www.efficientmanufacturing.in
EFFICIENT MANUFACTURING
MAR 2015 I VOLUME 06
Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong
EFFICIENT MANUFACTURING
VOL 06 | MAR 2015
GAME changing innovationS
Witnessing global trends in manufacturing technologies
www.efficientmanufacturing.in
FOCUS Metal cutting EM - Interview
P. 42
Round-table Vision promising budget P. 28
P Ramadas
Managing Director, Ace Manufacturing Systems (p. 26)
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Used more than 10,000 times worldwide in lathes ROTA-S plus 2.0, manual chuck from SCHUNK
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E D I TO R I A L
Technology trends to look for...
“Integrating modern-day information technologies into machine tools make them more attractive and above all, easier for the operator to control�
Manufacturers, today, have an increased focus on technologies that automate, simplify and enhance the efficiency of work sequences and optimisation of manufacturing processes involved. Integrating modern-day information technologies into machine tools make them more attractive and above all, easier for the operator to control. In addition to the technological advancements, the general trend is incorporation of styling and operatorfriendliness. For example, emulating the smartphones, machinery control systems now feature a touch-screen. In conjunction with the design of other equipment, this combines to produce an attractive visual appearance. New concepts for minimising change-over times in turning operations, enhanced operator-friendliness by using innovative information technologies, complete machining of workpieces for enhanced productivity, dry machining, using carbon-fibre composites in machine tools and tools, flexibility for large machines, laser & 3D printing, enhanced metrological efficiency, machine tools with parallel kinematics, expansion of tool management and enhanced efficiency for tools, user-friendlier interfaces in CAD/CAM, these are a few technology trends to look for in the coming years. In this context, industrial trade exhibitions have developed over the years as important platforms to showcase the path-breaking production technologies that have created the foundations for maintaining corporate competitiveness against globalised competition. Exhibitions like IMTEX, EMO and IMTS have very much evolved, projecting as a diverse showcase of global manufacturing technologies. Numerous solutions get presented in these shows in response to the latest social and commercial trends. The Cover Story in this issue presents some of the important technology trends and innovations witnessed during IMTEX, with experts commentary from industry connoisseurs. It highlights the latest machines, efficient technical solutions, productsupportive services, sustainability in the production process, automation systems, and much more. In short, it shows how Indian manufacturing is raising the competitiveness at par with global players so as to meet the challenges in the domestic market.
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
Focus
Metal Cutting 10 16
26
NEWS “THE MARKET GROWTH IS DIRECTLY AFFECTED BY THE FINANCIAL GROWTH�
Interview with Jeffery S Foregard, GM - Asia & Europe & Member of the Board of Directors, ANCA Machine Tool
88
SHOWCASING LATEST TECHNOLOGY STANDARDS
APPROACHES FOR EFFECTIVE MACHINE TOOL UTILISATION
Interview with P Ramadas, MD, Ace Manufacturing Systems
The article briefs on the important components of effective machine utilisation by maximising the required timeline for metal cutting
VISION PROMISING BUDGET
The feature focusses on the measures introduced in the Union Budget 2015-16, to develop a manufacturing friendly environment
INNOVATIVE GRINDING TECHNOLOGIES
A post-event report on the Motion Meeting 2015 by United Grinding, held in Switzerland
42
TO ENHANCE COMPONENT MANUFACTURING�
ROUND-TABLE 28
EVENT REPORT 84
“IMPLEMENTING ROBUST & LEAN PROCESSES
MANAGEMENT STRATEGIES 34
80 “ESTABLISHING OUR BRAND IN INDIA IS A
TRANSFORMING MANUFACTURING MODEL
MAJOR CHALLENGE‌�
The article analyses the critical role technology plays in addressing the modern business challenges
Interview with Dilip A Chauhan, Director—Business Development, Henfux India
A post-event report on the IMTEX 2015, and Tooltech 2015
NEW PRODUCTS
Country Special: CHINA
82
NC series standing die spotting machine; Engraving & milling spindles; Machine tools for compressor & rolling components; Centreless grinding machine
83
Volumetric lubrication systems; Vertical machining centre; 6-axis coordinate advance milling & drilling machine
74 CHANGING INDUSTRY LANDSCAPE
The article briefs on China’s current changing ideological emancipation & concept innovation 78 “LOOKING FORWARD TO CO-OPERATION BETWEEN INDIAN & CHINESE ENTERPRISES�
Interview with Chen Huiren, President & CEO, CMTBA
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CONTENTS
Technology
HIGH SPEED MACHINING 46
TEST & MEASUREMENT
Reducing machining time
66
The article deals with the parameters to be considered for implementing successful HSM
Saving time saves nine
The article briefs on how Primo™ twin probe system, developed by Renishaw has helped Victory Precisions to reduce part set-up time
New Products 92
MACHINING 50
Cost-effective cutting solution
MACHINE VISION
An application story on the high performance Haas CNC machine tools used by Telgelgo 54
60
Building monitoring & alarming system
The article highlights how Eigen Innovations has developed smart hardware module with the help of FLIR
Innovation in precision boring
The article features an innovative asymmetric boring solution for increased productivity & cost reduction
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Sensor-based adaptive arc welding
Cover Story GAME CHANGING INNOVATIONS
An insight on the evolving trends in the Indian manufacturing industry, as witnessed in IMTEX 2015
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SPECIAL FEATURE
The article highlights how the emerging sensor technology allows robotic automation to address welding challenges
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CNC grinding machine with turning function; Right-angle precision gearbox; Hydraulic press machine; Non-clog sewage submersible pump Digital process planning application; Visualisation solution; Automatic 3D design tool; Highfeed milling cutter CNC solution with software version 4.7; Digital control of spindle speed & power-stroke speed; Compact four corners double-sided insert
Columns 07 08 96 96
Editorial Contents Highlights – Next issue Company index
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MARKET | NEWS
Saint-Gobain celebrates 350th anniversary Saint-Gobain had recently celebrated 2014, it has registered sales of about its 350th anniversary, along with setting ` 4,800 crores. For the company, the sights firmly on the future and, in Indian market presents a huge particular, in India, with its strategy opportunity for growth. “On our 350th anniversary, we aim to strengthen this ‘Shaping the Future.’ commitment even further by becoming “India has been an important market the reference for sustainable habitat in and investment destination for us. We India and doubling our business in the believe that it can play an important country in the next few years,” added role in shaping the future by designing, Mahajan. manufacturing and distributing building According to the company, two large and high-performance materials, which entities, Grindwell Norton Limited provide innovative solutions to meet (GNO), a publicly traded company, and the challenges of growth, energy Saint-Gobain India (SGI) and a few efficiency and environmental protection. Venkat Subramanian, MD, Gyproc; Anand Mahajan, General Delegate for smaller entities house Saint-Gobain’s This is the core of Saint-Gobain’s India, Sri Lanka and Bangladesh and B Santhanam, President, Flat Glass businesses in India. “Specifically for strategy,” said Anand Mahajan, General Business (Glass & Sekurit), kickstart the 350th anniversary celebrations India, we will focus on three strategic Delegate — India, Sri Lanka & priorities that are sustainable habitat, innovation, and local manufacturing. Bangladesh, Saint-Gobain. The company has entered India in 1996, and has achieved strong and We have also planned to double our business in India and to exceed sales profitable growth since then. Today, it is a leader in all its major businesses, of ` 10,000 crores by 2019,” added a company official. > MORE@CLICK EM01552 | www.efficientmanufacturing.in and has 20 manufacturing sites and about 4,900 employees in India. In
Bharat Forge partners with Boeing to supply titanium forgings Boeing has signed a multi-year contract with Bharat Forge to supply titanium forgings to be used in the wings of next-generation 737 and 737 MAX. The company will supply pre-machined forgings to Boeing in the first quarter of 2016. “We have mastered the stringent process requirements for titanium forgings and will be supplying critical forgings for wing components. This also confirms our resolve to meet the ‘Make in India’ drive”, said Baba Kalyani, CMD, Bharat Forge. The titanium parts will be heat-treated, shaped According to Baba Kalyani, in a forging press, and machined by the CMD, Bharat Forge, the company before being shipped to Boeing company has mastered the for finish machining into components. The stringent process requirements components will, then, be installed in 737 for titanium forgings and 737 MAX wings at Boeing’s assembly plant at Renton, Washington. “We are pleased to welcome Bharat Forge into our supply chain as they have an impressive record of performance across many industries,” said Kent Fisher, VP & GM—Supplier Management, Boeing Commercial Airplanes. > MORE@CLICK EM01553 | www.efficientmanufacturing.in
