VOL 07 | APR 2016 | ` 100 www.efficientmanufacturing.in
Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong
EFFICIENT MANUFACTURING
EVOLVING LEAN PRACTICES
Road to lights-out manufacturing
FOCUS Casting & Forging EM - Interview Michael Bremer
President Cumberland Group – Chicago (p. 22)
P. 32
SPECIAL FEATURE Green manufacturing P. 52
Perfect, Precision, Progressive Machine Technology HYUNDAI WIA Machine Tools pours its whole efforts on every process of production and distribution, covering from self-reliant designing to manufacturing and after sales service.
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Aerospace companies must plan manufacturing earlier to reduce risks to program affordability. Smart Innovation Position Brief
&GGJDJFOU NBOVGBDUVSJOH XJUIJO CVEHFU BOE TDIFEVMF targets is an imperative for successful aerospace and defense companies. The “Product Realization� solution GSPN 4JFNFOT 1-. 4PGUXBSF QSPWJEFT BFSPTQBDF 0&.T and suppliers a process-driven solution to enable manufacturing decision-making earlier in the lifecycle. This closed-loop solution supports early manufacturing planning during the program pursuit and bid process to mitigate risks that could impact program affordability. Concept to Build – " TVDDFTTGVM QSPHSBN QVSTVJU requires selecting the concept design that not only meets functional requirements, but satisfies manufacturability. You must also prove concept viability to customers. With Product Realization, you gain greater confidence in your bid process by including manufacturability analysis of alternative concepts.
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E D I TO R I A L
E D I TO R I A L
Fueling the innovations Manufacturing is changing rapidly and growing exponentially. At the same time, the manufacturing industry finds itself on the cutting edge of technology, year after year, and 2016 is no exception. In fact, 2016 promises to be one of the most outstanding and innovative years for advancing manufacturing technology in history. At EM, it’s been our consistent efforts to bring forth the technology trends that are fueling the innovations and transforming the manufacturing world, and not surprisingly which are expected to impact the manufacturers. The Cover Story in this issue introduces the emerging technologies in machine tool condition monitoring by which the machine tool can continuously assess the current status of cutting and grinding variables and make commensurate adjustments in process. The Round-table this time discusses the long-term roadmap for reaching the optimum level of smart manufacturing, where the participants are talking on the current state of the factories in India. According to them, the concept, idea and smart technologies are available, but the execution is not widespread. It calls for increased focus and right strategies towards creating an environment for smart manufacturing. While the Market Trends section talks on the key trends likely to shape manufacturing in India, the Focus section discusses on how to make product development processes optimised in the casting & forging industry. Stay tuned to know more on how technology will radicalise the manufacturing landscape.‌!
EDITORIAL ADVISORY BOARD
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net Sonali Kulkarni President & CEO Fanuc India Satish Godbole Vice President, Motion Control Div Siemens Ltd S Ravishankar Managing Director DMG MORI India Vivek Sharma Managing Director Yamazaki Mazak India
Vineet Seth Managing Director India & Middle East Delcam Plc
Dr K Subramanian President, STIMS Institute, USA Training Advisor, IMTMA
N K Dhand CMD, Micromatic Grinding Technologies
Raghavendra Rao Vice President Manufacturing & Process Consulting Frost & Sullivan
Dr P N Rao Professor of Manufacturing Technology, Department of Technology, University of Northern Iowa, USA
Dr Wilfried Aulbur Managing Partner Roland Berger Strategy Consultant
Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
EM | Apr 2016
5
CONTENTS
Market
08
Management
NEWS
INTERVIEW 22
14
Focus
“We have a three part strategy for future roadmap of ThingsWorx�
CASTING & FORGING
“Eliminate waste, but create new value�
32
Interview with Michael Bremer, President, Cumberland Group – Chicago & Executive Director, the Chicagoland Lean Enterprise Consortium Group
Interview with Lau Shaw, VP – IoT Sales, ThingsWorx, a PTC business
Getting cast components right the first time
The feature discusses on getting cast components right the first time, to ensure that the product development processes are optimised, non-iterative and productive
TRENDS 28
Top manufacturing trends in India for 2016
The article highlights some key trends likely to shape manufacturing in India in 2016 and beyond EVENT REPORT 56
Opting German production technology
ROUND-TABLE 24
Roadmap for smart manufacturing
The round-table discusses how industries can strategise their roadmap to reach an optimum level of smart manufacturing
A post-event report on the VDW Symposia, recently held at Chennai and Pune 16
COVER STORY Road to lights-out manufacturing
The feature discusses factors like sensing technologies and software for machine tool maintenance to address the key challenges in machine tool condition monitoring
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CONTENTS
Technology
INDUSTRIAL ROBOTICS 36
A global model for tool selection
MANUFACTURING IT 44
The feature examines the advances in mechanics & controls that are enabling the practical and economical application of lightweight robotics for manufacturing on an increasingly broad scale
Development of 3D roll forming machines
The article discusses how to make use of modern CAE tools to analyse state-of-the-art research on 3D roll forming PLASMA CUTTING
GEOMETRIC DIMENSIONING & TOLERANCING 40
48
Effectively applying measurement data
The article explains how a well-defined dimensional engineering process enables collection and analysis of relevant, meaningful variation measurements at every stage
EM | Apr 2016
The many faces of plasma cutting
A read on the facts to be considered, while choosing mechanised or manual plasma cutting systems
New Products 61 3D imager; Milling head units; Gouging shield for air plasma systems; 62 Clamping chucks; Sealing rings; Gauging software; Cutting tool inserts; 63 Universal grippers; Coolant system; ECM drilling machines;
SPECIAL FEATURE 52
Re-modelling green measures
The article illustrates how the Godrej Appliances facility at Shirwal has evolved in achieving a sustainable manufacturing and growth over the years
Columns 05 06 64 64
Editorial Contents Highlights – Next issue Company index
7
MARKET | NEWS
CII appoints new council
FARO® announces 4th Asia Pacific 3D user conference
Sudhir Mehta, Chairman & MD, Pinnacle Industries, has been recently elected as the Chairman of CII Western Region for 2016-17. He takes over from Sanjay Kirloskar, Chairman & MD, Kirloskar Brothers, and is a serial entrepreneur who has started and successfully led several manufacturing ventures. He held various positions including Director, Force Motors; Director, Rivulis Irrigation; Chairman, Kider India; Vice Chairman; Indaux India; Director, Emesa Elevator Components & MD, Man Force Trucks. Also, Ninad Karpe, MD & CEO of Aptech, has been elected as the Deputy Chairman of the CII Western Region for 2016-17. Aptech is a global education company, and now operates 1,300 plus centres in India and China, as well as 40 emerging countries. Since joining the company in February 2009, he has been aggressively pursuing a strategy to position Aptech on the world stage as a truly global provider of learning solutions.
FARO Technologies recently presented the fourth edition of the annual FARO 3D user conference, specifically organised for the Asia Pacific region. With plans for two exclusive sharing sessions to be held in Beijing, China and Tokyo, Japan; it will once again serve as an important platform for the 3D community to take advantage of various knowledge-exchange interactions and networking opportunities. As per Markets and Markets, the global 3D terrestrial laser scanning market would reach $3.7 billion by 2020, at a compound annual growth rate (CAGR) of 9.0% from 2015 to 2020. Additionally, findings from Research and Markets have projected the 3D scanning market in the Asia Pacific region to net over a billion dollars by 2018, at a CAGR of 15.1%. As per Joseph Arezone, MD—Europe, Middle East & Africa and MD, Asia Pacific, FARO, “We recognise value in providing an interactive venue for the industry to connect with one another, and to engage in discussions about recent ground-breaking technologies in the market.”
Hero Motocorp opens ` 850 crores R&D centre in Jaipur
KPIT joins hands with Massachusetts Institute of Technology
Hero MotoCorp recently inaugurated its global Centre of Innovation and Technology (CIT) in Jaipur, Rajasthan. Built with an investment of `850 crores, it is a reinforcement of Hero’s commitment to innovate sustainable mobility solutions, for the world, in India. “CIT is the result of our bold vision to position Hero MotoCorp as the The facility is a giant stride in the leading source of innovation company’s endeavour towards and green technology. This strengthenin in-house technology facility is a giant stride in our capabilities relentless endeavour towards strengthening our in-house technology capabilities. Rich in diversity, it brings together a multi-national group of automotive experts, creating an environment of engineering excellence and innovation. With the CIT now becoming operational, we have the ideal combination of world-class infrastructure and talent pool to ‘Innovate in India’, not just for the country but for the world,” said Pawan Munjal, CMD & CEO, Hero MotoCorp. The facility, which boasts of test-tracks within the campus, houses the technologies in product design & development, testing and validation.
KPIT Technologies recently hosted the prestigious Industrial Liaison Program with Massachusetts Institute of Technology (MIT) —‘2016 MIT Innovation for an Emerging India Workshop’, at the KPIT campus, Pune. With talks by eminent research scientists and academician from MIT, as KPIT joins hands with MIT well as leaders from the manufacturing & technology industries, the workshop delved into the development & application of cutting-edge innovations in India & around the world. The MIT Industrial Liaison Program 2016 discussed innovations in diverse fields such as harnessing the Internet of Things (IoT) for health & wellness; transforming ‘data-driven’ artificial Intelligence through machine learning; solar energy & digitising fabrication for manufacturing amongst several ground breaking domains. The sessions also focused on how big data can be utilised to improve operations and processes in businesses, resulting in business growth and better lives. Ravi Pandit, Co-founder, Chairman & Group CEO at KPIT Technologies was the keynote speaker at this event. The workshop also included a panel discussion on starting and running a tech company in India with industry experts.
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EM | Apr 2016
NEWS | MARKET
DMG MORI with customised solutions at DieMould 2016 DMG MORI showcases customised solutions for users from the die & mould with specialised application technicians who always develop optimum segment at the DieMould manufacturing solutions for the tool exhibition in Bengaluru. It and mould making sector. presented 4 high-tech machines Industry 4.0 is dominating the and innovative production discussion of the future like no other, solutions for the industry, live in even in the sector of machine tool operation. construction. As the leading A key feature in the range of manufacturer of metal removing products and services of the machine tools worldwide, DMG MORI company is also its specific supports its customers on their way branch orientation. Thanks to to digital transformation of innumerable projects in the die & manufacturing process chains with mould making branch, DMG the app-based CELOS® system, which the machine tool manufacturer MORI has been able to build up a first presented around three years wealth of application-specific ago and which it has consistently expertise from which its DMG MORI has been able to build up a wealth of application-specific expertise from which its customers today benefit continued to develop in a targeted customers today benefit. manner ever since. Using this Die & mould applications have ranked high at DMG MORI for many years and this has resulted in an uniform user interface for machine and office PC, employees in shop floor enormous wealth of experience in this sector on one hand, and the and job scheduling can manage, document and visualise job order, process development and continued development of path-breaking manufacturing and machine data. Also, with the ecoMill 600 V at the fair, DMG MORI is presents the new technologies on the other. The HSC Center in Geretsried and the Mould Laboratory in Japanese Nara impressively underscore this competence generation of the ecoMill V series.
MotulTech participated at SIMODEC 2016
Micromatic Machine Tools launched drill tap centre
MotulTech had recently participated in Simodec 2016 (Salon International du décolettage ), the international bar turning exhibition held on March 8-11, 2016. This fair, held every two years in La Roche sur Foron in the Arve Valley, in La Roche sur Foron in the Arve Valley, meets suppliers and actors in the heart of the French and European bar turning industry. MotulTech, with a large market share in the neat machining oils in MotulTech had received good response in Haute Savoie, was present Simodec 2016 this year to meet customers, prospects and machine tool suppliers and reinforce its reputation. The MotulTech stand, positioned in Hall D has seen the influx of great days with a local industry in strong recovery. However, visitors from close abroad Swiss, Italy-or farther -Maghreb, Eastern Europe were numerous as well and quotation requests have even been established for Iranian prospects. The exhibition was also the occasion to present the new MotulTech film that will soon be available to all sales teams. MotulTech is constantly seeking to provide new solutions taking account of the needs of users, their specific constraints and operating costs.
Micromatic Machine Tools recently launched the new high speed drill tap centre DTC – 400 XL at their technology centre in Bengaluru. It is the latest contribution to Indian manufacturing from the stable of Ace Manufacturing System. The event was graced by Dr S Devarajan, Senior VP—TVS Motor and launched the new product. He also shared with the audience, his vision and The machine was launched by Dr S deep insight of Devarajan, Senior VP– TVS Motor manufacturing & machine tools and the importance of various aspects of TPM & lean manufacturing. Present at the occasion were N K Dhand, MD, Micromatic Grinding Technology; P Ramadas, MD, AMS & VP, IMTMA; TK Ramesh, CEO, Micromatic Machine Tools. The inaugural event ended with a vote of thanks from Sreekanteswar Shankarnarayan GM—Market Development & Strategy, Micromatic Machine Tools, with the assurance that the company would continue to work towards new products to improve productivity and support Indian manufacturing to become globally competitive. DTC – 400 XL delivers high accuracy and high productivity at an optimal price.
EM | Apr 2016
9
MARKET | NEWS
Tata Motors partners with Bharat Forge & GDLS Tata Motors has recently signed a strategic agreement with Bharat Forge Commenting on the partnership, Ravi Pisharody, Executive Director— Limited and General Dynamics Land Systems (GDLS) of the US, for the Commercial Vehicles, Tata Motors, said, “Through this partnership, we will Indian Ministry of Defence (MoD’s) be better positioned to help the prestigious Future Infantry Combat country realise its ‘Make in India’ Vehicle (FICV) program. Tata Motors vision, for the first completely will lead the consortium, with Bharat indigenised combat vehicle, at the Forge Limited as a partner, while same time cater to the opportunities General Dynamics Land Systems will available right here in India.” As per bring in its much proven expertise in Baba N Kalyani, Chairman & MD, combat vehicle platforms. Bharat Forge Limited, “Our proposed Tata Motors will play on its partnership will constitute an strengths related to design, important milestone, to help meet development & integration of mobility the Indian Government’s objectives platforms, while Bharat Forge will to strengthen indigenous defence bring on board its competence with capabilities, and particularly in land fighting platforms and manufacturing Tata Motors will play on its strengths related to design, development & systems, with the FICV.” Donald strengths. General Dynamics’ proven integration of mobility platforms Kotchman, VP—Tracked Combat expertise, as SOSI (a system of Vehicles, General Dynamics Land systems integrator) in various integrational programs, will bring in the Systems, said, “We have established a track record of delivering and required competency enabling Tata Motors, the lead integrator, to offer a sustaining international programs, in a timely & cost-effective manner truly indigenous solution for this ‘Make’ program. To be developed under throughout the platform’s life. Led by Tata Motors, we look forward to the ‘Make Category’, the FICV is a high mobility armoured battle vehicle, for working with our consortium partners in supporting the ‘Make in India’ infantry men to keep pace with new advancements in weaponry system. initiative, developing the Indian FICV.”
