EFFICIENT MANUFACTURING
VOL 06 | JUN 2015 www.efficientmanufacturing.in
EFFICIENT MANUFACTURING
JUNE 2015 I VOLUME 06
Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong
GREEN MANUFACTURING
Energy, products & processes
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FOCUS Metal forming
P. 38
SPECIAL FEATURE Laser processing P. 70
EM - Interview Hugh Dowding Director & Head MotulTech
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Cover Inside MITUTOYO.pdf
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HAIMER Power Clamp: Reliable shrinking – Fastest in the galaxy.
Shrinking Technology Tooling Technology
Balancing Technology
Measuring Instruments
Haimer India Pvt. Limited | Indo-German Technology Park | Survey No. 297-299 | AT & Post-Village Urawade, Taluka-Mulshi IN Dist. Pune-412108 Maharashtra | Phone: +91-20-66 75-05 51 | Email: haimer@haimer.in | www.haimer.in
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E D I TO R I A L
Transforming to green! “The more you know about green processes and products, the better position you are in to contribute to green manufacturing drive”
The environment around us, today, is in a poor shape and environmental problems have become a primary threat to the society. With this, consumers are not only becoming increasingly aware and conversant with green, but they are also adopting green habits and buying green products. While consumers believe that as individuals, they can and should contribute to sustainability by adopting green products, they also hold manufacturing companies to a higher standard when it comes to being green. That’s why many of the companies now want to fully leverage the potential of green and adopt comprehensive green strategy so as to get the most from their sustainability initiatives. Going green is nice, but not if it hinders your ability to compete in the realities of the marketplace. With the right approach and defined goals, green manufacturing, which includes green products and/or green processes, holds potential economic benefits including long-term cost savings, waste reductions and process efficiency improvements. Whether the focus is on green products or green processes, a green approach to manufacturing is important and valuable. Having said that, the more you know about green processes and products, the better position you are in to contribute to green manufacturing drive. With this, we are bringing you the Cover Story on this topic in this issue that discusses on what it takes to go green, emerging technologies for making the traditional businesses greener as well as creating completely new ones, challenges in adopting green, and implementation framework. Happy reading!
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net EDITORIAL ADVISORY BOARD Sonali Kulkarni President & CEO Fanuc India
N K Dhand CMD Micromatic Grinding Technologies
Dr Wilfried Aulbur Managing Partner Roland Berger Strategy Consultant
Dr K Subramanian President, STIMS Institute, USA Training Advisor, IMTMA
Vivek Sharma Managing Director Yamazaki Mazak India
S Ravishankar Managing Director Walter Tools India
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
Satish Godbole Vice President, Motion Control Div Siemens Ltd Vineet Seth Managing Director India & Middle East Delcam Plc
Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
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CONTENTS
Market
Management
10 NEWS
Focus
32 “We are looking for opportunity to work with end-users�
16 “WE SEE A BIG BENEFIT FOR INDIAN
COMPANIES IN 5-AXIS METHODOLOGY�
Interview with Rajeev Vaidya, MD, Open Mind Technologies India
18 “Maximising investment with 3D
Interview with Rajiv Bajaj, GM - India, Stratasys AP
Metal Forming
38 Building Nextgen sheet metal CAM
The article highlights the nextgeneration CAD/CAM systems and enabling technologies for punching, laser cutting and bending machines
34 Indigenous eastern innovation
printing�
Interview with Hugh Dowding, Member of the Board of Directors, Motul SA, France and Director & Head - MotulTech
A report on the facility visit to the technology centre of FEMCO at Pune.
Market Trends 20 Building a ‘Make in India’ brand
The article features the importance of driving manufacturing in India by establishing dynamic infrastructure
Cover Story 26
Green manufacturing
A read on how successful transformation into green manufacturing will bring benefits for the nation and business community
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CONTENTS
Technology
Cover image courtesy: Shutterstock
PLM/DIGITAL MANuFACTuRING 42
Configuring production processes
CuTTING TOOLS 62
Machining ISO-S materials
The article analyses productive solutions for specific industry applications
The article deals with the application benefits of PLM to enhance productivity
TEST & MEASuREMENT SuRFACE TREATMENT 48
66
Solutions for machining industry
The article details the advantages of standard coatings, while suggesting ways by which impressive results can be achieved
SPECIAL FEATuRE 70
Meeting aerospace challenges
The article underlines the importance of aersopace manufacturing industries to work closely with high precision quality standards
COuNTRY SPECIAL: JAPAN 74
MACHINING 56
Prototyping with machining centre
The article details on NEXX helmets that are manufactured with Haas vertical machining centre
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Exploring laser dimensions
The feature details on the factors contributing on adopting laser technology in the manufacturing space
AEROSPACE MANuFACTuRING 52
Reducing part set-up time
An application story on the use of the PrimoTM probe system used by SuMax Enterprises
Recovering manufacturing industry
The article briefs on the industry performance and latest technological advancements in the Japan machine tool industry
New Products 77 CNC turning grinding compound machine, CNC tool grinders, Ring cutting band saw, Metal 3D printing systems for dental parts 78 Solenoid valve, Compact design for cable protection; Electrochemical machining solutions, Contour measuring system 79 Tool grinding toolholder, Thread chaser insert holder, Double margin indexable drill, Oil mist recycling machine
Columns 07 08 80 80
Editorial Contents Highlights – Next issue Company index
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MarkEt | news
Brush Group leverages on ANSYS solutions
Adani plans 1,000 MW solar park in Tamil Nadu
Brush Group has recently boosted the performance of its generators for gas, steam and hydro-turbine drive applications by leveraging Ansys’ multiphysics engineering simulation solutions. The company chose Ansys simulation to reduce the six-month lead time for new design generator manufacturing and to reduce the extensive costs and complexity of design modifications. “The smallest units weigh at least 40 tonne, take up to six months to manufacture and contain many small design change opportunities, some with The tools accurately simulate unmeasurable aspects. So, it is simply impossible the impact of mechanical to take each new design option to the point of changes on the airflow physical prototyping. “Simulation software, within a turbogenerator especially integrated, multiphysics simulation, is vital to reduce the variables that these design changes create in a virtual environment before moving to production,” said Sarah Allen, Generator Development Manager, Brush Turbogenerators. The Brush Group is leveraging ANSYS solutions for structures, fluids and electronics. The tools accurately simulate the impact of mechanical changes on the airflow within a turbogenerator.
After announcing solar parks in Gujarat and Rajasthan, adani Power has recently confirmed their plans to set up a 1,000 MW one in Tamil Nadu. The proposed energy park is likely to attract around `7,000-crore investment. The sources said a deal had been signed with the state government and the project is at an exploratory level. The project would be developed in four phases. The company is planning to set up the park at Kamuthi in Ramanathapuram The project would be developed in district, around 550 km south of four phases Chennai, and is in the process of acquiring approximately 5,000 acres, the sources said. The construction would commence in the next eight months and the company might look at replicating its Rajasthan model. This would be an integrated solar photovoltaic manufacturing facility, with an investment of up to $4 bn (`25,000 crore). The development comes against the backdrop of the centre’s decision to set up 1,00,000 MW of solar capacity by 2022.
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Enhancing productivity & aid in next-gen design
Kaizen’s 10th incremental improvement competition
Geometric recently announced the availability of a new version 4.0 of its kirloskar Brothers’ all-women Coimbatore facility has emerged as the automated design for manufacturability solution, DFMPro for NX™ software. winner in 10th Kaizen Incremental DFMPro version 4.0 delivers enhanced design flexibility with newly Improvement Competition organised by added support for additive the Quality Circle Forum of India (QCFI) in manufacturing, tubing and Chennai. Kaizen is a system of continuous sand casting processes. NX, improvement in quality, technology, developed by Siemens’ processes, company culture, productivity, product lifecycle management safety and leadership. In today’s corporate KBL Coimbatore team received (PLM) software business, is environment, Kaizen activity is one of the two “Excellence Awards” for the an integrated 3D computer- benchmarked tools that enhance the presentation made by teams on the aided design, manufacturing and engineering analysis (CAD/CAM/CAE) growth of any organisation. KBL Coimbatore theme of “Process Improvements” software. With a variety of processes being used for manufacturing parts in team received two “Excellence Awards” a single product, DFMPro can help design engineers learn and apply for the presentation made by teams on the theme of process Improvements. manufacturing best practices for different processes, thus, avoiding “We are honoured to receive this recognition for our continual quality downstream rework and cost problems. Design problems that result in improvement practices. KBL’s Coimbatore plant encourages its employees secondary operations and support structures for additive manufacturing at all levels in various undertakings at the facility to participate in all our and hot spots, porosity, high shrinkage and cracking issues during sand quality enhancement initiatives. Employee involvement has helped in casting process can be avoided. Tubing, leakage and performance issues creating a work-friendly environment and helped increase productivity at can be avoided using DFMPro. With v4.0, NX users can gain access to the the plant. We continue to make incremental improvements in our processes to make them more efficient,” said Dr Raj Kumar, Plant Head – Coimbatore. introductory additive manufacturing suite on request. > MORE@CLICK EM01673 | www.efficientmanufacturing.in
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MarkEt | news
Promoting sustainable development practices Frost & Sullivan recently concluded its 6th edition of the ‘Green an integral role in the field of sustainability in India. Nitin Kalothia, Manufacturing Excellence Awards’ (GMEA) and India Sustainability Summit Director-Manufacturing & Process Consulting Practice, Frost & Sullivan, (previously referred to as the Green Manufacturing Excellence Summit) reiterated that, “Sustainability is an indispensable part of being resilient, at Hyatt Regency, Mumbai. Frost & Sullivan’s Manufacturing & Process proactive, and progressive with changing times. Companies need to Consulting Practice has been promoting collaborate with its key awareness and adoption of sustainable stakeholders across the development practices across Indian value chain to maximise manufacturing companies through a the benefit of this initiative, healthy benchmarking and incisive stand-alone focus will not feedback process under this awards be sufficient”. This year’s platform. Multiple sub-parameters award model brought ranging from sustainable strategy, risk together experiences from management, stakeholder engagement, the previous editions to occupational health and safety systems, include the concept of environmental management, and social ‘shared value’ that involves accountability are tracked under the Various organisations from the Indian manufacturing sector shared their creating economic value aegis of sustainability through this knowledge & experiences from their sustainability journey in such a way that it also platform. At the summit, various generates value for all the organisations from the Indian manufacturing sector gathered under one stakeholders by addressing their needs and challenges. The re-engineered roof to share their knowledge and experiences from their sustainability model supports shared value by giving equal importance to creating journey. Best practices from companies across industries were shared partnerships with all those who have an interface with their organisation. > MORE@CLICK EM01675 | www.efficientmanufacturing.in along with strategic keynote presentations by industry stalwarts who play
SKF signs agreement with ReGen Powertech
Stratasys partners with Creaform
SkF has recently signed a strategic agreement with Regen Powertech. Stratasys recently announced a joint marketing partnership with Creaform, Under the terms of the agreement, a worldwide leader in portable 3D measurement solutions. This new SKF will supply pitch and yaw bearing partnership empowers users to leverage cutting-edge 3D scanning sets and mainshaft bearings for the technology and world-class 3D company’s 1.5 MW wind turbines. “This printing technology designed to agreement positions us as a strategic streamline the process across partner with a key manufacturer of various industries and applications. wind turbines in India. These bearings With a professional-grade solution, SKF will supply pitch and yaw will be manufactured at SKF’s the user is able to accurately scan bearing sets and mainshaft state-of-the-art manufacturing facility any 3D object and quickly generate bearings for Regen Powertech’s at Ahmedabad. This is a reflection of print-ready files or even perform 1.5 MW wind turbines SKF’s response and commitment to the direct 3D-scan-to-print. “3D printing and 3D scanning go hand-in-hand. government’s ‘Make in India’ program,” This combination is targeted at allowing companies of all types to accelerate said Shishir Joshipura, MD & Country Head, SKF India.“ReGen has been their product development processes and ensure that their products truly buying main shaft bearings from SKF since its inception. The partnership meet the needs for which they were designed. We believe that Creaform’s with SKF has helped ReGen to grow in the Indian market. The new Go!SCAN 3D scanners and VXmodel Scan-to-Print software are the perfect agreement signed for supply of pitch and yaw bearings are another step complement to Stratasys 3D printers,” said Marco St-Pierre, Division Vice towards strengthening this partnership between the two companies. SKF President — Innovation and Technology, Creaform. “There is clear and has always been the preferred partner for ReGen and this relationship will natural synergy between our technologies, audiences and applications, and continue to grow,” says Madhusudan Khemka, MD, ReGen Powertech. partnering with the market leader is a tremendous opportunity for us.” > MORE@CLICK EM01676 | www.efficientmanufacturing.in
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> MORE@CLICK EM01677 | www.efficientmanufacturing.in
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MARKET | NEWS
Indo-German Business Forum VDMA recently organised Indo-German business forum along with the three technical service fee payable on transfer of technology would encourage knowledge partners ASA & Associates manufacturing and eventually promote LLP, BDB India, and Euro Asia Consulting the ‘Make in India’ initiative of the Indian in Pune, Bangalore and Chennai government. Introduction of Goods & respectively. The forum showcased Service Tax (GST) from April 2016 would various measures taken up by the be a game changer for the manufacturing Indian government towards the future sector as it would bring about significant growth of manufacturing by initiating cost efficiencies by integrating the National Manufacturing Policy with a entire tax structure into one single piece target to achieve 25% share of GDP and of legislation. Increase in threshold from creating 100 million additional jobs in `50 to `200 million of domestic transfer manufacturing sector by 2025. Indian pricing transactions would result into government will have to develop lesser compliances for companies in specific actions to rejuvenate the SMEs. It also discussed the localisation manufacturing sector and grow at 14% and the sourcing strategies. In-house CAGR for next 10 years to achieve the production process make localisation target. However, to achieve this there is The forum showcased various measures taken by the Indian government comprises localising not only the a need to overcome major challenges towards the future growth of manufacturing product, but also adapting the like competition from developing and production processes to realise localised developed countries, complicated tax structure, skill development, low R&D cost structure and achieving similar quality levels to reduce production investments, poor infrastructure and slowing global economy impacting costs and increase margins. > MORE@CLICK EM01678 | www.efficientmanufacturing.in exports. The reduction in tax rate from existing 25 to 10% on royalties &
Demand for machine tools takes a breather in Germany
WIKUS inaugurates its first manufacturing plant in India
During the first quarter of 2015, order bookings for the German machine tool industry were down by 8% compared to the first quarter of 2014. Domestic orders fell by 19%, while orders from abroad shrank by 2%. “Compared to a strong first quarter in 2014, demand for machine tools is currently taking a breather,” said Dr Wilfried Schäfer, Executive Director, The fall in demand results VDW (German Machine Tool Builders’ primarily from the significant Association). The fall in demand, he said, downturn in domestic orders results primarily from the significant downturn in domestic orders, crucially reflecting the high base effect of last year’s strong equivalent period. Compared to the first two months of 2015, however, March reveals a perceptibly better picture. “The German economy is trending upwards, as the latest IFO Business Climate Index makes clear. Due to the weak euro and the low raw material prices, we anticipate that domestic demand from our high-export-ratio customer sectors, too, will gather momentum in the months ahead,” added Schäfer.
WIKUS had recently unveiled its new manufacturing unit at Chakan, Pune. This unit claims to serve answers to the selection of right band saw blades with high quality performance with a wide range of innovative products, which satisfies customer’s requirements. “We’re delighted that this new unit is equipped to ‘Make in India’ and well-positioned to meet the market demand for sustainable The unit will offer high precision sawing technologies in the sawing technology country. “With high quality performance, this unit will offer high precision sawing technology to the customers and will help to increase our distribution reach. It also focuses more towards reaching the customers for after sales & services,” said Mukund P Bharadwaj, CEO, WIKUS India. Wilhelm H Kullmann found ‘WIKUS’ Spangenberg (Germany) in 1958. With 50 years of experience in developing & manufacturing high performance cutting tools, the company has initiated positively steps towards India for establishing the manufacturing unit to serve Indian customers.
> MORE@CLICK EM01679 | www.efficientmanufacturing.in
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German Machine Tool Industry European orders underpin demand for German machine tools Order Intake [Index, nominal – 12 months moving averages] 240
original values
moving average
200
160
120
80
Orders 1Q 2015, % to previous year Total: -8%
Domestic: -19%
40
Foreign: -2%
0
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
Note: Index basis shipments 2010=100, data until March 2015 Sources: VDW, VDMA
30.04.2015
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Verein Deutscher Werkzeugmaschinenfabriken e.V. (VDW)
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© 2014 Siemens Product Lifecycle Management Software Inc. Siemens and the Siemens logo are registered trademarks of Siemens AG. All other trademarks, registered trademarks or service marks belong to their respective holders.
