusing primarily on high-precision tools, metrological and testing technology, research, and tool data interchange. “At the VDMA forum, we shall be aiming to show what solutions our sectors are offering in order to translate the concept of Industry 4.0 into shopfloor reality,” explains Markus Heseding, Executive Director of the two associations. “We already have a good track record with a forum of this kind, and are looking forward to a high attendance.” Specifically, the “Innovative Solutions for Industry 4.0” event will be informing its participants on issues like intelligent clamping systems and how production processes can be simulated by networking tools and software,tool life-cycles monitored, and costs reduced. The presentations there will elucidate how the self-monitoring machine tool support the quality assurance processes involved, or what an automated measuring cell can achieve in a production process featuring Industry 4.0. Contributions from the companies concerned offer insights into highly sophisticated metrological technology and high-precision tools for challenging tasks. The presentations will cover the advantages of standardised tool data for simulations, tool management and presetting, as well as the research work being performed at the universities. The following companies and universities will be presented at the VDMA’s event: Cimsource, Diatest, Emuge, Etalon, Fagor Automation, Fraisa, Gühring, Haimer-Microset, Hainbuch, Iscar, Kelch, Mahr, Mimatic, Obern-dorferPräzisions-Werk, OSG, Römheld, Sandvik, TekonPrüftechnik, promicron, Vargus, FraunhoferInstitute for Production Technology in Aachen, GFE-Schmalkalden, Bremen University, TU Dortmund, Bayreuth University.
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Industry News | NEW LAUNCHES
Lift productivity and lower energy waste If you can’t see it, you can’t manage it. Eco-monitor exposes energy consumption as data that can guide your efforts to optimize energy efficiency, and also serves as an early warning system for preventative maintenance. It lets you monitor changes in energy consumption and identify potential problems long before they seriously impact performance. With Mitsubishi Electric’s visualization technologies, your productivity can go up as your energy waste goes down. Contact information www.mitsubishielectric.com/fa
CNC’s Mastercam 2018 integrates Sandvik Coromant CoroPlus ToolLibrary
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NC Software, Inc., developers of Mastercam,in partnership with Sandvik Coromant, has announced the integration of Sandvik Coromant CoroPlus ToolLibraryinto the new release of Mastercam 2018. The integration of the CoroPlus ToolLibrary allows Mastercam customers to save precious time searching for desired tools and building 3D tool assemblies that can be brought directly into Mastercam via the ISO 13399 data format. For the integration, Mastercam developers worked closely with Sandvik Coromant product management to let users import 3D tool assemblies directly into Mastercam’s toolpath operations. Users of Mastercam benefit from having the correct tooling for the material and for the type of machining operation, plus an accurate, 3D model that can be used for visualization and collision checking in addition to the time savings. Dave Boucher, Director of Product for CNC Software said: “In the past, customers had to search through thousands of catalog pages and cross-reference multiple sources to create the tool assemblies needed to machine their parts. Now, they can save significant time and effort by quickly searching and building 3D, virtual tool assemblies using the CoroPlus ToolLibrary interface, and importing them directly into Mastercam when they program their parts. As a digital databaseand part of a customer’s digital machining environment, they get instant access to the latest cutting tool data and technology available.”
Pernilla Lindberg, Product Manager Process Planning at Sandvik Coromant stated, ”The tool library solution allows you to put the different tool items together – for example a milling cutter, the inserts, and the holder – and then have an accurate representation of the actual tool.” She added, ”To partner with, and avail the support of a leading CAM (computer-aidedmanufacturing) software provider such as CNC Software and Mastercam, we are excited to expand the digital machining environment and foster the standardization of cutting tool data.”
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Industry News | NEW LAUNCHES
Seco Tools launches new global website The idea is to provide robust content and optimised user experience
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eco Tools, a Fagersta, Sweden-based global provider of metal cutting solutions for milling, turning, holemaking and toolholding, recently launched its new global website, www.secotools.com, to guide manufacturers to metal cutting solutions. The new secotools.com helps customers improve productivity and navigate complex metalworking processes with access to robust product and technical information, best-in-the-industry resources and support in one centralised location. “At Seco, we understand that in today’s competitive marketplace, manufacturers need fast and reliable solutions to their complex metalworking challenges,” said Lars Bergstrom, CEO of Seco Tools. “The new secotools.com makes it easier for our customers to find the products and support they need to increase productivity.” The site features an efficient search engine and navigation that allows users to quickly and easily find what they need from any device, around the clock. The enhanced search functionality helps customers obtain fast solutions by locating tools and cutting strategies tailored to their needs.
Among the site’s many powerful new features is Suggest, an advanced online product selection tool, which guides part manufacturers to the right metalcutting solutions perfectly matched to their unique application requirements. Based on user input, Suggest quickly identifies and provides users with a complete tooling recommendation. Users benefit from the site’s new Seco Online Store with smooth, fast and easy ordering. Customers can increase productivity with quick access to real-time product, pricing, discount, and local stock availability information. The store also gives customers visibility into order status, as well as shipment and order history. Additional features include but are not limited to a news and events section which keeps customers and partners current with access to the latest news, articles and events and a download center with easy access to the industry’s best metalcutting resources. Flexible and adaptive, the site’s design allows for an optimal viewing experience across a wide range of devices, whether users are accessing the site via a desktop computer, laptop, smartphone or tablet.
To experience the new Seco Tools website, please visit www.secotools.com.
Headquartered in Fagersta, Sweden and present in more than 45 countries, Seco Tools is a leading global provider of metal cutting solutions for milling, turning, holemaking and toolholding. For more than 80 years, the company has provided the technologies, processes and support that manufacturers depend on for maximum productivity and profitability. For more information on how Seco’s innovative products and expert services bring success to manufacturers across all industry segments, please visit www.secotools.com
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Industry News | NEW LAUNCHES
Okuma launches nextgeneration LASER EX machines Laser Ex machines are super-multitasking machines that can do a bunch of manufacturing processes at once
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kuma has developed LASER EX smart machines with stateof-the-art laser applications to achieve the ultimate in processintensive machining. The LASER EX Series represent the world’s first multitasking machines that perform milling, turning, and grinding, as well as hardening and additive manufacturing processes. The Laser Metal Deposition (LMD) with a variable laser achieves precision control, from high efficiency to high definition additive manufacturing. The laser spot diameter: ø0.4 to 8.5-mm (infinitely variable control).
Compared to hardening in conventional heat treatment systems, this process is quick and produces less distortion resulting in dramatically improved throughput. There are five models that comprise this LASER EX series that can be used for a wide range of work pieces. The MU-8000V, MU-6300V, and MU-5000V are based on vertical machining center 5-axis machines. The MULTUS U3000 and MULTUS U4000 are based on Okuma’s multitasking machine design. The MU-8000V LASER EX for ø1,000-mm parts is the world’s largest machine for additive manufacturing.
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Industry News | UTILITY
VERICUT CNC machine simulation, verification and optimization software simulates all types of CNC machining. VERICUT Force is a physics-based optimization method that determines the maximum reliable feed rate for a given cutting condition based on the following three factors: maximum chip thickness, maximum allowable feed rate, and force on the cutter.The software operates independently, but can also be integrated with leading CAM systems.. Picture: CGTech
Maximizing the Use of Simulation Software There are ways to get the most out of NC verification and simulation software that every NC programmer must know.
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C verification and simulation software has been used by aerospace manufacturers for more than 20 years, yet some NC programmers do not take advantage of the whole range of benefits it offers. Given the expense of each machined part, NC simulation is generally regarded as an important step in the machining process. Simulation checks each machining operation as it is programmed, or as a final check after the programming is finished and post-processed for the specific machine. It’s typically a quality checking process that ensures
the part is cut as expected from the generated NC programs,without the risk of a machine collision. These are valuable uses that justify software cost, often many times over. However, some resourceful companies have discovered that simulation software can be used to benefit their shop in ways that others overlook, sometimes even in ways that were unintended by the software developer. Evolving strategies
One of the easiest ways to get more from simulation software is to simply use it – test new,
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unproven, machining strategies virtually as an analysis laboratory. Other than the time required to virtually create and test new methods, there is no physical cost. An NC programmer can try and fine-tune radical new ideas several times over. A few hours spent trying out different methods could potentially save many hours of machine time, reducing tool and machine wear, wasted materials, energy costs, and human fatigue. CAM vendors are developing new 5-axis strategies which are more complex; they are also developing new 5-axis roughing strategies that are improving the process of machining. New processes and new techniques must be employed and 5-axis machine simulation software that accurately represents each 5-axis machining cut in great detail will provide the necessary confidence to succeed. This also allows for new invention, experimentation and success with new techniques.
5-axis machine’s capabilities. Machining before machine arrival
Even today, with ups and downs in machine tool sales, there is still considerable time between the date when the machine is ordered, and the date that it is installed and ready to cut the parts. With simulation software, the manufacturer can be ready to create parts on the first day the machine is installed. CGTech has partnerships with many of the leading machine tool companies and they will often supply the CAD geometry for its joint customer’s machines – before the machine is even shipped. The manufacturer can then be proving out programs right away. Some of the customers can discover the efficiency and suitability of the machine configuration ordered even before the machine is delivered. By catching the machine specification mistake early, the customer can change the order before the machine is delivered.
Removing the fear of multi-axis machining
CGTech, the developer of VERICUT software, has encouraged its customers to push the software to its limits. This can be well described using an example involving a creative NC programmer for a large aerospace engine manufacturer. They were looking for a faster way to make the leading edge of a titanium fan blade, and the NC programmer theorized that a new machining method could make the difference they needed. Traditionally the process for making the part took many hours using a grinding technique. The NC programmer believed the part could be created using a 5-axis mill, but he knew he would need to convince his management before tying up the expensive machine for many hours cutting a test part. By using VERICUT to simulate the process, the programmer was able to create a video/review file to prove the process would work. According to the Association for Manufacturing Technology, 5-axis mills and mill/turn machines have increasingly become popular, for a good reason. They enable the manufacturer to drastically reduce machining time and the number of set-ups required to complete a job. Simulation software takes the fear out of programming a multi-axis machine. When an NC program can be simulated, from the same code that will be sent to the machine, there is no excuse for not taking full advantage of a
Opting for the right machine
The aerospace manufacturer working on the leading edge took the idea a step further. After proving the 5-axis milling process could work, they were ready to order production machines. Rather than simply picking the machine from a catalog, they designed the machine in their simulation software, where they had already proven the process would work. These files were then sent to the machine tool builder who built the machine exactly to their specifications as described in a virtual machining simulation. Another leading aerospace company created programs for more than 200 parts and proved them using virtual simulation software even before the arrival of machines on their shop floor. All the machines ordered were built using virtual simulation software and all NC programs were proved on a virtual machine. The machine loading plan was also prepared, thanks to accurate cycle times provided by simulation software. Once the machines arrived, they cut the parts without any further delay. By maximizing the use of simulation software, shop floors don’t need to wait for NC programs. There are always opportunities to improve an existing process, and simulation software can help by giving the NC programmer the freedom to try practically any machining technique in a virtual world. Only creativity and a good virtual platform are required to accomplish the job.
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Industry News | CUTTING EDGE
Increasing speed and throughput with optical encoders for high quality prints With higher resolutions (beyond 1000 DPI) playing a key role in colour rendition and becoming the norm in commercial printing industry, printer speed and throughput have become key competitive differentiators for superior quality output. Poor printer performance from the viewpoint of motion control may happen as a result of gross encoder error and could affect the print-head positioning accuracy – leading to the reduction in the speed and stability of the linear motor.