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Making Indian MSMEs globally competitive According to CII SME Summit 2015, the micro, small & medium enterprises (MSME) sector contributes nearly 8% of the country’s GDP, 45% of the manufacturing output and 40% of the exports. It provides the largest share of employment after agriculture. MSMEs are the nurseries for entrepreneurship & innovation and are widely dispersed across the country. It produces a diverse range of products & The theme of the summit was ‘Making Indian services to meet the needs of MSMEs globally competitive’ the local & global market, along with the the national & international value chains. Highlighting the challenges that MSMEs are facing in today’s economy, K Nandakumar, Chairman, CII (WR) Sub-Committee, Chairman & MD, Chemtrols Industries, said, “Since, MSMEs contribute nearly half of the country’s manufacturing output, it is important to make them globally competitive so that India can contribute effectively to honourable Prime Minister’s vision of “Make in India.” > MORE@CLICK EM01554 | www.efficientmanufacturing.in
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MARKET | NEWS
Building on rapid innovation The 4th Asia Manufacturing Supply Chain improvements; learn & benchmark from other Summit was held from February 18 to 19, companies; know the best practices & market 2015 in Mumbai. The two-day event gathered trends; streamline operational process and the manufacturing & logistics executives with align these processes with overall business the theme “Rapid Innovation”. The keynote strategy; explore new collaboration session was addressed by Prof Dr rer pol Carl opportunities and forge relationships with the B Welker, IUBH School of Business & lean six sigma professionals. Management. Besides, the conference featured an exhibition The event included panel discussions and area with 20 top level companies showcasing presentations with over 20 vital industry their products & services. It was also a good topics from 40 senior global manufacturing & networking event where consultants, logistics supply chain professionals from companies solution providers and eProcurement solution across Asia. The agenda of the presentation The event provided the opportunity to ensure business & service providers discussed how they centered on the key issues & challenges faced process delivers across the organisation played an integral role in strategic by SCM & logistics professionals across the procurement strategy. With over 250 world. Well-experienced speakers shared their perspectives on the attendees, the summit brought together the leading thinkers and presentation. practitioners in manufacturing, logistics and supply chain to network, learn, The event provided the opportunity to ensure that the business process debate challenges, discuss trends & share ideas. The summit witnessed delivers across all levels in the organisation through the latest in strategy, more executive insight from manufacturing & supply chain peers and more planning and change management techniques; validate strategic vision & thought-leaders in the industry providing with actionable take-aways. > MORE@CLICK EM01555 | www.efficientmanufacturing.in investment decisions with industry leaders; create value through process
Junker Group honoured with ‘Leader of Technology Award’ Junker Group has been recently felicitated with the Shanghai General Motors (SGM) “Leader of Technology Award” in China. SGM confers awards on its best suppliers in a range of categories once every two years. The company is one of two machine manufacturers Rochus Mayer (third from the left) accepted the from Europe to be among award from Shanghai General Motors this year’s winners. The award recognises continuous investment in the development of new, economical grinding machines for grinding a wide range of different car components, from crankshafts to nozzle pins. “We invest heavily in the development of new machines and technologies. This makes us particularly proud to have been distinguished with the award of Technology Leader by one of the world’s biggest car manufacturers”, said Rochus Mayer, CEO, Junker Group, on receiving the award against the the backdrop of a show to launch new car models complete with firework display. > MORE@CLICK EM01556 | www.efficientmanufacturing.in
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GE opened its manufacturing facility at Pune GE’s multi-modal manufacturing facility was recently inaugurated at Chakan, Pune, by Hon’ble Prime Minister, Narendra Modi. Inaugurating the facility, Modi said that there were immense possibilities for manufacturing in India. “India’s demographic dividend is a magnet to attract investment. The Government is working towards creating a skilled talented workforce, which will attract the world to India. Hon’ble Prime Minister Narendra Global technology (Vishwa Dhan) and Modi inaugurated the facility the talent of Indian youth (Yuva Dhan) can together result in a win-win situation for all.” He also congratulated the company for the state-of-theart manufacturing facility they had set up, and welcomed GE’s announcement for further investment. He said this was a big boost to the ‘Make in India’ initiative. The company has invested around $120 million (around `740 crore) to set up the facility, where a single machine can cut across businesses such as oil and gas, rail and aviation and make products for different sectors. > MORE@CLICK EM01557 | www.efficientmanufacturing.in
EM | Mar 2015
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MARKET | NEWS
ZF Friedrichshafen AG inaugurates its plant in Pune ZF Friedrichshafen AG has recently opened its new plant in Chakan, Pune. help us provide a compelling value proposition to our customers.” With a total investment worth nearly ` 150 crore (€20 million), the plant is Speaking on the launch of the new facility, Piyush Munot, MD, ZF India, said, spread over an area of 85,000 sq mts (21 acres). This facility marks an “We have established our presence in Pune in 2010 by introducing high important milestone in the centennial performance transmissions, followed year of ZF Group. by chassis components both for “This new plant is an important commercial vehicles and passenger investment in the centennial year of cars. Today, we enhance this product ZF Group”, said Wilhelm Rehm, Board portfolio by launching passenger car Member, ZF Friedrichshafen AG & clutch systems. These are specially Global Head—Material Management. designed to meet the demanding Over the years, the company has been driving conditions in India.” successful in localising high Currently, the company’s presence in technology products in India. “Now, India consists of eight plants spread we will focus on the ‘Make-in-India’ across Pune, Pantnagar, Gurgaon, theme and source quality products for Chennai, Coimbatore and Madurai, its global portfolio”, he added. The facility marks an important milestone in the centennial year of ZF Group with around 3,000 employees. The Commenting on the development, new facility will have approximately Rudi von Meister, President—Asia-Pacific, ZF, said, “This multi-product 200 employees. It will also be a home to the headquarters of the afterfacility will house our car powertrain technology and commercial vehicle market sales and services, engineering and administration of technology divisions as well as ZF services under the same roof. The the company. > MORE@CLICK EM01558 | www.efficientmanufacturing.in synergies from this consolidation will enable us to improve efficiencies and
KBL inaugurated its warehouse facility in Kirloskarvadi
Renishaw’s new pioneering encoder goes into space
Kirloskar Brothers recently inaugurated its warehouse facility at Kirloskarvadi, Maharashtra. The warehouse currently stocks all fast moving spares for KBL’s range of small & medium industrial pumps. This will enable the company to quickly deliver spare parts to customers in industries such as coal, sugar, chemical process, oil and gas, power, building & construction and municipal water. “The opening of this warehouse and service centre will enable us to offer high quality services to our The company showcased its customers. It will also help us to formulated comprehensive range of increase our distribution reach. This greases available in India new initiative will provide comprehensive and proactive service facilities to our existing and potential end users,” said Jayant Sapre, Director, Kirloskar Brothers. With consumption-based stock and IT-enabled process to monitor consumption and re-ordering of parts based on customer demand, it will help the company to reduce the delivery time of spare parts for small & medium pumps.