Siemens’ software solutions deployed at Bosch
German machine tool industry expects growth in 2016
Siemens’ integrated suite of computer aided design (CAD), product data management (PDM) and product lifecycle management (PLM) software solutions are replacing the legacy system of German automotive supplier Bosch in its Electrical Drives division. Starting in summer 2016, Siemens NX™ software and Teamcenter ® software will serve as the common development platform for the division’s global operations. Bosch has been using CAD/PDM/PLM software from Siemens in other business units for several years. Its decision to expand into the electrical drives division is part of its strategic plan to consolidate its diversified tool landscape with a unified methodology for modeling, design & collaboration. “Siemens PLM Software believes that today’s automotive suppliers offer require a systems-driven approach to product development that combines systems engineering with an integrated product definition. To facilitate systems-driven product development (SDPD), we provide product line engineering capabilities, a consistent process-enabled framework for mechatronic engineering, advanced modeling & simulation, an intuitive user experience & an open PLM environment,” said Urban August, Senior VP & MD, Siemens PLM Software, Germany.
As per VDW, for 2016, the German machine tool industry is cautiously optimistic. “We’re expecting moderate growth of 1% in 2016,” said Dr Heinz-Jürgen Prokop, Chairman, VDW. This prognosis is based on capital investment from the major customer sectors, global figures for machine tool consumption, and finally the order bookings at Germany’s machine tool manufacturers. For the investments, Oxford Economics, VDW’s forecasting partner, was in the autumn of last year expecting a global As per Dr Heinz-Jürgen Prokop, VDW increase of 4%. The principal is expecting moderate growth of 1% drivers are traditionally the in 2016 automotive industry, followed by the electrical engineering and electronics industries, metal product manufacturers, and the mechanical engineering sector. Machine tool consumption is predicted to rise by 4.2%. Europe tops the rankings here (plus 4.6%), closely followed by Asia (plus 4.5%) and America (plus 2.5%). Order bookings at German machine tool manufacturers, an indicator for medium-term business activity, showed a moderate rise of 1% in 2015, to reach 14.9 billion euros.
10
EM | Apr 2016
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MARKET | NEWS
Achieving success in noise emission tests The e-spool from igus, a cable reel for energy chains, has passed all the noise tests in the igus test laboratory with flying colours. This means it has distinguished itself as an ideal solution for applications in noise-sensitive areas, such as in stage engineering. With the space-saving e-spool, energy, media or fibre optic data cables can be run together in a single system, as it requires no slip ring.
e-spool is an alternative to conventional cable reels for very tight radii and installation spaces
igus operates the largest testing laboratory in the industry with a floor area of 2,750 square metres, where all products have to pass various tests. There, more than 3,000 basic and user-specific tests are performed annually for energy chain systems alone in 180 test facilities under real conditions. These include tests at various temperatures and pressures, or even in contact with chemical substances. Tests are, for example, also conducted in the special noise chamber.
at full extension to 12 metres, the integrated return spring held the required tension of the pull-out e-chain at all times, and a maximum rotational movement of the used igus twisterband the e-spool has surpassed the required 24,000 double strokes by far, completely trouble-free.
e-spool subjected to test
The latest test results prove that the e-spool is ideal for use in noisesensitive applications such as stage installations. Finally, moving stage elements must be moved as smoothly and quietly as possible, at the same time the energy supply system needs to be as compact as possible in order to manage with the limited space. Similarly, factories or logistics centres, where noise emission limits are increasingly becoming a norm, are suitable areas of its application. But there are even more features such as the strain relief of the cables, the variable guiding in all directions, as well as halogen-free components support the use of an e-spool. The e-spool energy supply system is available in standard catalogue sizes of four to 14 metres. For special projects, which are either particularly compact or for very long extension lengths up to 50 metres, igus also offers customised special solutions.
It was here that the e-spool from igus was subjected to an intensive test for its noise emissions during operation. e-spool is an alternative to conventional cable reels for very tight radii and installation spaces. In the tests, the cable-friendly energy, data and media supply system of the latest generation has been proved extremely quiet. In particular, the absence of slip rings minimises the noise development significantly in this special reel. An e-spool equipped with ‘anti-vibration matting’ was able to reach levels below 46dB (A) in these tests. The tests in the igus test lab also proved the performance of the e-spool with respect to its service life. It was also tested for compliance with the service life expectancy for a customer. This result was amazing:
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Suitable for noise-sensitive applications
EM | Apr 2016
MARKET | INTERVIEW
“We have a three part strategy for future roadmap of ThingWorx” Lau Shaw, Vice President—IoT Sales, ThingWorx, a PTC Business, in this interaction with EM, discusses the company’s acquisition of ThingWorx, while analysing the benefits of IoT to redefine opportunities in the business model How has Internet of Things been driven by convergence of market forces and innovation of enabling technologies? In the automotive sector, the rise of IoT has been driven by the convergence of market forces and parallel innovation of enabling technologies. As products have evolved, their capabilities have multiplied, creating new forms of value and even doing things well beyond their primary function. This transformation is shifting the sources of value and differentiation to software, the cloud, and service, and spawning entirely new business models. To capture this great wave of value creation opportunity, manufacturers have an urgent need to rethink nearly everything — from how products are created, operated, and serviced.
Elaborate on PTC’s acquisition of the ThingWorx platform to create high value IoT applications? We have a three part strategy for the future roadmap of ThingWorx and our solutions. This includes real-time product connectivity and condition monitoring to the existing PTC lifecycle management solutions as prebuilt offerings to our customers, selling the ThingWorx platform technology to allow our customers develop their own innovative applications that will help differentiate their business and realise strong business value, while developing new solution opportunities enabled by the connectivity, along with condition monitoring capabilities provided by ThingWorx.
How the transformation to IoT is redefining opportunities for competitive advantage and spawning entirely new business models? The ThingWorx acquisition extends PTC’s strategy by accelerating its ability to support manufacturers seeking competitive advantage as they create and service smart, connected products. It will continue to help customers in a wide range of industries, seeking to leverage IoT, including telecommunications, utilities, medical devices, agriculture, and transportation, as well as an emerging partner network of IoT-enabled service providers.
What is the way forward for PTC in India in the IoT and SCP space? In terms of technology, we would continue to innovate and come up with new upgrades of CAD products. We have Creo 3.0, which was launched recently and offers a lot of benefits that customers can appreciate. Through that, we are looking at the replacement market also. This means we can replace a lot of competing products. We also have this ability to co-exist with competitors, for customers who are using their products. We are very strong at services part through our PLM, thus, improving the business processes by its usage. Thus, we are looking at different pieces of the customer and for a manufacturing company, product development is just one part. There are other areas where we can squeeze profits and provide efficacies. For the upcoming few quarters, consolidation and expansion of our CAD in India is very relevant, especially for channels, because we need them to drive our flagship product in India, which is CAD. The matured products are being directly dealt with PTC because technically the wherewithal and knowledge to drive these products resides in PTC at this point. ☐
What are the tangible benefits of IoT? IoT facilitates Smart Connected Products. IoT and SCP ease the entire process of manufacturing and servicing as everything is connected to a cloud or server. It provides quick information on everything, related to equipment or product that will help enterprise to rectify the issues on time and to provide advanced services, which in turn will generate more revenue by cost savings. All of this software and hardware resulted in faster time to market, improved asset utilisation and optimisation, lower total cost of ownership, workforce efficiency, enterprise risk management and smarter expenditures.
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EM | Apr 2016
C O V E R S TO R Y
TECHNOLOGY
EVOLVING LEAN PRACTICES
Road to lights-out manufacturing
A large majority of the control issues facing us today revolve around the condition of the cutting tools. Using current technologies as well as the emerging technology to monitor the condition of the tools, lightsout machining operations will become a feasible and highly costeffective solution. The feature discusses factors ranging from sensing technologies & software, to machine tool maintenance to get an in-depth look at the key challenges in achieving ‘lights-out’ machining. Jon Iverson Chief Executive Officer OPTIS
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EM | Apr 2016
TECHNOLOGY
C O V E R S TO R Y
While there is a high degree of machine control today, the challenges to achieve lights out operations for machining revolve around the highly-dynamic environment in which the machine tool functions
Lean manufacturing or smart manufacturing, is as valid today as it ever has been. How can a process that eliminates waste and increase resource utilisation and productivity become outdated? These are business critical issues and always will be. However, the theory of lean, and how it is put into practice is evolving. Necessarily so, as manufacturers strive to remain competitive in an industry where new technologies are opening up advanced opportunities. Focusing on the things existing now, but evolving to an elevated role in ‘Factory of the future’, or ‘Industry 4.0’ as the Europeans deem it, machine tools make up one of the most significant and critical areas of manufacturing for the production of durable goods. Herein, we will look at the key challenges to industry’s aspirational goal of ‘lights out’ machining operations – eliminating current required interventions during operation and enabling operator-less running of equipment – and the evolution of some of the technologies that are taking us there. While there is a high degree of machine control today, the challenges to achieve lights out operations for machining revolve around the highly-dynamic environment in which the machine tool functions. Work material metallurgies vary. Cutting and grinding tools, fluids used for cooling and lubricity, and even machine components, all degrade over time as they are being used at varying rates or can break at any given point. All these factors and more contribute to this highly variable and dynamic environment.
Elements enhancing machine operations The success of ‘lights out’ machine operations is highly dependent on three main elements: t Sensing technologies t Software and analytic models t Machine tool health and maintenance Each of these in their current state must continue to evolve
EM | Apr 2016
to the point at which all of these variables can be accounted for constantly in order for the machine tool to make necessary adjustments throughout a given production run. There are many existing, developing and emerging technologies in each of these areas that will potentially play key enabling roles in changing the current machining paradigm. Many of these will ultimately be incorporated into highly sophisticated intelligent machine tools that will sense the current condition and provide machine correction and remediation, which takes into account the many dynamics that occur during machining the part.
Sensing Touch probes, laser and vision systems utilise metrology and/or optics based technologies to determine tool wear and part quality in line with machining forces. Tool Data Management (TDM) and Analytics manages & organises the data for tools, jigs, fixtures, measuring equipment to keep track and for inventory management of cutting tools and their condition. Tool data management technology will eventually be incorporated into Manufacturing Execution Systems (MES), which serve as a knowledge-base for all information in a facility. Combining tool condition with production cycle and quality information can be used to estimate the necessary supply of tooling and ensure the uninterrupted flow of the ‘lights out’ operations. Tool Condition Monitoring (TCM) monitors the condition of the cutting tools relative to wear, breakage, collision, and availability (missing tool). In addition, some systems are capable of adaptive control and spindle condition monitoring. Machine vision inspection is concerned with locating, identifying, measuring, and inspecting manufactured parts. The quality/metrology data is collected from parts either on the shop floor or within the controlled environment of a metrology room. The data can be gathered in the form of a point cloud using magnetic field, laser, or camera link
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C O V E R S TO R Y
TECHNOLOGY
Machine vision inspection is concerned with locating, identifying, measuring, and inspecting manufactured parts
technology. Machine vision provides for less intrusive inspection (less handling) and less contact with the actual component leading to higher throughput along with higher quality components. Today, machine vision is commercially available in various non-machining industries and for use outside of the actual machine itself, such as for inspection. While still evolving for the machining process, there are issues such as coolant mist, chips and other environmental concerns that need to be addressed. These systems could play an important part of any ultimate solution. Looking into the future, another potential key enabler to ‘lights out’ machining are ‘smart’ inserts and tools. A smart tool or insert is the generic denomination of a cutting insert that has some form of sensing capability that allows users to monitor the process and/or the condition of the cutting tool. These would allow much more accurate control of tool condition and prevention and prediction of tool breakage. This technology is in the early research stage and is not commercially available, but once available, it could revolutionise tool condition monitoring and play a key role in the future of machining.
Software and analytic models Most solutions today only address the starting point of the cutting or grinding process parameters, which often only serve as a starting reference point. What is needed for ‘lights out’ machining are analytic tools that continually adjust to the current operating conditions. In common practice, the control mechanisms of a
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computerised numerically controlled (CNC) machine follows pre-programmed and constant speed and feed-rates for each cutting segment of a given shape. Thus, the NC programs cannot take into consideration any dynamic variations encountered during cutting. A solution to this inflexibility is to use adaptive control systems, which continuously monitor the cutting conditions in real time and provide automatic cutting parameter (such as feed or speed) optimisation. Adaptive control is often part of tool or machine condition monitoring systems and involves different sensing, data processing, and actuation solutions. A typical adaptive control system monitors the power or cutting forces of a cut in real time, and adjusts the feed rate in order to obtain optimised cutting conditions. Adaptive control technologies are still evolving as new machine tool control, sensors, and concepts continue to evolve. The reality is that the software and analytic models required for full ‘lights out’ machining will require highly dynamic, multi-objective optimisation software. This software will not only need to optimise itself for the given conditions, but also for total cost consideration to operate at maximum overall efficiency. This means optimising to balance cutting speed/ feeds versus tooling costs and part quality to provide the best performance and cost against your specific objectives.
Machine tool health and maintenance Obviously, breakdowns in equipment, notwithstanding previously mentioned cutting tool breakage can jeopardise achieving a ‘lights out’ process. If your machine breaks, or is not functioning, all the other
EM | Apr 2016
TECHNOLOGY
C O V E R S TO R Y
Using current technologies as well as the emerging technology to monitor the condition of the tools, lights-out machining operations will become a feasible and highly cost-effective solution
technologies that make things run just won’t! Today’s complex and advanced machining processes demand highly sophisticated and costly maintenance strategies. When you observe that across many industries 15% – 40% of manufacturing costs and machine downtime are typically attributable to maintenance activities, it becomes a real issue toward the industry aspiration of lights out operations. There are significant technical challenges in machine tool condition monitoring and subsequent maintenance regimes. Current technologies typically ascertain ‘normal’ versus ‘abnormal’ behaviour – whether it is via vibration, spindle loading, thermography, used oil analysis, ferrography, amongst others. This works fairly well for primary applications utilising condition monitoring today for equipment operating at constant or near constant loading, such as hydroelectric, gas & steam turbines for power generation or large compressors. While all relevant, the highly-dynamic environment of machining poses real challenges when employing existing technologies. The issues become evident when trying to identify which component of a subassembly is degrading or failing to the point that the machine tool is becoming either nonoperational or incapable of generating parts within required specifications. Operational safety, maintenance, cost effectiveness, and asset availability have a direct impact, not just on the competitiveness of organisations, but the viability for the future of ‘lights out’ machining. Besides maintenance costs, machine availability has a direct impact on the organisational agility and efficiency of an organisation. Unscheduled or frequent breakdowns create
EM | Apr 2016
significant obstacles to the implementation of modern management strategies that are known to improve productivity and reduce production costs. Proper maintenance will result not only in machine uptime and savings in repair costs, but also in an increase in quality of the manufactured parts, and in decreasing the costs associated with safety and environmental preservation. These technologies are still evolving as new machine tool control, sensors, data analysis and concepts continue to evolve. Monitoring the health of the complex systems that make up the entire machine tool as a system are still in the research and development stages. The evolution of machine-tool health monitoring and management systems will probably become standard in the future as a necessity.