Renishaw’s optical encoders on printers
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Flora Digital’s Wide Format Ink-Jet Printers
The Background The maximum resolution of a healthy human eye is generally found to be 350 DPI or 73 µm (1 arc min) at the normal reading distance (250 mm). Irrespective of future breakthroughs in printing technology, there are physical limitations on what is discernible with the naked eye - print resolutions of 400 DPI and above will appear indistinguishable in most cases. However, higher resolutions beyond 1000 DPI play a key role in colour rendition, for instance in facilitating sharper and richer colours via cyan-magentayellow-black (CMYK) halftoning. With higher resolutions becoming the norm, printer speed and throughput have become key differentiators for efficient and quality output. Flora Digital is a leading brand specialising in wide-format inkjet technology for the commercial print industry. A product of Shenzhen Runtianzhi Digital Equipment Co Ltd (SRDEC), Flora Digital offers ultra-violet (UV) inkjet printers that leverage high-value components to ensure cutting edge performance. Commercial printers comprise print-heads, linear and rotary motors on multiple axes, a motion control system and substrate transfer system. The application of Renishaw’s RGH41 encoders on multiple axes has enabled Flora Digital printers to ensure the highest levels of print outputs. Flora Digital UV printers use a conventional drop-on-demand (DOD) inkjet head with micropiezoelectric technology. By changing the shape of piezoelectric ceramic components in an ink reservoir behind each print-head nozzle, the amount of ink pulled into and expelled out of the nozzles can be accurately controlled with the application of a suitable electric charge. Ink droplets can thus be ejected in a wide range of precisely controlled sizes. Once ink is transferred to the substrate, UV light is used to dry and solidify each layer in turn. The Challenge Poor printer performance emerging from printhead performance, ink-quality and the motor and motion control system capabilities typically manifests in the form of streaking in the printed
Renishaw’s RGH41 series encoder
image, stitching errors and the appearance of colour artefacts. From the viewpoint of motion control, encoder accuracy is vitally important. Gross encoder errors (including cyclic errors) affect the positioning accuracy and lead to a reduction in the speed and stability of the linear motor. It increases the magnitude of motion tracking errors, resulting in irregular print-head motion. While inkjet print-head and supporting carriage are undoubtedly the most important parts of a printer system, other components such as mechanical transmission and motion controller also have a key role in superior print performance. SRDEC project director Miss Sunny Yu explains, “The speed and throughput of printing equipment really depends on the printhead’s maximum firing frequency. Higher firing frequencies allow faster print-runs and improved overall throughput and are clearly advantageous. However, the position of the print-head needs to keep pace with the firing response. In order to achieve this, a linear motor with independently developed controller hardware was chosen to give a maximum print speed (in 2 PASS mode) of 315 square metres / hour.” High response linear motors respond with high speed and acceleration once the ‘command’ signal is received from the controller. This assures that the print-head drops ink in the right place and at the right time. Linear motors by far outperform mechanical transmission in
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Industry News | CUTTING EDGE
Renishaw’s optical encoders (close up view)
responding with the agility needed for high quality printing applications; and the encoder’s role is to precisely track the motion of the linear motor at all times. The Solution Flora Digital chose Renishaw’s RGH41 series encoder for its high maximum operating speed of 15 m/s to meet their current requirements of commercial printing equipment. Miss Yu comments, “In recent years, we have developed a variety of high-volume and wideformat, flatbed, UV inkjet printers with print widths up to 5m. We use the highest resolution print-heads available– up to 1200 DPI in binary print (monochrome) mode. Flora inkjet scan axes (printer X-axis) use a linear motor setup with Renishaw’s RGH41 linear encoder system and RGS40-P gold tape scale for feedback control. Designers selected an encoder resolution of 1 micron (µm) for this application. A servo-driven feed-axis (Y-axis) is also responsible for material handling and positioning of the substrate during the printing process.”
The printing plant environment is very intensive; downtime for maintenance invariably results in economic losses. Renishaw’s RGH41 encoder system gives excellent performance, higher axis speed, and peace of mind. Shenzhen Runtianzhi, Digital Equipment Co Ltd (China)
The Results The Renishaw RGH41 encoder series has a total cyclic error of less than ±300 nm, which is appropriate for smooth velocity control of the print-head. Miss Yu says, “After almost a decade as a Renishaw customer, the performance of the RGH41 encoder has proven to be very dependable, as one would expect from such a trusted brand. The RGS40-P gold scale has been especially designed for the printing industry and is relatively easy to clean and maintain.” Open-type encoder systems are cost effective and durable and are preferred for inkjet printers as the working environment in the printing industry is generally clean. However the encoder design should account for dust particulates, ink and other types of contaminants. Renishaw’s advanced optical filtering technology sieves non-periodic signal contributions, caused by contamination of the scale, and ensures a high-fidelity output signal. The scale can be ordered in coiled lengths up to 50 m, so that the engineer can simply cut to the required length for an axis. Miss Yu concludes, “The printing plant environment is very intensive; downtime for maintenance invariably results in economic losses. Renishaw’s RGH41 encoder system gives excellent performance, higher axis speed, and peace of mind. Indeed, customers have remarked that contamination to the scale during printing operations does not impact encoder performance. Engineers also appreciate the easy installation and set-up features, especially when installing scale on 5 m wide printing machines.” Renishaw’s RGH41 encoder is ideal for commercial printing as it guarantees speed and cost optimal performance. In recent times, Flora Digital has become a competitive global printing brand and is a Renishaw customer of LM10 magnetic encoders as well as RGH41 encoders.
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Industry News | EVENTS & PROMOTIONS
Motul Tech to Power Ducati Bike Racing in Spain
R
eale Avintia Racing has entered into a sponsorship agreement with Motul Tech. Raul Romero, Esponsorama CEO, and Stephane Mathieu, General Manager of Motul France, signed the contract at the Spanish Gran Prix yesterday (see pictures). The Motul Tech logo will be part of the livery of the Reale Avintia Racing Ducati Desmosedici GP bikes. It will also be displayed on the riders Hector Barbera and Loris Baz at all the circuits around the world. Motul Tech is the special division of the French Industrial Product company. It develops high performance industrial fluids and lubricants in France and all over the world, to sell them on the world markets.
We are pleased to join Reale Avintia Racing as a sponsor and to work with their riders Loris and Hector. In Motul, we share the values and fighting spirit of this team, and that’s why we think that this agreement is another step to consolidate our relationship with MotoGP. We welcome Reale Avintia to the Motul Tech family and I hope we can achieve great goals together.” STEPHANE MATHIEU General Manager Motul France
To get the support from a brand like Motul Tech is really important for us. More than anything else, I hope that this agreement will be the start of a long partnership. The team is growing year by year and I’m convinced that with the Motul Tech sponsorship, we are heading towards an even better future.” RAÚL ROMERO CEO Esponsorama
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Industry News | EXPANSION
Schuler installs state-of-the-art blanking line at thyssenkrupp facility in Silao, Mexico The facility produces up to 45,000 aluminum and steel parts per day. It also Increases annual processing capacity by 70 percent.
Since the beginning of 2016, the Schuler blanking line has been in operation at the Silao facility of thyssenkrupp Materials de Mexico. Image: Schuler
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T
he automotive industry in Mexico has been growing steadily in the recent years. To meet this increased demand, thyssenkrupp Materials de Mexico S.A. de C.V. expanded its operations in Silao, Guanajuato, by installing a state-of-the-art Schuler blanking line featuring ServoDirect Technology. The line produces up to 45,000 aluminum and steel parts per day and has increased the site’s annual processing capacity by 70 percent (up to 270,000 metric tons). “thyssenkrupp is proud to be the first supplier in Mexico to offer customers a combined blanking line for carbon steel and aluminum blank processing,” said Olaf Voss, President, thyssenkrupp Materials de Mexico. “The introduction of the Schuler blanking line has ensured we continue to offer customers cuttingedge capabilities to meet their growing needs.” Since early 2016, the line has been processing aluminum and carbon steel for exposed and unexposed automotive applications, including high-strength steel up to 1,200 N/mm² of tensile strength. Thus, allowing thyssenkrupp Materials de Mexico to meet the automotive industry’s needs for lightweight construction. Ranging from the coil line all the way to the stacker, Schuler supplied all the components, which are precisely coordinated and operated by a single control and safety system. “When we sought to expand our Silao facility, we needed highly reliable machinery that met our increased capacity requirements,” explained Voss. “With its high degree of automation, Schuler was a natural fit, as its line allows for quick product changes and smooth operation throughout the entire process.” ServoDirect Technology ensures maximum flexibility and productivity At the heart of the line is a highly efficient 800 metric ton servo press with energy storage and an output rate of up to 75 strokes per minute. Depending on the type and size of the blank, productivity is increased by up to 150 percent, compared to a blanking line equipped with a conventional mechanical press, thanks to the programmable slide motion. Using optimized slide characteristics, Schuler’s ServoDirect Technology not only ensures maximum flexibility and productivity, but also keeps the wear on dies and machinery to a minimum. In addition, lines using this technology are ideally equipped to process the widest variety of material, such as aluminum or high-strength steels. Even surfacesensitive material can be handled safely on the same line at the highest production rates.
Schuler supplied all the components from coil line to stacker. Image: Schuler
However, a highly productive press is only half the battle. Coil feeding in front, as well as blank stacking behind the press need to be able to catch up: The coil line features a maximum coil speed of 120 meters per minute, and the roll feed with servo direct drive boasts an acceleration of up to 13 m/s². Belt cleaning devices and wipers all along the blanking line reduce cleaning intervals, with separate pairs of rolls for steel and aluminum, including automatic cleaning units with a quickchange system. The “Stop2Drop” stacking system at the end of the line guarantees high part quality without stopping marks and increased output rates for parts wider than 1,500 millimeters.
About the Schuler Group – www.schulergroup.com Schuler is the world market leader in metal forming technology. Schuler offers presses, automation solutions, dies, process technology and service for the entire metalworking industry and lightweight automotive design. Customers include automobile manufacturers and suppliers as well as companies from the forging, household appliances, packaging, energy, and electronics industries. Schuler is the market leader in minting presses and supplies systems solutions for the aerospace, railway and large pipe industries. In 2016, Schuler achieved a turnover of 1,174 million euros. Following the acquisition of die manufacturing company AWEBA and with a majority holding in Chinese press manufacturing company Yadon, Schuler employs around 6,600 members of staff in 40 countries. The Austrian ANDRITZ Group holds a majority share in Schuler. About thyssenkrupp Materials de Mexico – www.tkmna.com At its Silao facility, thyssenkrupp Materials de Mexico S.A. de C.V. offers steel blanking and warehousing services for aluminum and steel products in the automotive and aerospace industries. With further locations in Saltillo and Puebla, the combined workforce totals around 450 employees. thyssenkrupp Materials de Mexico is a unit of thyssenkrupp Materials NA, Inc., a leading North American provider of production materials and integrated service solutions. With over 2,900 employees, the company has annual sales of 2.4 billion euros and operates in more than 90 North American locations. All in all, the global thyssenkrupp group has more than 155,000 employees in nearly 80 countries developing technologies, products and services for sustainable progress. In fiscal year 2015/2016, thyssenkrupp generated worldwide sales of around 39 billion euros.
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Industry News | EXPANSION
DMG MORI Expands Portfolio with LASERTEC 30 SLM With the LASERTEC 30 SLM, DMG MORI has expanded its additive manufacturing portfolio to include ‘Powder Bed Processes’
W With the new LASERTEC 30 SLM SAUER GmbH and DMG MORI are consolidating their position as the world’s first full-liner in additive manufacturing with both hybrid and selective laser melting machines.
ith a majority shareholding of 50.1% in REALIZER GmbH from Borchen the DMG MORI Group has now strengthened its position in the field of additive manufacturing. DMG MORI already has extensive expertise in the field of laser deposition welding with powder nozzles (laser metal deposition) through SAUER GmbH.. With the new LASERTEC 30 SLM SAUER GmbH and DMG MORI are consolidating their position as the world’s first full-liner in additive
manufacturing with both hybrid and selective laser melting machines.“Selective laser melting in a powder bed opens up completely new areas of application for our customers.That is why this is the perfect complement to our LASERTEC 3D machines in the field of advanced technologies,” said Christian Thönes, Chairman of the Executive Board of DMG MORI Aktiengesellschaft. Sophisticated components in top quality The LASERTEC 30 SLM is equipped with a powder bed that has a volume of 300 × 300 × 300 mm.With this method powder is applied in
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layers onto the work platform and melted by means of selective exposure.When the melting procedure is finished, the platform is lowered to the amount of the respective layer thickness and the procedure then repeated with a new layer of powder.The process enables the production of high-precision 3D components with layer thicknesses of 20 to 100 µm depending on the surface quality and build-up rate - and it does so with no great impact on the production costs. Even complex grid and honeycomb structures, which cannot be realised with other methods, can be produced in high quality in this way. As SLM technology allows the use of different materials, its fields of application range from the automotive and aerospace to the dental and medical industries and on to include tool and mould making.Thanks to a low porosity (0.1 to 0.5 percent) the components made of aluminium, stainless steel alloys, titanium and Inconel excel through extremely good properties similar to those of the basic material.DMG MORI also offers application-specific fibre laser sources of 400 Watt to 1 Kilowatt. The LASERTEC 30 SLM guarantees efficient and cost-effective production thanks to its low argon consumption of only 70 l/h and integrated powder conditioning that ensures optimum
The exchangeable powder module means it takes less than two hours to change the powder.
powder handling.Moreover, the exchangeable powder module means it takes less than two hours to change the powder.An end-to-end software solution with a uniform user interface from CAD-File (RDesigner) to process control (ROperator) simplifies operation of the LASERTEC 30 SLM. In order to round off the SLM manufacturing process ideally DMG MORI also enables subsequent machining on its highly dynamic machining centres from the group portfolio.This guarantees maximum component accuracy and best surfaces.