The European Space Agency’s Sentinel-1A satellite was recently launched from the European spaceport in Kourou, French Guiana with Renishaw’s new space-encoder technology installed on the advanced Optical Communications Payload (OCP) of the satellite; part of a revolutionary inter-satellite laser communication system. The OCP provides an optical Low Earth Orbit (LEO) to Geostationary Earth Orbit (GEO) communications link via a pair of Laser Antarctica Peninsula image from Communication Terminals (LCT) by space Tesat Sentinel-1A telecommunications company TesatSpacecom (Tesat) of Backnang, Germany. Tesat required a new rotary (angle) encoder for the coarse pointing assembly (CPA) of its 2nd generation LCT, which is essentially a telescope with coherent receiver and transmitter hardware. The space-qualified encoder was developed in collaboration with Tesat and shares much of its core technology with Renishaw’s proven TONiC™ encoder range. Radiation hardening, combined with Renishaw’s extremely robust optical detection principle, has resulted in the encoder achieving qualification.
> MORE@CLICK EM01559 | www.efficientmanufacturing.in
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> MORE@CLICK EM01560 | www.efficientmanufacturing.in
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MARKET | INTERVIEW
“The market growth is directly affected by the financial growth” Jeffery S Foregard, General Manager - Asia & Europe and Member of the Board of Directors, ANCA Machine Tool, illustrates the latest technology advancements initiated by the company and underlines the need of the revival of the financial & banking sector to sustain growth in the Indian machine tools industry, during an interview with Srimoyee Lahiri. Excerpts… With the ‘Make in India’ initiative, how are you synergising your strategies with the customer requirements? Each customer is different with a different set of requirements. We are tailoring specific packages for specific customers. On the other hand, pricing in the market plays a big role. Since we specialise in CNC tooling, cutting and grinding, we work closely with the customer to tailor the supply of the product and target a specific market. What are the latest innovations in the offing? The latest technology developed by us is in linear motions. We own a complete new machine, which is the FX series and on that we have deployed the linear motor technology, introduced by ANCA. The FX series consists of three machine levels— FX3 Linear, FX5 Linear, and FX7 Linear. Suitable to multiple machining projects (light manufacturing, regrinding, full production), the series’ best performance and productivity range is for tools up to diameter 12 mm. It offers grinding capabilities for tools up to 200 mm diameter. Maximum wheel diameter is 8 mm. We produce our own software with our own control developed & manufactured by the company. What is your focus on R&D? Our R&D team is based out of Australia. We are constantly looking at new developments and also improving existing platform. We contribute around 10% of our revenue to R&D in the areas of machine mechanical, electrical and software. What is the general demand trend witnessed in the Indian machine tool industry? With the backdrop of ‘Make in India’ initiative and the arrival
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of new government, there’s a lot of positive vibe amongst the crowd. Customers are now showing the general interest in the technologies and products offered in this platform. Going forward, the next 3 to 4 years will witness this positivity in the industry. The only challenge is the financial & banking sector. It is an absolute disaster and a lot of revival in this sector is required. The loans provided in India compared to China, Europe or USA is a nightmare. Thus, the market growth is directly affected by the financial growth. How has been the performance of the machine tool industry in 2013-2015? The performance of the machine tool industry has really been good. We have seen some growth over the past few years. It is steadily growing in India by 3% YOY. Since India doesn’t have a tailored market, we are looking at a gradual growth in demand in this country. What is your agenda for 2015-2016? With the launch of the new FX series and by making strong push in the global market, we are seeing a lot of activity in the IT sector, particularly in the mobile phones. We are ideally targeting Apple & Samsung and the entire IT sector, where we see a major growth. The company, being a market leader in quality CNC grinding machines and CNC systems, has steadily evolved through policies of innovation and technology and a determination to produce machines that satisfy our customers’ requirements and exceed their expectations. After 40 years of working with the industry, we continue to find new ways to deliver products that respond to market needs. ☐ > MORE@CLICK EM01561 | www.efficientmanufacturing.in
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Special HSS improves toughness, wear resistance as well as extends dramatically the tool life. Unique flute shape makes better chip evacuation. New point geometry enhances the Machine ability properties All applications regardless of machine condition: Good or Poor. Advantage against regular HSS drill is, Performance improvement by minimum 20%.
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C O V E R S TO R Y
TECHNOLOGY
GAME CHANGING INNOVATIONS
Image courtesy: Shutterstock
Witnessing global trends in manufacturing technologies
Highlighting the evolving trends in the Indian manufacturing industry, IMTEX 2015 was the apt platform to review & address the latest trends, as well as expose users & manufacturers to a range of value added machining solutions under one roof. This article details on the game changing innovations and underlines how Indian companies should provide an advanced position to R&D to strengthen the global positioning of the Indian machine tool industry. 20
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Srimoyee Lahiri Sub-editor & Correspondent srimoyee.lahiri@publish-industry.net
Maria Jerin Features Writer maria.jerin@publish-industry.net
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TECHNOLOGY
Given the current gap between demand and supply, there is a clear need for adding capacities in the machine tool sector. Indian companies are catching up with the speed of technological development and to showcase this, IMTEX 2015 provided a huge platform for the machine tool manufacturers. One of the general trends witnessed during the event was exhibitors moving to the next level of innovation in the incorporation of performance, access, ergonomics and aesthetics in their machines. The focus was on innovations that automate, enhance the efficiency of the work sequences involved and the productivity of machining operation. Numerous solutions presented are also motivated by currently expanding industrial sectors, like the aircraft industry and the energy utilities. The recent joint study by ACMAIMTMA-Roland Berger Strategy Consultants, has suggested that the growth rate for Indian machine tool suppliers could be higher, due to import substitution in the automotive industry in light of fluctuating exchange rates. Indian manufacturers have raised the competitiveness at par with global players to meet the challenges of the domestic customers. Here’s a look on the latest innovation and technology trends emerging in the Indian machine tools industry.