Automotive suppliers must accelerate innovation to adapt to new realities. Industry Breakthrough Position Brief.
Automotive OEMs are racing to make smarter, more efficient vehicles. Demands to double fuel economy and cut emissions in half over the next decade are driving major changes in powertrain and vehicle architectures. OEMs are also expanding the use of electronics and embedded software. And all of this is happening during a time when global markets are rapidly growing. To stay competitive in such a dynamic environment, Tier 1 suppliers have to embrace change without exposing themselves to risk. They need top-notch program execution to deliver innovation on time, on budget and within quality standards. More specifically, Tier 1 suppliers must improve electronics and software development in the context of an overall system to deliver increasingly complex products for a growing number of product variants that get engineered and manufactured all over the world. Suppliers need a standardized, simplified approach to: 1) optimize designs and accelerate validation, 2) enable crossdiscipline development, 3) adapt to changing global demands and 4) improve visibility into program execution and risk. Extended teams must be able to collaborate efficiently to bring together mechanical, electrical and software systems flawlessly. Siemens PLM Software calls this new approach “Executing Program Innovation.” And the engine that drives it is a
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collaborative platform that improves cross-functional knowledge sharing and overall decision-making. With this platform, Tier 1 suppliers gain a better understanding of how their decisions affect everyone in the value chain...as well as their bottom line. Strategies to achieve fuel efficiency and emission standards Improving efficiency of the drivetrain
59%
Lightweighting vehicles Greater reliance on embedded software to control systems
48% 42%
Investing in hybrid technology
39%
Investing in electric drive technologies
30%
Improving battery performance
30%
Investing in fuel cell technology
29%
Other
7%
0% All respondents
20%
40%
60%
Percentage of respondents, n = 218
Source: “How Prepared is the Automotive Industry? Solutions for Meeting Fuel Efficiency and Emissions Standards.” January, 2014. Aberdeen Group, Inc.
Siemens PLM Software has helped many of the industry’s top Tier 1 suppliers deliver more innovations—on time, on budget and to specifications. If you want to learn how to overcome the new challenges of the automotive industry, download a free white paper at bit.ly/autoinnovation.
6/8/2015 5:09:48 PM
MARKET | INTERVIEW
“We see a big benefit for Indian companies in 5-axis methodology” Rajeev R Vaidya, Managing Director, Open Mind Technologies India, in this interaction with Megha Roy, discusses the application areas of hyperMILL®, while suggesting adaptive tool geometries to provide higher efficiency Can you brief us on the application areas of hyperMILL®? What are the latest innovations happening in the CAD/CAM Applications of hyperMILL® include complex mould & die industry? machining for tool rooms and automotive industry, tire Additive manufacturing will replace material removal in moulds, engine and structural parts as well as landing gears in some areas, especially in aerospace industry, where the parts aerospace, R&D areas, prototyping, turbine wheels and rotors, will have to be smaller, lighter and, therefore, more complex blades, bladed disks, shrouds, impellers. to be machined. Standard CAD systems do not anymore fulfill the requirements for CAM, therefore a dedicated CAD How does your products enable cost-effective & efficient development to meet the CAM needs is required. New adaptive manufacturing processes? tool geometries will provide higher efficiency in roughing & hyperMILL® reduces programming time of high-quality NC surface finishing, CAM systems will allow the programming programs. It offers a patented, automatic of machine-integrated measuring and collision avoidance technology to make will provide NC-integrated methods to machining safer, better and faster. The dynamically react on the measuring results. CAM system offers the ability to program CAD/CAM systems will interface with the latest machining technology within an the CNC controls not only through NCeasy-to-use user interface. It comes with an programs, but will also access internal CNC all-in-one (unified) PP including 2D, 3D and data to match machine data like tools and 5-axis machining, which requires no manual origins with the programmed data. editing. Any workpiece can be programmed easily Brief us on the latest solutions from your with hyperMILL®. All strategies for 2D, 3D, company for the die & mould industry. HSC, 5-axis machining and mill-turning are 5-axis milling machines of different available in a single user interface. As far as configurations utilise strategies to achieve the user is concerned, it means continuous economy in terms of mass production of die processes and minimised machining times or moulds, not forgetting quality. We see a for maximum process safety, cost-effectiveness and quality. big benefit for Indian companies in 5-axis methodology with machine and CAM software to get best results. The number Can you highlight on the integrated solutions offered by your of dies & moulds are increasing and the 5-axis technology is company for automated programming & optimised processes? already in production modes in various big and small tool One of the features of hyperMILL® is the numerous automation rooms (commercial tool rooms also). hyperMILL® CAM options, with which efficient machining of complex strategies are designed to meet these demands too. workpieces is easy to implement. With our feature and macro technology hyperMILL®, user can standardise & automate the What are your further expansions plans in the Indian market? programming of geometries like hole and pocket features. It India is a growing market which offers a big potential in offers many options for using CAD geometry information for different industry sectors, such as aerospace, mould & die and CAM programming. Also, CPF (Customised Process Feature) energy. Since years, we are having our own subsidiary in India, allows the user to identify repeated geometric components and we want to extend our business and to grow further. ☐ > MORE@CLICK EM01681 | www.efficientmanufacturing.in to apply predefined manufacturing sequences for it.
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MARKET | INTERVIEW
“Maximising investment with 3D printing” Rajiv Bajaj, General Manager – India, Stratasys AP, in an interaction with Maria Jerin, briefs the advantages of 3D printing technology, while analysing the company’s initiatives in making the technology affordable to Indian market
Having worked with the CAD/CAM industry for many years, how do you strategise your initiatives in taking 3D printing technology to the next level in India? 3D printing offers revolutionary advantages throughout the manufacturing process, right from conceptualising to final product creation. Extending my experience from CAD/CAM industry, here in India, we have plans to work with relevant verticals like education, healthcare, manufacturing and government departments to increase 3D printing’s reach in the country. We are going to organise the first India 3D Printing User Forum this year, a platform to allow manufacturers, opinion leaders, designers and engineers to exchange their expertise and experience. While ‘Customer first’ remains our priority, we also work closely with channel partners to deliver service excellence. What applications are best suited to Direct Digital Manufacturing (DDM) process? How DDM takes the leading edge over traditional manufacturing? 3D printing benefits go beyond just prototyping; Direct Digital Manufacturing being one of them. It can help tide over many conventional design and manufacturing limitations, producing durable tools, patterns, moulds and production parts that may not otherwise be feasible. It will not replace traditional manufacturing methods, but are likely to work hand-in-hand within the industrial environment, helping manufacturers and factory owners maximise investment through best-suited solutions according to their design and production needs. One best example is that of the leading aircraft manufacturer Airbus producing more than 1000 flight parts on its Stratasys FDM 3D Production Systems for use in the first-of-type A350 XWB aircraft. Airbus used the 3D printed parts in place of traditionally manufactured ones to increase supply chain flexibility, enabling delivery commitment on-time. What is your company’s initiative in making 3D printing technology affordable to Indian SMEs? Our professional products and solutions can help SMEs
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spark ideas, modify their ideas quickly at an initial stage, and accelerate time-to-market, to capture the largest business potentials ahead of their competitors. With the option of 3D printing production systems, SMEs can even manufacture products in low volume and cost-effectively with reduced production time. Our 3D printing systems range from entry desktop 3D printers to professional grade workstations, in parallel to a comprehensive range of materials, providing truly scalable 3D printing solutions to drive adoption by manufacturers ranging from medium and small enterprises to heavy industries. What are the latest 3D printing solutions in the offing in India as well as globally? Recently, we have launched 11 new 3D printing products and materials at Euromold 2014, including two new Fortus FDM production systems as well as a significant expansion of our triple-jetting Connex line of multi-colour, multi-material 3D printers. We launched our first experience centre in Bangalore showcasing wide range of 3D printing product portfolio, solutions and applications. Brief about the new facility in Bangalore. How will it support the growing demand for 3D printing solutions? The 3D Printing Experience Centre in Bangalore features Stratasys’ latest PolyJet™ and Fused Deposition Modeling (FDM®) technology. It also exhibits a wide range of 3D printing materials - PolyJet photopolymers and FDM thermoplastics. It allows our customers to see our innovative technologies in action and realise the values and advantages of 3D printing technology. We recognise the importance of bringing the technology closer to where its customers are, to bridge the gap and ensure higher awareness among local population. We will set up a couple of more such experience centres in other parts of the country this year, to stay closer to our customers and to support the market’s growing 3D printing requirements better. We are also accelerating our workforce expansion in India to meet the growing demands of our products and market. ☐ > MORE@CLICK EM01682 | www.efficientmanufacturing.in
EM | Jun 2015
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MARKET | TRENDS
Building a ‘Make in India’ brand The part-two series of the article features the importance of driving manufacturing in the country by establishing a dynamic infrastructure. Capacity and efficiency improvements in infrastructure should be the focus area for the government. As new approaches such as “Industry 4.0” become more prevalent, it becomes key to enable not only roads, ports, railways and other projects, but to also drive dynamic telecommunications and internet usage in the country. Globally, emission standards are becoming more stringent with the EU generally leading the charge. Looking at CO2 emissions, European targets for 2020 are, for example, about 65% more aggressive than those of the US. India is the world’s third largest Green House Gas (GHG) emitter with 6.6% of total global emissions [behind China (25.4%) and the US (17.3%), 2010 numbers]. India cannot abdicate her responsibility towards a cleaner and sustainable future both from a global and even more importantly from a local
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Dr Wilfried G Aulbur Managing Partner India Chairman Middle-East Head Automotive Asia Roland Berger Strategy Consultants wilfried.aulbur@rolandberger.com
perspective. The current discussions around air quality in major Indian metros clearly indicate that awareness of pollution and its impact on quality of life is increasing in India as well. Green manufacturing requires a green manufacturing framework, i. e. a consistent approach to sustainability across the value chain. A green strategy must cover green procurement, green processes, green products and green marketing as well as green reporting and risk management. Procurement, for example, must focus on energy procurement, eco-friendly raw
EM | Jun 2015
TRENDS | MARKET
India remains a laggard in the world of innovation - for every patent India files, China files 35 patents!
materials and supplier management that drives sustainability may need to be leveraged to satisfy investors who demand down the line to Tier I, II and III suppliers. Processes need to carbon disclosure. Examples of successful, green manufacturing initiatives in be optimised constantly via eco-efficiency analysis, waste analysis, water and energy conservation, etc. Products need to India abound. Take Godrej’s “Fast Card” as one example. It is a be designed to minimise eco impact along the product life smokeless paper mosquito repellent that provides a mosquito cycle and marketing needs to address and appeal to the values free environment for 4-5 hours at the cost of just ` 1. To reach and sustainability needs of customers. Last but not least, such an aggressive price point dictated by the needs of the reporting and risk management needs to focus on efficient customers (farmers in rural areas that would like to get one communication of green approaches to all stakeholders and night of undisturbed sleep), Godrej had to re-invent the needs to be pro-active in terms of anticipating and fulfilling product and its production process. The mosquito repellent formula was changed to reduce water content and to allow for future regulations. Sustainability will fundamentally change the way citizens rapid drying hence reducing both water and electricity look at manufacturing and plants. Take the German company, consumption during the production process massively. Clearly, Wittenstein, as an example. In 2012, Wittenstein invested in a green manufacturing is not only the right thing to do but also brand new production facility in the middle of a residential enables companies to provide profitable solutions even for zone near Stuttgart, Germany. In a noise and emission sensitive “Bottom of the Pyramid” customers. Germany, Wittenstein's factory is low-noise and zero emission, hence enabling it to be embedded in an urban environment. Leveraging global best practices Direct benefits from the plant are offered to residents in the In the coming decades, India will need to transform herself vicinity such as offering surplus heat from production for house heating free of charge. In the future, intelligent energy from “copy and paste” manufacturing to innovation driven systems will influence production processes such that energy manufacturing. While global innovation leaders in India exist intensive production will only be executed if energy demand today, the task is to transform industries and companies such in the neighborhood is low. Flexibility of production is that innovation leaders are the norm rather than exception. Market factors driving this need are many. Customers are enhanced due to the short distances between employees' homes and their work place. Quality of life of workers is improved at constantly becoming more sophisticated and individualised. This requires covering of more market niches and subthe same time. Indian companies, and especially Indian MNCs, hence segments, shorter time-to-market for products and increased need to pursue green manufacturing initiatives due to a number risks of R&D amortisation. Technologies, such as Industry 4.0 of factors such as resource scarcity, climate change, import that we discussed earlier in this paper, threaten to negate dependence, government regulations, etc. Customer pull for competitive advantages if not mastered. Alternative “new” green products is continuously increasing and – if not taken R&D areas (China, Eastern Europe, etc) may win the race for seriously - may be leveraged by competition to create product manufacturing and related service jobs based on better and brand differentiation. Opportunities for profitable and products and higher margin retention and hence higher green manufacturing increase due to advances in science and competitiveness of their companies. Stronger global IPR laws
EM | Jun 2015
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MARKET | TRENDS
In recent years, China has intensified knowledge-intense work and managed to emerge as a new innovation powerhouse
may have a negative impact on “Copy and Paste” manufacturing. India’s “Hero” culture The key reasons for driving innovation in China include the Creating a “Make in India” brand will require consistency following : Incentives and subsidies from the Chinese government: and excellence in manufacturing and engineering across the China has initiated extensive programs to increase R&D value chain. It will also require the same consistency across activities including a USD 600 bn investment program to industries. “Country of Origin” brands are not built by a few support focus industries during the 12th five year plan, companies achieving world-class standards but by an ecosystem wide-ranging tax exemptions on equipment imports and of companies that convinces local and global customers time substantial subsidies for R&D. Policies have been issued to and again of the quality, performance and value of their strengthen intellectual property protection. products and services. Need to respond to local market needs: Chinese companies India still has significant improvement potential in this and MNCs are increasingly localising their R&D to cater to area. Take the domestic machine tool industry as an example. rapidly changing and increasingly sophisticated consumer Without a doubt, a high-performing domestic machine tool tastes. Setting up R&D centres increases reaction speed and industry will be crucial for transforming India into a provides a competitive boost to service a large and growing manufacturing hub. The key customers of the machine tool market. industry [automotive (47%), non-electric machinery (21%), Crucial importance of R&D for Chinese MNCs in their quest electronics/electrical machinery (15%) and aerospace & to penetrate global markets: Increased investment in R&D by defense (15%)] depend on high-quality, high-performing local firms is driven by their desire to cater not just to China machines to drive their business to global levels. but also to serve the global market. R&D on high value-added India’s position in terms of both consumption and products is crucial for Chinese firms to tap these markets. production of machine tools leaves room for improvement, Rapidly increasing knowledge resources and attractive especially if compared to China, a country with a similar human capital: Availability of highly skilled labour at population size. While domestic production of machine tools comparatively low costs drives R&D efforts in China both for as percentage of total market has increased from 18% to 41% domestic firms and MNCs. during the FY09-FY14 time period, it remains woefully low in Concerted Chinese efforts have resulted in impressive international comparison with corresponding negative impacts growth in both R&D personnel as well as number of patents on the balance of payments. filed. India’s challenges are similar to the ones listed for China. A key reason for the continued dominance of imported To turn these challenges into opportunities, India should machine tools is the strong preference of customers in India actively leverage global best practices. Blue prints for increased towards imports for high value add work. Results of a recent R&D performance exist. Take Fraunhofer from Germany as an ACMA-IMTMA-Roland Berger study clearly indicates that example. Fraunhofer’s mission for applied research is to benefit advantages for imports are factors such as alignment with private and public enterprises and to drive competitive strength environmental best practices, achievement of very high through innovation. Fraunhofer operates with a variety of tolerances, lower total cost of ownership and technology business models and has been instrumental in improving leadership. Domestic players mainly outperform international products, commercialisation of new technologies, etc globally. competition regarding spares availability, service support and
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EM | Jun 2015
MARKET | TRENDS
A domestic machine tool industry will be key for transforming India into a manufacturing hub; indigenisation levels are insufficient but increasing
pricing. Flexibility to meet customer requirements is seen as another strength. As far as weaknesses are concerned, commonly mentioned concerns regarding domestic players include poor reliability, workmanship and build quality; limited technology, design, application engineering; limited standardisation, quality of sub parts; poor integration & customisation of peripheries; commitment to quality and lead time; process capability and not plug & play, poor documentation. These weaknesses are severe and not limited to the domestic machine tools industry. Similar observations can be made across industries as Roland Berger’s experience with operational performance improvement programs in India has shown. All these weaknesses can and must be addressed in order to transform manufacturing in India. Drivers for change are many. A qualified dual education program for labour and continuous education activities for labour are necessary. If manufacturing is supposed to drive India’s economy it is high time to respect and invest in the people that will have to make it happen. Co-operation of government and industry potentially similar to the work of the Chambers of Commerce in Germany will be key to drive this initiative. Incentive systems for labour as well as white collar should be fair and have a significant variable portion tied to quality and on-time performance. A “chalta hai” attitude is not acceptable in today’s hyper-competitive world and pay checks in addition to continuous communication are a good way to drive cultural change. Checks and balances need to be implemented in companies and driven from the top. Change can only happen if top management takes an active interest in driving process and efficiency improvements. Only what gets measured will get done. Certifications need to be treated with the respect that they deserve. The importance of an ISO certification is not to prepare yourself for the audit, get a piece of paper and then