The LASERTEC 30 SLM is equipped with a powder bed that has a volume of 300 × 300 × 300 mm.
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Industry News | CUTTING EDGE
Marposs introduces
New TBD HS The New Programmable System for non-contact high-speed tool breakage detection is here Non-Contact Tool Breakage Detection System
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M
arposs S.p.A., the Italian measurement and control technology leader, has recently introduced the new TBD HS (High Speed), its wide range of products for tool checking for milling machines and machining centers. The new TBD HS is a programmable system for non-contact checking of hi-speed tools, particularly committed to those applications where there is a need for hi-speed spindles, with speed ranging up to 80.000 rpm. Thanks to its rotary switch selector, the TBD HS is able to recognize a particular tool in two different ways, depending on the actual rotational speed, thus minimizing cycle times, generally crucial in this kind of process. Selecting the feature “Quick Recognition”, the tool checking is performed for 10.000 rpm spindle speed and its multiples. It is also possible to choose “Hybrid Recognition” if the speed is 1.000 rpm and its multiples or 10.000 rpm and its multiples. With a reflective, clean tool, an impressive 150 msec checking time is achieved, approximately half the time compared to the standard TBD. High spindle speeds and small tool dimensions lead to the need for a fine adjustment for positioning the TBD HS in a very precise way: that is the reason why an effective system has been designed to make accurate and easy the searching procedure of tool verification. The tool breakage detection performed by the TBD HS is improved by the presence (on request) of a blower for cleaning the receiver glass: taking advantage of the usual standard inlet, both in terms of air flow and pressure, it has developed a solution to protect the glass from scraps without increasing the air consumption. Moreover, when the conditions are particularly harsh because of the aggressive presence of shavings, there is the chance to substitute the standard protection glass with one in sapphire crystal; it being 9 out of 10 its hardness degree
on the Mohs scale. This kind of protection lets the receiver perform always at its maximum, no more damaged by the extreme machine conditions. The Genesis of TBD Companies in the industrial sector, which lay emphasis on productivity, aim to implement tool measurement solutions that are quick, accurate and reliable. Aware of such need and willing to develop an application that could avoid affecting production efficiency, Marposs presented TBD, the Tool Breakage Detector, a time-saving laserbased solution for broken machine tool detection. TBD on milling machines and machining centres allows the highest level of control on the process, thanks to a very short tool checking cycle. A fast and reliable detection achievable by the TBD helps reduce production time and prevents expensive work-pieces scrap that usually results from wrong cutting processes by damaged or broken tools. All the functionalities are contained within the TBD unit compact housing, which can be mounted outside the machine area, saving space on the table. It is possible to choose among different working modes, which endow TBD with a great flexibility. Switching the power to the maximum gives TBD the chance to recognize a tool placed at a longer distance (up to 2 meters), with a standard capability to check the breakage. If a smaller tolerance is required, the reduced power can be set obtaining a smaller beam. Furthermore, a user can choose the filtering level of the signal. In fact, during the checking cycle, some coolant drops could interrupt the beam or coolant stuck on the tool could create variation in the signal received. Setting “Hi Filter” makes the software of the TBD more restrictive in order to give the more reliable response. On the other hand, choosing “Low Filter” TBD responds in a faster way, as the filter is less severe. Lastly, with TBD you can choose the appropriate range of spindle speed, up to 5000 rpm.
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Book Excerpt | DR MARK GOULSTON
How to Deal with the Irrational and Impossible People in Your Life Or How to Counter the Modus Operandi (M.O.) of Irrational People
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When you understand irrational people’s M.O.s, it’ll be easier for you to realize that their weeping, coldness, whining, withdrawal, or attack-dog behavior isn’t really about you. Instead, it’s about them and their need to feel in control. Moreover, as you’ll see, knowing a person’s M.O. will show you the best way to counter it.
Emotional
Logical/Practical
Irrational Person’s M.O.:
Irrational Person’s M.O.:
Emotional people believe they need to vent or they’ll explode. There- fore they cry, scream, and slam doors. They tend to overpower you because they’re willing to escalate a situation to a point that’s unbearable for a sane person.
These people think they’re in control only when they stick to the facts. As a result, they become terse, cold, and condescending. They tune out anything that seems illogical and nearly always view displays of emotion as “acting crazy.” Your Reaction:
Your Reaction: You may try to mollify these people by giving in to them so you can stop the unending emotional upheaval, or you may become so tired of it all that you just try to escape from them.
You may start feeling and acting more emotional and angry in response to these people’s dry and logical statements and the way they cut you off with icy logic. They also have a way of causing you to feel ashamed of even having feelings.
DR MARK GOULSTON
Author of Get Out of Your Own Way and Just Listen Dr Mark Goulston, MD, is a top psychiatrist, consultant, coach, and business adviser. Author of the bestselling Just Listen and Get Out of Your Own Way, he blogs for Harvard Business Review, Fast Company, Business Insider, Huffington Post, and Psychology Today; cohosts a weekly radio show; and is featured frequently in major media, including The Wall Street Journal, Fortune, Newsweek, Time, CNN, Fox News, and the TODAY show. For information on the Goulston Group, go to: http:// goulstongroup.com or contact them at: info@goulstongroup.com
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Book Excerpt | DR MARK GOULSTON
Manipulative / Needy Irrational Person’s M.O.: These people believe that to be in control, they need something from you that they can’t supply themselves. So they whine, wheedle, and make excuses. If you suggest ways they can help themselves, they say, “Yes, but . . .” If you don’t give them what they want, often they try to control you by making you feel guilty.
Your Reaction: These people evoke in you a nearly constant need to reassure them, which eventually gets exhausting and makes you resent them. If you go the extra mile to walk them through fearful situations, you’re likely to find yourself becoming a regular crutch because they can’t or won’t move a step without you.
Hopeless/ Withdrawn
Your Reaction: When these people are unrelenting, you may transition from feeling guilty and frustrated to feeling annoyed, put-upon, and ashamed of your deep desire to say something mean to them. You may give in to them just to get rid of them—even though you know they’ll just come back for more.
Fearful
Irrational Person’s M.O.: Hopeless/withdrawn people feel that the world will only hurt them, so their M.O. is to hide from it. No matter how hard you try to convince these people that they can be happy in the future, they spend enormous amounts of energy trying to convince you that you’re wrong and that nothing will work. Your Reaction:
Irrational Person’s M.O.: Fearful people feel like they’re constantly surrounded by threats. When something triggers their fear, they lash out wildly like a frightened dog. They also are much more comfortable than you being perched between fear and panic (because they are there so often).
These people’s negativity may leave you feeling frustrated, sad, and a bit hopeless yourself. Trying to help them increases your chances of becoming part of their downer cycle as they suck the energy out of you.
This book is life changing. A must-read for dealing with the uncooperative and stubborn people in your life.” –DR MARK GOULSTON, author of the New York times and global bestseller ”What Got You Here Won’t Get You There” If I had known that ’talking to crazy’ coult be so simple, I wouldn’t have drive myself crazy all these years trying to do it.” –KEITH FERRAZZI, author ”Never Eat Alone and Who’s Got Your Back” Talking to Crazy
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Martyred
Know-It-All
Irrational Person’s M.O.:
Irrational Person’s M.O.:
People who play the role of martyrs make a point of refusing to ask for help, even when they desperately need it.
Know-it-alls like being the only expert on any topic, even if they’ve never “been there” or “done that.” They will find cracks in any idea you offer, even if it’s correct. They know that if they can make you feel stupid, you’ll lose confidence and often back off and become submissive. Their M.O. is to belittle, mock, or con- descend to you.
Your Reaction: These people initially make you feel guilty for not helping, even though they won’t give you a chance. Over time, however, their martyr act can make you feel annoyed and exasperated.
Your Reaction: These people may make you feel small, insignificant, not good enough, and sometimes ashamed—as well as resentful.
Bullying Irrational Person’s M.O.: Bullies believe they’re in control only if they’re making you fearful and submissive. That’s why they actively attack, threaten, or belittle you. The more afraid they make you feel, the more powerful they feel. Your Reaction: These people make you feel scared, intimidated, weak, and powerless— as well as angry. You may strike back, steam inside, or simply retreat and ruminate about what you could have done instead.
Sociopathic Irrational Person’s M.O.: These people (who technically are sane, but often are irrational in a unique way you’ll read about later) are hiding secrets. Their M.O. is to terrify you so you won’t find out what those secrets are (or worse yet, expose them to the rest of the world). Your Reaction: These people will make you feel afraid and even “creeped out.”
Talking to Crazy Visit us at: www.amacombooks.org Call +01 800-250-5308 for information on bulk purchases
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Company Feature | SLTL
LIKE A DIAMOND:
Shaped Under Pressure
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We take risk. When I can visualize that certain things can be done, then I immediately take risk. We try to mobilize funds and get investments for new innovations. In fact, our company invests our profits in to our own Research & Development activities and new innovations.” Dr. Arvind Patel Chairman Sahajanand Laser Technology Limited (SLTL)
How An Indian Entrepreneur Changed the Face of The Global Diamond Industry
Dr. Arvind Patel – A Technopreneur Dr. Patel’s inclination and liking towards science and technology was evident at a very young age. Coupled with the deep interest in the science, he developed a zeal to create things and make them work. The success achieved by Dr. Arvind Patel has not been just due to luck – it has involved a series of events in the life of this entrepreneur. The Early Years Dr. Patel went through a lot of challenges and struggles in his formative years. Reflecting on the early childhood days, Dr. Patel says: “There have been many critical points in my life. But I think one of them which can be considered as life changing and the biggest transition of my life was to know about Community Science Centre. In my childhood I was not a very intelligent student as compared to other students; especially in the eyes of my teachers. In fact, I failed twice in school; once in the second standard and again in the eight standard. Fortunately, my hobby lay in science; I used to think continuously about science and how science could be used for the mankind.” At that point of time, the Patel family was residing at the Shahibaug area of Ahmedabad. Through one of his friend, he came to know about Community Science Centre (CSC), also known as
Vikram A. Sarabhai Community Science Centre (VASCSC). Dr. Vikram Sarabhai had founded the Community Science Centre at Ahmedabad in 1966. During those days, Professor A.R. Rao of CSC inspired young Arvind a lot. Narrating his experience with Prof. Rao, Dr. Patel says: “Prof. Rao created many techniques and models of practical mathematics. He used to give us many mathematical puzzles and I used to solve it. He changed my life.” It was like young Arvind had transformed. Prof. Rao had instilled a sense of confidence and self-belief in the young, budding technologist. Legacy of resilience Dr. Arvind Patel’s father worked in a textile mill as a supervisor; he was, in fact, more of an engineer in approach and practice. Even though he could pursue his studies only till the 9th standard, he retained and continued his interest in the field of electronics which was like a hobby for him. He used to enjoy repairing radios, tape recorders and other similar electronic gadgets. This life experiences shaped up young mind of Dr. Patel. Soon, young Arvind had made up his mind that he would pursue studies in the field of electronics and be an electronics engineer.