What was witnessed? Man-machine integration: The Indian machine tool companies have now come to an understanding of the rising level of automation, which is acceptable in the user sector and blends with the man-machine integration. Suggesting this, Shailesh Sheth, Chairman — Programmes Committee, IMTMA, says, “Machines integrated with robots such as machine tending and pick & place are a good level of automation that can produce the stated number of pieces per hour. But the automation of machine-to-machine integration is costly and minimises the requirement of human labour. Thus, a proper manufacturing output is the one that integrates man and machine. In a complete production line conveyers & gantry robots are integrated to reduce the effort of man. The Indian companies have incorporated this appropriate level of automation, which suggests a positive and good level of innovation. There are
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C O V E R S TO R Y
some areas in the complete lines of production that need to be automated because each station has to be in a balanced state.” Indian companies have shown a good beginning towards this development. Companies like Jyoti CNC and TAL Manufacturing Solutions have come up with such level of automation that perfectly blends with the man-machine integration. “Most of the customers are looking for automation not only for changing parts but also for loading and unloading of parts, cleaning, inspection and preparing parts for the next step. With the help of robots and integrated software, we are developing products to provide solution for big to medium sized companies. With the integration of automation, the efficiency can be increased from 65 to 85% ensuring quality and reliability,” says Vijay Zala, Executive Head – R&D, Jyoti CNC Automation. High precision machines: So far, in the minds of customers, Indian machines are good for the purpose of roughing. However, this perception is now gradually changing. Domestic manufacturers have come up with products, which are very close to the precision level and therefore, can meet the challenges of the domestic customers. Highlighting this, UCAM has launched the Noah series under the Nimble Machines brand. It is a 6-axis CNC gear hobbing machine that offers high productivity and precision with the incorporation of highlevel technologies like electronic gearing, advanced software and the direct drive systems. The machine is developed at par with the global standards. On the other hand, GrindMaster in technical collaboration with Balance Engineering of USA, has launched Crankshaft Dynamic Balancing Machine, the CRH_ MQL600 for automotive crankshafts. “The machine gives the customer key process advantage in terms of accurate balancing under 10 gm cm consistently and zero job rejection & rework,” says Sameer Kelkar, Executive Director, GrindMaster. Diversification: In early 2002, especially the automotive sector, witnessed increased investments as global majors started to outsource manufacturing to India. This led to a spurt in demand for machine tools. The machine tool industry, since then, has been growing at a healthy rate, even exporting general purpose and standard machine tools to industrially advanced
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C O V E R S TO R Y
TECHNOLOGY
Shailesh Sheth, Chairman, Programmes Commitee, IMTMA, shares the general overview of manufacturing technology trends showcased by Indian machine tool manufacturers
countries. But now, with the changing demand trends, the industry is looking for more options to survive in the domestic market. Many Indian companies have widened the range to complete their metal cutting portfolio, thereby providing solution to non-auto segments like infrastructure, power plant, railways, defence & aerospace, die & mould, etc. So, these are the segments where lots of machinery is developed by Indian manufacturers, that witnesses the next level of innovation. Multiple operation machines: In multiple operation machines, Indian machines have still not achieved the complete level of multi-tasking. But there are a lot of machines with inprocess measuring. “Normally, in machining, one may come to conclusion of rejection after the production of the first component. With online measurement, this can be avoided and the first product waste can be saved. There also many machines with in-line washing or deburring. But still some developments that combine milling & turning and turning & grinding needs to happen. Indian machine manufacturers have been in the half way of the journey,� said Sheth. Single set up machines are popular where multiple operation machining can be done at one time. Since loading and unloading is time consuming, the concept has undergone a change with minimum amount of handling with zero idle time. This is where the concept and the need of multitasking machining has emerged with the philosophy that minimises the amount of handling in machining. Understanding this requirement, a similar trend has been observed where BFW has launched the twin spindle high-speed VMC for productivity enhancement in precision aluminium component machining. The machines’ integrated patent pending technology has the capability to convert raw
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Innovation witnessed by Indian manufacturers t Good level of understanding in automation that blends with man-machine integration t *OEJBO NBDIJOFT IBWF DPNF WFSZ DMPTF UP UIF level of high precision machining to meet the challenges of the domestic customers t .BOZ *OEJBO DPNQBOJFT IBWF XJEFOFE UIF SBOHF UP DPNQMFUF UIFJS metal cutting portfolio, thereby providing solution to non-auto segments like infrastructure, power plant, railways, defence & aerospace, die & mould, etc. t *O UFSNT PG NVMUJQMF PQFSBUJPO NBDIJOFT *OEJBO NBDIJOFT IBWF completed the journey half and still half way to come. t %FWFMPQFE MPX DPTU NBDIJOFT UP DPNQFUF XJUI DPVOUSJFT MJLF $IJOB Innovations in progress t The biggest gap is in the area of larger component machining. There is not enough production of larger machines in India. t - BDL PG LOPXMFEHF JO IBOEMJOH AEJGGJDVMU UP NBDIJOF NBUFSJBMT MJLF titanium, molybdenum, used in aerospace & medical engineering t .BDIJOFT XJUI TJOHMF TFU VQ NBDIJOJOH NJOJNVN BNPVOU PG handling t 1SPEVDUT BOE TPMVUJPOT GPS UIF AGBDUPSZ PG UIF GVUVSF UIBU incorporate offline monitoring, digital application, CNC group controllers, sensor technology, etc.
products to finished parts. It is developed for the single set-up machining of two wheelers and passenger car parts. On the requirement of multi-tasking machines, Zala avers, “We are competing with imported machines. We are more into developing multi-tasking machines. Customers demand a single machine that takes care of all operations such as milling, turning, grinding and gear cutting. This is the latest trend in the industry which is looking for high flexibility and minimal volume of production in terms of operations�. Low cost machines: Development has happened in the peripheral areas like work-holding devices, clamping, fixturing and tool holding. Also, on some of the commodity products, like standard volume driven products; companies have come up with new price ratios, e.g. CNC lathe with the linear tooling have catalogue price of ` 10 lakh. This shows Indian companies are gearing up to compete with low cost supplying countries like China.
What to expect? Larger component machining: Currently, the biggest gap is in the area of larger component machining. There are larger workpieces like axles that measure 1 m to 1.6 m long. It needs CNC machines heavy enough to carry those big wheels large diameters, gun barrel shells, aircraft cones, etc, that are very big. “There is not enough production of larger machines in India.