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forget about it till the next audit. Certifications are crucial to drive quality, consistency and efficiency across companies and the corresponding processes must become part of the DNA of an organisation. Consistent investment in R&D is a must. Currently, domestic machine tool manufacturers spend on average 0.5% of their turnover in R&D, a ratio that is 5x less than that of foreign machine tool manufacturers that tend to dwarf local players in size. Cross-industry collaboration is a key to ensure a seamless customer experience of product and related services. A critical review of old relationships with suppliers is necessary. Only those suppliers that live up to quality and on-time delivery requirements as well as take an active part in driving the development of the products have a right to survive. Supplier evaluation, management and development are hence key competences of companies going forward. Last but not least, government needs to review its policy towards SMEs. Companies with just a few employees are not the ones that will drive manufacturing prowess in India. Consolidation and professionalisation of the supply chain is a must to drive manufacturing performance. While SMEs, e.g. in Germany, are the backbone of the German economy, these SMEs are as big as many of India's medium and large companies. Industries such as automotive or aerospace need a certain critical size of suppliers; government policies should support this process of consolidation rather than focus on companies that are too small to be able to invest in the future of Indian manufacturing. The actions listed are by no means exhaustive, however, illustrate that driving manufacturing in India is possible if and only if the corresponding hard work and investments are put in place.☐ > MORE@CLICK EM01683 | www.efficientmanufacturing.in
EM | Jun 2015
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TECHNOLOGY
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C O V E R S TO R Y
GREEN MANUFACTURING Energy, products and processes Green manufacturing involves transformation of industrial operations in three ways, green energy, developing and selling green products and employing green processes in business operations. Companies can think about the role of these technologies in their business strategy in two different ways – building a new green business, and using technology to ‘Green’ an existing one. The feature discusses on how successful transformation into green manufacturing will bring tremendous benefits, both tangible and intangible, for the nation and the business community. 26
Coverstory_Jun_2015.indd 26
Arindam Bhattacharya Managing Director, The Boston Consulting Group bhattacharya.arindam@bcg.com
Rahul Jain Partner & Director, The Boston Consulting Group jain.rahul@bcg.com
EM | Jun 2015
6/5/2015 9:35:47 PM
TECHNOLOGY
C O V E R S TO R Y
Improved company or brand image, top concerns driving Green
While the growth in manufacturing sector’s share in GDP to and promoting green initiatives and their benefits to all 25% by 2022 is necessary, the country’s environmental concerns stakeholders. need to be mitigated — the manufacturing sector must use energy and resources efficiently, and minimise generation of waste. It Transformation to green manufacturing is estimated that even if every factory, power plant, car and The society’s rising concern for green can be grouped into aeroplane are shut down, the average global temperature would still increase by 0.6°C in this century. ‘Green Manufacturing’ or three broad categories: rising emissions, fast depletion of scarce sustainable industrial activity is now the need of the hour and natural resources, growing waste generation and pollution. no more an empty slogan. Successful transformation into green Manufacturing companies can address these concerns by manufacturing will bring tremendous benefits, both tangible focussing on three areas: Green energy: It involves production and use of cleaner energy. and intangible, for the nation and the business community. A recent global survey by BCG reveals that as many as This is the first and most obvious step given the dependence 92% of the companies surveyed are engaged in green initiatives. of industry on energy. Green energy includes both deploying Manufacturing companies that adopt green practices renewable energy sources like CNG, wind, solar and biomass, benefit not only through long–term cost savings, but equally and achieving higher energy efficiency in operations. importantly, from brand enhancement with customers, better Green products: Developing greener products is the second regulatory traction, greater ability to attract talent and higher step in this transformation. ‘Recycled’, ‘low carbon footprint’, investor interest. However, these benefits require a long ‘organic’ and ‘natural’ are becoming popular buzzwords term commitment and making trade-offs against short-term which are associated with green products. Developing green objectives, as the economics of green manufacturing is still products can often mean higher costs. However, by developing green products that are sought by consumers, and effectively evolving and not well understood as yet. The motivation for adopting green has varied across sectors. marketing them, companies can derive additional volumes and Some take it up owing to regulatory compulsions (example: price premiums, which can offset their cost of development. power), while others see it as an opportunity to build a stronger Green processes in business operations: This entails efficient brand with consumers (example: retail). Steel manufacturers use of key resources, reducing waste generation through have adopted green initiatives to stabilise rising energy costs, lean operations, bringing down the carbon foot–print and while automobile companies have seen it as an opportunity to conserving water. Employing green processes improves launch electric and hybrid cars to meet increasingly stringent operational efficiency and lowers costs. emission regulations. The impact of green initiatives also varies by the industry sector. For example, green initiatives in Technologies for green manufacturing the power sector have the maximum impact on reducing CO2 emissions followed by transportation and then the industrial Today, there is a plethora of new and emerging technologies sector. that aid in both, making the traditional businesses greener, as Successful implementation of green manufacturing requires well as creating completely new ones. For example, technologies going beyond small standalone initiatives, and adopting an for reducing GHG can be classified into five broad categories: integrated three–step framework: (a) planning for green as a Carbon sinks: This category consists of emergent technologies core part of business strategy, (b) executing green initiatives related to Carbon Capture and Storage (CCS) being developed across the value chain by shifting towards green energy, for use in power plants that are fired by fossil fuels such as coal. green products and green processes and (c) communicating These technologies enable capturing and storing CO2 in ways
EM | Jun 2015
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C O V E R S TO R Y
TECHNOLOGY
Framework for economic assessment of Green initiatives
such that it does not enter the atmosphere. For example, CO2 from fossil fuels is trapped and stored in underground wells under intense pressure which keeps it in liquefied form. Efficient fuels: This category encompasses a class of technologies that use cleaner fuels for generating power. Examples include biomass, hydro power, Integrated Gas Combined Cycle (IGCC), etc. Consumer green: This involves using clean and efficient fuels at the user end and solutions covering demand side management. For example, off–grid solar power applications like solar water heating and building insulation are included in this category. Green transportation: Electric vehicles, fuel cells, and bio– diesel are some examples of this category. Industry efficiency: This category refers to the use of green production methods and technologies in traditional industries such as iron and steel, cement, refining, chemicals, etc. Multiple such technologies are emerging in each of these industries. Each technology within these five categories can be further characterised on two dimensions – maturity (nascent versus established) and availability (local versus global). While some technologies such as biomass, hydro and off–grid solar score higher in terms of their relative technological and commercial maturity, there are others like tidal waves, wind offshore and concentrated solar power which are relatively nascent. Similarly, while technologies such as IGCC and CCS are globally available for use, others such as geo–thermal and waste to energy are available only in select geographies. Categorising technologies on these two dimensions provides guidance in making business model choices. It also helps strike a balance between opportunistically harnessing the revenue pools of today and proactively positioning for capturing future revenue pools. Depending on their appetite for resource commitment, companies can make fundamentally different choices.
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Challenges in adopting green Even in tough market conditions, the business case for green remains compelling. There is greater recognition of the imperatives of becoming green and understanding that green has to address all three areas – green energy, green products and green processes. However, companies face challenges on various fronts, most critically in providing leadership for such an effort. Companies have to transition from approaching green as limited, often isolated initiatives with narrow focus to a more holistic approach; meeting regulatory compliance to developing eco–advantage; and viewing initiatives as cost centres to assessing them as business opportunities. This calls for a major transformation which to succeed, requires a systematic approach and a framework addressing the three principal impediments to decisive action: t Companies don’t fully understand drivers and issues relevant to them and their industries, and what sustainability means to them. t Companies face difficulties in modelling the business case – or even finding a compelling case for sustainability. The initiatives are not a priority for most, and often the economics are not well understood as technologies and costs are still evolving. t Even the companies that adopt green initiatives perform these activities as peripheral to their core business and not integrated into their corporate strategy. Hence, the execution is flawed and they fail in realising the full benefits.
Implementation framework Becoming green is a long journey of transformation. To succeed, adequate attention is required on planning and execution of the initiatives. Early wins and successes are
EM | Jun 2015
The eight pillars of TP
6/5/2015 9:35:54 PM
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C O V E R S TO R Y
TECHNOLOGY
Framework for companies to successfully implement Green
important to build momentum. It calls for a fully committed top management, tight periodic reviews and constant internal and external communication. A simple three–step implementation framework can be followed covering all three areas of action – green energy, green products and green processes. Plan: Green initiatives must be factored into the business strategy, future resource planning and budgeting exercises. For example, companies need to plan comprehensively to increase the use of green energy, shift the product portfolio to green products and overhaul business operations towards green processes. A sustainability charter, based on short term and long term goals, must be laid out with green targets and metrics. Companies should develop green indices or scorecards quantifying the impact of the green initiatives they have undertaken, set specific targets on those indices and track progress against those targets. Execute: With a robust plan in place and targets clearly defined and monitored, green needs to be integrated across the value chain and made a part of the core business. t Green energy: Manufacturing companies with high energy consumption need to shift towards using cleaner energy and plan for increasing the efficiency of its use. Setting up captive wind or solar power generation units and using energy efficient practices, such as installing LED lighting or better use of daylight in building design, can go a long way towards reducing the energy intensity of operations. t Green products: To move towards a green product portfolio, companies should conduct an evaluation of their products based on (a) how green are the resources and energy being used, (b) how green is the product during the lifecycle of its use, and (c) how green is the manufacturing process. By quantifying these parameters, companies can assess the
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Coverstory_Jun_2015.indd 30
green value of their product offering. In the planning stage itself, companies should set out targets for this metric, and then periodically assess progress against those targets. t Green processes in business operations: Companies need to gradually redesign business processes used in different parts of the value chain. This could include shifting to more sustainable manufacturing options, making changes towards reducing waste, increasing recycling, reusing resources and incentivising all suppliers, channels, customers and employees to adopt similar measures. Communicate: Along with well thought–through implementation, a well formulated promotion campaign for green initiatives is equally important to fully leverage their potential benefits. Customer education campaigns about green product offerings and green orientation of the firm in terms of energy and processes can translate into increasing revenues.
Conclusion The transformation journey to green manufacturing has just started. While there are a few early adopters, the industry at large needs to develop comprehensive plans to address all three areas — green energy, green products and green processes. The Government has to play an effective facilitator role in this transformation with both stronger incentives on one hand and regulatory mechanisms on the other. The industry associations can bring the different stakeholders together and support the roll-out of a communication strategy. The prize for success is enormous for both individual manufacturing companies and the country as a whole. Failure is no more a choice. ☐ Courtesy: CII, BCG > MORE@CLICK EM01684 | www.efficientmanufacturing.in
EM | Jun 2015
6/5/2015 9:35:57 PM
MANAGEMENT | INTERVIEW
“We are looking for opportunity to work with endusers� Hugh Dowding, Member of the Board of Directors, Motul SA, France / Director & Head - Motultech, in an interaction with Maria Jerin, discusses the recent trends in coolants & lubricants and the best metalworking practices adopted by the manufacturers to become more environment-friendly With the evolving manufacturing scenario, how do you envision the current metal cutting fluid market, globally and also in India? Certainly the manufacturing scenario is evolving with the continuing expansion of global automotive components market which is the biggest volume user of metalworking fluids globally. In a more conventional sense, the use of composites, high strength steels, structural cast aluminium parts and magnesium alloys are changing the requirements for metalworking fluids. Recently, with the advent of 3D printing, the US-based company Local Motors, has managed to blend co-creation with the world of small-scale and micro-manufacturing, to bring a whole new area of projects to life. The idea of micromanufacturing actually goes back to production changes made in Toyota. Now, Toyota Production System is again creating a revolution in manufacturing with its new flexible production line concepts such as Kanban. Whilst many of these technologies are still at the concept stage in India, the ambition to become the centre of component manufacture will be impacted in the future.
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Management Interview_MOTUL.indd 32
How do you look at the opportunities and challenges within the industry? There are no easy wins and competitors never sleep, but overall, we are with a lot of optimism. Global wealth is increasing and along with it people’s aspirations. So, markets like India will continue to grow and look for solutions from professional and service minded partners. What are the emerging trends/innovations in coolants & lubricants segment that offer productivity improvements in the metalworking industry? Trends in the lubricants sector, particularly in metalworking, are less driven by the desire to improve productivity and more by regulatory constraints. However, the need to re-formulate products gives opportunities to make high performance metalworking fluids that are free from chlorine and sulphur with extremely low foaming tendency. In the field of associated fluids, choosing a combination of high quality lubricants slideway oils, super clean hydraulic fluids, synthetic gear oils and compressor oils, all play their part in extending the life of the machine and lowering total operating costs.
EM | Jun 2015
6/5/2015 8:06:56 PM
INTERVIEW | MANAGEMENT
CANDID SIX t If not in this industry, where would you be? 3FTUPSJOH BOE TFMMJOH DMBTTJD DBST t What is your favourite pastime? 4LJJOH ESJWJOH XBMLJOH JO UIF DPVOUSZTJEF t What are you currently reading? * E MPWF UP TBZ #SPOPXTLJ T "TDFOU PG .BO CVU JU T NPSF MJLFMZ UP CF B DBS NBHB[JOF t Which is your dream car? 'FSSBSJ 48# GSPN UIF FBSMZ T t Your dream holiday destination? )PNF t Uniqueness of India that appeals to you‌ 5IBU UIF JOEVTUSJBMJTBUJPO BOE DPNNFSDJBMJTBUJPO IBWFO U TQPJMU UIF DVMUVSF BOE UIF JOIFSFOU DBMN PG *OEJBO QFPQMF
What are your recommendations to the end-users for on mineral oil or in the case of water based fluids, the ultimate optimum combination of the right metalworking fluid and disposal can be minimised by techniques such as evaporation cutting data to optimise the machining strategy as well as or reverse osmosis. workplace safety in a holistic manner? The trends in health and safety are naturally driving the industry How do you make your solutions cost-effective for the towards products that should be safer for users. Following the Indian SMEs? guidelines and training provided by a competent supplier, SMEs ultimately should not be treated differently. Being allows the users to play their part in successfully managing smaller does not mean being less professional and the training fluids in their own premises. However, some of the new fluids in techniques of fluid management offered by suppliers such behave differently. For example, with old fashioned chlorine as MotulTech should be embraced and implemented in every containing fluids, the machining strategy in terms of feeds and size of company. speeds needs to be modified to extract the best performance. In these cases, analysis and successful interpretation of the data What is your outlook on the potential for metalworking provided by modern machines is essential. In the area of high fluids in the Indian industry? What are your company’s pressure aluminium die-casting, MotulTechBaraldi provide expansion and growth plans for the Indian market? the monitoring equipment and software ensuring the user to India is a fast growing market with increased technology and professionalism year-on-year. The influx of global players into optimise the efficiency of the die-casting process. the market signifies this and contributes to the improvements These days, manufacturers are looking for ways to make in the manufacturing industry. We already have top-class their metalworking practices more environment-friendly. professional team from a variety of impressive backgrounds. They are supported by local manufacture and technical service. What is your take on this? The European Waste Framework Directive sets the basic The search is always on for professional distributors and we concepts and definitions related to waste management, recycling, are also looking for an opportunity to work with end-users to recovery. The greatest efficiency comes from extending the life improve processes. Our business grew dramatically in 2014 of the fluid and tooling. Without compromising effectiveness, and is on track to mirror that growth in 2015. Success is never professional suppliers know how to assist with this. Instead of guaranteed but is within reach! � > MORE@CLICK EM01685 | www.efficientmanufacturing.in fluids to be disposed, they can be recycled/re-refined. If based
EM | Jun 2015
FORM-3.inddInterview_MOTUL.indd 1 Management 33
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c o M pa n y p r o f i l E | M A N A G E M E N T
Indigenous eastern innovation Keeping in mind the Indian market requirements, FEMCO’s Technology Centre at Pune offers test cut trials to the demanding customers. Team EM has recently visited the state-of-the-art Technology Centre to witness their wide range of machines that are competitive in the global landscape. Spread over 40,000 sq ft, Far East Machinery Company (FEMCO) is the first Taiwanese company to establish a Technology Centre in India, which is located at Global Raisoni Industrial Park, Pune. The company has been operating for more than 65 years as the machine tool manufacturing brand in Taiwan, catering to various industry segments like heavy engineering, oil & gas and aluminium alloy wheels. The company realised the potential offered by the Indian industry and started its Indian operation Fatty Tuna India in 2011, aiming at long-term penetration in the Indian market. The company commenced Indian operation with three people and, today, it has a strength of 15 people who look after sales, application and services of the machines manufactured. In last five years, the company has reached various milestones in its journey. It has established the technology cum demo centre in 2012 to demonstrate the technical capabilities for the Indian market. In the successive years, resident offices were opened in Gujarat and Delhi.