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Company Feature | SLTL Experiencing entrepreneurship After his SSC, Dr. Patel wanted to pursue BE in Electronics at L.D. Engineering college, Ahmedabad but he could not get in due to low SSC percentage. Even so, determined to get in to electronics and communication, he chose to pursue a Diploma in Electronics at A.V. Parekh Technical Institute (AVPTI), Rajkot. After completing his diploma, Dr. Patel got job in a Mumbai-based medical company engaged in the business of X-Ray machines, ECG machines and many other related products. They wanted a salesperson for the Gujarat market. Dr. Patel took up that assignment. While on the job, he came across a course in the area of Bio-Medical Engineering. He found it to be interesting and enrolled for the program. Dr. Patel stretched his days to do justice to both -- mornings and evenings he would spend on meeting doctors for business and the afternoons on the course. He earned a Diploma in Bio-Medical Engineering from Technical Education Board, Gujarat in 1983. Soon thereafter, he decided to start a business. Dr. Patel recounts: “In those days there was a growing demand for stabilizers. So I started making stabilizers and motor protecting devices for farmers. I created a small setup on the terrace of my house.”
He was handing the designing and testing part and his younger brother worked as a technician taking care of assembly, purchase and other similar tasks. His father also handled some part of this business after his textile mill hours. They roped in a partner-cum-investor who handled the marketing part. Thus was born a small company called Sahajanand Electronics. They bought the necessary equipment for the business and invested around Rs 20,000. However, the business did not work and they sold out entire equipments and machineries for Rs. 19,000. Finally, he exited that business. He attributes two reasons for failure; market characteristics and the need for working capital due to extended credit period demanded by the dealers. Dr. Patel felt that he should still get some more knowledge of the market. More Life Lessons Post his first business experience, Dr. Patel ventured into the area of biofeedback devices which are normally used for paralysis and other related complexities as a part of physiotherapy. However, there was only one physiotherapy institute in Ahmedabad. He soon realized that it was not a right path and gave up on that project. Subsequently, Dr. Patel joined L.D. Engineering
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College as a part-time student. Alongside, he got an opportunity to work at Indian Space Research Organization (ISRO), Ahmedabad. He worked at ISRO for two years from 1984 to 1986. During this journey he came across laser machine for the first time at ISRO. On the completion of degree in engineering from L.D. Engineering College, Dr. Patel joined Gujarat Narmada Valley Fertilisers & Chemicals Limited (GNFC). Another defining chapter in the life of Dr. Patel was to unfold. One of the leading ice-cream manufacturer and brand Vadilal Industries had imported a machine which had gone defunct. However, the seller could not send technicians due to the Ahmedabad riots of 1989. Dr. Patel father was approached by a Vadilal consultant to look at the machine. He accompanied his father when he went to inspect the machine. The Patels assured the plant manager that they would fix the machine in a week and quoted Rs. 5000 for the repair. The manager agreed. Dr. Patel delivered as per the promise. Interestingly, Dr Patel was drawing salary of Rs. 5000 at GNFC at the time. Vadilal people took him to other parts of the manufacturing plant which needed maintenance and repairs. It was a great opportunity; he bagged
work order of around Rs. 2 lakh. He sensed an opportunity and soon after resigned from GNFC. Enter: Laser Tech At the time, Ahmedabad and Surat were important textiles industry hubs. Dr Patel’s business of machine repair and maintenance needed expansion. He asked one of his friends to market his work in the Surat market. Incidentally, this friend’s father-in-law was into business of diamond polishing. This led Dr. Patel to a visit to a diamond polishing facility where he found to his surprise that all the work being done was manual. He thought about the possibility of introducing laser technology in the diamond polishing industry which would reduce the manual work and improve efficiency by a big measure. He had seen that ISRO used laser cutting machines to shape ceramic objects. He figured that laser could also be used to Diamond was also hard substance and laser technology can be used for job as another application. He came back to Ahmedabad immediately and embarked on the new venture. One of Dr. Patel’s friends who was in the diamond polishing industry came forward to help with investment. An early survey of the market suggested that a machine that could cut
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Company Feature | SLTL diamonds was an immediate need considering the importance of it to the jewellery making industry. That led the partners to import a laser-cutting machine from Switzerland. But, the machine was not suitable for Indian conditions; it failed after two months. They soon realized that the importing the machine was not the solution. They had to create an indigenous version of the machine that suited the Indian conditions of high humidity, extreme temperatures and erratic electric supply. Apart from making the machine suitable for Indian climate, the machine should be simple to use, since most of the operators in the diamond industry were not technically trained to operate high end complex machines. So the start-up team decided to visit a lasertech trade show in Germany to understand all its uses in different industries. They were very excited to see that every component of the machine that they had conceived was available. They imported parts and assembled the machine in India. They were ready with the first machine after three months. A small firm with the name of “Sahajanand Laser Technology” was formed and a manufacturing facility was started at Daman.
They had many teething problems but the attributes that helped Sahajanand Laser through all the problems were constant innovation and the process of creating new products for different industries and applications using laser technology. The core idea was to create indigenous versions of many such high-tech machines which would suit Indian conditions. Sahjanand Laser saw many proud moments in is journey. One instance was when the company participated in a pan-India exhibition at New Delhi and Dr. Manmohan Singh, the then finance minister of India, spent more than half an hour to understand use of laser technology in the marking technology used to avoid duplication of coins. Another proud milestone was when the company provided laser solutions and machines to the Indian defense industry at some critical moments; especially after the 1998 nuclear experiments. Due to sanctions and ban on India, vendors from Israel stopped supply for few key laser solutions; Sahajanand Laser quickly filled the gap. Reflecting on many such events in the journey, Dr. Patel says: “We Indians need to think differently. We should not underestimate our abilities. Thankfully, due to the Mars Mission and other such projects; the world has started looking at our technological capabilities in different way. A large number of scientists working with NASA are
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Indians and many of the very successful and noted doctors in working in the USA are also Indians. If they can create wonders there, they can also do the same wonderful things here in India.” Ordeal by fire The most challenging phase for Dr. Patel began in 2008, when during an investor presentation, he suffered a severe stroke, which led to brain hemorrhage, right in the midst of the presentation. Dr Patel continued talking and answering the questions of the investors. He did not realize the severity of his condition but knew that something was wrong; he could not move his hand or leg. He just kept on talking to the experts for more than 10 minutes. The presentation went through and was appreciated. Dr. Patel was asked to leave the presentation room and told that they would discuss the matter internally. As he moved to get up from his chair, he could not control his body and fell down on the floor. He was rushed to the emergency room and subsequently underwent surgery. It was tough time for him and his family both on the personal and business fronts. A German company acquired by SLTL was was running into losses. Things worsened. Soon, Dr. Patel also lost his memory and his abilities to speak and read. It was time to persist and win the biggest battle of his life. In his words, “Usually, I don’t sit down; in fact I never had any experience of being in the wheelchair before that incident. But, I made
up my mind that I had to get well; so I started exercising in morning, afternoon, and evening. Within two months, I went to the factory premises and I used to sit there. I wanted to come back to join my business again. But then I lost memory as well. When, I would be reading a newspaper, people would laugh at me because whatever I was reading was different from what I spoke. I tried to discover the mystery behind the human brain; how it works and how it functions. I realized that it could recover with mental exercise with the support of medicines.”
Proud Moments Dr Arvind Patel has played a key role in the building of Chandrayaan-1, India’s first mission to the Moon. His company, Sahajanand Laser Technology Ltd (SLTL), supplied several components for Chandrayaan-1. Scientists used some of these components to send pulses of infrared laser to a strip of lunar surface. SLTL has participated in several other projects of Indian Space Research Organization (ISRO). It has also provided laser solutions and machines to the Indian defence industry at some critical moments, especially after the 1998 nuclear experiments.
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Much to the surprise and delight of everyone around, Dr. Patel fought and won the battle. His resilience and persistence have seen him through all his challenges. Professionalizing the Business Over a period of time Dr. Patel realized that for the long-term growth and sustenance of SLTL, he needed to professionalize the management. He created a cadre of professionals within the organization to take up leadership positions. In his view, any organization aspiring to grow should over period of time professionalize the management. They had started to move in this direction way back in 2003-2004. Dr. Patel has steered the company successfully despite the entry of many firms in the same line of business. Instead of fighting the competition with lower-cost, inferior products, he has chosen to fight by introducing better solutions and products. Surging Ahead Through the years, Mr Patel has forged SLTL as an innovation company that looks at all the emerging opportunities in the science and technology field. Dr. Patel believes in making and creating the difference the world by creating new innovations which benefit India. He is working on solar, white coal and other sustainable renewable energy solutions especially for rural India which can power villages in a very cost-effective manner. The company has evolved into a group of companies operating in many areas, such as Sahajanand Software Pvt. Ltd. and Lancer Medical Technology Pvt. Ltd. and others. SLTL has participated in nation-building as part of some of the recent projects of ISRO; some of them
have received extensive media coverage and have received praise from the Prime Minister Shri Narendra Modi. The company has carved out a special niche and achieved a position in an industry which is rapidly moving and wherein technology of today becomes obsolete tomorrow. The company has achieved this position with an inhouse multi-disciplinary R&D team comprising research scholars, software engineers, electronicmechanical-instrumentation engineers and laser specialists among others. Message for Entrepreneurs Dr. Arvind Patel has been a great inspiration for the coming generation of the technology based enterprises. He devotes his time interacting and also helping technopreneurs. He believes that as a result of life evolution, many opportunities get unfolded. But an entrepreneur should see those things and visualize. According to him an entrepreneur should be able see things and visualize before creating those innovative solutions. An entrepreneur should be able to create common thread between opportunities, challenges and innovation. He says: “As an entrepreneur I never worked for money. It is all about liking and passion to do something innovative. That is why whenever, I am invited for as guest speaker particularly for young students of MBA or technology, I say that if you find out your liking then you progress very fast. Otherwise you will only be following others. When, I created laser technology-based solutions, the industry did not exist in India. I created products first and then showed it to people. People do not believe what they have not seen. It continues as our philosophy even as of now.�
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About SLTL: Cutting-Edge Innovation Sahajanand Laser Technology Limited (SLTL) is the company that has epitomised the term ‘Trailblazer. The foundation of this organization has been built on the idea of disruptive innovation -- just after its establishment, SLTL invented fiber laser cutting machine, a machine which went on to become a gamechanger for the metal forming industry. The inventor of fiber laser cutting machine, Dr. Arvind Patel founded SLTL in 1989. Eventually Sahajanand Laser Technology Limited emerged as the first Indian company responsible for laser-cutting revolution across the globe. With an aim to make metal forming process simpler and quicker than ever, SLTL set up the operations in 1992 in Gandhinagar, Gujarat. The inception of the company’s service diversification took place in 1995, and since then it have ventured into multiple disciplines across the spectrum which are: Cutting, Marking, Welding, Micro Machining, Solar Cell Scribing/Cutting, ad Diamond Processing and Scanning. It has explored all of these mentioned domains keeping laser at the center of its deliverables. SLTL is a global leader in Computer Numeric Controlled (CNC) Laser services, a highly advanced service used by a few manufactures internationally. SLTL introduced the Laser Diamond Sawing system in India in 1992, which established a milestone in the industry. The company has been actively contributing to the industrial development of India, ever since. SLTL’s strength is its ingenious research and development department, through which the company has marked its presence as the world’s largest manufacturer of CNC laser systems for the diamond industry. As an endeavor to bring ease of usability, SLTL has come up with its in-house laser marking interface named MARK PRO. Thanks to its dedicated research team, SLTL is an undisputed leader in its domain in India’s diamond industry. The Indian subcontinent, South East Asia, Middle East, Russia, China, Europe, USA, Canada, and Latin America have become SLTL’s exporting destinations for laser-based applications. Following the legacy, SLTL’s recent initiatives have focused on the improvement of metal forming process. SLTL has launched sheet stacker and loading unloading machine in 2016 for the first time in India, and the machines have set newer performance benchmarks in the metal-forming works at the factories.