Conclusion Today, the needed technologies are evolving at an increasing pace toward the ultimate goal of ‘lights out’ machining. This solution will likely incorporate all or parts of each of these technologies such that the machine tool can continuously assess the current status of cutting and grinding variables and make commensurate adjustments in process. About OPTIS OPTIS is a joint venture that brings together the deep machining expertise, analytic tools and process improvements of TechSolve with the heritage and global commercial reach of Castrol, to deliver transformative efficiency to the manufacturing industry in North America and beyond. For more information, visit: http://www.optis-solutions.com/. ☐
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MANAGEMENT | INTERVIEW
“Eliminate waste, but create new value ” …says Michael Bremer, President, Cumberland Group – Chicago; VP of Manufacturing Excellence Awards process for the Association for Manufacturing Excellence (AME); and Executive Director of the Chicagoland Lean Enterprise Consortium Group. Author of a few books on Six Sigma, he has been a speaker for the American Quality & Productivity Center and the Association for Manufacturing Excellence, and the White House Conference on Productivity. Excerpts from his interview with Shekhar Jitkar... How has the global manufacturing industry evolved, according to you, in the last ten years in terms of technology adoption, market expansions, global partnerships, strategic developments, and operational excellence? The rest of the world is catching up to the US, Canada and Europe in terms of operational excellence. Some differences still exist, but the gap is much smaller. The internet continues to bring suppliers, manufacturers and customers closer together. Manufacturing improvement actions for the last 20/30 years have focused inside the plant. There is going to be much more collaboration across the supply chain moving forward as organisations seek to gain a competitive advantage. The US companies are becoming more export oriented, and as they become more efficient it will put more pressure on companies in emerging economies to improve more effectively and holistically. There will be a resurgence of manufacturing capability in the US as people have come to realise there is not much leverage for an economy in just focusing on financial services. If the US economy is growing that is good news for manufacturers around the globe.
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Which are the breakthrough technologies and management concepts that are shaping manufacturing operations and thereby businesses in the present times? According to me, certainly, 3D printing is going to have more and more of an impact. Innovation with nano-technology will also have a major impact on creating new materials. Manufacturers using nano-materials will need to take a holistic perspective including environmental impacts in order to avoid costly negative consequences resulting from irresponsible behaviours and short-term thinking. Please suggest top five change drivers for the global manufacturing industry evolving into its future. Low cost labour will be less and less of a factor moving forward. Companies applying a holistic total cost model will give more consideration to other major cost items such as: labour skills and flexibility; quality, reliability and durability (which will become more important from an environmental perspective); country risk; where to place (keep) production or software development core competencies in order to facilitate future innovation; and distribution reliability as well as costs.
EM | Apr 2016
INTERVIEW | MANAGEMENT
“If you are going to execute significant change, you need to find ways to see your world differently and to get in touch with ‘reality’ as it truly exist” Michael Bremer
The top 5 change drivers would be: t People, people, people! Ability to find and develop talent. People will be attracted to organisations that treat them with respect and develop their skills and capabilities. Elite organisations create an environment where associates are encouraged to give that little bit of extra effort = passion and engagement t Rapid prototyping (faster lead times) t Ability to more deeply understand customer requirements and total cost of the supply chain t Safety of intellectual property and cyber security - ability to more easily identify fake products t Use of sensors to track manufactured product, provide feedback for early maintenance, and develop closer relationships with customers t More collaborative practices across the supply chain where companies partner together to pursue joint growth opportunities. How are the transforming/emerging economies and changing trade relations likely to influence the manufacturing sector growth globally? Manufacturing growth spurs economic growth. Every dollar spent in manufacturing generates $1.48 in the economic growth. This would be a huge multiplier that provides a pathway to higher living standards, so long as it is done in a way that avoids long-term damage to the environment. There is a fine line between manufacturing growth spurred by the government -vs- growth driven by the private sector. A balance is needed between the two perspectives. For example, much of China’s manufacturing growth has been driven by the government spending and regulations. If the government chooses wisely the economy looks like a winner. If on the other hand, the governmental regulations foster unwise investments you get bubbles like Japan in the 1990s and perhaps China in the 2020s. Governments in emerging economies for the last 20 years have benefited from outsourcing activities in the US, Canada and Europe. This model will be changing and it will be interesting to see if governments in emerging economies can adapt to this.
EM | Apr 2016
Policy makers need to recognise whether their decisions impact global market opportunities. Governments need to build up their competitive advantage just like companies. What in your opinion can be defined as the key to success in modern manufacturing companies? Would you like to recommend any best practices? I have referenced the development of people several times. In terms of improvement effectiveness elite organisations seem to do five things much more effectively than the rest: Explain Why – It is critical to help people understand the purpose before proceeding any significant distance down the improvement pathway. Once again this applies from the top to the bottom of the organisation. The organisation needs clear strategic direction and a meaningful business model. At a department level the purpose needs to shift away from the activities the department does and instead focus on the (usually internal) customers the department serves. Gain a new perspective – If you are going to execute significant change, you need to find ways to see your world differently and to get in touch with ‘reality’ as it truly exist. Interestingly, this is true at the senior leadership level and it cascades all the way down to an operator or associate level. People’s perspectives need to shift in order to transform. Invest in people – Once progress has been made on the first two steps then it’s time to invest in people. Organisational, department or functional leaders create an environment where people can become smarter and bolder; where they can do their best work. This includes compensation practices, coaching, training/skills, and development. Focus on value – While it is good to eliminate waste, it is better to create new value. Your customers do not care about your waste, they only care about the value you provide. It is far easier to collaborate when seeking alignment with the customer. Do the right thing – Trust, accountability & engagement. Have a broader perspective than “me” or “my department”; think about the organisation as a whole, and ultimately from an overall supply chain perspective. Make it easy to see if the right thing is being done at the right time. ☐
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R O U N D - TA B L E | M A N A G E M E N T
Roadmap for smart manufacturing While there is a lot of buzz around smart manufacturing, the reality is that in India, most industries are not smart-ready. In fact, some industries are not even clear about the roadmap for automation that would lead to being smart-enable. To discuss the parameters that will help create a platform for smart manufacturing in India, a panel discussion was organised during the 1st Symposium on Smart Manufacturing, organised by IMTMA. Excerpts from the discussion‌ Smart manufacturing transforms traditional factories from cost centres into profit centres that progressive businesses will strategically invest into increase of sales. According to industry experts, the epicentres of supply and demand are shifting, thereby, creating complex supply chains. Users demanding high levels of customisation are driving fierce competition in pricing and forcing manufacturers to strive for highest levels of efficiencies. As global manufacturers continue to wrestle with
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Megha Roy Features Writer megha.roy@publish-industry.net
consolidation and harmonisation, they also want to achieve world-class operational excellence. Today, advanced manufacturing technology is rapidly transforming the global competitive landscape. It will improve worker safety and protect the environment by making zero emissions, zero-incident manufacturing possible. However, while making manufacturing smart, there might be possible risks and challenges in the chain of consultancy-evaluation-
EM | Apr 2016
M A N A G E M E N T | R O U N D - TA B L E
M A N A G E M E N T | R O U N D - TA B L E
selection-implementation-risk mitigation-ROI, etc. Suggesting a roadmap to reach the optimum level of smart manufacturing, while addressing such challenges are G Ganapathiraman, Country Manager, ARC Advisory Group India and Naresh Kantoor, Managing Director, Encon Systems International.
Towards making Indian factories smart-ready As per Ganapathiraman, Indian factories are smart-ready, but have yet to implement smart technologies effectively. “The concepts, ideas and smart technologies are available, but execution is not widespread. The focus must be on creating awareness that a smart factory is connected, collaborative, competitive and sustainable,” he says. However, Kantoor believes that smart concepts have been widely adopted in telecommunications, but it is still a far cry as far as manufacturing sector is concerned. Speaking on how to make factories smart, Ganapathiraman opines that manufacturers should build their smart infrastructures with an eye towards both current and future requirements. “As smart manufacturing is a continuous improvement process across the manufacturing value chain from the product development to delivery, a good place to start would be to determine what smart manufacturing can do to enhance operations, and if it represents a sound business value proposition,” he suggests. It is also important to reach a level where machines are successfully & appropriately automated with data interchange capabilities. “Our focus has to be to make a right strategy, while we meet our present-day automation needs, and at the same time, adopt technologies so that they are a future-enabled too for integrating them to get data in the direction of making the system smart,” highlights kantoor.
Parameters for smart manufacturing While drawing up a long-term roadmap towards creating an environment for smart manufacturing, it is important to understand that it is a continuous journey towards achieving operational excellence. Ganapathiraman encompasses this as business optimisation, standard technologies and methodologies, manufacturing optimisation, finally leading to the manufacturing evolution. “The most compelling reason for moving from traditional to smart manufacturing is market pressure. Some significant factors include need for lower costs, to achieve faster time-to-market; customer demand for top
EM | Apr 2016
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R O U N D - TA B L E | M A N A G E M E N T
“If we are buying new equipment, getting those IIoT-enabled in the first place will be a good idea” quality goods; fierce competition in a global market; fast changing requirements & flexibility to fulfill these,” he avers. As per Kantoor, rather than strictly sticking to low cost now, one should go for value automation, which are not only capable of meeting the current pressing demands, but at the same time, none of it goes redundant when we start expanding and interconnecting for making them smart.
Addressing risk & challenges There are multiple risks and challenges at every stage of making the manufacturing unit smart. Highlighting some, Ganapathiraman includes process and people maturity that is not high enough for adoption, lack of technology standardisation, budgetary constraints and IT security. To overcome these obstacles, he says, “Smart manufacturing can be implemented in phases like assessment of overall manufacturing facilities; plant & enterprise-wide integration; from plantwide optimisation to manufacturing intelligence.” Currently, the type of equipment and the control hardware that manufacturing set-ups have varies so much that connecting them together becomes a difficult task. Kantoor explains this as, “If we are starting journey now, it would be a good idea to have a proper strategy in place so that whatever equipment we are choosing are smart enabled, and to do so, external consulting may be necessary if in house strength is not available. ROI just on the basis of manpower cost, as most of the companies do now, is not really the right way to look into overall justification of the cost of automation. Hence, those additional costs must be factored and provided for in this chain,” he shares.
Knitting the smart infrastructure Ganapathiraman believes that seamless integration between processes, technologies, best practices and people knits and orchestrates the entire smart manufacturing infrastructure. “Smart manufacturing will need to integrate all the business processes along the value chain through seamless data connection to improve productivity and ensure efficiency. The eco-system that makes smart manufacturing a reality consists of intelligent assets with sensors & actuators, data services, communications, embedded apps and processes driven by DCS, PLC, micro-controllers etc; mature and robust ICT infrastructure; machine to machine (M2M) solutions;
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Naresh Kantoor, Managing Director, Encon Systems International
“Smart manufacturing will need to integrate all the business processes along the value chain” G Ganapathiraman, Country Manager, ARC Advisory Group India
Industrial Internet of Things (IIoT); Internet and cloud infrastructure and mobility,” he says. Kantoor raises his concern on whether machines at present are capable of getting its control system integrated over Internet? Or can certain modules be added to make it enable? He further suggests, “If we are buying new equipment, getting those IIoT-enabled in the first place will be a good idea. Do not forget to build enough safety interfaces built, as more we get smart, likely risks of intrusion and malware is also greater.”
Optimising deployment process Optimising deployment process for economic, environmental and sustainable impacts as well as the impacts related to energy, safety and productivity is of prime importance today. “This can be done in a systematic manner,” says Ganapthiraman. “Data and protocol variability can be addressed by a library of machine compatible devices/protocols by collaboration of expert niche players in the respective areas. The shop to top IT / business system integration is addressed by creating integration protocols with knowhow provided by the ERPs and IT systems, which work seamlessly with the device libraries. Such ecosystems are the key to the future to make technology talk the business language; to keep the costs down; and to ensure quick adoption of the systems with measurable business KPIs by the manufacturing organisations,” he adds. Kantoor opines that enabling to take right informed decision at the right time directly impacts the plant productivity by minimising losses, which a delayed decision could have caused. “Hence, the best deployment process will be to select the right technology at the first place, even if it is bit expensive, and gradually move on from one section to another for better visibility and productivity,” he says. ☐
EM | Apr 2016
MARKET | TRENDS
Top manufacturing trends in India for 2016 Although there is a great diversity in the technology adoption maturity rate of Indian manufacturers, it is now an established fact that most of the large companies use IT tools such as ERP, CRM, SCM, etc to efficiently run their businesses. The article highlights some key trends likely to shape manufacturing in India in 2016 and beyond. In India, the manufacturing industry is currently being shaped by several factors. The government’s ‘Make in India’ initiative is set to become a key influence on the manufacturing landscape. Indian companies such as Hero MotoCorp, Mahindra & Mahindra, Cipla, Sun Pharma, Tata Motors, Sona Group and many other well-known businesses are advanced users of IT. Partner this with the acceleration of automation and growing experimentation with disruptive technologies, such as 3D printing and robotics, as well as innovation on the shopfloor and throughout the supply chain and it’s easy to see why the industry needs to become more agile and resilient.
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Anish Kanaran Channel Director Epicor Software—Middle East, Africa & India akanaran@epicor.com
With this in mind, following are some key trends that are likely to shape manufacturing in India in 2016 and beyond: ‘Make in India’ will gather momentum: The ‘Make in India’ programme aims to increase the share of manufacturing in India’s GDP. The aim is to grow the share from the current 15% to 25% by 2022—and position India in the top 50 in the World Bank’s ease-of-doing business index (it slipped to 142nd place in 2014). This initiative is creating a buzz amongst global manufacturers and Indian companies are making the most of this to boost their existing manufacturing facilities in India or set up new projects.