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Company profileFemco mjer.indd 34
Srimoyee Lahiri Sub-editor & Correspondent srimoyee.lahiri@publish-industry.net
Maria Jerin Features Writer maria.jerin@publish-industry.net
State-of-the-art Technology Centre The Technology Centre provides a detailed view of the company’s products to customers who are not able to travel to Taiwan. Stating the establishment of the technology centre, B P Poddar, Vice President — Sales & Marketing, FEMCO India, said, “We can’t take every buyer to Taiwan. So, to make them understand our machines better, we have set up this state-ofthe-art Technology Centre, where the customers can come and see the performance of the machines before making purchasing decisions. Our application team offers test cut trials to the demanding customers.” Adding further on the company’s sales strategy, he said, “We are not only offering standalone machines, but also complete solutions, which includes pre-sales, application engineering support, installation & commissioning. This is done through well qualified and factory trained engineers, support through warrantee and after warrantee services as well as timely spare parts availability.”
EM | Jun 2015
6/8/2015 5:04:21 PM
M A N A G E M E N T | c o M pa n y p r o f i l E
“After analysing the Indian market, we are moving fast to bring in more machine models so as to meet customer demands” David Chuang, President & Vice Chairman, Fatty Tuna India
The company’s product range comprises horizontal boring machines, horizontal boring machines with integrated facing head & automatic tool changer on facing head, horizontal lathe machines, VTLs and alloy wheel manufacturing solutions. Commenting on the company’s presence in the Indian market, Poddar averred, “We have analysed the market requirements. Our engineering and R&D teams are working very closely, and as a result, we exhibited horizontal boring machine with integrated facing head and automatic tool changing on facing head in IMTEX 2015.”
“We are concerned towards market readiness to use multi-tasking machines that can carry out turning, milling and boring operations in one machine” B P Poddar, Vice President — Sales & Marketing, FEMCO India
Technology at affordable price
Poddar shared that the company has plans for manufacturing machines in India. “There is a huge demand for aluminium Further elaborating the market reach of these machines, alloy wheels in the Indian two-wheeler market. There is a Poddar added, “Our market share is almost 25 to 30%, possibility that the existing manufacturers of alloy wheels will considering the global sharing of these machines. We are highly enhance their capacities and new manufacturers will come. In successful in supplying machines to China as well. As far the this segment, we are finding a bigger chunk of market. So, Indian market is concerned, we are able to sell the boring initially we will start assembling parts of these machines and machines in good numbers with advanced technology and at later, we will convert the assembly line into production. We are much better product price. Customers are able to buy these evaluating the entire model for the Indian market, where we machines with similar quality of imported machines from can offer them the technology at affordable price.” Speaking further on the Indian market requirements, David Europe & Japan at 60% of the cost.” Commenting on the fluctuating Indian market, Poddar Chuang, President & Vice Chairman, Fatty Tuna India, believes that in recent years, oil & gas industry is not doing well. commented, “The Indian heavy engineering segments are “There is not a huge demand and we are facing ups & downs,” he showing robust growth of about 20% YOY. This will offer us said. Looking into the market situation, he added that the small larger business opportunities in future. After analysing the valve manufacturers were used to work with two machines that Indian market, we are moving fast to bring in more machine involve manual set-up changes and production downtimes. models so as to meet customer demands. With highly reliable “We are concerned towards market readiness to use multi- products, we are able to offer cost effectiveness. We are a tasking machines that can carry out turning, milling and boring complete solution provider.” The company plans to bring more appropriate machine operations in one machine. The multi-tasking concept of our FT-2 machine is capable to offer processes, which otherwise models and configurations to meet industry demands. customers carry on with HMC & VTL. So, downtime is reduced Evaluating various industry segments and geographical regions, drastically and therefore, the customers can make more number Poddar concluded, “We will expand our reach to various of parts. Now, many customers have seen our products. They important industrial locations. We have taken the feedback started understanding the operation involved in it. It has been from the market and our design team has already started well received and accepted by valve and oil & gas industry working on it. We are developing new horizontal boring segments. This concept increases productivity, up time of machines with automatic pallet changing mechanism. This will be slightly smaller in size than our existing machine to meet machines and profitability,” he suggested. the huge demand of the market. The machines will be available to Indian market after 6-8 months.” ☐ The way forward Looking further to meet the Indian market requirements,
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> MORE@CLICK EM01686 | www.efficientmanufacturing.in
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Building Nextgen sheet metal CAM Currently, multiple methods are adopted by sheet metal CAD/ CAM software vendors, depending on budget constraints and other technological constraints like linking 3D with existing 2D CAD/CAM systems, legacy data formats, reusing existing software components, etc. The article highlights the nextgeneration CAD/CAM systems and enabling technologies for punching, laser cutting and bending machines. Sheet metal product manufacturing industries have been mainly using 2D drawings so far. Most of the CAD/CAM softwares for sheet metal are designed to work mainly with 2D drawings, which require substantial user interaction at various stages, thus, having an adverse effect on productivity. Adoption
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Dr T R Kannan Solution Architect Geometric Ltd. TR.Kannan@geometricglobal.com
of 3D modeling in this industry is on the rise now. 3D modelers are generally feature-based modelers, which claim to provide feature data for downstream manufacturing. Many of these modelers support direct modeling too. Manufacturing could be either in-house or outsourced. For in-house manufacturing,
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F O C U S | M E TA L F O R M I N G
Sheet metal CAD with 2D CAM
though 3D models are available for parts, users have to convert 3D models into 2D flat patterns to process in CAM software currently. For outsourced manufacturing, this process becomes much more difficult when 3D model in some neutral format is sent to these manufacturing vendors for manufacturing. Major issues in 3D models in neutral formats are loss of feature data and unfold data, requirement of separate software for unfolding, translation errors, etc. There is a good need from this industry to improve CAD/CAM productivity by introducing automation at various stages and use 3D models directly from end to end.
Sheet metal manufacturing A physical sheet metal part could have base flange, bend flanges, holes, cutouts and formings. In the flat state before bending, a part can have holes, internal cutouts, formings and blank (flat external profile). Manufacturing often starts with standard sheets. The sheet is first cut using a punching machine or a laser/waterjet/plasma cutting machine or a combination machine. Combination machines such as laser-punch, lasershear, etc help to improve manufacturing productivity. Multiple parts are generally nested together for effective material utilisation before processing in these machines. All these machines can cut holes and cutouts and punching machine are used for making formings. Punching machines require standard punching tools for standard shapes and for non-standard shapes, nibbling with standard tools or laser cutting is used. Some companies use shearing machine for sizing, i.e. for creating blanks for large parts, before processing in cutting machines. Bending is performed finally using a panel bender or press brake to create the 3D shape of the part.
2D sheet metal CAD/CAM Sheet metal product data in 2D is generally represented as orthographic representation and additionally flat pattern with bend data is also generated in 2D. All these are generated using
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a 2D-sketcher CAD that has capability to draw 2D entities. Flat pattern is generated manually by providing suitable bend allowances for bends. Bend tables are used to get bend allowances or bend deductions, which depend on sheet material, bend radius, bend angle and sheet thickness. Nesting is performed using 2D flat patterns. Formings are marked in flat pattern with centre of pressure and tooling annotations manually. Some CAM systems provide auto-tooling for standard holes and standard cutouts. Cutouts can be single hit cutouts or multi-hit cutouts. Single hit cutout profiles are matched with punching tool profiles available in the tool database for autotooling. Punching/laser tool path is generated in punch/laser CAM.
3D sheet metal CAD/CAM Sheet metal product data in modern 3D CAD modelers generally contain both 3D representation and flat pattern in its native format. Most of the CAD modelers do not provide CAM for sheet metal machines such as punching, laser cutting and bending machines. For manufacturing, users have to rely on third party CAM softwares. In such scenario, various methodologies are adopted to link 3D CAD and CAM.
Enabling 2D CAM to take 3D data as input 3D kernel based approach: 2D CAM software companies prefer to add an additional unfolder software module, which can import 3D models from any CAD software and generate 2D flat pattern. CAD data may come from any 3D modeler either in native file format or in standard file formats. To open these models, translators are required. When CAD data is imported in any 3rd party CAM software using translators, feature data and flat pattern, data are lost and only the 3D boundary representation data is extracted. This requires an unfolder module, which can generate flat pattern from 3D data. To process 3D model into
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3D sheet metal assembly created in SolidWorks
flat pattern, 3D kernels are generally used. Translation errors complicate unfolding of such imported 3D models and require user interaction or sometimes require complete recreation of flat pattern. Bend data is either extracted automatically or entered manually. The major advantage of kernel based approach is to reuse the 2D CAM without any change and the software becomes capable of handling both 2D as well as 3D input. This type of software is suitable for manufacturing vendors who generally do not design or modify the designs. Such vendors receive CAD data from multiple customers in various formats and simply manufacture the products. Developing all the sheet metal modeling functionalities require huge development efforts and investment. A major advantage of this approach is integrated CAD/CAM software in a single application at a lesser end-user licensing cost. Further, with modular design of the software, they are also able to cater manufacturing vendors without modeling module at even a lesser licensing cost. 3D modeler based approach: CAM softwares sometimes utilise 3rd party CAD softwares and build add-ins to unfold and generate output in required format for CAM. CAD and CAM softwares remain two independent applications that are integrated by a common file format, which is generated as output by CAD and taken as input by CAM. The advantage of this type of approach is use of 3rd party CAD modeler for modeling, rather than developing all those functionalities and faster software development cycle at a lesser investment. But the licensing cost of the software is generally higher and the newly developed add-ins have to upgraded with every upgrade of CAD modeler. Building a next generation 3D CAD/CAM: Working completely with 3D from start to end has its own advantages. For example, when bending simulation is in 3D, it is easier to visualise the bending process and user experience is much better. Similarly, for parts with punched forming features, 3D representation is better than 2D representation in flat patterns. 3D representation of forming features also facilitate auto-
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tooling to a better extent. In 2D, parts have to be manually segregated as per thickness and material before nesting whereas in 3D representation, segregation of parts in assemblies can be automated. This kind of automation can save huge time involved in this activity and helps to improve end-user productivity. Most of the laser/waterjet machine manufacturers make 2.5-axis machines, 5-axis machines and tube cutting machines. Multi-head machines with 2.5-axis for all heads or with 5-axis for few heads is also common. Multi-head machines with both 2.5 and 5-axis are capable of cutting 2.5D nested layouts as well as 5-axis profiles and they require a CAM software that is capable of satisfying both 2.5-axis and 5-axis cutting. But, currently 2D CAM softwares for 2.5-axis cutting and 3D CAM softwares with 5-axis milling module are generally used for 5-axis laser/waterjet cutting. For tube cutting laser, use of 2D/3D CAM is common. But all these softwares are mostly independent applications and there is no integration between these. A CAD/CAM software that is capable of 3D modeling and CAM for punch presses, 2.5 and 5-axis laser/waterjet machines, tube cutting laser and bending machines will be most desirous by end users and machine-tool manufacturers.
Conclusion Rising global competition and customer demands are driving the future course of sheet metal CAD/CAM softwares. User-friendly softwares with a high level of automation that improves productivity are the need of the day. Given the need for next generation CAD/CAM softwares for sheet metal manufacturing, it is quite important to choose the best technologies to stay ahead. With Geometric products and technologies, sheet metal machine tool manufacturers and CAD/CAM ISVs can reap considerable benefits in terms of development cost and development time. � Courtesy: Geometric > MORE@CLICK EM01687 | www.efficientmanufacturing.in
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Configuring production processes A key technology that help companies manage their entire product development process right from concept development, design, validation to manufacturing through configuring and implementing ideal workflows is Product Life Cycle Management. The article deals with the application benefits of PLM to enhance productivity. The multi-faceted processes of product design, engineering and manufacturing have evolved to become much more interdependent, inter-disciplinary, entangled in iterative, long and complex design and development processes. So, how can a company make sense of it? How can they create order and symmetry in this cross functional & multilateral working environment? How does a company streamline processes and optimise workflows to increase productivity? These are the challenges that any company involved in product development faces. Huge investments in infrastructure and resources, enormous amount of data generation, silo departments or dispersed manufacturing and R&D set-ups, big budgets and lower bottom-line, maximising productivity
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Vivek Mahajan National Technical Support Manager - PLM, DesignTech Systems Ltd vivek.mahajan@designtechsys.com
and throughput through best use of existing facilities make it a monstrous task for the companies to align these functions in a cohesive, coordinated and structured environment to build an agile, lean, competitive and productive organisation.
Addressing challenges The solution to these challenges can be found in latest technologies in CAD/CAM/CAE, PLM, digital manufacturing and Additive Manufacturing solutions. These technologies can help companies to compress their design and development cycle, build robust products, get designs right the first time, augment product design innovation, streamline workflows
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t e c h n o l o g y | p l m / d i g i ta l m a n u fa c t u r i n g
and configure optimised production processes, manage and control design data, optimise use of resources including machines, money, man-efforts, facilitate cross department functioning and achieve better data integrity between geographically dispersed facilities, achieve cost and time efficiency and hit the market early.
Automating the work flow A key technology that can help companies manage their entire product development process right from concept development, design, validation to manufacturing through configuring and implementing ideal workflows is Product Life Cycle Management commonly referred to as PLM. It can assist companies to reduce wastage of time, man efforts, machines,
materials and other resources, manage data better, and bring more discipline and coordination between cross functional teams, departments & facilities, thus, enhancing overall performance and productivity of the company. PLM basically helps companies integrate, configure and manage their design data, processes, and work flows right from the initial stages of product development cycle, i.e. concept stage to design, simulation and validation, right through to manufacturing and releasing the product to market. It helps companies with the setting up of effective data management systems, efficient workflow and process configurations, and overall system validation. In addition to this, it automates the work flows that helps exert a strong grip on the product development process, and thereby bring more control and discipline, and streamline the overall development cycle. Advt
THE INDUSTRIAL LUBRICANTS DIVISION OF THE GROUP METAL WORKING FLUIDS SPECIALTY LUBRICANTS MAINTENANCE LUBRICANTS HIGH PRESSURE DIE CASTING QUENCHING FLUIDS
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Atlantic Lubricants & Specialities Pvt. Ltd. 301, Ketan Apts., 233, R.B. Mehta Marg Ghatkopar East, Mumbai 400 077 Tel: + 91 22 2501 1960/2501 1961 Fax: + 91 22 2501 1928
Motul 119, boulevard FĂŠlix Faure 93300 Aubervilliers - France TĂŠl.: +33.1.48.11.70.30 43 Fax.: +33.1.48.11.70.38
p l m / d i g i ta l m a n u fa c t u r i n g | t e c h n o l o g y
Digital manufacturing solutions help create 3D simulations of plant design
Towards synchronised development process PLM typically works within and addresses five primary functional areas namely requirements management, project management, engineering process management, manufacturing process management and supplier relationship management. Benefits of PLM include end-to-end management of data, information, process and resources, collaborative product development, synchronised development process, zero-idle time, early time to market and increased market success. While PLM can oversee the broader performance of the R&D departments, however, for a company to enhance their productivity and manufacturing quality, they need to set-up plants that rid them of all the bottlenecks in the processes, for example, unnecessary human efforts, duplication of work, a dysfunctional or incongruous plant layout and processes, etc. Digital manufacturing can enable companies to virtually simulate their plant layouts and processes in a 3D environment, which can help them anticipate, identify and address the bottlenecks in the manufacturing processes to establish processes that are smooth and streamlined.
Enhancing manufacturing efficiency From manual manufacturing processes used in earlier times, the industry, today, has made a shift towards digital manufacturing. Digital manufacturing solutions help create 3D simulations of plant design, which includes man-machine interaction to help define the most efficient, safe, non-iterative and non-interfering or hindrance free manufacturing processes. Right from assembly lines, human ergonomic simulation to robotic simulation, plant layout, etc. could be defined and analysed virtually in the 3D environment. Digital manufacturing solutions & technologies help the companies configure optimum work flows during the plant layout stage, which enables the companies in enhancing the productivity and overall output of the company. Issues concerning to constraints in manufacturing or feasibility of
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manufacturing, popularly referred to as ‘manufacturability concerns’ or ‘ergonomic constraints’ are very difficult and highly expensive to rectify once the plant, work flows and processes are established. A prior validation would help companies identify such concerns at the earlier stage of planning and would hence save the time and cost of rectification. Even the existing plant could be rendered virtually and modified to see how manufacturing efficiency can be enhanced, which then can be implemented by the companies in their physical plant space.