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Cut, Clean, Protect and Pack A Learner’s Guide to Chemical Process Optimization
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ndustrial technologies have rapidly developed since the Industrial Revolution, and technological progress during the 19th century had been significantly promoted by the great inventors of that century. Over the years, new technologies and methods have been developed through research and development. The advancements of both science and technology have resulted in incremental development and disruptive technology. The rise of technologies is a result of present day innovations in the varied fields of technology. These technologies combine power to achieve the same goals – productivity and cost reductions. Chemical Process Optimization is a methodology in which all the interlinking chemical process steps of a plant are optimally coordinated with each other all the way from the design and development to actual implementation. CCPP (Cut Clean Protect and Pack) Solution Engineering is a unique approach which harmonizes technologies and expertise to create value. The overall objective of this proposition enables customers to delegate performance ownership of their operations right from raw material stage up to finished product stage to one partner. While they can focus on their core processes without worrying about the chemistries interacting with their parts, a team of experts from the partner works on a module to map, study, suggest and implement optimizations in processes, products and technologies. The CCPP Solution Program begins with understanding Technical and Commercial needs. After in-depth study, chemistry expert team recommends cost effective process optimizations and value based product recommendations. A joint action plan is prepared for a Product Benefit Demonstration (PBD) and subsequent steps carried out by dedicated service team under the supervision of chemistry expert team and customer representatives. On completion of the PBD, technical teams manage replication and monitor success even after the PBD and Kaizen or continual improvement process is initiated. Any solution should ensure Tangible value benefit in productivity or CPC reduction Integration with existing systems and processes 100% elimination of performance or quality problems
Economic usage of products HSE (Health, Safety and Environment) and Environmental adherence Ease of application, implementation and usage Meeting the objectives of customer’s customer Synergize qualitative improvements Typically in manufacturing, a component journeys through various stages of operations right from raw material to finished goods. The first common step is actual component manufacturing by metal cutting/removal or forming. Additionally there can be processes, like hardening, quenching, buffing, plating, painting etc. Before the dispatch to the customer, these components are rust-protected and packed. To ensure efficient protection, the components surfaces need to be as clean as possible. All these operations involve usage of chemicals of diverse chemistries and at times several suppliers. Harmony between all these chemicals is crucial but often neglected till the time failures and rejections occur. Let’s talk about the four main stages and how to optimize and harmonize in bit more detail. Cutting Neat Cutting In an era of ever-increasing speeds and loads and problem of mist and evaporation control, conventional mineral base oils are being replaced by superior refined base oils with higher saturated hydrocarbons and reduced sulphur contents. Neat oil cutting technology embodies usage of Hydro Cracked Group II base oils which provides the basis of its superior anti-oxidation properties combined with chlorine free extreme pressure anti-wear additives in one single extraordinary process. Group II base oils are refined using a hydro-processing method known as “Hydrotreating” that reduces its sulphur content to less than 0.03% and increase its hydrocarbon saturation to levels of 90% and above. Due to the inherent benefits of this most European machine manufacturers have approved the use of these oils in their machines. Water-Soluble Cutting HSE has always been a prime focus in Metal working industry. Over the years metalworking fluids have been one of constant changing
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chemistries. As new worker-safety rules that limit particulates, chlorinated paraffins, and exposure levels have taken effect, lubricant providers have had to significantly modify formulations. The new age water-soluble fluids makes use of Advanced Surfactant Technology, buffer biostability technology and chlorine free ester based EP additives which are tuned to the different processes and types of metal. ‘Microemulsions’ formed by such watersoluble cutting fluids form significantly smaller oil particle sizes compared to conventional mineral-soluble oil or semi synthetic macro emulsions. These ‘micro-emulsions’, visually appear to be translucent, or even transparent and have inherent advantages of providing clean appearance, excellent corrosion protection, long life of cutting fluid, and cooling capabilities, good wetting properties and emulsion stability. They are also designed to increase sump life through slow release of buffer bio stability and provide better skin friendliness. Additionally, speeds and feeds can be stepped up and better size control obtained. The usage of these technologies usually results in cutting-tool life improvements by 1.2 to 4 times, cutting parameters intensifying by 20 to 60% and productivity increase by 10 to 50%. Clean Intermediate Cleaning or Parts cleaning is becoming more and more essential to many industrial processes, as a prelude to Painting, Plating, Phosphating, Assembly, Welding, Rust Protection and Packaging. In recent times with awareness amongst users, mild alkaline cleaners are being preferred over conventional high alkaline cleaners that are generally sodium or potassium hydroxide-based chemicals. Water-soluble cleaners need to strike a fine balance of ingredients, structure and polar character of a cleaner to meet specific requirements of the industrial applications. Modern cleaners harness the abilities of multifunctional Power Surfactants (combinations of non-ionic and cationic surfactants) to deterge versatile organic and inorganic soils. These cleaners reduce the surface tension by adsorption at the liquid-gas interface. This dynamism induces superb cleaning effect without compromising on the critical factors for industrial applications such as foaming where bubbles are rapidly generated and need to be stabilized. New age neutral cleaners also outperform other conventional acidic and alkaline cleaners which have a tendency to cause surface
Mr Balwant Bains, GM Product Management & Marketing, Zavenir Daubert India is Product marketing leader with a demonstrated track record of envisioning, building and launching new sustainable brands. Over 14 years technocommercial B2B sales & marketing experience. The areas of domain expertise include chemicals, automotive and industrial products. In the past Mr Bains has worked with leading companies such as Castrol and Ashland.
defects and leave residues which may be delirious to further downstream operations. Corrosion prevention, de-emulsification, buffer stability properties are introduced through addition of various specialized additives. Protect Several studies over the past 30 years have shown that cost of corrosion to industrial economy is quite high and it is approximately costs 3.1% to the country’s Gross Domestic Product. Today, as companies seek ways to reduce costs yet maintain quality in all stages of manufacture, storage and shipment, innovative solutions for corrosion control are a need of the hour. Typical Applications to protect metals from rusting are: In-Process, In-house storage, domestic Shipping and export shipping (mostly clubbed with VCI). The recommended application is through dipping, spraying or brush. There are certain factors governing the selection of protection products like metals to be protected, the duration of corrosion protection required, atmospheric conditions, ease of application, ease of removal,
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other factors such as aesthetics, coating film characteristics, process compatibility and cost versus performance objectives. Corrosion is inevitable but with the modern advanced technology, we can prevent it. Effective and efficient protection products are based on the Contact Corrosion Inhibition Technology (CCI) giving excellent protection in areas of high humidity and temperature. In conventional oils and greases, molecules lack polarity allowing oxidizing elements to permeate results in corrosion and rejection. Protection products with polar molecules create a barrier and do not allow any oxidizing elements to permeate which will increase the lifespan of a part, as well as reduce maintenance and replacement costs. Vehicle bodies are constantly threatened by rust due to weather conditions peculiar to India, such as high temperature, humidity as well as salt damage due to seawater and tidal winds at coastal areas. Corrosion failure can occur despite other paints and coatings applied by the OEM’s. CCI waxes and coatings with polarity can provide long term protection to vehicle bodies. Pack Export packaging, OEM and JIT packaging, packaging for the replacement market, in process protection, long term preservation require the usage of VCI products. The main benefits of the VCI Technology lie in its ability to self-apply and dissipate and it is based on the combined principles of polarity and volatility.. When metals are in the vicinity of VCI products, the chemicals volatize in the ‘enclosed’ environment and form a protective molecular layer, which prevents moisture, salt, dirt, oxygen and other materials from depositing on the metals and inhibits corrosion. There are two main product categories VCI Papers and VCI Film. The technology is based on the concept of volatility and polarity, where volatile “V” components are added to Corrosion Inhibiting “CI” Components. The VCI molecules align on the surface of the metal to a depth of 3-5 molecules and form a layer. This layer makes the surface passive and creates a barrier that prevents oxidation resulting in corrosion prevention for the required period of time In addition to the VCI Technology as mentioned above, DAUBERT VCI Films are manufactured using a special multi-layer technology, which exceeds in performance in comparison with other available VCI Films in the market. The three layers are A. Moisture Barrier Layer, B. High Strength Layer and C. VCI Protection layer.
The ‘micro-emulsions’, visually appear to be translucent, or even transparent and have inherent advantages of providing clean appearance, excellent corrosion protection, long life of cutting fluid, and cooling capabilities, good wetting properties and emulsion stability.
Following are the factors that influence the effectiveness of VCI Products Quality of Corrosion inhibiting chemicals and their effectiveness on the metals. Water solubility/effectiveness of the corrosion inhibitor in the presence of moisture and/or high humidity. Ratio of chemicals in the formulation or Amount of VCI on the carrier (paper, poly, etc). Carrier (natural neutral kraft paper or polyethylene film) used. The overall packaging design and the conditions expected during packing, shipping and storing. The chemicals industry sector is one of the most regulated (REACH, GHS/CLP, OSHA) as regards to the health, safety and environmental (HSE) protection, as well as climate change and energy issues. On the other hand, the users need cost effective high performance solutions which are in tandem with their own product technology advancements. The impetus is on the chemicals partner to provide a systematic approach in identifying and developing suitable solutions in tune with today’s quality and environmental responsibilities. It can be seen in the metal working fluids technologies moving to products based on natural gas, the cleanestburning fossil fuel which is affordable, available and environmentally acceptable.
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Primer | TECHNOLOGY
FIPFG – What’s that? The sealing world is huge and manifold. The reason for it is simple: in our highly industrialised world, the electronic and technical components need to be sealed in the best way as to maintain their functions. Hereby the interplay of the part to be sealed and the sealing is essential, in particular construction and stability of the part as well as adhesion of the sealing on different surface materials. One sector in the world of sealings with growing importance is represented by the liquid 2-component foam sealings and potting compounds for encapsulation of elements. Today they can be found in various applications from car building, electronics, switch board cabinets, air filters, packaging, household appliances to lighting and photovoltaics.
Finished aluminium printed part (Hinge)
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ue to the globalisation of production Sonderhoff’s foam gasket solutions are used by industrial suppliers to seal their parts in many countries worldwide. For instance, structural components and modules that are used in the automotive manufacture must remain tightly sealed after their assembly. The reason is obvious: the interior space must be dry and clean and humidity and dust must be excluded, because such influences can easily become a risk for the safety of the car and the driver. Sonderhoff offers a broad range of various 2-component foam sealings and potting products with optimal protection against moisture, dust, temperature, chemistry, lubricants or other substances. They also help to temper vibrations. Automated process for application of fluid sealings The 2-component foam sealing products from Sonderhoff Chemicals (Cologne/Germany) are polyurethane based FERMAPOR K31 and silicone based FERMASIL. They are applied directly to the part in a fully automatic procedure – the so called FIPFG (formed in-place foam gasket) technology. It involves using a dispensing machine from Sonderhoff Engineering (Hörbranz/Austria) with a mixing and dosing head for the sealing application which is moved by the CNC controlled three-axis
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2D application on a level surface
2D application in a groove
3D application on a level surface
3D application in a groove
Examples for FIPFG applications:
Power distribution: Part of a switch board enclosure door
linear robot. Alternatively, a part handling six-axis robot guides the part under a fixed mixing and dosing head. A chemical reaction then causes the liquid material to foam up and generates a seamless gasket as a result. Even the most complex construction element shapes and the smallest grooves do not represent obstacles. For flat sealing surfaces without grooves and even on vertical surfaces it is possible to apply foam gaskets if they have a paste-like consistency due to high material viscosity. Advantages of FIPFG technology for the benefit of an economic production The FIPFG technology is compared to the traditional way of manual insertion of rubber seals (EPDM, TPE, NBR) efficient and very economic. The advantages are a constant sealing quality with a steady seal height. Further advantages are a high degree of process reliability at fast production speeds. This leads to cost savings as well as lower cost of personnel through a higher degree of automation. With FIPFG the material costs are
Automotive: cover of a drive belt cover
Lighting: housing of a moistureproof luminaires.
very low because raw materials can be utilized up to almost 100%. There is no material waste as is the case with prefabricated inserted rubber seals that cause punching offcuts. FIPFG-sealings perfectly adhere to many different surfaces of industrial parts and great variety of shapes including three-dimensional geometry. Foam sealings, which are compressible in itself, have utmost elasticity in order to compensate gap dimensions. In addition, the customer has the possibility to adjust the degree of hardness by varying the material mixing ratios and to change seal height and width by different dosing output. Mutual influence between part construction and sealing Amongst over 1000 Sonderhoff formulations the right selection of seal material is essential to correspond to the individual operating conditions of the part and the particular customer requirements. Hereby it is important to know that the part and the sealing need to be considered
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PRIMER | TECHNOLOGY
Sonderhoff Mixing and dosing system DM 40x with mixing head MK 600
as an entity that has to achieve the required seal effect together. That can be examined by numerous test and protection standards, as for instance, NEMA 4 und 12, IP- protection up to class 68, UL50/50 E, UL 94 HF1/HF2 or FDA conformity. Thus, the right choice of gasket material is determined by the construction of the part and
its specific operating conditions. It, therefore, makes sense that the design engineer takes into account exact position and geometry of the sealing at the earliest possible date of the product development. He needs to consider whether a sealing groove would be necessary or how inclined contours can be best sealed. Taking all into account, the FIPFG technology with the use of a Sonderhoff mixing and dosing system is an efficient and economical application procedure. As a result the 2-component technology FIP (Formed In-Place) for potting and FIPFG (formed in-place foam gasket) for foam sealing has become the industry standard in many fields like switch board enclosure, electronics, automotive, air condition, filter, photovoltaic, packaging or household appliances.