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C O V E R S TO R Y
TECHNOLOGY
Grindmaster launches gear deburr and chamfer model, SCT-3 machine at the hands of Ceglia Teodoro, Samputensili Division Director, during IMTEX 2015
This gap needs to be bridged by the Indian manufacturers�, said Sheth. Speaking further on this, Zala says, “Now, we are in the stage of developing infrastructure. To develop infrastructure heavy industries play a big role. We have launched big turning centres for heavy engineering industries like mining, power engineering, railways, etc. We have milling machines to cater to these industries, so, for turning, we have developed these machines�. Difficult-to-machine materials: Indian industries are used to machine standard materials like aluminium & steel. But, when it comes to non-standard high alloy steels like titanium & molybdenum, which are used in aerospace & medical engg, etc, there is a lack of knowledge on machining those materials. It needs different toolings with different cutting speeds, different coolant processes and the change in the whole machining gamut. At present, the major constraint is in the level of experience from where innovation needs to be derived. Factory of the future: The manufacturing industry in India is ZFU UP FOUFS UIF [POF PG A'BDUPSZ PG UIF GVUVSF 4VHHFTUJOH UIJT Sheth opines, “We are still not able to envisage what the factory of future would look like in terms of digital applications, CNC group controllers and offline monitoring. These concepts can be brought in India by global customers who set up the manufacturing base in India. We have achieved milestones in following TPS system. But there are not enough machines for factory automation. We need to work on the concept of “smart factory of the future�. Speaking on the initiatives, Dr M S Kulkarni, faculty incharge of the NIDAAN project (An indigenous diagnosis and prognosis system for machine tool spindle bearings) developed by Indian Institute of Technology Delhi, says, “We look at mass manufacturing customers, who cannot afford to keep their
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machines down at the production time that incurs huge loss. One of the factors, which affect the machine tools in terms of downtime is the spindle failure. This is mission critical stage and here the condition monitoring system is advisable. Analysing this challenge, we have developed this indigenise product. One of the objectives is the diagnostic analysis that tells exactly the nature of the problem and the remaining life of that part. This, now, has been filed for a patent and has been implemented on Micromatic Grinding machine. Going forward, we are also developing software with internet connection to access from remote systems�.
Global innovations At IMTEX 2015, numerous solutions were unveiled by global companies. DMG MORI premiered an operator control level with a touch-screen. It allows the user consistent management, documentation and visualisation of order, process and machine data. Similarly, Yamazaki Mazak with its new MAZATROL SmoothX, established a dramatic evolution in machine tool performance that spans the entire part-production landscape, from programming and setup to metal removal operations to automation and monitoring / data collection & transfer. In general, high-speed machines are expensive and take up valuable shop-floor space and may often sit idle. Auxiliary spindles, while more flexible and less expensive, have performance issues. To address this challenge, Colibri Spindles’ has introduced the spindle technology, SPINJET HSM Jet spindle, which delivers the results manufacturers seek, making it a real alternative to investing in a high-speed machine. Through a patented passive dynamic damping system called steadyline vibration damping, Seco Tools has improved
EM | Mar 2015
9:44:01 PM 3/13/2015 9:21:35
TECHNOLOGY
the dynamic rigidity of milling and turning assemblies that increases productivity, improves surface finish and boosts both tool and spindle life. “In this system, the vibration absorber is positioned, where deflection is highest in front of the bar. The absorber damps the vibration as soon as it is transmitted from the cutting tool to the body of the bar, thus limiting the deflection of the tool,” says Raymond Tugend, Application Engineer, Winning Solutions Expert, Seco Tools. With traditional methods of manufacturing, such as subtractive and formative processing, topological optimisation has to make certain compromises. However, Additive Manufacturing (AM) doesn’t suffer from the same limits. As a result of building the part up layer-by-layer, more complex designs are possible with no need for tooling or cutting. Therefore, forms can be created that are closer to the optimum design. Taking advantage of this, Renishaw’s Additive Manufacturing technology, AM250, allows them to create a titanium alloy frame that would be both strong and light using
C O V E R S TO R Y
topological optimisation. The company has showcased this bike frame with individual sections have been bonded together and the new frame is some 33% lighter than the original.
Conclusion The major crunch in the Indian machine tool industry is that the companies spend a minimum amount of their revenue in R&D. Worldwide the benchmark is somewhere near to 3 to 4% of the turnover. But presently, this is a rare sight across the industries. Some companies spend up to 10% on R&D in order to develop the new products and to keep the lifecycle of the products as short as possible. Most of the companies confuse New Product Development (NPD) with R&D. Indian companies should provide an advanced position to the R&D teams, which will provide more opportunities and strengthen the global positioning of the Indian machine tool industry. ☐ > MORE@CLICK EM01562 | www.efficientmanufacturing.in
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EM | Mar 2015
Coverstory_Mar_2015.indd 25 FORM-1-2.indd 48
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MANAGEMENT | INTERVIEW
“Implementing robust & lean processes to enhance component manufacturing” P Ramadas, Managing Director, Ace Manufacturing Systems, in this interview with Maria Jerin, discusses that aerospace, manufacturing for IT (mobile phones & other electronics), defence projects and energy sectors will be the future of the Indian manufacturing industry, while analysing the current demand scenario What is your success mantra behind designing new machines What is your focus on operational excellence models towards and building an organisation culture that instils a sense of achieving long term goals in your organisation? ownership in the employees? We are currently working on implementing robust and lean We provide products and solutions with minimum cost of processes to enhance the component manufacturing and ownership. With continuous evolution and R&D efforts, we machine assembly capabilities. Strong emphasis is given are narrowing down the gap between Indian machine tools towards process centric approach with automated processes and imported ones significantly. Contributing to the growth of and leveraging of advanced information technology. Design Indian economy by substituting imports is also a factor behind standardisation, minimisation of number of parts, effective new product development. planning systems, reducing lead time of manufactured items, Caring for employees’ personality & professional vendor development programs, improvement of process development and growth is the overall reason for employees’ efficiency of component manufacturing and assembly are some involvement as the part of the organisation. Our motto, “In of the key initiatives being undertaken. Importance is also Pursuit of Excellence” is being inculcated in the employees to given to employee engagement initiatives such as 5S, Kaizens become excellent professionals. and small group activities.