Implementing success mantras Companies that want to remain relevant in changing market conditions need to make corresponding changes in their design & development processes. Redundant technologies will stunt a company’s growth. Means to success is as important as the success itself to ensure long lasting and consistent success. It is crucial that companies keep striving to build and produce great products, remain innovative and adapt themselves time and again by reinventing and evolving their processes to achieve higher productivity. Companies that make inspection of current processes, comprehension of new solutions, anticipating market changes, and in accordance adapting to redefine their goals of products and productivity a habit, will always remain a leader in their industry. Shrinking product life cycles, growing imperative to develop innovative products faster & better than the competition, and higher bargaining power of the consumers has necessitated the companies into product design and development to adopt these latest technologies in product design and manufacturing. This would help them compress their design and development cycle, and hit the market early with smarter products that perform, offering them to the consumers at competitive rates, thus, remaining resilient and relevant in today’s rapidly changing market space. ☐ > MORE@CLICK EM01688 | www.efficientmanufacturing.in
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Solutions for machining industry In metal processing, surface solutions such as PVD coatings (physical vapour deposition) improve tools so much that customers can benefit from enormous economic advantages. The article details the advantages of standard coatings and suggests the various ways by which impressive results can be achieved if all the factors are coordinated with one another, from the starting material up to the post treatment. Machining is a metal-cutting process that has to fulfill increasingly high demands with regard to productivity and processing speed. The friction arising during the process and the wear on components and tools are major loss factors. According to the German Society for Tribology, a loss of about 5% of gross social product arises annually in industrialised countries through the effects of friction and wear alone. Tool coatings counter these mechanisms and are thereby essential nowadays in machining. As a provider of innovative surface technologies, Oerlikon Balzers has been developing tailor-made system solutions for decades to make tools more resistant, more productive, and longer lasting. The special feature of this holistic approach is the consideration and streamlining of all the influencing factors. Starting from the application-specific requirements, the company finds the best-possible combination of pre and post treatment of the tool surface coating material,
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layer architecture, system technology with which the coating will be applied.
Targeted pre and post treatments The cutting tool is subjected to high pressure (more than 2 GPa), high temperatures and thermal cycling stresses in the modern machining process. The pre and post treatment as well as the coating must be adapted to the application. There are various pre-treatment methods available that prepare the tools for a subsequent coating process and significantly improve the coating adhesion at the same time. Together with the coating, a preparation of the cutting edge of the tool leads to increased cutting speeds, feed rates, and longer service lives. The post treatment (edge preparation, surface treatment, and structuring) also plays a decisive role, in particular, in
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Dodda Nekkundi Industrial Area - 2nd Stage Mahadevapura, Bangalore -560048, Karnataka, India
Phone Fax
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s u r fa c e t r e at me n t | t e c h n o l o g y
Functional coating properties, such as the layer hardness, the phase stability, and the tribological properties, can be adjusted by a different distribution of the elements within the layer
avoiding the initial wear, which can occur, for example, through cutting-edge buildup (adhesion of material from the workpiece to the cutting tool). Numerous tests have shown how great the impact of the pre and post treatment of tools can be on productivity. For example, performance gains of more than 100% in gear-cutting tools can be achieved through specific preparations.
Coatings for demanding working conditions The requirements that are placed on coatings can be very different. As high temperatures arise at the cutting edge during machining, high resistance to thermal wear becomes extremely important. The following properties are expected from modern coatings: excellent high-temperature properties, resistance to oxidation high hardness, even at high working temperatures, microductility (plasticity) through a nano-structured layer design. In the case of high-performance tools, optimal adhesion of the coating and well adapted residual stress are decisive factors. This applies, above all, to the interaction between the base material and the applied coating. The coating material should have the least possible affinity to the material being worked on.
Tailor-made coatings Aluminium-based coatings, such as Oerlikon Balzers’ BALINIT LATUMA, the aluminium chromium nitride based BALINIT ALCRONA PRO or the nanolayered BALINIT PERTURA, are often used in the machining industry. In these aluminium-based coatings, a thin but dense aluminium oxide layer forms as a result of the high temperatures during the machining. This layer then continually and independently renews itself and protects the coating and the base material below it from oxidative decay. The required hardness and resistance to oxidation can be adjusted through a variation of the aluminium content and the layer morphology. The resistance to oxidation, for example, can be improved through an increased aluminium content, nano-structuring, or micro alloying (i.e. alloying with low-percentage element proportions).
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In addition to the chemical composition of the material, the layer architecture can also considerably alter the properties of a coating. Different tool properties arise depending on the distribution of the elements in the microstructure of a layer. Today, several individual layers with different chemical compositions can be combined to achieve customised properties. This trend will increase even more in the future, in particular, through new system and process technologies.
Coating technology for the future Nevertheless, innovation in tool coatings is not limited to coating design and chemistry. It also comes with the industrialisation of ground-breaking deposition technologies such as the S3p technology, which combines the advantages of arc evaporation and sputtering. In arc evaporation, a small spot of a high electrical current moves on the surface of a target. The material immediately melts and the metal vapour condenses on the work piece. Because of the explosive nature of the process, metal droplets are formed, which may cause a rough surface on the coating surface. Reactive gas can be introduced to form compounds. Sputtering, on the other hand, is a process whereby atoms are ejected from a solid target material due to bombardment of the target by energetic particles. In thin-film coating, this is achieved by accelerating Argon ions towards a solid target where they knock out metal atoms which are collected at the work piece. Compounds such as metal nitrides are formed by introducing gas in the vacuum chamber. Developed by Oerlikon Balzers, the S3p technology succeeds in combining the advantages of both technologies in an industrial solution: high ionisation without droplets, smooth coating surface, very high coating density and hardness; and excellent adhesion. Its unique process allows to customise coatings in such a way that they precisely fulfil the requirements of the respective application. The coatings based on the S3p technology, are marketed under the BALIQ coating brand. � Courtesy: Oerlikon Balzers > MORE@CLICK EM01689 | www.efficientmanufacturing.in
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A E R O S PA C E M A N U FA C T U R I N G | T E C H N O L O G Y
MEETING AEROSPACE CHALLENGES This article to be presented in two series discusses the various challenges faced by the Indian aerospace manufacturing industry in competency development & establishing world class technologies to meet the stringent aerospace requirements Aerospace manufacturing industries have to work with very Aerospace Defence Contractors Accreditation Program). This high precision quality standards. The parts have to meet very progam has laid down minimum qualifying program for any stringent dimensional accuracies, owing to its airworthiness organisation to become an aerospace supplier. This program requirements. Till recently, the aerospace manufacturing applies to all the special processes like welding, NDT, heat industries were largely based in the USA and Europe. However, treatment and surface treatment. Any supplier who wants to due to government policies and domestic requirements in the supply parts to primes shall have AS9100 accreditation followed recent past, there is a phenomenal growth in the Indian by the NADCAP certification. Godrej Aerospace is equipped aerospace industry as well. Also, there is a tremendous potential with facilities accredited by AS9100 & NADCAP. for the product in export market due to its QCD parameters. Currently, the Indian industry is facing challenges in Owing to the strength of the Indian industry, world leaders in competency development & establishing world class this industry are keen to find the Indian industries/partners, technologies to meet the stringent aerospace requirements. who can meet their quality, cost and delivery requirements. In the past, any aerospace part supplier / manufacturer had Special requirements in aerospace to meet specification requirement of individual customer The aerospace industry needs to have the following (primes). Currently, all the aerospace primes have come together and set-up a body called NADCAP (National requirements—
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T E C H N O L O G Y | A E R O S PA C E M A N U FA C T U R I N G
Unlike other industry, the aerospace industry is working with very stringent safety margins
High strength to weight ratio: The aerospace alloys have a biggest challenge of lowest in weight and highest in strength. These high strength, light weight alloys are challenged to meet higher performance expectations and stringent regulatory requirements at lowest life cycle cost. To meet this requirement, the difficulty in manufacturing is always ignored. Corrosion resistance: Resistance to corrosion is of paramount concern in aerospace materials since the costs of corrosion, with its material degradation, continue to escalate more than one realising it. Basically, the corrosion comes from fuel, xidizer insulation and service conditions. Conventional stainless steels can provide the corrosion resistance needed for many demanding applications, but increasingly they lack the combination of high strength, toughness, fabricability and damage tolerance. Standard high-strength low-alloy steels (HSLA) may offer the high strength needed for some difficult applications but lack the corrosion resistance. The high stakes in materials can be appreciated better when examining the needs of two pertinent industries—aerospace and military. With its landing gear hardware, wing assemblies and other airframe components made of high strength stainless steels, the aerospace industry must achieve superb performance, long term safety, reliability, durability and low life-cycle costs – in short, aircraft that will fly for 40 years with minimal maintenance. Some high performance alloys offers weight savings, improved corrosion resistance, higher strength while achieving lowest possible life cycle costs. The overriding objectives here are reliability and perpetual readiness (meaning no crippling rust from corrosion and ability to maintain peak mechanical performance). Temperature and working conditions: The envelope of air
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that surrounds the earth varies in pressure and temperature throughout its entire height. When the flight enters into high altitude and low altitude, it experiences extreme temperatures and shocks. When it enters the troposhere zone (30,000 - 50,000 feet), it faces variable temperature, water vapour, turbulence and storms; similarly, when it enters the stratosphere zone (50,000 feet to 50 miles) it faces relatively constant temperature of -55 degrees Celsius, little water vapour, jet streams and little turbulence. Normally, the temperature is generated through combustion, friction and radiation at high altitude. In the entire flight of aircraft along with vibrations and shocks, it faces the temperature range from +50o C to -55o C. In case of spacecraft, in some cases, it faces -200o C to +200o C. Safety margins: Unlike other industry, the aerospace industry is working with very stringent safety margins. Earlier, the ultimate aircraft structural factor of safety is defined as the ratio of design ultimate load to design limit (or actual applied) load on the structure was equal to 1.5, which used to take care of defect in material, poor workmanship and design in accuracies. But nowadays, the safety margin shrinks to as low as 1.1 to 1.2, which only takes care of aeroelastic effects, fatigue, flutter, dynamic effects, structural complexity and aerodynamic heating. No margin is kept for variation in manufacturing and defects. This poses high challenge in working with the aerospace industry.
Requirement of exotic alloys As mentioned above in aerospace industry, one has to deal exotic, high strength, light weight and corrosion resistant alloys with mostly thin gauge sheets. As the designer focused mainly on strength and efficiency of the material, machinability and
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A E R O S PA C E M A N U FA C T U R I N G | T E C H N O L O G Y
The metallurgical characteristics which give titanium its favourable properties can be reproduced, by selection of an appropriate practice
weld ability is always a big challenge. To achieve the required quality standards, exotic process and technologies to manufacture these parts are needed. Given below is the list of exotic alloys used in aerospace industry and its peculiar properties. Steel alloys: High-strength, low-alloy steel is a type of alloy steel that provides better mechanical properties or greater resistance to corrosion than carbon steel. They vary from other steels. So, they are not made to meet a specific chemical composition but rather to specific mechanical properties. They have carbon content between 0.05–0.25% to retain formability and weldability. They also give good safety margin and high temperature resistance. AISI/SAE 4340 combine deep hardenability with high ductility, toughness, and strength. It has high fatigue and creep resistance. It is often used where severe service conditions exist and where high strength in heavy sections is required. Aluminium: The following characteristic renders aluminium as desirable materials for aircraft applications. It is light in weight, yet some of its alloys have strengths exceeding mild steel. It retains good ductility at subzero temperatures, has high resistance to corrosion, and is not toxic. It has good electrical & thermal conductivity, as well as high reflectivity to both heat and light. It also has high resistance against impact and shocks. It is non-sparking and nonmagnetic. Titanium: These alloys are widely used in aircraft because of its light weight, high strength, and performance at elevated temperatures. It is as strong as steel, yet 45% lighter. Titanium alloys will work continuously at temperatures up to 600°C, resisting creep and oxidation, and down to liquid nitrogen temperatures without loss of toughness. It will survive indefinitely without corrosion in naval applications, and most
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chloride environments. The metallurgical characteristics which give titanium its favourable properties can be reproduced, by selection of an appropriate practice, in welded joints for most titanium alloys. The oxide film, which is the basis of the metal’s corrosion resistance forms equally over welds and heat affected zones as over parent metal, and other than in a few very harsh environments, weldment perform identically to parent metal in corrosion resistant service. TIG process is one of the easiest to weld titanium; the weld pool is fluid and its combination of low density and high surface tension enables good control of the weld surface profile and penetration, even when unsupported. Cobalt alloy: This alloy is also known as Stellite-25. It is a cobalt nickel- chromium-tungsten alloy that combines excellent high-temperature strength with good resistance to oxidising environments up to 1800°F (980°C) for prolonged exposures, and excellent resistance to sulfidation. It can be fabricated and formed by conventional techniques; this alloy has good forming and welding characteristics. It can be welded by both manual and automatic welding methods, including gas tungsten arc (GTAW), gas metal arc (GMAW), shielded metal arc, electron beam. It exhibits good restraint welding characteristics. Nickel alloys: High quality weld joints are readily produced in nickel alloys by conventional welding processes. However, some of the characteristics of nickel alloys necessitate the use of somewhat different techniques than those used for commonly encountered materials such as carbon steel or stainless steel. Nickel alloys have major application in hot zone of the engine (aircraft turbine engine), in aerospace fabrication. Courtesy: Godrej Aerospace Part 2 of the article will be published in the next issue > MORE@CLICK EM01690 | www.EfficientManufacturing.in
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Our Lean Selection speed reects our own core values. Speed, high performance, efďŹ ciency.
JUNKER Lean Selection speed High-speed cylindrical grinding.
The Lean Selection speed grinds shaft-type components and cutting tool blanks at impressive speeds. One or two high-performance grinding spindles mounted at the swivel-action wheelhead (B axis) work using both the plunge-cut and QUICKPOINT grinding methods. This facility makes the grinding machine extremely flexible and capable of implementing several grinding operations in a single clamping. The Lean Selection speed cylindrical grinding machine is ideally suited for the grinding of small and medium-sized series: It not only operates with outstanding cost efficiency, but also benefits from operating simplicity and fast retooling.
Erwin Junker Maschinenfabrik GmbH India Branch Office Office No. 104, City Square 29-2, K.M. Gandhi Path, Bhamburda Shivaji Nagar, Pune 411 005
Phone: +91 20 255 33 896 E-Mail: info@junker.in
www.junker.in
A member of JUNKER Group
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MACHINING | TECHNOLOGY
Prototyping with machining centre
NEXX was the first manufacturer in Portugal to produce motorcycle helmets made from carbon fibre - an extremely stiff, strong, yet light material. These days, all the company’s high-end products use a mix of fibreglass, carbon and kevlar, to provide an extra level of shock absorption and impact resistance. Composite helmets now represent nearly 60% of the company’s turnover. The company’s range of helmets is wide, with many different
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colours, styles and decorative materials to choose from, depending on whether the buyer intends to ride a scooter to work or an enduro bike across Africa.