EM | Apr 2016
TRENDS | MARKET
As a result, the use of technology such as an enterprise resource planning (ERP) systems will assume greater significance for manufacturers. A next-generation, or modern, ERP system will help businesses become more competitive by integrating all their processes internally and, therefore, increasing visibility across the business from supply chain to customer service. Additionally, by having an ERP system in place, they are better placed to interact with the external world of suppliers, partners and customers—and even with the Government for taxation, compliance and regulatory requirements. Such ERP tools can also provide firms with the necessary infrastructure to combine the prevailing enterprise trends of SMAC (Social media, Mobility, Analytics and Cloud computing). Customer-centricity will drive innovation: Much of what companies do will start to be driven by customer likes and behaviour. In a highly competitive environment, a manufacturer’s ability to respond quickly to customer preferences will become a key differentiator. To create a customer-centric approach, businesses need to respond
quicker, change tactics dynamically according to market demand, analyse and act upon internal and external data, and deliver their products to customers faster than ever before. Today, modern ERP solutions offer functionalities that make tracking and predicting consumer preferences much more reliable. Deep analytics and business intelligence tools provide actionable data for manufacturers and it is becoming possible to monitor product trends and adjust production cycles to cater to new customer demands (for instance, a particular colour in cars or type of fabric in apparel). Digital transformation will leapfrog: Emerging digital technologies such as robotics and 3D printing and their impact across the manufacturing value chain will trigger higher adoption of these technologies among manufacturers. With manufacturing organisations now expected to be agile and receptive to customer demands and other market forces, digital transformation and innovation will become central to optimising operations, driving innovation, complying with regulatory changes and meeting customer demands. Companies will also increasingly look to integrate
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MARKET | TRENDS
Today, modern ERP solutions offer functionalities that make tracking and predicting consumer preferences much more reliable
technology such as ERP and product lifecycle management (PLM) software with their manufacturing execution systems (MES) to increase efficiency; tying design innovation, business execution and manufacturing processes together. This trend will gather pace in 2016 and will enable manufacturers to gain more detailed insight into how to bring products to market quickly and how to better meet fast-changing customer demands. Compliance and regulatory measures will gain ground: Compliance and regulatory procedures are increasingly becoming critical for manufacturers in India. For instance, the government lab detection of lead in Nestle’s popular Maggi noodles caused a furore in the market in 2015 (and hundreds of crores in losses to the company). Another example is the proposed Goods and Services Tax (GST) which, when implemented, will unify the multi-layered indirect taxation system. Given this heightened focus on corporate governance and compliance, organisations need to turn their attention to internal controls. The right technology can help provide organisations with effective mechanisms for achieving regulatory compliance together with performance improvement. ERP systems are becoming increasingly popular as a solution in this area because they can both optimise business processes and generate the data needed for regulatory compliance. In this context, IT solutions will play a more significant role than ever before. For example, by quickly sharing data between a customer relationship management (CRM) system, an ERP system and a traceability system, a manufacturer can find out the exact number of affected products that have been sold to customers and, thus, act swiftly to manage an appropriate
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response. This agility will allow the company to recall only those products that have been affected, rather than issue a general recall advisory based on generic information—resulting in cost savings and less reputational damage. Operational transformation will become a more pressing need: As manufacturing becomes ever-more competitive, more and more companies will need to transform their operations by integrating digitally connected processes that improve responsiveness and productivity. For instance, they will use more sensors in their manufacturing plants and connect these through IP (Internet Protocol) in order to enable a real-time information exchange between the systems used on the shopfloor and other enterprise systems. This in turn will increase the speed and accuracy of decision making in areas such as materials procurement, repair orders, workforce mobilisation, etc. Supply chains will become more agile: Customer demands are increasing in the wake of the growing pressure exerted by e-commerce and hyper-connected consumers. Because of this, manufacturers will need to make their supply chains and logistics networks faster and more flexible. To meet the need to constantly track the movement of goods across their supply chains, businesses need to step up their use of GPS solutions as well as ERP systems that provide better support for cloud, mobility and collaboration, among others. Visibility will need to increase from end-to-end as well as across devices to benefit all stakeholders in the value chain. With a new year bringing the opportunity for a new beginning, manufacturers in India should look to embrace new technologies. By adopting advanced ERP solutions, the manufacturing industry in India is set to move towards a more sustainable and agile way of working. �
EM | Apr 2016
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CASTING & FORGING | FOCUS
Image courtesy: Bosch Rexroth
Getting cast components right the first time Today, companies are under constant pressure to innovate faster and better than others. The feature discusses on getting cast components right the first time, to ensure that the product development processes are optimised, non-iterative and productive. Casting as a process has been one of the oldest manufacturing techniques known to mankind. Right since the monarchical era, casting as a method, was predominantly used to develop artilleries and weapons of various kinds. Today, in the times of industrialisation, the role that casting plays has expanded much more. It has widened to include a plethora of industrial applications. Then may it be developing automobile engine blocks, pump impellers and allied industrial components, to making jewellery, casting forms an integral part of product and/or components development. Despite radical reforms in manufacturing processes, casting as a production technique still adopted heavily to build complex products. Mostly known for using metals and alloys including ferrous
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Sreekanth Sunkesulapati Product Manager – ESI DesignTech Systems
and non-ferrous metals, casting process, in comparison to the other product development and engineering processes has evolved slowly to accommodate and apply the new and advanced technologies. Known to be one of the most critical and time-consuming functions in product development, casting processes were highly iterative, mainly because of their conventional or traditional ‘trial-and-error’ approach. Determining proper cooling, and solidification of the molten material was a challenge. Predicting porosity, distortions, deformations and residual stresses with the age-old techniques was also not easy. Developing accurate patterns was a different ball game altogether. Ensuring the patterns do not crack, proper filling and opening of the pattern, precise vent creations
EM | Apr 2016
FOCUS | CASTING & FORGING
Casting simulation will have to be material specific to avoid faults, fractures or breakages in the cast components
to avoid air entrapment without modern technology now seems like a nightmarish herculean task.
Optimising product development processes Today, when the companies are under constant pressure to innovate faster and better than the competition, they need to ensure that their product development processes are optimised, non-iterative and productive. The shelf lives of the products are diminishing faster than the pace at which the products are developed. Competition is intense and quality standards are paramount. One world – one market scenario has brought in lot of anonymous global competition. The only way for the companies or OEMs to survive, lead and make themselves resilient is if they build innovative products faster than the competition and launch them in the market at attractive prices prior to their competition and other players who develop products that could substitute yours. To ensure this, they have to establish and configure seamless product development processes, which also include getting your cast components right the first time. Every metal has different properties. For example, nonferrous metals such as gold, silver, platinum, titanium, etc are lightweights, have magnetic properties and are more malleable than the ferrous components. Ferrous metals such as stainless steel, cast iron, etc on the other hand are known for their strength and durability. Hence the melting point, the viscosity and porosity of every material differs and so does their use.
EM | Apr 2016
Simulation of cast components The factors that contribute to creating accurate and precise castings the first time will differ as per the individual material properties and hence cannot be universal in nature. Casting simulation will have to be material specific to avoid faults, fractures or breakages in the cast components. The technologies that we adopt to achieve this, need to understand the individual material properties, their behaviour under stipulated conditions, and predict the results or performance accordingly. May it be any type of casting, gravity casting, sand casting, iron casting, investment casting etc, developing accurate patterns is critical and non-optional. The key factors or parameters that companies need to look into to develop accurate patterns are precise core and cavity extraction, installing proper cooling circuit or channels, proper gateway location for the molten material to be filled, uniform pouring, cooling and solidification of the molten material, ensuring no sink mark formation and warpage, proper vent creation to avoid air entrapment and predicting any deformations or residual stresses.
Pattern making processes Pattern design is complex and critical to getting products developed right the very first time. This is the first step to the components development. Any design error can cost company additional time, money and necessitate the need to repeat the
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CASTING & FORGING | FOCUS
Once the patterns are designed using a 3D CAD software, they are traditionally machined or made out of wood
process of pattern development right from start, which could take away their competitive advantage. Lean, streamlined and seamless work processes help in optimising the product development cycle through effective utilisation of time, resources and monetary investments. Advanced 3D modelling software like NX CAD from Siemens is a great tool to develop even the most complex and intricate shapes and geometries efficiently. Being synchronous technology, NX CAD is capable of making design amendments on any design developed using other CAD platforms. This intuitive CAD software can help design components keeping in mind their manufacturability thus helping you get your product designs right the first time. Once the patterns are designed using a 3D CAD software, they are traditionally machined or made out of wood. The wood patterns, however, are extremely unreliable as the wood tends to swell or expand in the damp conditions, which makes developing accurate patterns a ‘try and doover’ type of process. In case of machined patterns, should there arise a need to change the pattern design due to an identification of design error then the cost and time incurred in re-machining the pattern is enormous. Today, industry is hence diverting from traditional and conventional pattern making processes to adopt a technique that can help them develop patterns in less than half the time, otherwise required in the traditional process.
Advent of 3D printing The technique, which is rapidly being adopted by the foundry industry is 3D printing. Once your pattern design is created using a 3D model, all you have to do is, to feed this design as an input to the 3D printer in the .stl format, which is available on all the leading CAD platforms. Then, the 3D printers that build the pattern layer by layer or Additive Manufacturing process can help you build a pattern in a couple
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of hours, which traditionally would take atleast twice as much time. Stratasys, a leading Additive Manufacturing company, through their production series machines can help develop patterns in high temperature production grade plastic or ABS+ plastic material, which is very strong, durable and can withstand high temperature. 3D printing not just reduces the time of development of pattern, but also significantly reduces the cost of error. If after having developed the pattern, a design error is identified, all that needs to be done is to make the necessary changes in the CAD model, and re-print the pattern in the 3D printer. This enormously reduces the time and cost of development of a pattern. Also, there is no-trial-and error process involved. Thus it improves your chances of getting your patterns right the first time.
Getting it right the first time Developing accurate patterns is only a part job done, in the entire process of developing precise cast components. The other magnanimous half includes the process of proper filling, solidification, predicting deformations, residual stresses and many other such vital factors required to develop precise cast components. Today, through technology evolution, there exist many casting simulation software that can help you get your cast components right the very first time. Casting today is no more a run-of-the-mill, traditional time consuming and iterative process it used to be. Through these modern technological tools, companies can develop extremely complex and huge cast components right, in their very first attempt. As good as it sounds, this is absolutely possible and can save company extremely high value nonrenewable resource like, ‘time’, and precious ‘money’ which can change the game in your favour making your company competitive, and leader in your segment. ☐
EM | Apr 2016
A U TO M AT I O N & R O B OT I C S | T E C H N O L O G Y
A global model for tool selection The feature examines the advances in mechanics & controls that are enabling the practical and economical application of lightweight robotics for manufacturing on an increasingly broad scale In today’s competitive landscape, manufacturing equipment must meet certain essential requirements like ease to set-up and implement into production operations (ideally portable); flexible; fast and compact and lightweight as possible. Pursuit of these requirements has helped drive the development of the lightweight robotics and desktop automaton solutions increasingly prevalent in the current manufacturing automation. By providing scalable and modular functionality in increasingly agile and compact packages, these solutions are dramatically changing manufacturing by enabling automation on a smaller and more flexible scale, and helping achieve the responsiveness necessary to compete in today’s rapidlychanging global markets. Among the tasks and processes, lightweight robotics are now employed for in many manufacturing sectors like feeding, screwing and mounting small components, setting adhesive
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points, electronic testing: approach to contact points, resistance tests, flexible positioning of workpieces and components, logistics and storing operations and sample preparation, dispensing, transport, and distribution (medical diagnostics).
What is a lightweight robot? Lightweight robots are particularly designed for transportability – portable and easily moved around – interaction with a priori unknown environments and humans. Robot mobility combines the requirements of a lightweight design with high load-to-weight ratio (close to the 1:1 ratio) and high motion velocity (tip velocity of 6m/s). Moreover, collaborative robots that interact with humans and in unknown environments require sensing and control capabilities to enable skillful, compliant interaction.
EM | Apr 2016
T E C H N O L O G Y | A U TO M AT I O N & R O B OT I C S
Lightweight metals or composite materials are used for the robot links
Structural and control considerations Lightweight metals or composite materials are used for the robot links. In fact, the design of the entire system is optimised for weight reduction to enable mobile application of the robotic system. In order to increase performance and/or safety of the arms, additional and sometimes variable mechanical compliance is introduced into the joints of some lightweight collaborative robots. Within the lightweight robot concept, a strong emphasis is set on robust performance as well as active safety for the human and the robot during their interaction. Compared to standard industrial robot control, the following aspects are of particular importance: t Extensive use of sensor feedback from the environment, including vision, force-torque sensing at the end-effector and in the joints, tactile sensing, and distance and proximity sensors. t The control implementation is not limited to position control, but also includes the interaction forces in the constrained directions using methods such as impedance control. In this way, instead of prescribing a position or a force, the dynamic relation between the two is prescribed, while the actual force and position resulting during interaction also depend on the environmental properties. t Position control has to compensate for the effects of the inherent robot elasticity (e.g., vibrations or the steady state position error) to ensure the performance of positioning & trajectory tracking. This problem also exists for industrial robots moving at high velocities, albeit to a lesser degree. t The robot needs control strategies that allow detection of unexpected collisions with the environment and with humans and to be able to react in a safe manner. In some lightweight robots, torque sensors in each joint play a key role for so called soft robotics control (i.e. impedance and force/torque control). These sensors allow implementing most of the aspects described above with high accuracy and performance.
EM | Apr 2016
Today, two principal types of lightweight robots are being produced: those with compliance and those without. Originally, manufacturing robots were caged: for humans to interact with them, parts were fed from outside the cage. Today’s compliant lightweight robots have no need for such barriers. Humans can be side-by-side with them because of built-in sensors that detect human presence and ensure safety, so workers can interact with them even when the robot is active. Other robots have lightweight structures but without the sophisticated sensing capabilities of compliant robots; workers cannot directly interact with them while the robot is active. Good examples of lightweight robotics commercially available today include the Barrett WAM™ arm, the Mitsubishi PA10 arm, the KUKA LBR iiwa, the DLR MIRO robot and the Festo EXCM planar surface gantry.