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EM | Mar 2015
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INTERVIEW | MANAGEMENT
CANDID SIX
How do you think an aspiring entrepreneur in India can benefit from the present manufacturing scenario? What would be your advice to them? As per the international forecast, manufacturing is expected to grow from the present 16% to 25% of GDP in the next 10 years in India. Until recently, Indian manufacturing industry has been largely dependent on the automotive sector and its supporting industries. However, the future is going to be for non-auto sectors such as aerospace industry, manufacturing for IT (mobile phones & other electronics), defence projects and energy sectors, which will contribute significantly to the manufacturing growth. The 11 mega projects proposed by the Hon’ble Prime Minister is going to add emphasis to manufacturing. Some advices for budding entrepreneurs include, looking out for sustainable opportunities in manufacturing that are likely to grow in the near future and being innovative in approach. What are the recent developments in multi-tasking and multiple operation machines? Technologies such as turn mill centres and mill turn centres are gaining popularity as parts requiring variety of operations can be machined in minimum number of set-ups. There is large requirement for machines with pre & post processes that are combined to minimise set-up times. Inspection and gauging as a part of components machining in a single cell to reduce lead time of manufacturing is being sought after. Automated work offsets, tool offsets, tool ware measure, etc, are some features offered with the machines. We have also developed 5-axis machining centres for demanding applications such as aerospace and energy sectors. With the background of rise in global competitiveness trends to develop machines with single set-up machining and minimum amount of handling; what are the latest approaches adopted by your company on the technology front? We are offering 1- and 2-axis rotary table machining centres to minimise set-up times and enhance productivity. Our innovation of twin spindle machining centres with & without rotary pallet changers have been very well accepted by the industry for high volume production in and out of India. Two identical components can be machined at a time in single
EM | Mar 2015
Management Interview_P Ramdas Ace Manufac.indd 27 FORM-1-2.indd 52
t If not in this industry, where would you be? * DBOOPU JNBHJOF MJGF PVUTJEF XIBU * N DVSSFOUMZ FOHBHFE JO t What is your favourite pastime? 8BUDIJOH IJTUPSJDBM BOE NZUIPMPHJDBM *OEJBO FQJDT BOE QBSUJDJQBUJOH JO QFSTPOBM BOE TPDJBM SFTQPOTJCMF BDUJWJUJFT t What are you currently reading? 5IF 4FDSFU CZ 3IPOEB #ZSOF BOE 3PNBODJOH UIF #BMBODF 4IFFU CZ "OJM -BNCB t Which is your dream car? *U JT B MVYVSZ DBS ZFU UP DPNF JO UIF NBSLFU XIJDI JT NPTU GVFM FGGJDJFOU t Your dream holiday destination? 4XJU[FSMBOE t One thing that people don’t know about you? 1FPQMF LOPX UIBU * BN B UPVHI NBO CVU WFSZ GFX QFPQMF LOPX UIBU * IBWF B LJOE IFBSU
set-up, promising almost double the productivity. Additional features like auto unloading, single machine loaders, and fully automation cell with unmanned operations are some solutions being offered. With increasing response during IMTEX 2015 and optimistic budget, how are you viewing the current demand trend for the machine tools? IMTEX 2015 was a grand success for AMS. As compared to 2014, demand for machine tools is undergoing a swift change. Budget also seems very manufacturing-friendly; the effect of which will be seen on the machine tool demand in the near future. We believe the next few years are going to be very bullish in terms of capital investments. There is an increase in production demand; the requirement to deliver more in a minimal lead time is trending. Quality and productivity demands are leading to evolution of technology. What are the latest growth strategies adopted synergising with the changing demand trends in the manufacturing industry? We are currently focusing on catering to the diversified customer base in new emerging market sectors. Enhancing existing products, development of new products and their promotions across all markets is being undertaken. We are gearing up for huge surge in demand by increasing its production capacity and also enhancing reliability of the products. We are also participating in over 10 international exhibitions overseas annually which has shown promising results in the recent years. � > MORE@CLICK EM01563 | www.efficientmanufacturing.in
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R O U N D - TA B L E | M A N A G E M E N T
Vision promising budget With the new government’s assurance to keep up the pace of reform, this feature aims at bringing the host of measures introduced in the Union Budget 2015-16, to develop a manufacturing-friendly environment, while analysing the challenges addressed in the budget, in discussion with the industry experts… As per the new GDP data, manufacturing has declined from 18% to 17% of GDP; and manufacturing exports have remained stagnant at about 10% of GDP. Finance Minister Arun Jaitley envisioned this challenge and unveiled a budget that aims to ramp up growth. The industry leaders commenting on the challenges addressed in the budget are L Krishnan, President – IMTMA & MD, TaeguTec India; Ravi Raghavan, CEO, Bharat Fritz Werner; T K Ramesh, CEO, Micromatic Machine Tools
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Maria Jerin Features Writer maria.jerin@publish-industry.net
and Mohini Kelkar, Director—Sales & Marketing, GrindMaster Machines.
India as an investment destination Foreign investors look for environments with minimum uncertainties in terms of infrastructure and other regulatory framework. They are looking to have their manufacturing hub
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M A N A G E M E N T | R O U N D - TA B L E
“The union budget has a clarity and is indicating continuity from the last budget. It also indicates the indent of not harassing investors unnecessarily” T K Ramesh, CEO, Micromatic Machine Tools
in countries like India, because of the availability of low cost manufacturing & engineering white collar talents. Speaking on the investment policy, Krishnan says, “Union Budget 2015-16 clarifies several uncertain issues relating to the policy with a clear roadmap. It is directional and specifies mid-term goals of the Government of India. The positive factor is the government’s commitment to build consumer market by bringing in GST.” On similar lines, Kelkar says, “The budget hints that retrospective taxation will not exist & this will ensure security to the foreign investor. They will get the feeling of stability, which will help in receiving more foreign investments. It is also proposed that various exemptions will be removed & corporate tax will be brought down to 25% from 30%. Such clarity & simplicity in tax laws will help not only foreign investors, but also Indians to focus on improving their operational profitability, rather than increasing the profits by working around the vague tax laws.” Highlighting on sustainable GDP growth, Raghavan opined that the macroeconomic indicators are clearly pointing towards environment of sustainable GDP growth at the outset. “The CPI and WPI inflation indexes show downward trends, current account deficit being low and foreign exchange reserves being healthy. All these indicators will boost investor’s confidence. Enabling indications like clear roadmap for GST implementation from FY 17, medium-term clarity on corporate taxation are encouraging steps from investor sentiment perspective.” Adding his thoughts on the budget, Ramesh said, “The union budget has a clarity and is indicating continuity from the last budget. It also indicates the indent of not harassing investors unnecessarily.” Speaking on job creation, he says, “There are no specific indications that will radically help job creation, but we have to wait for the future policy announcements.” On this, Krishnan opined, “We need to work further on land and labour law reforms for simplification.”
Ease of doing business The government has articulated its vision to improve ranking for ease of doing business from current levels to 50 as a clear medium-term goal. Emphasising this, Krishnan says, “We
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FORM-1-2.inddMar15.indd 56 Round-Table_ 29
“The positive factor is the government’s commitment to build consumer market by bringing in GST” L Krishnan, President – IMTMA & MD, TaeguTec India
“Good execution of all declarations will simplify “Doing Business in India” & will give a large boost to domestic as well as foreign investments” Mohini Kelkar, Director—Sales & Marketing, GrindMaster Machines
see visible activities happening in the government. However, the challenge will be to align these simplified processes with that of states and ensure that the states also simplify their processes to realise the impact of these benefits. We are optimistic.” Opining that the budget will simplify business process, Kelkar says, “The announcement of GST by April 2016 will go a long way in enhancing business environment & will certainly simplify business process. The announced e-biz portal is expected to give certain approvals on line. Good execution of all these declarations will simplify ‘doing business in India’ and give a large boost to domestic as well as foreign investments & industry.” Carrying the thought forward, Ramesh adds, “The budget is making simplification on the ease of doing business process indirectly. But it is the proposal of indent; we have to look into the details. Indications are there to simplify the business process; we will have to see the actual translation on the ground level.”
‘Make in India’ vision The budget is optimistic, but it misses some policy steps to
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R O U N D - TA B L E | M A N A G E M E N T
position India as a manufacturing hub and to create an environment for local production. Commenting on this, Krishnan adds, “ ‘Make in India’ is an idea and a campaign. In order to realise this vision, we need to do several reforms starting from ease of doing business, competitiveness, land availability and labour reforms. From the government’s side, the push in the defence & aerospace sectors will certainly accelerate the ‘Make in India’ campaign. However, we must realise that we are in for the long haul.” Highlighting on the optimistic budget, Ramesh adds, “The budget is silent on ‘Make in India’; we have to wait for the future announcements, because reforms can happen at any time.” Further adding, Kelkar says, “It is difficult to do this quickly & one should not expect dramatical results in one year. The budget is one instrument, but the reforms will depend on passing the bills for amending the acts. The hon’ble Prime Minister has met most of the CEOs of top 500 companies worldwide to promote ‘Make in India’ and it shows hard work & commitment towards this campaign. Industry believes that this initiative will give boost to the Indian economy.”