Creating premium helmet brand “We want people to see our helmets and know immediately they are made by Nexx,” says Helder Loureiro, Founder & CEO,
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MACHINING | TECHNOLOGY
For design departments, who need functional parts or moulds and dies, a CNC machine tool can offer a much more practical and versatile solution
NEXX. “Our business is driven by ideas and passion. To bigger R&D facilities. The company has also invested in robots, innovate, create new products and get them to market quickly semi-automated paint shops and precision machinery for the bigger factory. With the promise of financial help from the EU, is essential.” Loureiro worked originally for another helmet manufacturer Loureiro also decided to invest in the company’s product in Portugal, but grew disillusioned with the company and his development department with the purchase of an additive RP role. As a result, he decided to quit and, with the help of three machine to manufacture prototypes - a function that at the investors, launched Nexx. Founded in 2001 and based in time was being outsourced. “Using subcontractors to produce prototypes is not a Anadia, near Porto, Nexx helmets are already sold in 56 satisfactory arrangement. We wanted to keep the new designs countries around the world. “Since the beginning, the aim of the company was to create confidential and needed to be able to try many different design a premium helmet brand. Making a quick buck was never on ideas as quickly as possible. Using external suppliers made us the agenda. Instead, we planned to reinvest and build the vulnerable to delays, in particular. After some consideration, company,” believes Loureiro. Sales were good from the outset. we found a suitable rapid prototyping machine and we were At the time, alternatives were often bland – any colour you like fully prepared to go down the additive route. However, when it came to actually make the purchase, the distributor for Portugal as long as it’s black or white! “Our helmets were popular because apart from creating and Spain had recently gone out of business. We reassessed. I something unique, we focused on good quality & design at a didn’t feel comfortable buying the machine from abroad and competitive price,” says Loureiro. “In a way, you could say we have the training and support supplied from so far away. invented the fashion helmet. We attracted lots of customers, Around the same time, Haas Automation Europe ran a particularly in countries like France, where there’s a thriving promotion at an exhibition in Portugal, which caught my eye motorcycle culture. Riders in Europe, especially in cities like because the price of the Haas machine was more or less the Paris, Milan and London, are perhaps the most image-conscious same price as the RP machine,” averred Loureiro. For design departments, who need functional parts or in the world.” moulds and dies, a CNC machine tool can offer a much more practical and versatile solution. In the case of NEXX, a Haas Manufacturing prototypes VF-2 vertical machining centre proved to be the right The company’s early success enabled it to relocate to a new investment. “With the Haas CNC machine, we can go from facility, which is already being expanded to accommodate idea to prototype helmet within two months,” says Loureiro. “It
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MACHINING | TECHNOLOGY
Nexxpro now designs helmets for many customer groups, including men, women, and even children
means we do not outsource anymore; everything is done in- opportunities in the Far East, in place like South Korea, Taiwan, house. The machine is quick and we can try all sorts of different Japan and Indonesia. The scooter markets in some Asian designs in the time it used to take just to get one. ” countries have enormous potential. Little by little, we are growing worldwide.”
Customised designs
Future plans
Luís Da Fonte is head of design at NEXX. He believes that The company is also hoping to leverage its exposure on the being able to make their own prototypes is very important. “Without the Haas machine, it would be impossible to realise racing circuits of the world to boost its brand profile even the correct design in such a short period of time. We knew that further. “We are intending to sponsor in the Superbike World the Haas machine would be the best solution as we can do Championship,” says Varandas. “We are also targeting the bigger prototypes using the machine’s large table capacity than Spanish championship, and we already have sponsored riders would have been possible using an RP machine. We also use in the US. We have been in racing for about 3-4 years and we the VF-2 for producing aluminium & steel moulds. We could are gradually learning more as we go.” Today, NEXX sells 100,000 helmets a year worldwide – next not have done this with an additive system,” he says. In 2003, the company started using different materials to year’s goal is 120,000, all of which are designed and made at its enhance the brand’s ‘fashion’ appeal, such as leather, embroidery, site in Portugal. In terms of shape, there are four types of shell: metal inserts and rubber. The designs began a craze, which led full face, open face, maxijet and dual sport. All moulds and to rampant sales. Nexxpro now designs helmets for many prototype parts for new helmets are machined using the Haas customer groups, including men, women, and even children. VF-2. “Haas is already working full time - between 9 and 10 In 2014, the company won the renowned Red Dot design award hours a day. It’s been problem free and the support & back up we receive from the Portuguese distributor (HFO AfterSales) for its Switx model, one of its most popular. “Today, our number one market is Germany,” says André has been superb. There is no doubt we’ll need another CNC Varandas, Marketing Manager, NEXX. “But, other strong machine soon, and based on our experience I feel confident markets include France, Italy, Portugal, Brazil and the USA. buying another Haas,” concluded Loureiro. ☐ Different countries seem to prefer different things: in Brazil, Courtesy: Haas for example, they really love bright colours, whereas Germany > MORE@CLICK EM01691 | www.efficientmanufacturing.in mostly likes designs in black. We are very actively seeking
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C U T T I N G TO O L S | T E C H N O L O G Y
Machining ISO-S materials
Teun van Asten Engineer, Marketing Services: Solid Milling Seco Tools
Innovative engineering and technology drive continuing progress in the critical industries of medical, power generation and aerospace part production. Manufacture of the precision components made in those industries requires workpiece materials that provide high resistance to heat & wear, extreme toughness and unwavering quality & reliability. Prime examples of those materials are ISO-S alloys, namely nickel, cobalt and iron-based heat resistant superalloys (HRSA), and titaniums. The hot hardness, strength and creep and corrosion resistance of these materials prompt their use in a wide range of crucial applications. Machining ISO-S materials is challenging because alloys transfer heat poorly, also known as low thermal conductivity.
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The heat generated in machining (~1100 degree C to 1300 degree C) is absorbed by the tool and workpiece instead of being carried away in the cut chips. Thereby, tool life suffers, and part distortion can occur. The alloys also have tendencies to strain and precipitation harden when machined, increasing cutting forces and further degrading tool life. Lastly, the sticky behaviour of these materials creates uncontrolled built-up edge (BUE) and notch wear. Such stickiness is also known as a material’s ductility, a characteristic common in soft materials such as aluminium. Considering the difficulty of machining ISO-S materials and the expense of the parts involved, manufacturers pursue machining improvements that primarily focus on component
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T E C H N O L O G Y | C U T T I N G TO O L S
reliability & quality, with cycle time reductions coming in as a second priority. Maximising the benefits of the highperformance alloys requires the use of advanced tools and application strategies. Toolmakers fine-tune those tools & techniques to provide productive and reliable solutions for specific industry applications.
Medical applications To function properly and avoid rejection by the body, a medical implant must be chemically inserted, fully resistant to corrosion by bodily fluids. Accordingly, the biocompatibility and corrosion resistance of ISO-S materials make them an excellent basis for a wide range of orthopedic, dental, and other medical components. Manufacturing of medical implants is growing rapidly. The average age of the population of industrialised areas is moving higher, and so is the population’s average weight. Both factors have direct implications for wear of knee and hip joints and resulting demand for replacements. The popularity of dental implants has also grown in line with increased attention on cosmetic and dental health issues. Replacement of knee components: Two basic components make up a replacement knee. The femoral component imitates the round condyle prominence at the end of the thigh bone and attaches to the upper leg bone or femur. In turn, the femoral component bears on a polymer cup that rests in the second basic component, a titanium tray that is attached to the top of the lower leg bone or tibia. The poor heat transfer properties of ISO-S materials mandates the use of coolant in most machining operations.
However, medical regulators have strict rules regarding contamination by residual coolant and demand stringent and time-consuming cleaning processes. As a result, toolmakers are developing ways to machine medical parts “dry,� without coolant or emulsion. Seco, for example, has developed coolantfree processes to machine Ti6Al4V titanium tibal trays with special t-slot and form end mills. The operation is complete in less than 10 minutes, with good tool life, excellent product quality and contamination-free parts. Another effort to mitigate the effects of poor thermal transfer properties of ISO-S alloys involves replacing grinding operations with machining. The heat generated in a lengthy grinding operation can induce stress in a part and distort it. One manufacturer found that femoral knee components were often out of dimensional specification after grinding, resulting in a scrap rate of 20-30%. To solve the problem, our application engineers developed a five-step method to machine femoral components on a machining centre. The process uses ball end mills and a part fixture with a centrelock system that permits the part to be rotated during machining. This copy milling approach is well suited for less rigid part-clamping setups, which are often the case, when producing these complex 3D parts. Cutting time for the entire operation is about seven minutes. After machining, only a polishing operation is required, and that polishing process consumes less time than the polishing previously performed after grinding. Small dental parts: Specialised machining methods can help overcome the challenges of machining ISO-S materials. High feed milling strategies provide productivity combined with Advt
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C U T T I N G TO O L S | T E C H N O L O G Y
This Jabro tool assortment, which includes four custom and two standard solutions, is well suited for medical part manufacturers processing tibial tray components
long tool life. In a roughing operation on a dental component parts are used in the combustion sections to handle increased made of CoCr steel, a 3 mm-diameter JHF 180 cutter from the temperatures necessary for higher engine efficiency. Jabro endmill line was applied at a table feed rate of 4,000 mm/ Newer alloys, greater challenges: In the pursuit of efficiency min with a 2 mm axial depth of cut, 0.2 mm radial depth of cut, and increased performance, ISO-S alloys undergo constant and cutting speed of 66 m/min. In the cobalt-chrome steel, tool evolution. Metals producers develop alloys with greater capabilities to meet the demands of increasingly tougher life was 175 minutes. Many small medical & dental components are machined on applications. For example, established HRSA such as nickelcompact high-speed machining centres in laboratories and base Inconel 738 and cobalt-based SFX414 were engineered to dental offices. The small cutters these machines employ must operate in temperatures in the range of 850 degrees C to 1200 be engineered to withstand the rapidly changing chip loads degrees C. Some of the latest HRSA compositions such as GTD characteristic of profiling operations on small implants and 262 and Rene 108 are intended to perform at temperatures of other parts. To fill that need, we developed Jabro Mini JM905 1200 degrees C to 1600 degrees C. We have recently assisted with the machining of a new, and JM920 cutters. The tools are available in 4-flute versions in diameters from 0.1 mm to 2.0 mm, and in long overhang higher-performance alloy used in static components of a power lengths up to 16 x D. Despite their small size, the tools offer the generation turbine. With the material’s higher heat resistance strength and stability required for specialised small-part came increased machining difficulty; only 18 m/min cutting production, with dimensions that meet typical workpiece speed could be achieved, compared to a speed of 25-35 m/min typical with Inconel 718 reference material. requirements. Existing tooling wore out after only one turbine segment (320 mm cutting length), and the turbine manufacturer sought Power generation greater tool life. Seco developed a special cutter based on the ISO-S materials are also finding increased application in Jabro 780 tool geometry, which features a dual-core design that the global power generation industry. Despite current emphasis provides increased stability in tough cutting conditions. The on “green” energy sources such as wind, water, and solar, over tool was applied at the parameters used originally: cutting 60% of the world’s electric power is currently produced via speed of 18 m/min, feed per tooth of 0.015 mm and table feed combustible fuels. The majority of that power production of 43 mm/min. The new tool machined two turbine segments involves the use of gas and steam turbines. In addition, there (640 mm), an increase of 100% in tool life. Then, by reducing are ongoing efforts to make the turbines more efficient. Strong, cutting speed to 16 m/min and increasing feed per tooth yet lightweight titanium components, for example, reduce 0.017 mm, application engineers were able to further extend centripetal forces at high rotations per minute in the lower tool life to 800 mm (+ 150% tool life). ☐ compression sections of the turbines, resulting in faster Part 2 of the article will be published in the next issue > MORE@CLICK EM01692 | www.efficientmanufacturing.in rotational speeds. In addition to titanium components, HRSA
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T E S T & M E A S U R E M E N T | A P P L I C AT I O N
REDUCING PART SET-UP TIME An application story on the use of the Primo™ twin probe system with radio part setter & radio 3D tool setter, used by SuMax Enterprises to increase machine utilisation time and eliminating scrap, thereby reducing the time consuming tool setting process SuMax Enterprises was established in 1979 to facilitate additional capacity to manufacture different products for its parent company, Vijay Engineering, a manufacturer of tooling systems and high-precision parts. Today, SuMax has 65 machines, of which 35 are CNC machines used to produce high precision parts for automotive, machine tool and other industries. The company has the capacity to manufacture 1,00,000 components per month and focuses on the manufacture of precision parts, where a machining accuracy of ±10 microns is required. Manufacturing capabilities include turning, milling, broaching, cylindrical grinding and surface grinding. Inspection is carried out using a co-ordinate measuring machine (CMM).
Increasing machine utilisation time “During evaluation of a CNC machine, a trial on one of our critical components was conducted at a machine tool supplier’s facility and there for the first time, we saw part setting being
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done using one of the Renishaw probes. We found it very useful and were convinced to adopt this technology while manufacturing our parts,” said Rajesh Suttatti, Managing Director, SuMax Enterprises. Using a Primo system has helped the company to increase machine utilisation time, eliminate scrap and reduce the time consuming tool setting process. It was attracted to the Primo system’s ‘pay-as-you-probe’ concept with a low initial investment and a unique credit token system. Moreover, it safeguards the Primo system against any accidental damage by providing a comprehensive warranty. The system is available at an affordable price and aimed at providing a fast return on investment. Consisting of a radio part setter and a radio 3D tool setter, the system enables automated on-machine part setting, part inspection and tool setting. It helps to eliminate manual setting errors, improves accuracy and part conformance and reduces non productive time and scrap. This increase productivity, improve quality and
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T E S T & M E A S U R E M E N T | A P P L I C AT I O N
The Primo system helps in setting the steering worm shaft accurately for slot milling on a vertical machining centre
increase profits. The system is easy to use, simple to install and represents a low initial financial outlay. The innovative Primo credit token system offers users the flexibility to ‘pay-as-you-probe’. Its 6-month renewable tokens allow unlimited use of the Primo radio part setter and the Primo radio 3D tool setter within this period of time. The credit tokens are also available as an upgrade to enable unrestricted continuous use. A key benefit is the elimination of the need for extensive G-code knowledge. The system is supplied with GoProbe, an innovative ‘all-in-one’ software package that simplifies part setting, tool setting and calibration.
Automated part setting capability The Primo system was installed on a machine used for the precision machining of pump body castings and steering worm shafts. In the case of the pump body casting, establishing a datum edge accurately to avoid wall thickness variation was critical. Previously, the rejection rate due to variations in wall thickness had been 12%. Using the Primo system provided an automated part setting capability that was accurate and reliable, completely eliminating rejections of this kind. While machining the steering worm shaft, the dimension from the edge of the groove to the centre of the thread has a tolerance of ±0.1 mm. The start point of the thread in relation to the groove and orientation of the slot is critical. After threading is completed on the CNC lathe, the operator uses a rotary table to position the shaft prior to milling the slot on a vertical machining centre (VMC). This part setting used to take 15 to 20 minutes, whereas the actual machining time was 5 minutes. By establishing the orientation automatically, the system eliminated a complex manual setting operation and reduced setting time to just 2 minutes. For both these applications, inspection following the machining process indicates that process variation has been eliminated – a major advantage of the Primo system. “Without the probe the operator has to find edges and calculate the mean value to come to the centre. It is a process in
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itself and is a job, which can be done by an experienced person only. If it has to be done with a trainee or inexperienced person, then there is no alternative to Primo. He has to just call a code to find out the width of the part so as to come to the centre. It is a very simple process which any operator could pick up within 10 minutes,” said Suttatti.
No additional investment Prior to installation of the Primo system at SuMax, tool pre setting operations had to be carried out off-line in a tool crib by a skilled engineer. The operator would have to remove the tool from the machine, put it in a trolley and carry it to the tool crib, where inserts would be replaced or indexed. The engineer would measure the tool offset and enter it into the offset chart. The tool would then have to be taken back to the operator, who would replace it in the machine and manually enter the offset values into the machine’s controller before machining could take place. This method carried the risk of introducing errors when entering this data into the machine’s controller. “This entire process is eliminated by the Primo tool setter as now the operator has to just call a code and assign the tool to the code. Through a simple one-line program, the tool is called from the magazine to the spindle, the spindle then goes above the tool setter, travels down at a particular speed, touches the pre-setter probe and measures the offset. This process is carried out twice. In this process, all setting is done by the machine and the operator has to just change the insert on the tool. This saves lot of time and no additional investment is required like the material handling cost, manpower cost, etc,” said Suttatti. According to Suttati, Primo is worth recommending to other SMEs as it is worry-free probing because of the warranty available and the credit token system. “It helped us in reducing our part setting time and scrap on our components. The manufacturing sector will definitely benefit with this product,” he concluded. ☐ Courtesy: Renishaw > MORE@CLICK EM01693 | www.efficientmanufacturing.in
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S P E C I A L F E AT U R E | L A S E R P R O C E S S I N G
I M A G E C O U RT E S Y: Trumpf
Exploring laser dimensions
Today, different laser technologies comprising gas, solid and fibre are used for laser processing techniques, which include cutting, welding, drilling, marking and engraving. However, in the supply side, technology-based segmentation divides the market according to various laser technologies such as gas lasers, solid state lasers, fibre lasers and semiconductor lasers. The applications include cutting, drilling, marking and engraving, micro-processing, and advanced processing, whereas the demand side of the laser processing market comprises automotive, aerospace & defence, medical and machine tool industries. According to a new market research report of Laser Processing Market by Application (cutting, drilling, marking), Laser type (gas, solid, fibre laser), Machine Configuration (moving, fixed beam), Vertical (machine tooling, automotive), Geography, the value of laser processing market is set to grow
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Currently, the laser processing market is expected to witness high demand owing to wide applications of laser technology. The feature details on the factors contributing on adopting laser technology in the manufacturing space, while analysing the market drivers, which gives this technology an edge over conventional techniques
Megha Roy Features Writer megha.roy@publish-industry.net
at a CAGR of 6.18%, from $11.24 billion in 2013 to $17.36 billion in 2020. As such, Europe is expected to expand at a CAGR of 5.92%, whereas APAC at 6.1%, between 2014 and 2020. The feature briefs on the use of laser technology in the manufacturing landscape by industry experts Thomas Greg, Sales & Marketing, SPI Lasers UK; Maulik Patel, Executive Director, Sahajanand Laser and Soumitra Joshi, MD, Trumpf India.