Challenges in manufacturing Operations are generally categorised in two production models: high volume, low mix (i.e. long runs with relatively few part changes) and low volume, high mix (i.e. short runs with frequent part changes). Originally, it was only highvolume operations that were automated; however, as noted above, the momentum in manufacturing is going towards mass customisation, which means lower volume and higher mix. Therefore, successful manufacturing operations need to be leaner, more agile and operate at higher efficiencies than ever before. The significant challenges in automating manufacturing processes include: Part presentation: Parts are often presented in bulk and need to be channeled so that individual components can be consistently presented and handled in the assembly process. Manual methods significantly affect throughput and, therefore, some type of automatic feeding method or robotic handling is required. Machine access: Access to the machine tool for set-up and tool changes is critical. Automating the machine tool adjustment reduces downtime and eliminates any safety and
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A U TO M AT I O N & R O B OT I C S | T E C H N O L O G Y
Collaborative lightweight robots enable the operator and robot to work side-by-side without the need for guarding or disabling the robot
product consistency issues that could arise when making adjustments manually. Process rates: In all machining operations, shorter load/ unload time is important; in fact, in smaller part, shorter cycle operations, it is critical. Space and layout considerations: Most production equipment is positioned for manual operations and to maximise machine density. Creating operational space for a robot to load and unload parts can be difficult, especially if safety fencing is required. Cost: In North America, robotic automation has primarily been justified based on labour reduction. This is typically coupled with a short-term view of return on investment.
How lightweight robotics addresses these challenges For part presentation, while conventional vibratory solutions may work for some applications, they don’t work for others. In those cases, fixed trays and/or conveyors can be used as a staging area for the robot. The integration of visionbased solutions with robotic systems is proving to be the most flexible, lowest cost solution. Parts can be loosely positioned onto a tray, belt conveyor, or vibratory belt where the vision system will determine the part location and orientation. The vision system then transfers the information to the robot, allowing it to pick up the part. For machine access, with the large variation of robot configurations available, many alternative system layouts are possible. An overhead robot can be a good solution for tending multiple machine tools. With proper guarding, it can allow manual access to each machine without shutting down the robot system. Many types of robot mounts, bases and positioners can also be designed to allow temporary repositioning of the robot for machine access. Collaborative
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lightweight robots enable the operator and robot to work sideby-side without the need for guarding or disabling the robot. For process rates, piece rate is only one measure of an automation system. A more important measure of capability is net throughput. Robotic machine – loading systems have proven to have a much higher percentage of uptime than comparable manual processes. This additional uptime creates more available hours of operation per shift than the manual process, so a robot system with a slower piece rate can still have a much higher net throughput. Furthermore, robots continue to improve in terms of speed, reach, and payload capabilities. For space and layout considerations, as with the challenge of machine access, many space and system layout issues can be addressed with the variety of available robot configurations. One promising development: recent changes to robotics industry safety standards allow safety rated soft limits. Robots can now dynamically define operating space and restricted space based on the status of safety interlock signals. This allows tremendous flexibility in both system layout and access. In addition, robotic solutions are designed to be more compact and lighter for easy portability and reduced footprint. For cost, when justifying robotic automation, a range of factors must be considered, not just labour. A thorough return on investment evaluation must take into account all associated costs & savings, as well as changes in throughput. It can also be difficult to justify robotic automation because of the tendency to think “one-to-one”: one robot for one machine or one robot to replace one operator. Instead, manufacturers should look at multiple processes in a production area. In many cases, what appears to be a situation of one operator per one machine can turn into one operator per three or four machines when the bigger manufacturing picture is considered. ☐ Courtesy: Festo Corporation
EM | Apr 2016
G E O M E T R I C D I M E N S I O N I N G & TO L E R A N C I N G | T E C H N O L O G Y
Effectively applying measurement data The article explains how a well-defined dimensional engineering (DE) process enables collection and analysis of relevant, meaningful variation measurements at every stage from design through production, leading to engineering process improvement Manufacturers face many obstacles across the lifecycle of delivering a product to market. They often find themselves spending a lot of time reworking or repairing parts; with parts that fail inspection, but fit and function properly when assembled; with parts that pass inspection, but do not fit with other parts and assemblies; disagreeing with vendors over whether parts are made dimensionally correctly or not; with different understandings about design intent in regards to form, fit, and function by various groups within their organisations; dealing with team members who are intimidated when they see GD&T symbols on drawings and with high manufacturing costs due to tight tolerances on non-critical features. Many of these problems are the result of an unclear
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definition of product and process requirements and an underutilisation of existing measurement data. The case has never been greater for manufacturers to have a well-defined dimensional engineering (DE) process that enables the collection and analysis of relevant, meaningful variation measurements at every stage from design through production.
Closed-loop dimensional engineering process An ideal DE process, is explained below: Management commitment, build objectives and process strategies: A comprehensive DE process begins with the setting of directives at the start of a program and is integrated
EM | Apr 2016
T E C H N O L O G Y | G E O M E T R I C D I M E N S I O N I N G & TO L E R A N C I N G
into a company’s quality program throughout engineering and manufacturing. A DE process starts with the upfront identification of deliverables and a shared management commitment to them. In establishing clear build objectives, whether they relate to fit and finish (such as an airplane fuselage gap and step), or functional (such as a cockpit door closing efforts), the entire engineering and design community focuses on the characteristics of the design that are most critical to overall quality. The development of ‘robust’ build strategies also helps keep the engineering community focused on defining a build process that will achieve the desired quality defined in the build objectives. GD&T: Through geometric dimensioning and tolerance (GD&T), the build objectives are translated into a common and meaningful language for communication of part and assembly specifications to manufacturing. Tolerance analysis: Another key element of the DE process is tolerance analysis, which is also known as variation analysis. Tolerance analysis is used to predict dimensional variability of the assembly and pinpoint the source of variation. Tolerance analysis ‘drives’ the design (both geometry and tolerances) and assembly process to achieve the defined quality (build objectives) and cost requirements, while meeting the component manufacturer’s capabilities. Tolerance analysis offers engineering the opportunity to optimise component tolerances to maximise quality while minimising costs. Measurement plans: As a product moves into production, the results of the tolerance analysis identify critical features, also known as key characteristic controls (KCCs).). These KCCs define
EM | Apr 2016
what is critical to quality and must therefore be measured. Measurement plans are developed based on these key features, and are communicated to the manufacturing floor. Once the
measurements are made, the data is loaded into standardised reports to monitor build quality and support rootcause analysis for problem identification and resolution during the build process. Advt
No.21, Sec 1, Zhongshan Rd., Wuri Dist.,Taichung City 414, Taiwan Tel: +886-4-2338-2068 / Fax: +886-4-2338-2161 E-mail: royal@royal-spindles.com.tw
www.royal-spindles.com.tw
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G E O M E T R I C D I M E N S I O N I N G & TO L E R A N C I N G | T E C H N O L O G Y
A closed loop process enables the reporting and problem-solving process from the plant floor to be combined with the simulation analysis model used in the development stages
Dimensional data reports and root cause analysis: Graphical reporting systems enable a template-based approach to quality management. CAD model data and measurement data from plant floor gages provide the basis for reporting, analysing and problem-solving using a standardised easy-to-interpret format that is visible across the corporation.
Maximising use of measurement data One of the key advantages of this ‘closed loop’ DE process is that the entire organisation can consider the impact of what was found and solved on the plant floor, feed the pilot or prototype date back into the variation analysis model, and adjust for any issues within a given product program. A closed loop process enables the reporting and problemsolving process from the plant floor to be combined with the simulation analysis model used in the development stages. This allows the valuable inspection data to also be used for virtual assembly fitting and process optimisation throughout the DE process. As finite element analysis (FEA) became an industry standard within engineering, variation analysis has also become commonplace. What is not yet a common practice is using these same analysis models for fit validation with actual measured data. Citing an example, we can view the fit conditions of panels on a fuselage section. Based on the fit conditions and the assembly process issues identified during virtual assembly of this fuselage section, engineering has the ability to optimise the design based on foresight into the manufacturing requirements.
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Robustness and timing The Defense Advanced Research Projects Agency (DARPA) considers US manufacturing capability a matter of national security, and ‘robust design’ functionality is a key element of this capability. Timing is a critical element to design robustness. A well-defined DE process allows users to use simulation and analysis to evaluate design and assembly concepts up front, where problems can be identified early in the product development lifecycle when the cost of quality is virtually free. It has been shown that nearly 70% of a product’s cost commitment occurs in the earliest 5 to 10% of the development cycle. At this stage, the downstream impact areas are all affected by the specifications set during initial design. ‘Runaway costs,’ scrapped parts and reworks often result when specifications are not validated until after manufacturing is well underway.
Today’s solutions Existing solutions support the upfront engineering process and downstream quality management that maximise the use of measurement data through a closed loop DE process. Issues can be analysed and multiple solutions considered through simulation, and validated through automated reporting and analysis. In today’s highly competitive environment, aerospace and defence manufacturers must consider the tools available to maximise their use of measurement data and ultimately reduce costs, improve quality, and shorten their time to market. ☐ Courtesy: Dimensional Control Systems (www.3dcs.com)
EM | Apr 2016
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M A N U FA C T U R I N G I T | A P P L I C AT I O N
Development of 3D roll forming machines The article discusses how to make use of modern CAE tools to analyse state-of-the-art research on 3D roll forming, to improve & optimise current forming technology and turn the achieved results into reality by making a 3D roll forming machine out of the virtual data by using the simulation software package Roll forming of tubes and profiles with continuous cross sections is a well-established forming and welding technology, and also a very effective way to produce long parts in high amounts. However, this production method has been limited to parts with constant cross sections only. Thus, this method was not applicable to the parts in the automotive industry, as generally parts in the BIW have varying cross sections over their longitudinal axis. Over the past 15 years, R&D activities have been performed on the so-called 3D roll forming for automotive industry in Germany, Sweden, Japan, USA and China and several prototyping machines have been manufactured. data M, developer of the commercial CAE software COPRA®, has accompanied this process from its first steps and performed its own R&D activities by using its own design and simulation tools. Thus, a working technology allowing the production of variable cross sections of profiles and tubes by flexible rolling stands has been developed, including the development of a special roll form CNC control system, which allows for high speed forming:
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Albert Sedlmaier Managing Director data M Sheet Metal Solutions GmbH a.sedlmaier@datam.de
COPRA® AMC (Adaptive Motion Control)
What is 3D roll forming? In 3D roll forming, sheet material is roll formed in subsequent forming stands into a profile shape with—over the length—discontinuous cross sections. The material type is pre-cut (trimmed) before entering the forming line. Basically, two types of 3D profiles exist. The first type has a cross sectional variation in width, the second a cross sectional variation in depth. Profiles with a variation in width are used in architectural applications already for a number of years. A major field of application for these types of profiles with varying width is, however, heavy or light weight commercial vehicles. Truck beams have to be manufactured in large numbers of variations, differing in length, width or even different sheet thicknesses. The target is to make all these parts on one machine with the same tooling. To achieve best dimensional results, a new patented type of 3D roll forming stands has been developed.
EM | Apr 2016
A P P L I C AT I O N | M A N U FA C T U R I N G I T
A P P L I C AT I O N | M A N U FA C T U R I N G I T
Process-machine interaction The roll forming process is strongly affected by the properties of the roll forming machine. A typical example for such an interaction is the shaft deflection in the forming stands. With the increased application of high strength steels, increasing loads cause unpredicted behaviour of the stands and decrease profile quality. As the machine concepts for the production of 3D profiles get more complex, sophisticated development tools need to be used to analyse the whole process and its interactions with all machine parts, already at an early stage. This becomes particularly important as the kinematics of the forming heads for flexible roll forming lines grow in complexity. Even using CAD systems, engineers often do not understand the true system performance until very late stage of design process. Mechanical, electrical and other subsystems are validated against their specific requirements, but a full-system testing and validation comes late, which leads to rework. A promising approach to overcome these difficulties are coupled simulations with the help of FEA programs integrating multibody dynamics. Loads and forces computed by these simulations improve the accuracy by providing better assessment of how they vary throughout a full range of motion and operating environments. Components of the machine like electrical, pneumatic and hydraulic actuators, power supplies, the machine bed, etc can be dimensioned with a much higher precision, including a precise prediction of their life time using the predicted loading cycles. Moreover, the results of the forming simulations of 3D roll formed parts are used to adapt and optimise the tool paths to obtain required part quality. In an European research project, different factors influencing the product quality of roll formed profiles have been identified. In order to validate the virtual simulation model – representing the machine and the sheet metal forming, the results from experiments have been compared with virtual results. Special roll forming stands had got designed and equipped with sensors to measure directly the forming forces and torques. After successful validation of this approach, coupled simulations were intensively used by the author’s company in order to design components of the latest 3D roll forming machines. Results of the predicted forces and torques can directly be used for the mechanical design of the forming stands and also for the dimensioning of electrical drives. Moreover, modern CAE tools like COPRAŽ FEA RF are able to represent integrated operations in the simulation of the roll forming process like cutting or sweeping of the profiles. The target of advanced 3D roll forming machine concepts is to produce with one tool on one machine whole families
EM | Apr 2016
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M A N U FA C T U R I N G I T | A P P L I C AT I O N
Examples of integrated operations in COPRA® software: sweeping
of 3D profiles. As the demands of the automotive industry tends to more flexibility, the production lines need to be adapted accordingly. While the profiles, which are variable in width have already a good potential to be manufactured with this new flexible technology, much larger potential lies in shapes, which have a cross-sectional change in depth. Simply because, this kind of components are widely used in different types of cars, pick-up trucks or so called SUVs. Currently, the parts are manufactured by stamping operations. However, this process is limited with respect to possible cross sectional shapes – like C-type profiles, which are partly or completely closed, the top die cannot access the inside of the profile and can, therefore, only be roll formed. One other restriction is the use of high and ultra high tensile materials. In roll forming, perfect geometrical tolerances may be achieved by overbending, which can easily be integrated in the roll forming process. New production concepts and the resulting machines can only be developed with the help of state-of-the-art tailored CAE tools, considering most of the aspects of the production process and covering most areas of engineering. The application of these tools results in a high engineering efficiency, saving time & costs, and enhancing the quality. Besides sophisticated CAE tools, another key factor for roll forming this kind of parts is an effective computer control for the forming machines. The kinematic complexity of the advanced machine concepts requires high advanced motion controls with the possibility to run the optimised forming curves with minimised acceleration values for optimal forming results, high forming speeds and high production flexibility. A tailored 3D CNC package is being used to optimise the process in real time. The realistic representation of the forming stands and their kinematics using the real controller allows for the investigation of the actuator kinetics and the required working space of the forming robots using a virtual
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collision control system.