Boost for manufacturing The budget has a proposal to correct inverted duty structures & incentivise local manufacturing by correcting anomalies. Sharing his thoughts on this, Krishnan says, “This is welcome move. In the medium term, government will have to look at these aspects on an ongoing basis to correct anomalies and incentivise local value addition.” Stating her point, Kelkar believes that this is a logical step in globalisation. “This will provide level ground to Indian industry to compete worldwide & the weaker players will have to shape up or phase out,” she says. Adding further, Raghavan says, “Capital goods sector can look forward to reducing input costs as duties on essential imported parts have been slashed to 2.5% from 7.5%. Higher import duties on tax in SUV segment will help automotive manufacturing.” Speaking on the benefits to the machine tool industry, Ramesh averred, “This is much a long awaited move, reducing import duty from 7.5% to 2.5%, particularly for inputs of CNC machines. This will directly benefit the machine tool industry.
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EM | Mar 2015
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R O U N D - TA B L E | M A N A G E M E N T
VIEWPOINTS FOR MANUFACTURING-FRIENDLY ENVIRONMENT Ravi Raghavan, CEO, Bharat Fritz Werner, shares some points proposed by the budget for a manufacturing-friendly environment t $MFBS SPBENBQ GPS MPXFS DPSQPSBUF UBY PWFS OFYU GJWF ZFBST t 3FEVDUJPO PO UBYFT PG SPZBMUZ UFDIOJDBM TFSWJDFT GPS *OEJBO NBSLFU t (PWFSONFOU IBT QPTUQPOFE (""3 JNQMFNFOUBUJPO CZ UXP ZFBST BOE IBT DPOGJSNFE UIBU (""3 XJMM OPU IBWF SFUSPTQFDUJWF FGGFDU t (PWFSONFOU IBT MBVODIFE F CJ[ QPSUBM UP JOUFHSBUF SFRVJSFE SFHVMBUJPO QFSNJTTJPOT BU POF TPVSDF t (PWFSONFOU IBT QSPQPTFE UP JOTUBMM B DPNNJUUFF GPS QSFQBSJOH ESBGU MFHJTMBUJPO UP FYQFEJUF DMFBSBODFT
It helps in improvising cost price and will help in the direction of demand.�
Infrastructure development
enhanced by over 700 crores and will result in demand for machines.� According to Ramesh, the outlay for infrastructure development has not significantly increased. “Revitalise the public private partnership (PPP) mode of infrastructure development would be welcome,� he adds.
The budget intends to permit tax-free infrastructure bonds for the projects in the rail, road and irrigation sectors. Jaitley The budget way has laid out plans to boost infrastructure, relying on public According to Krishnan, the machine tool industry looks investment, as private investment remains week. Krishnan believes that the government’s allocation of ` 70,000 crores forward to stable, predictable growth of manufacturing sector. towards rail and road infrastructure development will go a long “We believe that it is some distance away. However, we realise way in giving a fillip to infrastructure development in India. He that medium to long term opportunities are exciting, and the says, “Government’s promise to clear new plug-and-play industry is preparing for the same,� he says. Indeed, the budget projects with all clearances in mind will dramatically improve is promising for the machine tool industry. Highlighting this, project execution and management efficiencies, as well as help Kelkar opines that the import of machines has become easier to build investor confidence.� Sharing similar views, Kelkar says, and duty barrier is not there now. She asserts, “Indian machine “The budget clearly spells out investments in roads, bridges and tool manufacturers will face a stiff competition. They have to port facilities. It seems they want to take it from 6 – 7 km per seriously review the input material cost, manpower cost, etc. day to 30 km per day of road construction. The emphasis is on Apart from this, they have to offer technologically superior concrete roads and not the tar roads. This shows that the products, which are also designed for high production volumes. government has long-term views and is looking at building Machine tools companies will have an opportunity to supply machines to MNCs who are setting shops in India.� road network of good quality.� Taking the idea forward, Raghavan believes that the budget Further elaborating, Raghavan says, “Higher allocation of funds for urban development & rural infrastructure will create shows a positive sign from the GDP growth perspective, demand pull for commercial vehicles and interest rate sensitive especially for the manufacturing sector. “We are upbeat about 2-wheeler segment. Thrust on agriculture infrastructure could the growth prospects and getting ready to serve the demand help tractor segment, which is currently in significant stress. pull, which the budgetory proposals will generate,� he adds. All these measures will create pull for auto and other Looking ahead to a productive manufacturing sector, on a manufacturing segments. In medium term, manufacturing concluding note, Ramesh believes that, specifically, for machine segment will have positive impact due to boost to construction tool industry, the significance is with the reduction in the rate segment – 100 smart cities, FDI in realty, income tax concessions of import duties that is the step in the right direction. “But for on home loan interest, etc. Defence and railways have received machine tool industry to do well, there must be stimulus in the good attention in budget. Proposals such as 49% FDI in defence, other industries like white goods, automotives, infrastructure 5,000 crores additional allocation of defence budget entirely on spending & general industry. Indications are good, we are capital account will spur public & private investments. The waiting for the action to start,� he says. � > MORE@CLICK EM01564 | www.efficientmanufacturing.in budget for plant machinery and modernisation has been
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FORM-3-4.indd 1
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M A N A G E M E N T | S T R AT E G I E S
TRANSFORMING MANUFACTURING MODEL Technology is the backbone of every business. It is an enabler, playing a significant role in profitability and growth. The article analyses the critical role that it plays in addressing the modern business challenges and leveraging the adoption of business software solutions Various technologies may be applied to the running of an organisation, but none are as critical to business success as
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FORM-3-4.indd 2 Management Strategies_Epicor.indd 34
a modern and flexible enterprise resource planning (ERP) system that offers a complete view of operations in
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real-time. It facilitates agility, speeds up processes and reduces their complexity, thereby reducing costs, improving
EM | Mar 2015
3/13/2015 8:28:27 7:49:37 PM 3/12/2015
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M A N A G E M E N T | S T R AT E G I E S
Business Drivers
Expansion into new markets
Managing a change in business model
New customer recruitment and retention
CIOs ranked their top three business drivers as expansion into new markets; managing a change in business model and new customer recruitment and retention
efficiencies and ultimately boosting profitability. There is a clear link between successful manufacturers and their understanding & use of ERP as a strategic tool for delivering a superior customer experience. The real winners are the businesses that shift their focus from inward to outward—moving beyond better price and availability to improved service levels, reliability and relationships. The most successful manufacturers choose ERP solutions that enable an easy evolution through the customer experience maturity model. New levels of agility, flexibility and ease of use in modern ERP systems make it possible for businesses to transition without having to reinvest heavily as their needs change. Competing by lowering costs and increasing product functionality doesn’t hold in the long term. Modern businesses have to combine technology and processes that embed a customer-oriented culture at all levels of the organisation to ensure they improve customer experience and stay ahead of the market.