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As per Joshi, laser has consistently reinvented itself since inception. So, the flexibility of lasers has led to the adoption of robotic laser processing and 5-axis laser cutting-welding in many areas. “This includes cutting of high-strength steel in today’s automobiles, medical devices, hard glass and steel parts
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L A S E R P R O C E S S I N G | S P E C I A L F E AT U R E
of mobile phones and marking of wafers in semiconductor industry, etc.” Laser processing provides clean & damage-free operation as it is a non-contact process. This is one of the most important factors contributing to the growing adoption of laser technology in manufacturing processes across the world. In this context, Patel asserts that the use of laser technology ensures accuracy. “Flexibility of laser system acts as an important factor to reach the complex geometries, even with best quality and at high speed. When it comes to micromachining, lasers are preferred to be the apt solution due to its immense accuracy and finish achieved through micron level machining. Laser cutting operation does not deliver immense pressure or leave any impressions close to the operational area of the material,” he said. As per a recent report by grandviewresearch, rapid adoption of lasers for material processing has changed the market scenario in the past few decades. So, the ability to offer accurate & high speed industrial processes as compared to conventional
techniques is responsible for large-scale adoption of laser technology in the manufacturing processes. The everincreasing use of lasers is also due to the quality of processing they can achieve, which is constantly repeatable, thereby, having a massive impact upon quality along with 24x7 operation. Commenting on this, Greg opined that any part manufactured with a laser never needs additional processing to be used in the next assembly. “The new designs in lasers with new materials are being used to lase and ever shortening wavelengths offer higher productivity with near to no heat effect upon the materials. Every day, a new material is attempted with astonishing results leading to new products. As such, lasers are changing the way humans are treated for illness and protecting them from explosives and other harmful substances being detected,” he averred.
Driving factors for laser processing The rising demand for efficient material processing Advt
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S P E C I A L F E AT U R E | L A S E R P R O C E S S I N G
Laser processing provides clean & damage-free operation as it is a non-
I M A G E CO URT ES Y: Trumpf
contact process
techniques in manufacturing industries and miniaturisation of electronic goods are majorly the driving factors for laser processing market. Greg points out that nearly 98% of items in all mobile phones are now produced with laser processing technology. He further said, “The key driver is being open to receiving customer sample material and trying to process it according to the requirement. The invention of new components, materials and applications is driven by inquisitive product engineers and the laser community devising new laser types to meet these challenges.” Patel believes process requirement to be the key driving factor for advanced laser solutions. “With the emerging nano technology & use of new advanced alloys, the need for specialised machining systems for various types of processing is raised. Meeting the quality & achieving productivity are the significant elements that determine the advancements of lasers,” he suggests. However, increasing environmental concerns pose a challenge to the growth of this market. Today, lasers are gaining high popularity in automotive applications too. Growing requirements of legislations in many countries to reduce greenhouse gas emissions of motor vehicles have triggered a global trend of reducing the weight of the vehicles. At the same time, demands on performance and crash safety are also continuing to rise. This has given birth to the use of light-weight materials like hot formed manganese-boron steel in automotive manufacturing. In this regard, Joshi opines that hot formed boron steel used in Chassis and ABC pillars are hard and not possible to be trimmed with conventional mechanical trimming operations. “They should be machined in unhardened microstructure zones. As this is not possible, lasers have proven widely successful as a ‘wear-free’ tool. Our lasers offer advantages like lower investment cost on a single tool like laser instead of huge multiple machines and expensive tools & dies. It also offers higher flexibility when starting production in low-volume runs, shorter setup times for part changes, optimised storage costs and batch sizes,” he said.
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Market drivers The major market growth drivers in this sector are demand in oil & gas, automotive, semiconductor & electronics sector; need of advanced processing tools for micro-processing applications along with research & development activities in the field of new laser technologies. Major processes employing laser technology include material processing, marking & engraving and micro-processing. Laser technology assists in cutting metals or non-metals, as well as for welding purposes. It proves highly beneficial for mining & drilling activities, particularly in crude oil extraction. The large number of advantages offered in comparison to conventional techniques, including waterjet cutting, is expected to fuel market growth in material processing. High degree of accuracy for engraving small details which would otherwise be a complex task is also expected to boost demand over the next six years.
Precision micromachining Laser-cutting machines represent manufacturing tools that are critical to the production of a range of manufactured parts to form metal components. According to Patel, lasers have replaced many conventional methods of metal forming. With the use of various alloys and hardened metals in cutting tools, automobile, defence, aerospace and general engineering, the process requirements have become complicated manifold. “Since laser never touches the work piece, so there is never any lubricant or tool wastage or re-sharpening needed. Gases are not often released, nor are water or other contaminants needed to be cleaned up after processing. With the adoption of robotic technologies, lasers can perform the same task 365 days a year with the same quality every day. Parts which can share a common edge now produce no waste between parts,” says Greg. Lasers represent manufacturing tools in the form of
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L A S E R P R O C E S S I N G | S P E C I A L F E AT U R E
Lasers represent manufacturing tools in the form of engraving, marking, scribing, hardening, cladding, cutting, drilling, and welding
engraving, marking, scribing, hardening, cladding, cutting, drilling, and welding. Laser micromachining in nanotechnology are used to fabricate micro structures, groves and channels. Highlighting this, Patel focuses, “In biotechnology, they are used as tool to process micro fluids, micro filters, drug delivery systems, needles, stents, etc. Apart from that, micro machined components are used in micromechanical systems & microelectronics, particularly on semiconductor devices and integrated circuit technologies.”
Applications On the basis of application, the market is bifurcated into automotive, aerospace, OEMs, electronics & microelectronics, medical treatment devices and packaging. The medical & microelectronics industry is expected to drive laser processing growth. Laser eye surgery demand is expected to continue gaining prominence within the forecast period. In addition, growth in the automotive sector, surging electronics demand, and emerging applications in oil & gas has led to laser processing market growth. According to Patel, with the use of various alloys & hardened metals in cutting tools, automobile, defence, aerospace and general engineering, the process requirements have become complicated manifold. The Asia Pacific laser processing market is expected to witness high growth in various regions including Japan, South Korea, India and China. This growth is attributed to several factors including manufacturing cost-reduction and growing number of OEMs and automotive industries. Stringent laser marking regulations by the FDA is expected to generate marking systems demand in the US. Elaborating on the applications of lasers, Joshi believes that lasers can be used to drill holes in a variety of materials, ranging from wood and plastics to metals and ceramics. “Some examples of laser drilled holes with our TruMicro lasers are
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tiny holes in fuel pumps of Bosch and Delphi injection system, gorilla hard glass cutting in Apple and Samsung mobile phones, cooling holes in aero-engine components, micro holes in PCBs, etc.”
Advantages over conventional techniques Resolution of laser machining is much evident to prove its capability against any conventional micromachining techniques. Lasers used in micromachining gems and electronics deliver resolution close to 1 micron, which is difficult most of the time in conventional methodology (using diamond). Less & controlled heat affected zone, clean & accurate processing, reduced angular distortion, minimal post processing and quick operation are the fundamental blocks that makes lasers much preferred over conventional micromachining techniques. Greg believes that lasers will increasingly replace conventional tools where mass metal does not need to be removed. “They are even incorporated into swiss style CNC 7-axis machines to nearly double the output of these very complex machines. With no lubricant to filter, no tools to wear or re-sharpen, no down time and precision quality every time, lasers will increasingly replace conventional tools, where mass metal does not need to be removed,” he said. Some advantages of lasers drilling over other mechanical processes include contact-free process that prevents contamination of the work piece & wearing of drilling tools, Speeds upto 1 ms per hole can be achieved through drilling. Universal tool for drilling of materials like rubber, wood, diamond and ceramics can be done. Lastly, low heat affected zone in laser drilling suits best for medical equipment manufacturing and semiconductor applications. ☐ > MORE@CLICK EM01694 | www.efficientmanufacturing.in
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C O U N T R Y F O C U S - J A PA N | M A R K E T
Recovering manufacturing industry Earlier, the Japanese machine tool manufacturers took interest in the applied development of NC (numerical control) technology. As a result of having aggressively introduced NC technology, Japan gradually achieved further development of the technology. The feature briefs on the latest technological advancement in the Japan machine tool industry, while assessing the machine tool orders in recent times. According to recent reports, the total value of Japan’s machine tool orders in April 2015 was ¥134.62 billlion. There was a decline of 8.7% compared to March, and marked the first month of decrease in three months. However, this figure represented an increase of 10.5% compared to the same month of the previous year, with April posting the nineteenth consecutive month of YOY growth. The total amount of orders topped ¥130 billlion for three consecutive months. The domestic orders fell by 12.8% from March, amounting to ¥48.77 billlion. This marked the first month of decline in three months. However, this figure was an increase of 39.0% over the same month of the previous year and marked the twenty-second consecutive month of YOY growth. Looking at
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major industries, orders compared to March fell by 14.5% in industrial machinery, by 1.7% in motor vehicles, by 19.4% in electrical & precision machinery, and by 27.4% in aircraft, shipbuilding & transport equipment. Foreign orders fell by 6.1% from March to ¥86.16 billlion. At the same time, foreign orders showed a decline of 1.0%.
Value production market Looking at the industry in terms of the value production, the total 2013 value of production of machine tools amounted to ¥886.4 billion. This accounted to about 7.2% of the value of production of the general machinery industry,
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M A R K E T | C O U N T R Y F O C U S - J apan
Statistics of metal cutting machine tools
which amounted to ¥12,309.8 billion, and only about 1.5% business facilities with 50 or more employees. In addition, of the value of production of the entire machinery industry, foreign trade statistics (exports) issued by the Ministry of which amounted to ¥59,757.4 billion. Yet, the superior Finance not only covers new machine tools, but also secondmachine tools are the crucial factor in manufacturing a hand machine tools. The Japanese machine tool manufacturers took a keen wide range of machinery. As per the survey of orders received from machine tools, interest in the applied development of NC (numerical in 2013, the total amount of orders amounted to ¥1,117.0 control) technology, which was developed in the United billlion, down 7.9% YOY. This marked the decline for two States in the first half of the 1950s. As a result of having consecutive years, but topped ¥1,000 billlion for three aggressively introduced NC technology, Japan quickly consecutive years. Domestic orders increased to ¥400.8 achieved further development of the technology. By the late billlion, up 6.6% YOY. Due to fulfilling the correction of super 1970s, world markets had already come to appreciate the strong yen brought about by the audacious monetary ease, performance of Japanese NC machine tools. By riding the and economic recovery through Monozukuri subsidy and growing wave of mainstreaming of NC machine tools, Japan others, active capital investments mere created after mid-year. took over in 1982 as the world leader in the production Products for general machinery posted ¥162.9 billlion, up volume of NC machine tools. 1.8% for automobiles posted ¥123.6 billlion, up 6.0% for Maintaining its pace-setting lead in machine tools, Japan electrical equipment and precision instruments posted ¥34.1 has managed to weather the shocks and twists of history, billlion, down 5.5% and for products for aircraft, shipbuilding including the end of the cold war between the East and the and transport equipment posted ¥22.5 billlion, up 18,8%. West, the collapse of Japan’s economic bubble, and the Foreign orders amounted to ¥716.2 billlion, down 14.4% YOY. reorganisation of the global auto industry. Keeping abreast of This marked the decline for two consecutive years and dipped the on-going globalisation of the world economy, Japan has below ¥800 billlion for the first time in three years, thus, carried out its responsibilities, supplying high-performance reflecting the decline of the Asian economy. machine tools to the world manufacturing industry. Starting in 2003, production volume began rising again, driven by surging demand in China and other new markets. Industry overview In 2007, the volume of production topped ¥1,300 billlion Looking at the composition of value of exports by category for the first time in 17 years, and the industry seemed awash of machine, machining centres accounted for 39.8%, turning in prosperity. However, 2013 saw the production volume machines for 24.8%. Thus, these two categories occupied over falling from last year for the first time in four years. It marked 60%. The composition of other categories are grinding & ¥886.4 billlion and was below a ¥1 trillion level for the first finishing machines accounting for 12.1% and special purpose time in three years. Turning to trade, imports greatly exceeded machines for 10.4%. A closer look at the figures shows that exports for a while during the post-war period because the export ratio (the value of exports / the value of production domestic machine tools did not at first have adequate supply x100%) stood at 86.5%, topping the ratio of overseas demand channels or technological capabilities. But exports rose in terms of orders (64.1%). The reason for this is because the sharply starting from the 1960s, when domestic machine METI’s Survey of Industrial Production Statistics covers only tools began showing competitive edges. Exports finally
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“Despite Japanese SMEs being relatively small & average size, they are renowned for their ability to maintain competitiveness on the bases of customisation and responsiveness to customer needs.” Yoji Ishimaru, President, Japan Machine Tool Builders’ Association (JMTBA)
topped imports in 1972. From then on, exports tended to rise despite occasional hiccups, driven by the strong international competitiveness of Japanese NC machine tools. However, in 2013, it decreased to ¥766.5 billlion due to the drop in Asian economy, Meanwhile, the value of imports has remained below ¥100 billlion, with the exception of 2005 & 2006. It has been increased for four consecutive years since 2009.
Recovering trend Japan’s economy is continuing its trend to recovery, together with the support by the government’s “Three Arrows” policy, consisting of bold monetary easing, fiscal stimulus, and growth strategy (structural reforms) to encourage private investment. Private capital investments in 2014 is gradually increasing, centred on replacement investments, bolstered by the effects of the introduction of reduction of taxes on capital investments. The factors behind these trends include progress in the correction of the strong ¥ and increases in stock prices as per the results of the monetary easing conducted by the Bank of Japan; effects of the government’s economic and tax policies expansion of monozukuri (craft of manufacturing) subsidies (total of ¥140 billlion, upper limit ¥15 million per subsidy) and abolition one year ahead of schedule of the special corporation tax for reconstruction with the establishment and expansion of the tax incentive investment in productivity improving assets. Its risks consist of prolongation of the anticipatory rush in demand ahead of the increase in the consumption tax; consumption tax increase (current 8% » 10% from October 2015 scheduled); the effects on emerging economies due to the United States’ contraction of quantitative easing (downturns in stocks, currencies, and credit); slowdown of the Chinese economy and the recurrence of the issue of European sovereign
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debt crisis in connection with the situation in the Ukraine and the Middle East geopolitical risks.
Progress of machine tools market JIMTOF 2014 marked the remarkable rise in machine tool orders in November by ¥1,39.05 billlion. It increased by 4% compared to October and marked the first month of growth in two months. This figure also represented an increase of 36.6% compared to the same month of the previous year, with November posting the fourteen consecutive month of YOY growth. The total amount of orders has topped ¥130 billlion for three consecutive months and has also passed ¥100 billlion for fifteenth consecutive months. Both domestic and foreign demands are expected to be driven by a recovery trend in the future. Domestic orders rose by 9.2% over October, amounting to ¥49.06 billlion. This marked the first month of increase in two months. In addition, this figure was an increase of 17.9% over the same month of the previous year and marked the seventeenth consecutive month of YOY growth. Looking at major industries, orders compared to October rose by 2.9% in industrial machinery, by 14.3% in motor vehicles, fell by 8.5% in electrical and precision machinery, and rose by 94.5% in aircraft, shipbuilding and transport equipment. Also, foreign orders rose by 1.4% over October to ¥89.99 billlion. This marked the sixth consecutive month-on-month increase. At the same time, foreign orders showed an increase of 49.6% over the same month of the previous year with November posting the thirteenth consecutive month of YOY growth. By region, orders from Asia rose by 2.5% over October to ¥46.27 billlion. It increased by 98.4% over the same month of the previous year. Orders from Europe rose by 21.1% over October to ¥17.67 billlion. ☐ Courtesy: JMTBA > MORE@CLICK EM01695 | www.efficientmanufacturing.in
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news | tEchnology
CNC turning grinding compound machine
CNC tool grinders
With Benign Enterprises’ CNC grinding machine and turning function, the complicated machining can be accomplished within one setup of workpiece, including internal turning, internal grinding, external turning, external grinding, tapered surface turning and grinding. The turning spindle can be mounted on Y-axis or Z-axis in order to cut the excessive tolerance before performing fine grinding. BMT-D320GT The grinding spindles on the Y, Z axes can perform coarse and fine grinding. With turning and grinding operations accomplished on this machine, workpieces concentricity and accuracy are assured. Moreover, both spindles can do grinding processes, one for internal grinding and one for external grinding or any combination, accordingly, many more complex grinding procedures can be completed on this one machine, accelerating the process and improving the accuracy.