Applications Recently, a 3D roll forming line for chassis long members (for commercial vehicles) has been developed, manufactured and been put into operation by data M. The profiles are unsymmetrically variable on both sides with a large number of variations in geometry. The large number of profile variations requires a special concept for the interface of the computer control, as the programming of the machine for a new part is completely done by software. The forming path is defined with the help of a simulation tool and then the result of the forming path along with some technological parameters is transferred by a process file to the control system. All the necessary machine settings are performed by actuators in the machine. Another advanced flexible roll forming line for 3D profiles variable in depth and height is currently under development. This new machine concept will offer the possibility not only to validate the simulation technology, but also produce physical samples for automotive applications.
Conclusion For the process design and the machine design, new simulation strategies need to be applied combining FEA simulations, multi-body dynamic simulations, CAD programs and kinematic simulations for workspace and collision investigations. With the 3 core competences required – high end simulation techniques using the standard roll form software tool COPRA® FEA RF, proven hardware components (flexible forming stands) and a newly developed computer control for 3D roll forming – data M SMS is planning and developing complete 3D roll forming lines for automotive industry. ☐
EM | Apr 2016
The interface to Industry 4.0
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electronic ifm electronic India Private Limited Plot No. P-39/1, MIDC Gokul Sirgaon, Kolhapur - 416234 Maharashtra Ph: 0231-2672770 E-mail: info.india@ifm.com Toll Free: 1800 233 2065
PLASMA CUTTING | TECHNOLOGY
The many faces of plasma cutting Plasma cutting is ideal for cutting steel, and its benefit include ease of use, higher quality cuts and faster travel speeds. The article highlights the facts to be considered, while choosing mechanised or manual plasma cutting systems. Plasma cutting is a thermal cutting process in which a beam of ionised gas heats an electrically conductive metal beyond its melting point and flushes molten metal through the kerf of the cut. The electrical arc is produced between the electrode (negative potential) in the torch and the workpiece (positive potential) being cut by ionising a beam of pressurised gas at a temperature between 14,000째 and 26,000째 F. The ionised gas (plasma) is constricted and focused through a nozzle, which produces a dense plasma arc that melts and severs various types of metal. This is the principal process for both manual and mechanised plasma cutting systems.
Manual plasma cutting Manual plasma cutting systems are moderately small power supplies that use a hand-held plasma torch for cutting various types of metals. These systems are manoeuvrable,
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Tex Whiting Consumable sales manager Hypertherm
versatile, and can be used for a variety of cutting applications. These power supplies have a range of cutting capabilities that is based on the output amperage of the cutting system. Power supplies commonly are rated as low as 7 to 25 amps and as high as 30 to 100 amps. Some power supplies, however, allow for hand-held cutting of up to 200 amps, but this is not typical. Manual plasma systems normally use shop air as the plasma gas and/or shield gas, and they are designed so that they can be used with several incoming voltages. The input voltage is between 120 and 600, utilising either one phase or three-phase power transmission. Manual plasma cutting systems generally are used by fabricating shops that handle thin metal, factory maintenance, farm maintenance, welding repair centres, metal service centres (scrap and dismantling applications), construction work (such as buildings and bridges), commercial ship manufacturing, trailer manufacturing, auto repair work, and
EM | Apr 2016
TECHNOLOGY | PLASMA CUTTING
TECHNOLOGY | PLASMA CUTTING
artwork. Typically, they are used in light-metal applications for trimming excess material. A typical 12-amp hand-held torch will cut a maximum of 3/16-inch material at approximately 15 inches per minute (IPM). A typical 100amp, hand-held torch cuts a maximum of 1 Âź inches material at approximately 20 IPM. Generally, a manual system is chosen based on the thickness of the material to be cut and the desired cutting speed. A system that delivers high cutting amperage cuts faster. However, when cutting at high amperages, it becomes increasingly difficult to control cut quality.
Mechanised plasma cutting Mechanised plasma cutting systems generally are significantly larger then manual plasma systems and are used in conjunction with cutting tables, including a water table or downdraft table with a gantry system that runs on various drives and motors. Also, mechanised systems have a CNC and a torch height control (THC), which may include initial height sensing and voltage control. Mechanised plasma cutting systems can be incorporated into a punch press, laser cutting, or robotic cutting system. The size of a mechanised plasma cutting configuration is based on the table and gantry being used. Tables may be smaller than 4 by 8 ft or larger than 48 by 120 ft. These systems are not easily maneuvered, so all of their components should be considered, along with the layout of the facility, before installation. Power requirements: Typical power supplies have a maximum amperage range of 100 to 400 for oxygen cutting and 100 to 600 for nitrogen cutting. Many systems have intricate cutting capabilities at lower amperage ranges, such as 15 to 50. Some systems allow for nitrogen cutting at 1,000 amps and higher, but they are not common. The incoming voltage for mechanised plasma systems is 200 and 600 with a three-phase power transmission.
EM | Apr 2016
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PLASMA CUTTING | TECHNOLOGY
The cutting speed and cut quality also depend on the plasma system, the CNC, and the gases selected
Gas requirements: Commonly used gases are compressed air, oxygen, nitrogen, and a mixture of argon/hydrogen for cutting mild steel, stainless steel, aluminium, and various exotic materials. Combinations of these gases are used as the plasma gas and assist gas. For example, for cutting mild steel, it is not uncommon to use nitrogen as the plasma cutting start gas, oxygen as the plasma cutting gas, and compressed air as the assist gas. Oxygen is used for mild steel (carbon steel) because it produces high-quality cuts in the material up to 1-1/4 inches thick. Oxygen also can be used as the plasma gas for stainless steel and aluminium cutting, but it produces a rough-looking cut. Nitrogen is suitable as a plasma gas and assist gas as it produces excellent cut quality on almost every type of metal. It is used for high-current applications, cutting metal up to 3 inches thick, and as the assist gas when cutting with nitrogen and argon/hydrogen plasma gas. Compressed air is the most commonly used gas, as both a plasma gas and an assist gas. It works relatively well for lowcurrent cutting applications in metals up to 1 inches thick, leaving an oxidised cutting surface. It is used as the assist gas when cutting with air, nitrogen, or oxygen plasma gas. An argon/hydrogen mix usually is the plasma gas of choice for cutting stainless steel and aluminium. It provides a high-quality cut, and it is required for mechanised cutting of material thicker than 3 inches Carbon dioxide (CO2) also can be used as an assist gas when cutting with nitrogen plasma because it cuts most metals and provides good cut quality. Nitrogen/hydrogen and methane (CH 4) are two other types of gas occasionally used in the plasma cutting process. Plasma and assist gases are only two of the critical choices that need to be taken into consideration when installing or using a mechanised plasma system. Gas tanks are available for purchase or rent, and they are offered in many different sizes, which mean an area needs to be created to store them. A substantial amount of wiring and plumbing for gas and coolant is involved with the installation of a mechanised
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plasma system. Beyond the mechanised plasma system itself, a table, gantry, CNC, and THC will need to be chosen. OEMs generally offer an array of equipment choices that are adequate for any cutting application.
What mechanised process makes sense? Because of the complexity involved in selecting a mechanised plasma cutting process, a substantial amount of time should be set aside to research various system configurations and criteria. The parameters to be considered are types of parts to be cut, number of production pieces cut per batch, desired cut quality and speed, cost of consumables and overall operating cost of the configuration (including consumables, electricity, gas, and labour). The size, shape, and quantity of the production parts may dictate the type of CNC, table, and gantry required. For example, production parts that are small and intricate may require a gantry with a specialised drive package. The rackand-pinion drives, servomotors, drive amplifiers, and encoders used on the gantry determine the cut quality and speed capability of the plasma system. The cutting speed and cut quality also depend on the plasma system, the CNC, and the gases selected. A mechanised system that has current ramping and gas flow ramping at the beginning and end of the cut will increase consumable life. Furthermore, a CNC with high storage capacity, a variety of programming capabilities (such as freezing the height of the torch at the end of the cut), and fast processing speed (input/ output communication) will lead to a decrease in operational downtime and an increase in cutting speed and accuracy. Ultimately, the decision to purchase or upgrade a mechanised plasma system or use a manual process should be based on the facts. Faced with such a decision, a fabricator should consider size, shape, and thickness of the material being cut. �
EM | Apr 2016
G R E E N M A N U FA C T U R I N G | S P E C I A L F E AT U R E
Re-modelling green measures Spread across 54 acre land, Godrej Appliances facility at Shirwal goes beyond boundaries in spreading green and lean manufacturing initiatives. It is the first plant in India to be felicitated with the GreenCo – Platinum award by CII – Green Business Centre. The article briefs on how the plant has evolved in achieving a sustainable manufacturing and growth over the years. ‘Mission on Sustainable Growth’ – a CII initiative, was adopted by Godrej & Boyce, at the behest of Jamshyd Godrej, CMD, Godrej & Boyce Mfg Co Ltd. The objective here was to involve the senior management of the member companies and seek their commitment to set voluntary targets for reducing intensity of resource usage. Some of the commandments embodied included control over fuel or power consumption, waste reduction or water conservation. This created awareness across the organisations, giving clear, measurable action points in every critical area, common to all businesses. The targets set were dovetailed into the performance management
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Hussain Shariyarr Senior Vice President—Operations Godrej Appliances hussain@godrej.com
system so that clear accountability and responsibility towards the environment could be established. Employees across all levels in businesses were drawn into the mission, which resulted in perceptible results across the company. The initiative helped institute an internal assessment system for the efforts towards sustainable manufacturing and growth.
Quest for the Platinum The Shirwal plant of Godrej Appliances embarked upon its GreenCo journey in August 2013. In 2010, we adopted the
EM | Apr 2016
S P E C I A L F E AT U R E | G R E E N M A N U FA C T U R I N G
There has been a 58% reduction in energy consumption in over 10 years. The team at Shirwal believes that it can be lowered even further to the best levels prevailing globally
Good & Green CSR initiative, which gave us a push to further realise our ambitious targets. We recognised that the ambitious targets set by us would not only help us make the platinum rating, but also help us becoming ‘Good & Green’ for the society.
Pursuing efficiencies in energy consumption In 2004-05, our energy consumption was 17 kwh/appliance, which stands reduced to 7.1 kwh/appliance in 2015-16 – a healthy reduction of 58% over the last decade. We were able to achieve this as a result of many significant initiatives, undertaken to reduce energy consumption, that were of a fixed and variable nature. Progressively, we converted the consumption that assumed to be fixed to a variable one. Our usage of renewable energy has been rising year-after-year. The initiative of pursuing efficiencies in energy consumption has led to the conservation of electrical energy of about a million kwh in the last three years, saving us a sum of ` 74 lakhs. As the savings have been larger than envisaged, the investment of ` 1.12 crores stands recovered in mere 1.5 years as against the planned period of 3 years. Our GHG emissions too have been reduced proportionately. There has been a 58% reduction in energy consumption in over 10 years. The team at Shirwal believes that it can be lowered even further to the best levels prevailing globally.
Reducing water consumption We have taken a number of measures ranging from the adding of five new bore-wells with recharge chambers, rain water harvesting and creating a water body in an innovative way on a hilly terrain. The water consumption has fallen from 132 ltr/appliance to 70 ltr/appliance, a reduction of 47% over
EM | Apr 2016
8 years. Frequent water crisis, triggered by vagaries of the climate, forces water authorities to shut off supplies from the nearby river, leaving us, high and dry. This nudged us to aim for becoming water neutral and eventually, water positive by 2015. We have taken a number of measures like adding of five new bore-wells with recharge chambers, rain water harvesting and creating a water body in an innovative way on a hilly terrain. We have spent approximately ` 50 lakhs on all these initiatives. They will help us reduce our dependency on water tankers for our supply.
Renewable energy In 2015-16, renewable energy is 24% of our total consumption as against mere 7% in 2010-11. Our gasifier plant, which generates producer gas, has been the star performer in this area. Producer gas is now used for firing our powder coating and other ovens. The refrigerator test labs have now switched over to solar heating instead of electrical energy. Now, even the computers in the offices are powered by solar energy. Going ahead, we intend to harvest solar power for cooking meals for our people. Some benefits are 5.6 lakh litres of diesel have been conserved in last three years, resulting in saving ` 91 lakhs, which is notwithstanding the fact that diesel prices have been increased by the government by 51% in the last three years. 1500M greenhouse emissions have been prevented on account of the above measures. Over next two years, we want the share of renewable energy to increase to more than 40% of the total energy consumption.
Material recycling The amount of hazardous waste sent to the landfill has dropped considerably by 55% in the last 4 years. Godrej
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G R E E N M A N U FA C T U R I N G | S P E C I A L F E AT U R E
The plant has taken a number of measures ranging from the adding of five new bore-wells with recharge chambers, rain water harvesting and creating a water body in an innovative way on a hilly terrain
Appliance is targeting zero waste to landfill by end of 2016. Consequently, we have embarked upon many innovative projects, e.g using ETP sludge and ash generated in burning powder coating hangers in brick making process. We have got the bricks tested in external labs for their performance and impact and they qualify all test requirements. A study conducted on our products confirmed that the recyclability of our products is nearly 100% and the recycled content ranges between 25-35%. Even in the future, we aim to retain 100% recyclability of all our products. Another innovative project undertaken by us deals with doing away with conventional carton packaging. We have introduced plastic film packaging for our refrigerators, which results in saving of 2.8 kg of packaging material, i.e. ` 50 per refrigerator. Considering the number of refrigerators we produce, this conservation amounts to saving of 1100 tonnes of paper per year and 17 trees are saved with every ton of paper. Besides, our recycling strategy has yielded impressive results. Items like thermocole and used empty silicon spray bottles are sold back to suppliers for reuse. Plastic lumps, rejections, foam and used oil are reused nearly by 100%, after some processing. Waste packing wood is used as a fuel for the producer gas plant and the waste paper is converted into pulp for recycling. We believe we are on a solid ground to meet our ambitious goals.
Green supply chain Our green efforts must extend to our larger family including vendors. As part of our cluster development journey, we took in 51 of our suppliers and introduced our green module midway into the journey. Our suppliers were enthusiastic and undertook several initiatives such as setting
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up of an effluent treatment plant, solar power for office computers, induction lamps, planting trees and cultivating lawns for making their campuses greener. A study of our critical suppliers has shown that over the last two years, water consumption has been reduced by 34.91%; energy consumption by 15.94% and waste generated is reduced by 7.21%. Our efforts have resulted in honouring our nation’s commitment to the Montreal and Kyoto Protocols regarding ozone depletion and climate change.