Company Portrait The Sonderhoff group of companies with its headquarters in Cologne / Germany is the leading system supplier and manufacturer of polymer sealing, gluing and potting formulations, dispensing machines and automation concepts as well as for contract gasket application services. The Sonderhoff System combines chemical and technical competence with creative engineering know- how in the fields of mixing and dosing of sealing material and process engineering provided with a comprehensive service entirely focused on satisfied customers. The sealing products from Sonderhoff are used for foam gasket, gluing and potting applications of various industrial components, for instance, from the switch board enclosure, electronics, automotive, air condition, filter, photovoltaic, packaging or household appliance industry. Sonderhoff Chemicals GmbH (Cologne / Germany) develops, produces and distributes worldwide polymer sealing, gluing and potting systems on polyurethane, silicon and PVC basis. Their performance is based on the experience of more than thousand formulations. The sealing material is applied onto structural components and modules of OEMs and industrial suppliers by the FIPFG / FIP (Formed In- Place Foam Gasket / Formed In-Place) technology. Sonderhoff Engineering GmbH in Hörbranz / Austria develops and distributes all over the world low pressure metering systems, from stand-alone dispensing machines to automation concepts according to customers’ specifications for fully automated production lines of foam sealing, gluing and potting. Sonderhoff Services GmbH (Cologne / Germany) and Sonderhoff Polymer-Services Austria GmbH (Dornbirn / Austria) have positioned themselves as toll manufacturers for foam gasket, gluing and potting applications with the highest precision. Their services comprehend individual sampling of prototypes as well as sealing, gluing and encapsulation of parts, from pilot application processes and small batches up to serial production for OEMs and industrial suppliers in Germany, Switzerland and Austria. Partner companies undertake the contract manufacturing of foam gasket and potting for the customers in Great Britain, Poland, India, Thailand, Japan, Korea and Brazil. The sister companies of the Sonderhoff Group in Italy, Spain, the U.S.A and China offer the complete range of sales, technical and contract gasket application services to the OEMs in these countries as well as production and sales of chemicals for the sealing formulations and the distribution of dispensing machines from Sonderhoff. Sonderhoff (Suzhou) Sealing Systems Co. Ltd., located in the Singapore Industrial Park (SIP) in Suzhou and part of the Sonderhoff group of companies, started its business in 2009 and has successfully grown since then. Sonderhoff in Suzhou is responsible for the exclusive sales and distribution of the Sonderhoff product range in China, from sealing and potting material to mixing and dosing machines. It also offers contract manufacturing services for foam sealing, gluing and potting. Sonderhoff Suzhou is prepared for technical services, machine maintenance and supply of spare parts. The systematically acquired application knowledge, more than 1000 formulations and the innovative power of the entire Sonderhoff group guarantee absolute customer orientation, tailor-made products and solutions in line with market conditions.
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Primer | PROCESS
Enhancing the Additive Manufacturing Process Chain The design freedom provided by additive manufacturing (AM) or ‘3D printing’ technology is an important enabler in cutting-edge product innovation. As part of the revolution in digital manufacturing, AM can radically simplify the production of complex parts, while simultaneously improving functional performance, reducing part weight and minimising component counts. Finished aluminium printed part (Hinge)
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The Background The 3DEXPERIENCE platform comprises a whole suite of 3D software applications to support complete product life cycle, from design and development to simulation and reliability analysis. Available to users on premise or oncloud, and accessible via a single user interface, it enables the creation of ‘social enterprises’ where collaboration in the product innovation process becomes simpler and more efficient. Topological optimisation is a key step in the manufacturing of 3D parts which ensures optimal material usage within a defined space. Dassault Systèmes’ CATIA applications for generative design assist in product modelling powered by the 3DEXPERIENCE platform. Dassault Systèmes’ companion DELMIA software application then enables users to design and test products in a simulated production environment. Importantly, the software manages product build set-up and the generation of laser (scan) tool paths required by the AM systems.
Simulation of the complete AM build process, including full product stress analysis and distortion prediction, is carried out using the 3DEXPERIENCE platform’s simulation application. Dassault Systèmes, a world-leading provider of 3D design software, 3D Digital Mock Up and Product Lifecycle Management (PLM) solutions, collaborated with Renishaw to streamline its 3DEXPERIENCE® platform to deliver a nocompromise end-to-end AM design experience. Renishaw employed a broad range of its state-ofthe-art precision manufacturing and metrology products for characterisation of the build process, design validation and automated process control of a final subtractive machining operation. These products included the flagship RenAM 500M metal additive manufacturing systems with laser powder bed fusion technology, QuantAM build preparation software, machine tool probing systems, EquatorTM gauging systems and CMM with REVO 5-axis measurement system. These, combined with the 3DEXPERIENCE
CATIA product design (Hinge)
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platform’s applications, delivered a seamless AM process and the end-to-end manufacturing solution required. To take full advantage of AM’s unique capabilities, however, complementary software tools need to be optimised to satisfy the new requirements of ‘design for additive manufacturing’ (DfAM) rules and guidelines. The Challenge The key challenge faced by Dassault Systèmes and Renishaw engineers was to achieve alignment of their respective virtual and real worlds - of 3D design, test and analysis software and metal 3D printing. Software needed to follow real AM build rules. The collaboration aimed to rationalise the AM design and manufacturing process so manufacturers can move away from an expensive ‘design – build – test’ approach to a ‘right-firsttime’ approach. More specifically, the project’s ultimate objective was to remove any need for the export of native CAD source files in a universal .STL triangulated file format – an export long proven to introduce manufacturing errors and a prime cause of loss of quality control in successive product versioning. The Solution Using 3D design innovations in the automotive industry as a demonstration and test mechanism, this software enhancement project was based around the design and manufacture of a futuristic door hinge for Dassault Systèmes concept car, Bleu.
Like Renishaw, Dassault Systèmes is committed to providing solutions which simplify the integration of 3D design and printing technology into all manner of production environments. This common thinking was instrumental in the project’s success. Dassault Systèmes provides the functional generative design and physics-backed manufacturing simulations which are a key part of the metal 3D printing process chain. Subham Sett, Director of Additive Manufacturing and Materials, SIMULIA, Dassault Systèmes
A complex, lightweight, double-wishbone type component, the hinge presented Dassault Systèmes and Renishaw engineers with an authentic production scenario demanding close attention to structural optimisation, multimaterial design and part consolidation. Working within the 3DEXPERIENCE platform, a radical 3D hinge design was produced using the CATIA generative design capabilities. Associated tool paths generated by DELMIA applications were imported into QuantAM for additional processing prior to handover to the RenAM 500M system. Following an iterative, closed-loop sequence of hinge design adjustment, simulation, printing and precision inspection, the specific AM build rules that needed to be integrated within the 3DEXPERIENCE platform’s software to achieve optimal hinge 3D design and printing were determined. Renishaw made an application programming interface (API) for its QuantAM software available to Dassault Systèmes for integrating with the DELMIA application leading to the generation of right-first-time 3D printing tool paths. The Results As a result of the collaboration between Dassault Systèmes and Renishaw, 3DEXPERIENCE platform users can now print directly to the complete range of Renishaw AM systems from within the existing native CAD environment. The need to export data files to an external system for additional postprocessing has been eliminated, thus reducing errors, time and cost for manufacturing. The enhanced CATIA, SIMULIA and DELMIA applications mean that innovative 3D product designs are now automatically optimised for both, manufacturing on Renishaw AM systems, and end functional performance. As a result, parts are produced more accurately from the outset, bringing lead time and material cost savings. The conceptual hinge for the ‘Bleu’ concept car also provided further real-world evidence of the benefits to be achieved by 3D design and printing. While in this case, the original and optimised part volumes were virtually identical, all the support structures were removed from the hinge design, creating a more elegant, more reliable and yet far simpler automotive product.
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Case Study | SUCCESS STORY
Verifying the Impossible How Connecticut-based Mallory Industries utilized Mastercam 2017 to take on complex aerospace projects and expand its customer portfolio.
With stock recognition, Mastercam knows where the material is which allows the software to make good decisions relative to tool paths. It certainly makes it easier,” said Fogler. They are able to push their machines to their full capacity by knowing what the machining process will look like through Verify and by relying on the toolpaths’ to cut time-consuming air cutting.
M
allory Industries, Inc., is an organized precision machine shop. The Farmington, Connecticut-based shop has two sides to its business: Aerospace and Commercial. Its 22,000 square foot shop is divided into three areas based on machine capability. It all certainly helps when Operations Manager Ken Fogler and his team receive orders for three-dimensional CAMS for the aerospace industry
as opposed to say CAMS for presses and pumps for the oil industry. But, when it comes to taking on unusual or large-sized jobs for either side, the team’s ability to verify that its machines can handle the work via its CAD/CAM software allows them to accomplish jobs they never thought possible. Founded in 1956, Mallory Industries specializes in grinding, high-speed vertical milling, CNC turning, and wire EDM machining of stainless steel, aluminum, titanium, and high-temperature
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alloys. Over the past few years, the company has invested heavily in its machinery, adding three high-speed vertical mills with full rotary tables that can handle parts up to 20-in. diameter, a twin-pallet horizontal machining center, two multiaxis lathes, and the wire EDM machine. While it’s daunting to spend hundreds of thousands of dollars in capital expenditures of this sort, the folks at Mallory look at it as a calculated risk because they could verify a part’s ability to be machined, prior to it actually being put through to the machine due to the Verify utility of its CAD/CAM software, Mastercam (from CNC Software). “When we quote jobs, we look at how we’re going to machine it, the process to do so,and then program it to go through these machines,” said Fogler. Whether the part goes through the multiaxis lathe area of the shop (there are two which combine milling and turning), the 3or 4-axis machining center area, or the 2-axis cell area, depends on the constraints of the machine itself. Jobs are modeled in SOLIDWORKS and imported into Mastercam, where the wireframe geometry is created. “We verify the final program in Mastercam so that we’ll see exactly what will be produced with no surprises. The Verify feature allows us to detect any discrepancies, measure and analyze, as well as provide collision detection. With
Operation Manager Ken Fogler updates one of several production scheduling boards located throughout the shop.
the cost of today’s equipment, I wouldn’t do it any other way. Once we know it all looks good on the computer, we’ll post it and send it out to the floor,” said Fogler. Black Hawk On-Screen Fogler and his team use Mastercam 2017, which not only includes the software’s Dynamic Motion technology, but also radial chipping which they were doing manually on the side via spreadsheet. “You can certainly get a program out quicker than in the old days using some of the advanced tools that the software has to offer,”he said. “And Verify helps us out a lot.” The team programs the part and then cuts it on the screen in one form via two modules – one for programming and one for verifying that the toolpaths will, in fact, work in real life. “It helps us on our end to know that what we see on the computer, we will see out on the floor so there are no mysteries,” said Fogler. The ability to run the machines fast and perform a virtual run prior to the actual run has given Mallory the edge when taking on complex aerospace projects. One of their favorite jobs involved the dashboard frame for the Blackhawk helicopter, an exceptionally large piece that was machined in several steps. “We had a couple of
Mallory continues to use the same end mills, drills and other tooling they have always used because they simply do not break when they are constantly engaged with the material and adjust to programmed changes in geometry. They are saving costs on consumable items and scrap–and even human resources–while realizing better throughputs and cycle times.