AncA has developed the FX Linear range, consisting of three new machines, namely, FX3 Linear, FX5 Linear and FX7 Linear. The range includes a significant number of important new technology releases and a complete FX Linear range body redesign that is technologically beneficial. They are ideal for light manufacturing, regrinding and full production. Its best performance and productivity range is for tools up to a diameter of 12 mm (1/2”). It can grind tools up to a diameter of 200 mm (7.78”). New features in the range include a new touchscreen customisable with Windows, handheld pendant for easier set-up and an easy to access loader door for slide out pallets. The machine is compact, but also has a large working envelope. Every part on the machine, from the positioning of the grinding wheel on the C-axis centreline to reduce thermal influence, to the ANCA designed linear motors, have been designed to enhance accuracy.
BENIGN ENTERPRISE | Taiwan Email: bematoco@ms11.hinet.net | Tel: + 886-4-2323-3016
ANCA Machine Tools | Bangalore Email: indiainfo@anca.com | Tel : +91-80-4219-8107
> MORE@CLICK EM01696 | www.efficientmanufacturing.in
> MORE@CLICK EM01697 | www.efficientmanufacturing.in
Ring cutting band saw
Metal 3D printing systems for dental parts
Everising has introduced a new ring saw – RV2007DH, a unique two head design to produce twice the cutting speed of two machines while only using the floor space of one. Each saw head will operate independent of each other with the blades running in the down direction but at different speeds to account for one head climb cutting while the other is chase cutting. Blade speeds will range from 15 – 105 m/min. The saw heads are designed Ring saw - RV2007DH to use hydraulic actuated carbide blades with blade speeds controlled with a constant torque vector drive system. The saw heads will feed into the cut on precision ball screws with cutting forces being precisely controlled through a servo control. The ball screw feed system will also detect part out of roundness and will ensure that the blade will not overfeed into the material. The special design work holding chuck will accommodate a large variation of material sizes eliminating the need to waste time changing out jaws and chucks. The chuck rotation drive is 5 HP and is fed to precise positions through a ball screw and servo controls.
Renishaw is offering its AM250 metal 3D printing machine fully optimised for producing dental parts. The metal 3D printing systems will not require further adjustment to achieve the production of high quality frameworks. To further enhance this offering the company will also supply cobalt chrome powder that can be used in the manufacture of dental frameworks. Suitable for 3D printing of a large variety of metal dental devices, the optimised AM250 is a AM250 Plus plac high volume 3D printing machine specifically aimed at the dental market. Fine tuned to the intricacies and challenges of dental devices, it is a popular alternative for those aiming to reduce the costs associated with milling operations and can replace traditional wax casting techniques by building dental frameworks from STL data as part of a digital workflow. The company has conducted its development with an emphasis on accuracy and quality of frameworks, quality and traceability of raw materials, and speed and reliability of manufacture. The key aim is to allow a rapid return on investment for its customers.
Everising Machine | Taiwan Email: evrs@everising.com.tw | Tel: +886-4-23505300
Renishaw | Pune Email: samina.khalid@renishaw.com | Tel: +91-90-4900-1589
> MORE@CLICK EM01698 | www.efficientmanufacturing.in
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> MORE@CLICK EM01699 | www.efficientmanufacturing.in
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technology | news
Solenoid valve
Compact design for cable protection
Chanto Air Hydraulics’ solenoid valve—VSY series, is low power consumption (0.95W, DC24V) and can be operated by PLC. Its volume is small with higher flow capacity. The CV factor is 1.7 to 3 times higher than the same volume. It is cost-saving and space-saving. The new design makes longer service life 50 million times in normal usage. Special rubber seals in the main valve make better durability and performance, greatly reducing valve failure VSY series under a wide range of operating conditions. Its body is compact design with hard-anodised and special machining to ensure durability.
igus has developed the twisterband HD for guiding energy, data and media cables to give operational and functional reliability in rotary motions with high loads. It combines the design features and qualities of the proven twisterchain, a circular energy chain for rotary motion up to a maximum of 360o, with its twisterband, the winner twisterband HD HT of the Red Dot Design Award. The new twisterband HD combines the strength and stability of the chain with the compactness, flexibility and the rotation angle of the band and therefore fills a gap between the two igus products. To deliver the "Heavy Duty" (HD) in the new "twisterband HD", the designers at igus have reinforced the band segments significantly and constructed it for more strength and stability. On the other hand, a hinge was developed for the connection of the individual segments, so that the twisterband HD withstands extreme loads with exceptional flexibility and rotational mobility (up to 20 times around its own axis). By using this design to connect the elements, the individual parts can be injection-moulded from the standard igus material for e-chains. The twisterband HD is optimised for temperatures below 0°C and therefore suitable for outdoor use.
Chanto Air Hydraulics | Taiwan Email: chanto@ms14.hinet.net | Tel: +886-4-2212-6177
igus India | Bangalore Email: Harish@igus.in | Tel: +91-80 49127809
> MORE@CLICK EM01700 | www.efficientmanufacturing.in
> MORE@CLICK EM01701 | www.efficientmanufacturing.in
Electrochemical machining solutions
Contour measuring system
Kennametal Precision Surface Solutions has announced Extrude Hone™ EVO, the next generation of electrochemical machining solutions featuring proprietary generator technology delivering from 3 kW to 100 kW power depending on machine configuration. EVO is available in various standard layouts: single or dual cell, or even in multi-cell configurations, thanks to the system’s modular design and construction. It is easy to configure and easy to integrate into modern production lines. The ECM technology is used in contouring, radiusing, polishing, deburring, and flow Extrude Hone™ EVO tuning applications. Essentially, it is a subtractive method that works on the principle of anodic metal dissolution. Each part to be machined requires a cathode (-) for selective material removal on the workpiece (+). For customers looking for specific machining operations, EVO integrates an interface for Dynamic ECM. Reliability being at the heart of the production control requirements, EVO provides for online monitoring and control of all relevant parameters. The online feature is also beneficial in delivering remote process demonstrations.
Mitutoyo’s Contracer CV-3200 series offers significantly increased productivity by combining fast traverse speeds, with many time saving and accuracy enhancing innovations. The series dramatically increases drive speed (X axis: 80 mm/s, Z2 axis: 20 mm/s) that further reduces total measurement time. It features a precision arc-scale built into the Z1 axis (detector). This allows the arc trajectory of the stylus tip to be read directly, thus minimising error. The series is equipped with an innovative detector arm that lowers work-piece interference while expanding the range in Contracer CV-3200 series the Z1 (detector) axis. The Z1 detector is also equipped with collision auto-stop to assure measurement safety even during high-speed movement. Additional safety features in the joystick unit include a drive speed control knob and emergency stop switch. It incorporates the Mitutoyo ABS (Absolute®) scale eliminating the need to reset the origin. Dedicated calibration gages enable the systems to perform sensitive calibrations including Z1-axis gain, symmetry, and stylus radius, in a single, simple operation.
Kennametal India | Bangalore Email: bangalore.information@kennametal.com | Tel: +91-80-2219-8444
Mitutoyo South Asia | New Delhi Email: delhi@mitutoyoindia.com | Tel: +91-11-2637-2090
> MORE@CLICK EM01702 | www.efficientmanufacturing.in
> MORE@CLICK EM01703 | www.efficientmanufacturing.in
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Tool grinding toolholder
Thread chaser insert holder
The new generation of SCHUNK PRISMO tool grinding toolholders promise more efficiency during production grinding and re-sharpening of tools. PRIMSO3 directly clamps every shank diameter between 3 mm and 20 mm fully automatically without using collet chucks or intermediate sleeves on the fly at a run-out and repeat accuracy of less than 0.005 mm. The tool shank is automatically centered in the toolholder during the clamping operation. An optimised interfering contour ensures a PRISMO3 better interference between the grinding wheel and the toolholder even in case of demanding operations. Users don’t have to invest in intermediate sleeves and collet chucks. Since the X-axis is independent from the tool diameter and does not change, every type of chuck jaw can remain at the same axial position, which allows unmanned machining of various drilling, reaming, and milling tools in small quantities without having to re-program the L1 dimension around the clock.
Seco Tools has developed its new thread chaser insert holder to bring high levels of precision and rigidity to threading operations that involve tough materials including the hard, gummy or high-chrome content ones used in the oil and gas industry. Such achievement is possible via a special carbide-pin locating system combined with a patented pocket seat surface pattern and P1 & P5 version of thread high-pressure coolant capabilities. chaser holder Working in unison with top and axial clamps, the holder’s locating system uses two horizontally oriented pins that rest at specific distances from the bottom of the insert pocket. The two-pin system ensures extremely precise insert positioning from insert to insert as well as plays a key role in the holder’s increased rigidity and insert support. As a result, the holder helps reduce the number of threading passes required to produce a full thread profile. The holder’s pocket seat surface pattern features milled scallops that provide even more chaser insert support.
SCHUNK INTEC INDIA | Bangalore Email: info@in.schunk.com | Tel: +91-80-4053-8999
Seco Tools India | Pune Email: seco.india@secotools.com| Tel: 020-137-667300
> MORE@CLICK EM01704 | www.efficientmanufacturing.in
> MORE@CLICK EM01705 | www.efficientmanufacturing.in
Double margin indexable drill
Oil mist recycling machine
TaeguTec has extended the new DrillRush line by introducing a double margin indexable drill with a diameter range of 8 mm to 19.5 mm. The new addition to the highly popular line opens the door to high surface roughness and high precision drilling applications and extends the application range of the successful DrillRush line by improving upon the DrillRush steel drilling (ISO P material) process. Known for its optimised edge geometry and innovative clamping structure, the addition to the DrillRush family continues the line’s remarkable performance compared to existing solid carbide or other conventional drills. With two guiding areas – four in total – on two cutting edges, the new double margin indexable DrillRush ensures high hole quality in relation to the cylindricity and straightness of the tool during the machining process. This new double margin indexable drill head enables reliable high quality hole machining which includes close hole tolerance, premium surface roughness and production stability.
Yung Tien Lubrication Technology has introduced oil mist collector that offers environmental protection and purification advantages as the blade rotation applies to the principle of centrifugal force to produce high pressure, low noise and large wind amount. This will quickly suck out the oil mist in the processing machine and thus, have no impact on human health. The carbon reduction advantage comes as factories equipped with Pressure relief grease lubrication central air conditioning will avoid cold air leakage, enhancing the effects of cold room and reducing the power consumption with the installation of oil mist recycling machine as well as extending the lifespan of machines. The company established in 1976, specialises in manufacturing, research and development lubrication system and each related oil duct disposition.
TaeguTec India | Bangalore Email: indira@taegutec-india.com | Tel: +91-98-8667-6473
Yung Tien Lubrication Technology | Taiwan Email: chiba.tw@gmail.com | Tel: +886-4-2528-4429
> MORE@CLICK EM01706 | www.efficientmanufacturing.in
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> MORE@CLICK EM01707 | www.efficientmanufacturing.in
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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 | Im p r i n t
Highlights - July 2015 impRINT Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Sub-editor & Correspondent Srimoyee Lahiri srimoyee.lahiri@publish-industry.net Features Writer Megha Roy megha.roy@publish-industry.net
»»Material Handling The material handling equipment industry complements the manufacturing industry by ensuring smooth and efficient distribution of goods. This industry responding with new equipment, technology, and systems that enable complete supply chain visibility, thus allowing customers to see how their investments are impacting their overall operation. The upcoming edition will thus feature latest developments in material handling technologies and associated innovations.
»»CNC & Machine Controls Presently, with the advancements in CNC technology, machines can work with precision and accuracy which is beyond human ability. With many reports indicating the future trend in CNC machine tool technology toward the reduction of the direct human involvement in the production activity, EM will focus on this evolving concept, recent case studies and experts’ insights on machine controls.
»»Education & Training Keeping in mind the increasing demand for skilled and experienced workforce in the machine tool industry, and the current state of training and education programmes in engineering institutes & the industry, the next issue will discuss challenges & measures to fill the competency gap among young engineering talent to become industryready and keep pace with global technology developments.
»»Solid Carbide Tools Modern solid carbide tools offer remarkable performance due to the combination of highly developed solid carbide substrate, optimised cutting geometries, controlled edge preparation and high performance coating. Analysing the market and technology trends in this domain, the next issue will feature industry views and case studies on applicability, pricing, customisation and reconditioning of these tools.
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Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Haimer India . . . . . . . . . . . . . . . . . . . . . . . . . 1 Hong Ji Precision Machinery . . . . . . . . . . . . . 59 Hyundai WIA India . . . . . . . . . . . . . . . . . . . . 19 ifm electronic India . . . . . . . . . . . . . . . . . . . 65 igus . . . . . . . . . . . . . . . . . . . . . . . . . . . 49, 78 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Janatics . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 JMTBA . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Jyoti CNC Automation . . . . . . . . . . . . . . . . . . 3 Kennametal . . . . . . . . . . . . . . . . . . . . . . . . 78 Kirloskar Brothers . . . . . . . . . . . . . . . . . . . . 10 Korloy India . . . . . . . . . . . . . . . . . . . . . . . . . 11 Mitsubishi Heavy Industries . . . . . . . . . . . . . . . 2 Mitutoyo South Asia . . . . . Front Inside Cover, 78 MMC Hardmetal . . . . . . . . . . . . . . Back Cover MMI India . . . . . . . . . . . . . . . . . . . . . . . . . . 61 MotulTech India . . . . . . . . . . . . . . . . . . . 32, 43 Oerlikon Metaplas . . . . . . . . . . . . . . . . . . . . 48 Open Mind Technologies . . . . . . . . . . . . . . . . 16 PMT Machines . . . . . . . . . . . . . . . . . . . . . . 13 Quaker Chemicals . . . . . . . . . . . . . . . . . . . . 31
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 Sovan Lal Tudu (Senior Designer) sovan.tudu@publish-industry.net Jogindar J Dumde (DTP Operator)
company Index Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Ace Micromatic Group . . . . . . . . . . . . . . . . . 17 Adani Power . . . . . . . . . . . . . . . . . . . . . . . . 10 Altair Engineering India . . . . . . . . . . . . . . . . . 51 ANCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Autocam Technology Co . . . . . . . . . . . . . . . . 63 Benign Enterprises . . . . . . . . . . . . . . 36, 37, 77 Blaser Swisslube . . . . . . . . . . . . . . . . . . . . . 29 Brush Group . . . . . . . . . . . . . . . . . . . . . . . . 10 Chanto Air Hydraulics . . . . . . . . . . . . . . . . . . 78 CII & BCG . . . . . . . . . . . . . . . . . . . . . . . . . 26 Comsol . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 DesignTech Systems . . . . . . . . . . . . . . . . . . 42 Erwin Junker Maschinenfabrik . . . . . . . . . . . . 55 Everising . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Faro Technologies . . . . . . . . . . . . . . . . . . . . 41 FEMCO India . . . . . . . . . . . . . . . . . . . . . . . . 34 FLIR Systems . . . . . . . . . . . . . . . . . . . . . . . 25 Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . . 12 Geometric . . . . . . . . . . . . . . . . . . . . . . 10, 38 Godrej Aerospace . . . . . . . . . . . . . . . . . . . . 52 Haas Automation . . . . . . . . . . . . . . . . . . . . . 56
Features Writer Maria Jerin maria.jerin@publish-industry.net
Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Renishaw . . . . . . . . . . . . . . . . . . . . . . . 66, 77 Roland Berger Strategy Consultants . . . . . . . . 20 Sahajanand Laser Technology . . . . . . . . . . . . 70 Schunk . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Seco Tools . . . . . . . . . . . . . . . . . . . 62, 69, 79 Siemens PLM Software . . . . . . . . . . . . . . . . 15 SKF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Sofimu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 SPI Lasers . . . . . . . . . . . . . . . . . . . . . . . . . 70 Stratasys . . . . . . . . . . . . . . . . . . . . . . . 12, 18 TaeguTec India . . . . . . . . 79, Back Inside Cover Trumpf . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Vargus India . . . . . . . . . . . . . . . . . . . . . . . . . 6 VDMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 VDW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 VR Coatings . . . . . . . . . . . . . . . . . . . . . . . . 67 WIKUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Yamazaki Mazak India . . . . . . . . . . . . . . 46, 47 YG1 Cutting Tools . . . . . . . . . . . . . . . . . . . 4, 5 Yung Tien Lubrication Technology . . . . . . . . . . 79
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 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
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