Product stewardship Products rolling out of Godrej Appliances Shirwal plant have done well in the domain of Good & Green. The Edge Pro range of refrigerators delivers a stellar 6-star energy performance, while being completely green in its usage of refrigerant and foaming agent. The ‘Green Balance’ split air conditioners are extremely frugal, consuming 20% less energy than conventional ACs. Our efforts have resulted in honouring our nation’s commitment to the Montreal and Kyoto Protocols, regarding ozone depletion and climate change. To conclude, I would like to state that our dash to platinum rating was a short one, only 18 days between the application for the award and the award itself. We now enjoy unique distinction of being the first facility in India having GreenCo Platinum rating. Only four plants in India have achieved till date this rating. Other plants having platinum rating are the second facility of Godrej Appliance at Mohali, ITC-Kovai & Vasavdatta Cement – Sedam. Going green has also enabled us transform our campus to a sylvan green landscape from a barren hillock. This transformation never seizes to amaze the visitors and our own people who now work in this healthy, soothing and cool facility. ☐
EM | Apr 2016
Image courtesy - IGCC
EVENT | REPORT
Opting German production technology For the fourth time in succession, the German machine tool industry showcased its capabilities in India with the one-day symposia organised in Chennai on 15th March and in Pune on 17th March. A post event report… The German machine tool industry continues to arouse keen interest in India. For the fourth time in succession, the VDW (German Machine Tool Builders’ Association) has joined forces with the Indo-German Chamber of Commerce to organise a one-day symposia recently in Chennai and Pune. 17 front-ranking companies like DMG Mori, EMAG, Gehring, Gleason-Pfauter, Heckert, Heller, Hermle, Kapp, Leistritz, MAG, Mauser, Open Mind, Peiseler, Profiroll, Samag, Schwäbische Werkzeugmaschinen and Waldrich Coburg showcased their products, solutions and services for modern-day industrial production operations. Around 240 customers from the automotive industry and its component suppliers, the general mechanical engineering sector, and the aviation industry accepted the invitation in Chennai; while 220 customers came to Pune.
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“This is already the fourth occasion that the VDW has been represented in two cities at a time with its symposia in India. This has proved to be a good idea, because of the country’s size and its regional distribution of industrial activity,” explained Klaus-Peter Kuhnmünch, Manager— General Affairs, VDW.
India’s machine tool market offers huge potential With a market volume of almost 1.8 billion euros, India came eighth in the world rankings for machine tools in 2015. The VDW’s British forecasting partner, Oxford Economics, expects the Indian economy to pick up speed in the years ahead, with industrial production output and capital investment both rising. The machine tool market is predicted to expand by
EM | Apr 2016
REPORT | EVENT
Networking with potential Indian companies
9 to 10 per cent in both 2016 und 2017. The growth of the Indian market is directly linked to improvements in the local infrastructures. “The slogan ‘Make in India’ is aimed at central investments on the spot, and creates ideal conditions for direct investments from abroad. We want to benefit directly from this welcome trend,” emphasised Gerhard Flores, Head of Technological Development and Patents, Gehring Technologies GmbH, Ostfildern, who was attending the symposium.
German manufacturers see a turnaround It was in 2007 and 2008 that the German machine tool sector achieved its biggest successes in India. Exports reached a figure of just under 300 million euros. In the two subsequent years, the worldwide financial and economic crisis caused them to shrink by a quarter. In 2014, for example, the volume of exports was a mere 150 million euros. In 2015, however, signs of a turnaround emerged, which the sector is keen to benefit from. To quote Dr Manfred Berger, Executive Vice President – Global Sales, MAG IAS GmbH in Eislingen, “It’s primarily the automotive industry and its component suppliers that are our principal focus in India. We are anticipating a significant growth in these customer sectors in the future. International component suppliers, in particular, are exhibiting growth potential of exceptional dynamism.”
Japan’s traditional role as leader under attack The most important foreign vendor nation is, of course,
EM | Apr 2016
Japan, which in 2014 supplied 25% of India’s imports. The German manufacturers, by contrast, as the second-largest supplier category, upped their share from 13 to 14.5%. The order situation in India, too, recorded growth of 41% in 2015, compared to the preceding year. Nonetheless, Japan’s leading position in India has strengthened over the past decade. The German machine tool manufacturers active in India are aiming to successively increase their market shares in relation to Japan. The sophisticated pricing structure plays a crucial role here as an important influencing factor. Maximilian Waizenegger, Regional Sales Manager at the machinery manufacturer Maschinenfabrik Berthold Hermle AG in Gosheim, explained, “India has for many years now been a very price-sensitive market. German machine tools are regarded as too expensive. We are observing, however, that increasingly more expensive machines are also being purchased, and that awareness levels for the importance of high quality on the spot are rising very significantly.” Jens Wunderlich, Authorised Signatory at Profiroll Technologies GmbH in Bad Düben, confirmed this statement, and also outlined two strategic approaches for how, in his view, it’s possible to handle the Indian market better in future, “Firstly, German manufacturers have to be prepared to provide technological support on the spot, extending above and beyond the needs of other markets. Secondly, as a company in India, you have to be prepared to modify your products to suit the market’s needs on the spot, which also means slimming down the machines to their essentials in line with the customer’s actual requirements, and providing local service support,” he said.
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EVENT | REPORT
Over 200 participants in attendance
Symposia are ideal platforms In order to enter into direct dialogues with Indian customers, and broker new business relationships, the VDW has for years now been offering its successful technology symposia in India. Firms like DMG Mori, Emag, Gehring, Heller and Profiroll are already involved for the fourth time. For Viktor Schulze, Sales Manager, Samag Saalfelder Werkzeugmaschinen GmbH in Saalfeld, the concept is a cogent one. “The symposia are a brilliant platform, not least for the smaller German vendors. The customers come to us, and are keenly interested. During the symposia, we had an opportunity to conduct intensive conversations. In addition, it’s a great to get to know more about the Indian market. Otherwise you’d have to do that by yourself.” Dr Berger of MAG IAS added, “The visitor quality in Chennai and Pune was very good, and I’m very satisfied with the entire event.” The event itself, and the product solutions being showcased by the German companies concerned are being well received by the Indian customers. K Mohan, Managing Director at the Indian automotive component supplier Sep India PVT Ltd in Hosur, puts it succinctly, “The symposium is a unique opportunity to familiarise yourself with the diversity of German machine tools. In contrast to a trade fair, you find out all you need to know in a single day, and can enter into direct discussions with the vendors concerned.” Ashol Aseri, Vice President—Aviation Division, Maini
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Precision Products Limited, Bengaluru, was primarily impressed by the performance spectrum of the German machine tools on show, and said “The automotive and aviation industries need maximised quality. Only German vendors can meet these expectations in terms of precision, efficiency and high availability levels, which is why we are only prepared to consider machines from Germany.”
German machine tool industry opts for can-do associates The VDW’s symposium was organised in conjunction with the Indo-German Chamber of Commerce. In the view of Hubert Reilard, Chamber of Foreign Trade President in India, the Indian subcontinent is an important market for the German mechanical engineering sector. Under the new government, particularly, India’s industrial sector is achieving notable development, and German vendors, with their production capabilities, could assume a crucial role for the country’s upcoming industrialisation thrust, he emphasises. Klaus-Peter Kuhnmünch of the VDW confirmed this, and added, “We, as the German machine tool industry, are confident that India will, in the future too, continue to develop with vigorous dynamism. Chennai and Pune, in particular, are home to the centres of India’s automotive industry and its component suppliers.” So, the association will also be present here in the future for the mutual benefit of Indian customers and German machine vendors.
EM | Apr 2016
REPORT | EVENT
“German & Indian companies can match-make together” …says Klaus-Peter Kuhnmunch, Manager—General Affairs, German Machine Tool Builders’ Association (VDW), in this conversation with Maria Jerin, during the one-day technology symposia organised in Pune. Excerpts… What is the significance of VDW Symposium in Chennai and Pune? German machine tool companies, since many years, are interested in the Indian market for business with the potential customers. VDW is building platforms like symposiums that help German companies to showcase their capabilities and technologies in the form of presentations for the Indian customers. We see this as a very exclusive opportunity. It plays a key role where German companies and Indian customers can match make together. It is a good way of doing business. This year, 17 front-ranking companies showcased their products, solutions and services for modern-day industrial production operations at the symposium. What is your outlook and expectations from the Indian market and its potential? India has a very big market with huge potential customers. Therefore, German companies see opportunities to make business in India, particularly at customers, from the automotive industry and its component suppliers, and the mechanical engineering sector, in general. In India, the market sentiment is better since last 2 years with new government promoting investments. So, we would like to take a part in this given development. Also, India is the third biggest market in the Asia for the German machine tool industry. Looking at the figures, the German machine tool orders intake from India in 2015 is increased by 41%, compared to the previous year. So, the business is growing and also opening up new avenues in different industrial sectors. How do you think these events in Chennai & Pune help VDW and its member companies fulfil these expectations? Around 240 potential customers in Chennai, mostly from the automotive industry, and 220 customers in Pune were a
EM | Apr 2016
part of the event. We are very happy with the response. The event provided networking sessions with lot of discussions for business possibilities with Indian customers. To an extent, some companies are in concrete negotiations with Indian customers. How was the performance of the German machine tool industry last year? Last year, German machine tool industry witnessed a good performance. We had the highest production outcome ever of more than 15 billion euros. VDW reports showed that in 2015, we had a growth of 4%, which was the highest production ever since 1997. This year, we expect another increase of 1% in machine tool production. Our main customers are currently in China, the US, Italy, and Mexico. The order intake from India has also increased last year by ranking 13th in terms of orders. We are more confident that its position will move up in the coming years. Going forward, what are the future plans for the Indian market from VDW? We will continue supporting our companies and their business here in India. In the upcoming IMTEX exhibition, VDW will organise German participation together with Indo-German Chamber of Commerce. We will come back in the next two years for the symposium. We have a close partnership with the Indian Machine Tool Manufacturers' Association, and we exchange figures between IMTMA and VDW. Also in recent years, we have noticed that the local Indian machine tool industry is getting better in terms of technology incorporation and business models. Though for some critical applications, machine tool exports from Germany are in demand and we are ready to provide it. ☐
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T E C H | TA L K
Work hardening, & how it affects machining
Work hardening is the process of a metal becoming stronger and harder by plastic deformation, due to changes in the crystal structure of the material. When you bend a piece of wire back and forth a few times, it becomes harder to bend at the same point. This becoming ‘harder to bend’ is work hardening. Some metals like low-carbon steel, pure copper and aluminium can only be strengthened this way. They are deliberately work hardened by hammering, rolling or drawing. Jewellery wire of silver and gold is commonly work hardened. In metal cutting, you can usually identify work hardening on the part visually – the cut surface appears shiny and slipper. A couple of big causes are as follows: t Machining with a depth of cut that is too low. The work piece gets compressed and springs back instead of being cut. Such repeated cuts cause repeated deformation and work hardening. t The tool’s cutting edge is not sharp, resulting in some of the material getting compressed instead of being sheared off. Work hardening can occur when cutting any metal at all – plain carbon steel, stainless steel, titanium, etc. It’s effect is to increase cutting forces, increase vibrations, reduce tool life and reduce part quality. To avoid work hardening, one can cut with sharp inserts or tools, use cutting parameters recommended by the tool manufacturer such as feed rate & depth of cut. One should not
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G V Dasarathi Director – Applications Cadem Technologies das@cncetc.in
I m a g e c o u r t e s y : Cadem Technologies
When a piece of wire is bent back and forth a few times, it becomes harder to bend at the same point. This becoming ‘harder to bend’ is referred to work hardening. The column talks on what causes work hardening and what can be done so as to avoid work hardening
Some metals like low-carbon steel, pure copper and aluminium can only be strengthened by work hardening
cut with a depth of cut less than 0.05 mm. In thread turning of stainless steel, it should be ensured that the depth of cut is more than 0.08 mm. This can happen without your knowing, because the canned cycle reduces the depth of cut in each cut to keep the cutting load constant. In addition, dwells and peck drilling should be avoided. ☐
EM | Apr 2016
NEWS | TECHNOLOGY
3D imager
Milling head units
FARO Business Technologies has announced the product launch of the new FARO Cobalt 3D Imager with on-board computation capability aimed at improving productivity and operations in the manufacturing sector. The Cobalt 3D Imager is an automated, non-contact variable field coordinate measuring sensor that is easily deployed within manual or automated Cobalt 3D Imager manufacturing workflows. Ideal for use directly in the production floor environment, Cobalt can be installed in conjunction with a rotary stage, robot, industrial inspection cell, or multiple imager array configurations. By combining blue-light projection, stereo cameras and powerful on-board processing, the Cobalt captures and processes millions of 3D data points in seconds. With high resolution, automatic exposure and high dynamic range, Cobalt expertly handles complex parts with fine details, varying colours, textures, and reflectivity. It delivers fast and consistent measurements, independent of the operator, for quality inspection and reverse engineering applications on parts, assemblies, and tools. It was designed to be the first imager in its class with dedicated on-board point-cloud processing.
PARA MILL offers new milling head unit, ML02-3000 that could be assembled to do vertical, horizontal and transverse milling operations. The NC milling head provide right hand side milling and left-hand side milling that allows for vertical, horizontal and reversed horizontal milling. Also, it is available to mount with the angular head. The lubrication system is lubricated by using automatic pump or automatic lubricator. The gearbox structure is fitted with high speed bearing and fixed well at both sides to avoid vibration during NC Milling Head ML02-3000 heavy duty cutting. The circulating oil with the slideway base cooling system reduces the temperature of the milling head. 90 ° angular head/Universal milling head can be equipped with the milling head unit. High precision, low noise and vibration free characteristics of the milling head provides different speed for machining function and also can be equipped for drilling machines and boring machines. The company is specialised in providing double-sided milling machines, horizontal milling machines, and milling head units.