Jobs are modeled in SolidWorks® and imported into Mastercam software, where the wire frame geometry is created. “We verify the final program in Mastercam so that we’ll see exactly what will be produced with no surprises. The verify function allows us to detect any discrepancies, measure and analyze, as well as collision detection. With the cost of today’s equipment, I wouldn’t do it any other way,” said Fogler pictured here programming a toolpath for a CAM product.
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The ability to run the machines fast and perform a virtual run prior to the actual run has given Mallory the edge when taking on complex aerospace projects such as this CAM and aerospace shaft.
CNC Programmer Jawael Velasquez and Machinist Marc Lassy discuss a job with Fogler.
programmers working on it,” said Fogler, “and, because it was so massive, we worked on one side and then the other, creating a program, verifying it, using the Dynamic toolpaths. We programmed one half, then the other, and merged it all together at the end, but we were all verifying on the screen exactly what we were doing and the final product was a good product right off the hop.” Fogler noted that while the process was tedious, it was flawless and was not possible without the Verify and Dynamic Motion toolpaths available within the software. The part was machined using one 3-axis machine. They started with a 6’x2’x1” thick piece of aluminum weighing 275 lbs., and implemented the toolpaths for the very first time. The Dynamic Motion toolpaths removed the material quickly, due to proprietary algorithms in the software that intelligently sense changes in the material, allowing the tool to remain in constant contact with the material with little or no stepovers. Because the tool is constantly engaged with the material, there are fewer tool
breakages as well. The team was able to whittle that piece down to 9 lbs. “You don’t have to go old school. With stock recognition, Mastercam knows where the material is, which allows the software to make good decisions relative to toolpaths. It certainly makes it easier,” said Fogler. They were able to push their machines to their full capacity by knowing what the machining process would look like through Verify and by relying on the toolpaths’ to cut time-consuming air cutting. Confidence to Perform Dynamic Jobs The team was also able to accept jobs they otherwise would never have considered because the risks to the machines were minimized. For example, when a $400,000 to $500,000 machine gets “banged up”, the costs to repair include a service call, and often, a $30,000 to $40,000 spindle. The software functions gave the team more confidence to produce a better product in less time. “Because this is a very capital-intense business, you have to take care of the equipment by managing the software. So, the more we know about the software, the better our results are on the floor,” Fogler said. They rely on their Mastercam Reseller, MACDAC Engineering, Inc., for training and support. “I think it is foolish not to have that support because sometimes you have projects that, if you didn’t have that support, you would not get them done,” said Fogler. He finds MACDAC’s expertise especially helpful when working with 3D models. It would seem that when pushing the machines faster, and cutting large swaths of material down to smaller sizes, tool costs would go up. Not so. Mallory continues to use the same carbide end mills, carbide drills, and other carbide tooling they have always used because they simply do not break when they are constantly engaged with the material and adjust to programmed changes in geometry. “When you break an end mill, not only is
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there cost associated with that, but the part may be scrapped and the machine goes off line. All these problems compile the cost,” said Fogler, noting that they are saving costs on consumable items and scrap – and even human resources - while realizing better throughputs and cycle times. The shop’s current job board is about three fourths full with new orders. Investing in the Future Recently, Mallory was recognized as one of 11 employers nationally as a Young Adult Employer Champion by the National Fund for Workforce Solutions. The Fund’s mission is “to drive practices, policies, and investments that enable workers to succeed in good jobs, provide employers with a skilled workforce, and build more prosperous communities”. The Hartford, CT-based, Our Piece of the Pie, has partnered with the fund to help
urban youth learn the educational, employable, and interpersonal skills necessary to gain and retain employment through relationship-centered internships and programming. According to Fogler, the internships serve to help the students decide whether manufacturing or engineering is the right career path for them. “I have interns from local high schools in every year trying to decide whether they want to get into engineering or not.” They are also committed to the future of manufacturing. If they can encourage these kids to get the proper training and education to replace the skilled labor that they know will be retiring soon, manufacturing will stay strong. The company has retained some of these students throughout the years, with some staying and some leaving to pursue four-year degrees. The company’s ability to take calculated risks with its current manufacturing capital, as well as its future human capital, have yielded just rewards.
The team programs a part, such as this aerospace lever, and then cuts it on the screen in one form via two modules – one for programming and one for verifying that the toolpaths will, in fact, work in real life.
The software functions give the team more confidence to produce a better product in less time. “Because this is a very capital-intense business you have to take care of the equipment by managing the software. So, the more we know about the software, the better our results are on the floor,” Fogler said.
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When a Recommendation Bears Fruit Almost five million people live in and around the Indian city of Pune. The industrial city in the western part of the country is known as the “Detroit of India“ because of its high concentration of automotive manufacturers and suppliers. These include TRIA Industries LLP, a small company that is meeting its customers‘ demanding quality assurance requirements thanks to the ZEISS O-INSPECT multisensor measuring machine.
O
riginally called Ishan Industries until a merger in 2014, the company has been active on the Indian market since 1995, particular in the areas of
development and production. In the past years TRIA Industries LLP, a company in the TRIA Group, has also gradually expanded to include the international market. Today it supplies a wide variety of precision components in India and
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The software is extremely user-friendly and makes measuring a breeze. It provides us with a clear overview of the most important measurement data in next to no time.” Lokesh Pihulkar Plant Head and Quality Manager TRIA Industries LLP
abroad, in particular for the automotive industry. The company‘s three facilities are all located in Pune. Here 150 employees work in two shifts to ensure 24/7 operation for the manufacture of different flanges and components for breaks
and engines. Their customers‘ top priority is uncompromising quality, and these days TRIA has no problem meeting these demanding standards. “But this wasn‘t always the case,“ recalls Lokesh Pihulkar, Plant Head and Quality Manager. Customer requirements have continued to increase over the past years, and these days narrow tolerances of three or four micrometers are often the norm. “We reached the point where we could not longer always guarantee this level of precision with the tools at our disposal and were unable to accurately measure all the parameters of our components,“ says Pihulkar. This challenge was particularly acute in the production of different flanges where each single detail counts so that everything runs smoothly
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We received excellent service from ZEISS and have a contact person right here in Pune. Referencing ZEISS has helped us come into contact with potential new customers.” Kedar Gowande Director - Operations TRIA Industries LLP
in the vehicle‘s powertrain. Previously, visual checks using gages were the primary means of checking precision and, due to the increased requirements, the number of rejects identified during inspection was growing – a real problem for TRIA. “We knew we had to change things and reduce the number of rejects,“ says Pihulkar. The company‘s close connections to their largest customer Continental helped Pihulkar and TRIA in their search for a solution. “Together we discussed the problem and how to solve it. Our customer gave us some valuable tips,“
recalls Pihulkar. And that was how the initial contact to ZEISS was established in 2015. A valuable tip After ZEISS was suggested as a potential solutions provider for TRIA‘s metrology quality requirements, everything happened quite quickly. At the IMTEC trade fair, which is held regularly in India, Pihulkar and Director of Operations Kedar Gowande contacted ZEISS directly and a decision was made on the same day to purchase a ZEISS O-INSPECT multisensor measuring machine.
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Now TRIA can perform both contact and optical measurements using their new ZEISS system. The ZEISS O-INSPECT shows off its strengths when measuring small to minuscule automotive parts, making it the perfect choice to accommodate TRIA‘s requirements. “We received excellent service from ZEISS and have a contact person right here in Pune,“ says Gowande. TRIA produces 10 to 15 different flanges, and on average approximately 15 features are measured per part. The ZEISS O-INSPECT enables ultraprecise probing thanks to probing forces in the millinewton range. This ensures true 3D measurements that provide clear information and form and location tolerances so that measuring engineers at TRIA meet their customers‘ exacting standards. “The system accommodates our needs perfectly,“ says Gowande. “We are proud to have a ZEISS O-INSPECT in our measuring lab. Of course we checked out the competitors‘ machines before making our purchase, but opting for ZEISS was ultimately an easy decision, says Gowande. He explains that there were ultimately three decisive reasons why the company decided to purchase the ZEISS machine: “First, and this should come as no surprise, there was the excellent reputation of the company and the brand; second was the professional reporting feature; and the third important factor was the recommendation from our customer who uses the same measuring machine.“ A significant reduction in rejects After purchasing the ZEISS O-INSPECT, the production process at TRIA has become significantly more efficient, and since then components are no longer turned down by customers. The rejection rate has also been drastically reduced: out of approximately 10,000 parts, just around 2% are identified as rejects. “We do not have any problems with the machine, everything is going great and our customers are pleased,“ says Lokesh Pihulkar. Four measuring engineers can currently operate the ZEISS O-INSPECT. ZEISS specialists in India instructed them on how to use the system and the accompanying ZEISS CALYPSO software. Quality Manager Lokesh Pihulkar sees this as the key to success: “The software is extremely user-friendly and makes measuring a breeze. It provides us with a clear overview of the most important measurement data in next to no time.“ A bright future The team at TRIA is impressed with not just the machine, but the entire package consisting of
Brief Profile
TRIA Industries LLP
the system, software and service. Yet as Director of Operations Kedar Gowande points out, the benefits do not stop there: “Referencing ZEISS has helped us come into contact with potential new customers.“ TRIA is already looking ahead to the future. It is expanding this year, and the construction of a larger production hall is already in the planning stages. This is where all three existing locations will be consolidated under one roof. TRIA‘s goal is to become an even more efficient one-stopshop to offer their customers optimum quality. Since the requirements in the automotive industry will likely continue to increase over the coming years, Quality Manager Lokesh Pihulkar and Director of Operations Kedar Gowande are already thinking about the next step in the area of quality assurance: “We have already considered 100% inspection and have our eye on another ZEISS product: the ZEISS O-SELECT digital measuring projector.“
The company TRIA Industries LLP is headquartered in Pune, India and manufactures and supplies SAE flanges, oval flanges, tube fittings and caps, hydraulic fittings as well as hot and cold forging components. These products are primarily used in the machine and automotive industries. Currently approximately 150 employees work at three sites in Pune.
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Exceeding Expectations
The Hainbuch mandrel holds rock solid and is absolutely accurate in the process.
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The Hainbuch Project Team [L-R] Thomas Helfer, Hainbuch Representative , Ilse Tresselt, Purchasing Manager at Steinel, Michael Tresselt, Process Developer at Steinel, and James Hepfer, Turning Shop Supervisor at Steinel.
When Steinel needed to improve its manufacturing flexibility, Hainbuch stepped up and excelled – and made many friends in the process.
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teinel Normalien AG, the Germanybased specialist and system provider in the stamping and forming industry, imposes the most rigorous requirements on manufacturing in terms of accuracy. In the course of permanent process optimizations, thanks to a new machine concept, and through the selection of suitable clamping devices, Steinel was able to significantly reduce its set-up and throughput times. Previously, the company was not as flexible as desired when it came to the huge effort involved in change-over from the jaw chuck to other clamping devices. Thankfully, those times are gone for good. With the new turning and milling center, the new clamping devices from Hainbuch, and a well-thought-out turning concept, Steinel manufacturing flexibility has been increased significantly. Now a wide variety of parts can be machined and work steps can be omitted. Thanks to the new concept systematically planned by
Steinel, it was possible to replace three machines to only one machine. It Started With A Routine Visit For Steinel’s two executives responsible for the project, Michael Tresselt, Head - Process Development and James Hepfer the Shift Supervisor of the turning shop, it was about time to rethink the entire machine concept. The idea was to replace the previous lathe and two other machines. The two were in agreement with the usefulness of the new machine and the clamping devices. That was the day when Thomas Helfer, a sales representative of Hainbuch dropped by at Steinel for a routine visit. Both men are very satisfied with the clamping devices and clamping heads from Hainbuch, which were already in use at Steinel. However, in this case a significant investment was involved and Tresselt and Hepfer were not entirely convinced of the solutions they had previously browsed.