FARO Business Technologies India | New Delhi Email: amrita.gokhale@faro.com | Tel: +91-11-4646-5656
PARA MILL PRECISION MACHINERY | Taiwan Email: para@paramill.com | Tel: +886-4-26800678
Gouging shield for air plasma systems Hypertherm offers new Max Control gouging shield for people wanting even greater control when gouging with Powermax® air plasma systems. The new gouging shield is designed for jobs in which the operator needs to remove a very precise amount of metal. The tip of the shield is engineered and machined in a way that allows the operator to create a very shallow gouging profile. The introduction of the Max Control gouging shield expands the offerings of Powermax gouging consumables, which include the existing Max Removal gouging shield and HyAccess™ extended gouging consumables. Max Removal shields are Max Control gouging shield designed to remove a large amount of metal and leave a deeper gouging profile, while HyAccess provides the extra reach needed when gouging in hard to reach or confined spaces. Max Control, Max Removal and HyAccess gouging consumables are available for Powermax systems using a Duramax or Duramax Hyamp™ torch. This includes the Powermax65® through the Powermax125® and older systems with Duramax retrofit torches such as the Powermax600®, Powermax900® and Powermax1650®. Hypertherm India Thermal & Cutting | Chennai Email: info@hypertherm.com | Tel: +91-44-23845361
EM | Apr 2016
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TECHNOLOGY | NEWS
Clamping chucks
Sealing rings
MAPAL has expanded its programme of narrow contour HTC clamping chucks, whose narrow shapes are produced without a restrictive brazed joint, thanks to Additive Manufacturing. These new chucks can directly clamp diameters of 3, 4 and 5 mm, now also allowing hydraulic clamping chucks to be used on the micro-scale, for example in medical technology or the HTC clamping for small diameters timepiece and jewellery industry. ranging 3, 4 and 5 mm The HTC with a narrow contour offers all the advantages of the proven MAPAL HTC (High Torque Chuck) technology, with the ‘T’ standing not only for ‘torque’ but also for ‘temperatureresistance’. The wide operating temperature range of up to 170 °C ensures additional process reliability. The balancing quality is G = 2.5 at a turning speed of 25,000 min-1. The chuck is suitable for all machining in contourcritical areas. It allows the tool to be clamped easily and quickly. In other words, no training courses are required on its implementation, and no high set-up costs or expensive peripheral devices are needed.
Trelleborg Sealing Solutions offers Zurcon® Glyd Ring® D that gives the perfect combination of sealing performance and service life, through optimised contact pressure and minimised heat generated from friction. The new Zurcon® Glyd Ring® D is manufactured from Zurcon® Z13 polyurethane material, which Zurcon® Glyd Ring® D has been specially developed to cope with pressures up to 500 bar / 7,250 psi at both sides of the seal and at temperatures up to +120 °C / +248 °F. The seal, therefore, gives long life, even under demanding conditions. Offering superb mechanical and elastic properties, the seal loses none of its resilience and can be used in cylinders with lower quality inner walls. Core industrial applications for Zurcon® Z13 Glyd Ring® D include construction machinery, earthmoving equipment, mobile cranes, forklift trucks and any other solutions involving mobile hydraulics. The seal offers superior resilience and good friction properties. It is compatible with hydraulic, mineral, synthetic and water-based fluids and with a hardness of 60 shore D offers outstanding wear resistance and hydrolysis resistance.
MAPAL India | Bengaluru
Trelleborg Sealing Solutions | Bengaluru Email: rohit.nair@trelleborg.com | Tel: +91-80-33729355
Email: info@in.mapal.com | Tel: +91-80-41782500
Gauging software
Cutting tool inserts
Renishaw offers Equator™ flexible gauge with the new INTUO™ gauging software, combined with a range of industry standard Renishaw probes. INTUO simplifies and automates the gauging of a wide variety of parts, removing dependence on the skill of manual gauge users. Reducing gauging inconsistency reduces scrap, whilst ensuring parts that are out of tolerance are always identified. INTUO with Equator is an INTUO™ gauging software with ideal alternative to multiple manual Equator devices such as vernier or digital callipers, micrometers and plug gauges. Equator is highly repeatable and runs fast automated routines, meaning significantly reduced labour costs. With many workshops using hundreds of manual gauges this cost saving can be considerable. INTUO, with minimal training, uses intelligent functions to help the engineer set up gauging of parts in a matter of minutes. Shopfloor operators then select and run those programs using the user-friendly Renishaw Organiser frontend software. The company is also launching the Equator Button Interface (EBI), with simple push-button controls for shop-floor operators.
Seco Tools has added larger insert sizes to its popular T4-12 line of square shoulder and helical milling cutters. This allows parts manufacturers to achieve increased depths of cut and higher metal removal rates when roughing and semi-finishing steel, cast iron and other workpiece materials. In continuing the value and stability T4-12 square shoulder and helical inserts of the T4-12 line, these largerrange sized inserts all come with four curved cutting edges that lower the tooling cost per part and ensure smooth machining operations. These inserts tangentially mount in their cutter bodies for increased performance stability and easier access to their mounting screws. Moreover, this type of mounting directs the cutting forces to the thickest part of the inserts, which contributes to the higher metal removal rates of these products. Cutter diameters for the larger T4-12 square shoulder inserts range from 25 mm to 125 mm (1" to 5"), with corner radii up to 3.1 mm (0.125"). The inserts also come in a wide selection of grades and geometries.
Renishaw | Pune
Seco Tools India | Pune Email: Bharati.Sawant@secotools.com | Tel: +91-21376-67406
Email: samina.khalid@renishaw.com | Tel: +91-20-4900-1589
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EM | Apr 2016
NEWS | TECHNOLOGY
Universal grippers
Coolant system
SCHUNK has extended its PGN-plus mega-seller with pneumatically powered universal gripper SCHUNK PGN-plus-P and electrically powered SCHUNK PGN-Plus-E. Three technical innovations distinguish the newcomer SCHUNK PGN-plus-P. First, there is the improved multi-tooth guidance. By enlarging supporting dimensions between the six loadbearing shoulders of the patented multi-tooth guidance, higher moment can be accommodated and, thus, longer fingers can be used. Secondly, permanent lubrication is provided via the PGN-plus-P continuous lubrication pocket in the guidance. Finally, the SCHUNK PGN-plus-P has an enlarged drive piston area, whereby gripping force is increased and higher workpiece weights can be handled. The electric SCHUNK PGN-Plus-E applies the highperformance features of the pneumatic flagship directly in the area of mechatronic handling. It also has modified the multi-tooth guidance for the accommodation of higher moment, a continuous lubrication pocket in the guide contour, and the proven diagonal-pull kinematics with a high surface coverage in all stroke positions.
Haas Automation offers the Haas Flood Coolant Ring, which is standard on all VM and VF series Haas machine tools, provides a cascade of coolant that thoroughly lubricates the cutting area, while dispersing chips produced during cutting. The coolant ring concept is a significant improvement over traditional hose-based systems. The ring’s Flood Coolant Ring fully adjustable nozzle tips direct precision coolant flow to the tool from many angles. The nozzles are easy to move, and the ring is positioned for maximum clearance and ease-of-use. While the Flood Coolant Ring serves as the main Haas coolant delivery system, numerous other cooling options are available. For instance, the Haas Programmable Coolant Nozzle, or P-Cool, can take up numerous positions to serve any tool selected, long or short. Another effective method of getting coolant to the cutting zone is to deliver a high pressure blast through the tool tip. Here, the Haas ThroughSpindle Coolant (TSC) system is available in either 300 or 1000 psi (20 or 70 bar) configurations.
SCHUNK Intec India | Bengaluru Email: info@in.schunk.com | Tel: 080-4053-8999
Email: tmiranda@haascnc.com | Tel: +91-8080902412
Haas Automation India | Navi Mumbai
ECM drilling machines For drilling of the necessary bores engine, builders are increasingly using the ECM technology offered by EMAG. This non-cutting production technology radically simplifies the whole process. The advantages of ECM drilling include simplicity, wherein there is no ridge and bur formation and there is consequently no need for chip removal; stability, wherein the microstructure is not damaged by thermal influences; speed, wherein multiples of bores (and workpieces) can be machined simultaneously; requiring ECM process no subsequent deburring; flexibility, wherein the process can be used both in hard and soft processing chains and savings, wherein the life expectancy of the boring cathode is extremely high. As such, the high tooling costs for deburring are avoided. The ECM method is ideal for difficult bore transitions and also simplifies the production process. Advantages like minimal tool wear and the total absence of adverse thermal effects on the workpiece has made the success story of the ECM drilling process in the commercial vehicle sector also to the attention of the passenger car sector. EMAG India | Bengaluru Email: HAshwini@emag.com | Tel: +91-80-4254-4400
EM | Apr 2016
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H I G H L I G H T S | C O M PA N Y I N D E X | I M P R I N T
Highlights - May 2016 IMPRINT Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Features Writer Megha Roy megha.roy@publish-industry.net
» Metal forming Metal forming tends to have more uniform characteristics across its subprocesses than its sub-processes than its contemporary process, cutting and joining. It enjoys industrial importance among various production operations due to its advantages such as cost-effectiveness, enhanced mechanical properties, flexible operations, higher productivity and considerable material saving. The next issue highlights the recent developments in the metal forming process.
» Power presses Power presses are dangerous machines, which have caused many accidents over the years. The causes include poor maintenance of the press, its safeguards and its control systems. The next issue of EM will provide information on the safe usage of power presses. » Industrial parts cleaning Owing to constantly increasing requirements in terms of efficiency, quality and environmental protection, the cleaning of industrial parts has become essential in manufacturing processes. A successful cleaning process requires careful selection of both the cleaning chemistry and equipment. Cleaning process is influenced by various factors viz. manufacturing process, cleaning media, surrounding conditions, work-piece quality, parts handling, testing process, etc. The next issue will highlight various solutions in industrial parts cleaning.
» Titanium machining Titanium is a popular material for the aerospace, marine, and medical industries. Titanium parts are stronger than their steel counterparts but weigh half as much. Furthermore, titanium components have twice the elasticity as steel parts, which make them ideal for applications that require flexible components that won’t crack or disintegrate under extreme forces. Next issue will features trends in this area.
Features Writer Maria Jerin maria.jerin@publish-industry.net Advertising Sales Sagar Tamhane (Regional Head - North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net Dhiraj Bhalerao (Regional Head - West & South) Contact: +91 9820211816 dhiraj.bhalerao@publish-industry.net Prabhugouda Patil Bengaluru Contact: +91 9980432663 prabhu.patil@publish-industry.net Advertising Sales (Germany) Caroline Häfner (+49 - 89 - 500 383 - 53) Doreen Haugk (+49 - 89 - 500 383 - 27) sales@publish-industry.net Overseas Partner Ringier Trade Media Ltd China, Taiwan & South-East Asia Tel: +852 2369 - 8788 mchhay@ringier.com.hk Design & Layout Jogindar J Dumde (Graphics Designer) jogindar.dumde@publish-industry.net Editorial & Business Office publish-industry India Pvt Ltd 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Tel: + 91 - 20 - 6451 5752
COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . .Page Ace Micromatic Group . . . . . . . . . . . . . 13 Ann Way Machine Tools Co . . . . . . . . . . 25 ARC Advisory Group . . . . . . . . . . . . . . . 24 BIEMH . . . . . . . . . . . . . . . . . . . . . . . . 45 Blaser Swisslube . . . . . . . . . . . . . . . . . 11 Cadem Technologies . . . . . . . . . . . . . . . 60 CII . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cumberland Group – Chicago . . . . . . . . 22 data M Sheet Metal Solutions . . . . . . . . . 44 DCS . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Dees Hydraulics Industrial . . . . . . . . . . . 49 DesignTech Systems . . . . . . . . . . . . . . . 32 DMG Mori . . . . . . . . . . . . . . . . . . . . . 1, 9 Encon Systems International . . . . . . . . . . 24 Emag . . . . . . . . . . . . . . . . . . . . . . . . . 63 Epicor . . . . . . . . . . . . . . . . . . . . . . . . 28 Faro . . . . . . . . . . . . . . . . . . . . . . . 8, 61 Femco . . . . . . . . . . . . . . . . . . . . . . . . 15
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Name . . . . . . . . . . . . . . . . . . . . . . .Page Festo Corporation . . . . . . . . . . . . . . . . . 36 Forbes & Company . . . . . . . . . . . . . . . . 31 Gedee Weiler . . . . . . . . . . Back Inside Cover Godrej Appliances . . . . . . . . . . . . . . . . 52 Haas Automation . . . . . . . . . . . . . . . . . 63 Hero Motocorp . . . . . . . . . . . . . . . . . . . 8 Hypertherm . . . . . . . . . . . . . . . . . . 48, 61 Hyundai WIA India . . . . . . Front Inside Cover ifm electronic India . . . . . . . . . . . . . . . . 47 IGCC . . . . . . . . . . . . . . . . . . . . . . . . . 56 igus (India) . . . . . . . . . . . . . . . . . . . 4, 12 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . 43 Jyoti CNC Automation . . . . . . . . . . . . . . . 3 Kim Union Industrial Co . . . . . . . . . . . . . 61 KPIT Technologies . . . . . . . . . . . . . . . . . 8 Mapal India . . . . . . . . . . . . . . . . . . . . . 62 Micromatic Machine Tools . . . . . . . . . . . . 9 MMC Hardmetal India . . . . . . . . . . . . . . 27
Name . . . . . . . . . . . . . . . . . . . . . . .Page MotulTech . . . . . . . . . . . . . . . . . . . . 9, 29 Optis . . . . . . . . . . . . . . . . . . . . . . . . . 16 Para Mill Precision Machinery Co . . . 61, 63 PMT Machines . . . . . . . . . . . . . . . . . . . 35 PTC . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Renishaw . . . . . . . . . . . . . . . . . . . . . . 62 Royal Precision Tools Corporation . . . . . . 41 Schunk . . . . . . . . . . . . . . . . . . . . . . . 63 Seco Tools . . . . . . . . . . . . . . . . . . . . . 62 Siemens PLM Software . . . . . . . . . . . . 2,10 Strausak . . . . . . . . . . . . . . . . . . . . . . . 39 TaeguTec India . . . . . . . . . . . . Back Cover Tata Motors . . . . . . . . . . . . . . . . . . . . . 10 Trelleborg Sealing Solutions . . . . . . . . . . 62 VDW . . . . . . . . . . . . . . . . . . . . . . 10, 56 YG1 Cutting Tools . . . . . . . . . . . . . . 20,21
Board of Directors Kilian Müller (CEO - Worldwide) Hanno Hardt (Head - Marketing & Business Development) Frank Wiegand (COO - Worldwide) Shekhar Jitkar (Publisher / Chief Editor) Subscription Cover Price: `100 Annual Subscription Price: `1000 em.india@publish-industry.net Tel: +91-20-6451 5754 Printing Kala Jyothi Process Pvt Ltd, S.No: 185, Kondapur, R R District, AP 500 133, INDIA Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of editorial contributions is only allowed with express written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted. Internet http://www.efficientmanufacturing.in Digital edition http://issuu.com/publishi/docs
EM | Apr 2016