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The quick change-over systems and the clamping devices are stowed safely and cleanly.
Then There Were Two Tresselt reports: “We then prepared an evaluation matrix of the quick change-over systems on the market. After a more precise test, Hainbuch’s flexible and highly accurate clamping devices convinced us.” In particular Hainbuch scored high particularly on the score of resilience against contamination and repeatability. Hepfer explains the difference of the two change-over systems: “With Hainbuch’s competitor, the system works via pull, with Hainbuch’s system you do have to turn screws, but the clamping device is more accurate and rigid. There are only six screws and they only must be loosened slightly, that’s why the process gets over quickly. The competing product has problems with its contamination-sensitivity. Even if tiny dust particles get in the system, the accuracy and rigidity suffer. The Centrotex interface from Hainbuch completely convinced us.” Tresselt adds: “For change-over accuracy, Hainbuch specifies two µm. This is absolutely important for us. With
our workpieces we have strict parameters that we must keep. When it comes to quality, whether standard products or customized solutions, we keep our standards high. We guarantee premium products with the highest quality. Moreover, with Hainbuch we get everything from a single source. With the Centrotex quick change-over system on the main and sub spindle, in combination with the hexagonal Toplus chuck size 100 and a size 260 jaw chuck, we get extreme flexibility and everything is interchangeable.” Another Challenge. Solved. By this time, the right clamping devices had indeed been found for the manufacturing of highprecision and durable guides, as well as pneumatic springs. But in addition, the cubic cast parts with interrupted cuts also needed to be manufactured on the new machine. These had been complexly manufactured on the two other machines with jaw chuck processes. Hepfer recalls: “First the parts
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considering what other workpieces we can clamp with the mandrel.” Big Savings Steinel places a high priority on flexibility. That makes sense, because the lot sizes for the standard cast parts and the pneumatic springs are small. However, with the new concept, Steinel wants to further reduce lot sizes in order to respond even more effectively and with greater flexibility to customer requests. Tresselt says: “When the new programs run optimally on the machine and the employees have a certain level of assurance, we will be able to reduce the lot sizes. For our employees, the handling with the new clamping devices works perfect. We have also purchased the compatible Monteq changing fixture and two storage containers, so that everything is cleaned up and available to the employees.” And to top it off, Hainbuch conducted a training course dedicated to set-up processes. Tresselt comments: “The training courses at Hainbuch are really great – the employees always come back with wonderful ideas, and immediately put into practice what they have learned during the course.”
The training courses at Hainbuch are really great – the employees always come back with wonderful ideas, and immediately put into practice what they have learned during the course.
were turned and then milled. This meant setting it up two times. Hainbuch recommend a mandrel for this clamping situation. We gave Hainbuch a sample part for a turning trial.” Tresselt states: “We were not sure whether with the Mando mandrel the workpiece would deliver on what Hainbuch had promised. But we were surprised at how tightly, rigidly and accurately the mandrel performed. We saved ourselves one operation, as well as the change-over time. This significantly shortened the through-put time, and the parts could also be machined very easily thanks to the minimal interference contour of the mandrel. We like the Mando system a lot, and now we are even
Service is the highest priority For Tresselt, in addition to all the savings and advantages associated with the clamping devices, the most important outcome was the outstanding support they received from Thomas Helfer. “If we have a problem, we can count on Hainbuch. Moreover, Hainbuch provides us with free parts, so we can run our trials. Before we decide and order, we like to check and test everything. Therefore, we are re-ordering the same clamping devices from Hainbuch for two other machines with bar loaders, so we can swap out over all three machines.” notes Tresselt. Brand Steinel The brand Steinel represents a family-run company in Villingen-Schwenningen, Germany with a rich tradition. Steinel Normalien AG was founded in 1925 by Bernhard Steinel. Today Steinel has approximately 150 employees and offers 25,000 different stock items and catalog products as well as tool manufacturing in the progressive composite technology and Bihler technology. Steinel pneumatic springs and composite systems are highly durable alternatives to conventional system springs in the punching and bending tool area. They deliver incredibly high forces in a minimal space. In addition to a broad standard assortment, Steinel also offers customized adapted products, as the only producing manufacturer in Germany.
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Primer | PROCESS
Seco Tools strikes a win-win with Hermle machines
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Established in 1988, Seco Tools India is an export oriented unit (EOU) supplying state-ofthe-art tooling solution to the global market. The company’s facility in Pune manufactures metal cutting tools besides inserts and carriers. Every year the facility and capacity at the manufacturing unit are being increased with special production unit catering to local customers.
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eco Tools India has been using Hermle machines at its manufacturing facility ever since the commencement of the unit. Explaining the reason behind this, Atul Mohkhedkar, General Manager (Production) of Seco Tools India said, “Choosing Hermle as our machining partner was easy. We are following the standard machine specifications and Hermle is one among them.” Technical Benchmark Mr Mohkhedkar added, “While selecting the machine, we conducted technical benchmarking. We looked into the thermal stability of the machine, reliability of operations, support availability and track record of the supplier within Seco and the entire industry. Since Hermle has special polymer concrete base, the thermal stability is good. Our workshop is exposed to almost 10 degrees of temperature variation in 24 hours and Hermle machines maintain the same. This prompted us to zero in on Hermle.” Mr Mohkhedkar further noted that the reliability of Hermle machines has helped in maintaining the accuracy. He also gave props to the support from Hermle’s local office. Beyond Sales A Seco tools official averred that since Sico manufactures different components, the tolerance level varies. “On Hermle machines, it
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varies from 4 microns to 30 microns which is well within our expected tolerance level. Even process capability is well maintained on these machines,” he said and added that with Hermle promises reliability of operation and process capability. “If we require after-sales service, Hermle’s support from Germany as well as local back office is very prompt and good.” he said. When asked about Hermle’s service support backup, the official said, “Once we had a major problem in the machine. When we discussed it with Hermle officials, they deputed one of their engineers from Germany who reached our manufacturing facility on the very third day. Their
team is always there as and when required and we are satisfied with the service backup.” Satisfaction Guaranteed “Since it was Seco that marked the start of Hermle’s sales in India, the machine manufacturer gives primary supplier benefit to us. Even the availability of local service is good. Even as breakdowns in the machines are limited, their service engineers visit us whenever we call them. Even the competency of the people as well as company is good and service documentation is extremely proper that creates very less problems in the machine,” Mr Mohkhedkar added.
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Choosing Hermle as our machining partner was easy. We are following the standard machine specifications and Hermle is one among them.” Atul Mohkhedkar General Manager (Production) Seco Tools India
When asked whether Seco is satisfied with Hermle’s performance, the official replied: “Yes, we are really satisfied. Interaction between Seco and Hermle will be as it is and will increase yearafter-year. We are looking forward for better and improved support from Hermle in the future,” Mr Mohkhedkar concluded. Partners in Growth Noting that Hermle is a market leader in 5-axis machining centres, Mr Maximilian Waizenegger, the Regional Sales Manager of Hermle Machine Tools, said that Seco Tools is using the machining centres developed by Hermle since past many years and are satisfied with the performance of the machines. “For Seco, using Hermle 5-axis machines has been a great experience since the rotary table is very rigid and reliably designed. This is one of the reasons why we are market leaders,” he said. Elaborating on Hermle-Seco partnership, Mr Waizenegger said, “Seco is most important for us. In India, we share a strong relationship. Hermle started supplying machines in India after Seco purchased these machining centres. We also
share a good relationship with Phillips Machine Tools India. We have a good product and the machines are reliable that helped us develop long standing relationship.” “The most important thing is that we are able to give prompt after-sales support and remain close to the customers, which is very important for Hermle. Even Seco has approved the kind of support they are getting from Phillips Machine Tools India. Now we have to convince others and establish ourselves more in the Indian market,” he said. “Now that we have Phillips Machine Tools as our partners in India, the spare- part support will be good. Our machines are 100-percent manufactured in Germany and the target is to maintain the quality of the machines. I think the one reason why people are buying Hermle machines in India is the availability of technical support and training locally. We have to maintain customer relations. We believe that the quality of after-sales service reflects in the quality of machines and are happy to partner Phillips Machine Tools India in this endeavor of ours,” Mr Waizenegger concluded.
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COMPANY INDEX Association of Manufacturing Technology Bosch Ltd C G Tech CNC Mastercam Dassault Systemes
21 10 20,21
51 to 53
Delmia Software
52,53
DMG Mori
28,29
Dr. Mark Goulston EMO Hannover 2017
32 to 35 8 to 12
Esponsorama 25 German Machine Tool Buiders Association (VDW)
9
Hainbuch
62 to 65
Hermel Machines
66 to 69
Industry 4.0 Mallory Industries
12 54,55
Marposs 30,31 Ministry of Heavy Industry & Public Enterprises
10
Mitsubishi 14 Motul Tech
25
Okuma 18 Philips Machine Tools India Renishaw Sahajanand Laser Technology Sandvik Coromant
69 22 to 24, 52, 53 37 to 43 14
Schuler 26,27 Seco Tools Shenzhen Runtianzhi Digital Equipment Co. Ltd. (SRDEC)
16, 66 to 69 23,24
Sonderhoff
48 to 50
Steinel
62 to 65
Tata Advance Materials Ltd
Vo l u m e 1 – I s s u e 1 M U M B A I
J u l y / AU G 2 0 1 7
14, 54 to 57
10
Thyssenkrup 26
IMPRINT Managing Director / Publisher: Preeti Mishra E: preeti.m@meshmixmedia.com M: +91 9820488203 Editor: Preeti Mishra E: editorial@meshmixmedia.com / meshmixmedia@gmail.com Creative / Production / Technical: MeshMix Media Team E: advertise@meshmixmedia.com / creative.meshmix@gmail.com Sales & Marketing / Content Supported by: MeshMix Media Private Limited Apna Media Administration: Sr. Admin Manager: Ekta Jagasia accounts@meshmixmedia.com M: +91 9324595918 Place of Publication: Meshmix Media Private Limited # 63, Ruia Park, J. R. Mkahtre Road, Juhu, Vile Parle West, Mumbai, Maharashtra – 400049, India Editorial Office: Meshmix Media Private Limited # 1003, 10th Floor, C-Wing, Runwal Pearl, Off Ghodbunder Road, Manpada, Thane West, Maharashtra - 400607, India. Contact: +91 9324240965 CIN No: U74999MH2016PTC287532 Volume 1, Issue 1, Printed by Meshmix Media Private Limited, India
United Grinding
10
Zavenir Daubert
44 to 47
Zeiss
58 to 61
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Whether published or not, no material will be returned and remains the property of the publishing house, which may produce or reproduce deemed to fit. Advertisement materials are provided by the organizations and brands whose identification is published within the same
TRIA Industries
58 to 60
ADVERTISERS INDEX CG Tech DMG MORI
72
Dynamic Manufacturing India
15
Machine Insider
17
MeshMix Media
19
Motul Tech
13
Published and Printed by Preeti Mishra on behalf of MeshMix Media Private Limited Printed at Pentaplus Printer’s Pvt. Ltd. 20/1, 4th Main, 5th Cross, Industrial Town, Rajaji Nagar, Bangalore-560044, Karnataka, India and Published from 63, Ruia Park, J. R. Mhatre Road, Juhu, Vile Parle West, Mumbai, Maharashtra – 400049, India. Editor: Preeti Mishra
PMT Machine
71
Publishing frequency: 6 times per year
Haas 3
Zavenir Daubert
2
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