Technology is business critical Earlier, business leaders focused on
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the product and the resources needed to manufacture it where technology played a transactional role. Now, it’s clear that without technology to facilitate the manufacturing process; profitability, growth and expansion are virtually impossible. Technology is critical to globalisation, resulting in aggressive adoption of business software solutions as companies leverage the power of IT to manage multinational operations, drive workplace productivity and efficiency. The economies of emerging markets like India, the Middle East and Africa are growing at a significant rate and represent significant opportunity. Globalisation driven by trade and investment is aided by technology, which paves the way for multinational businesses to make their mark by taking advantage of opportunities in largely untapped markets that may offer cost effective labour, untapped resources and uncluttered markets. Strong competition from low cost economies threatens many manufacturers in mature economies by challenging them on various levels, including price and time to market. This is where customer service and innovation become differentiators. An ERP system that is
flexible, agile and responsive is critical to achieve this. A proven ERP system evolves with a business, supporting expansion by acting as an enabler. The business impact of these solutions, applications and underlying technologies make or break a business. This has led to a significant change for the CIO’s role.
The role of CIO Around 79% of surveyed CIOs and other senior executives agreed that the role of the CIO changed within the last five years. The most prominent change noted was the transition of the CIO from being an improver to being an influencer. Improvers are hands on, controlling costs, increasing efficiency, optimising processes and making sure the business gets the IT that it needs. Their focus is on doing things better. Influencers are tomorrow’s transformers - they do things better by using technology to solve business challenges and alleviate pain areas.
The new role of modern CIO CIOs ranked their top three business initiatives as transforming IT function
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Super precision, high-performance endmill Ă˜ 20 mm with 4 flutes 27 mm flute length, 16 min. cycle time, variable helix and unequal index. Ground with the GrindSmartÂŽ528XW
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info@rollomatic.ch
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M A N A G E M E N T | S T R AT E G I E S
Reduces the complexity of, and speeds up key operational processes
Improves productivity of employees
ERP Critical to Business Success
Helps to reduce operational costs
According to CIOs and senior executives surveyed, a clear Enables better visibility into business
understanding of the direction of the business has had the most significant impact on the role of the CIO
to support the need for business agility, improving IT user experience for employees and improving IT infrastructure for enterprise connectivity. Non-CIOs ranked what they perceived as being the top initiatives for their CIO colleagues as improving the IT user experience for employees; optimising, streamlining and the supply chain; and improving IT infrastructure for enterprise connectivity.
Addressing challenges of modern businesses
Speed, reinvention, agility and innovation are critical to the success of any organisation. Serious about optimising performance and gaining competitive advantage, a staggering 90% of respondents to the survey agreed with this statement. The enterprise application market in India, the Middle East and Africa is growing as organisations explore the benefits of investing in such Business initiatives for CIOs solutions. Small & medium enterprises CIOs ranked their top three business are now aware of the fact that investing drivers as expansion into new markets; in enterprise applications such as ERP managing a change in business model will help them to streamline and integrate and new customer recruitment and their business processes enabling retention. Non-CIOs ranked the top operational efficiency. This can business drivers for their CIO colleagues ultimately catapult them on a path to as expansion into new markets, managing become a global player. a change in business model and getting According to CIOs and senior products to market faster. It is interesting executives surveyed, a clear to note that new customer recruitment understanding of the direction of the and retention & getting products to business has had the most significant market faster go hand in hand when it impact on the role of the CIO. Second to comes to profitability. this is investing in IT infrastructure to With all of these factors considered, improve agility and responsiveness, it is clear that the role of the CIO is followed by sourcing technologies that increasingly important to forward accelerate business processes. thinking businesses who want to gain a Other senior executives felt that competitive edge. He is becoming investment in IT infrastructure that responsible for the most critical areas of supported decision making and more adaption that, if done correctly, will take efficient processes are a direct result of the business to another level. the need for speed, reinvention, agility
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and innovation. This shows that both parties, in their respective roles, are focused on the same objectives. Here, these factors are more critical than in markets where competition is fierce and growth is imminent for those who go above, when it comes to meeting customer needs and ensuring excellent customer service. By incorporating best practice for integrating lean strategies to enhance workflows, reduce waste, and nurture problem-solving approaches, ERP systems have been gaining traction due to their ability to harmonise and optimise many parts of the manufacturing chain and thereby improve the customer experience.
ERP critical to business success Around 76% of CIOs and other senior executives agreed that best in class companies perform better because of their use of business systems, and that their ERP system is the enabler of their businesses. It is the most significant tool in their pursuit for optimum performance and profitability. 65% of CIOs and 38% of non-CIOs agreed that ERP had reduced the complexity of and sped up key operational processes. 46% and 43%, respectively, said that ERP enabled better visibility into their business. These were
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S T R AT E G I E S | M A N A G E M E N T
followed by helping to reduce operational costs and improving the productivity of employees This provides further evidence of how modern ERP system is perceived as increasingly critical to business success and has an increasingly significant impact on the performance.
ERP providers must invest heavily in research and development (R&D) to ensure that their solutions can keep
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abreast of change. ☐ > MORE@CLICK EM01565 www.efficientmanufacturing.in
Looking towards future When asked to rate the technological enablers in order of importance for future investment, respondents ranked mobile applications, software as a service (SaaS), social applications and platform as a service (PaaS) highest. Mobile solutions have opened up new opportunities for cost savings, employee productivity, market reach and engagement, streamlined operations, responsiveness and service quality, among many others. Corporate trends such as ‘bring your own device’ (BYOD) and mobile enterprise apps attest to strong industry-wide recognition and appreciation of the huge impact of mobility According to the Aberdeen Group, the need for instant access to ERP stems from the need to cut costs through efficiency and visibility. Instant access to ERP improves efficiency, especially in organisations with operations in multiple geographical locations or with employees out in the field. Instant access to data also enables decision makers to react to problems without delay and facilitates a quick response to the needs of its customers. Choosing an ERP solution developed by an industry leading provider who takes a visionary approach to business software is critical for all manufacturers.
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March 3rd ~ 8th , 2015 EM | Mar 2015
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Booth No. I0616
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I M A G E C O U RT E S Y: EMO Hannover
M E TA L C U T T I N G T E C H N O L O G I E S | F O C U S
EFFECTIVE APPROACHES FOR MACHINE TOOL UTILISATION To maximise the utilisation of a machine tool within the limits of its capabilities requires an intelligent, balanced approach in the development of cutting parameters. This article talks about the important components of effective machine utilisation by maximising the required timeline for metal cutting, and quicker and easier ways to manipulate cutting tool application parameters that helps to achieve optimum performance with the existing machine. Achieving maximum productivity and profitability in machining operations result from optimisation of the entire metal cutting process. The foundation of that effort is intelligent application of cutting tool parameters in combination with full utilisation of machine tool capabilities. There are two main
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Patrick de Vos Corporate Technical Education Manager Seco Tools seco.india@secotools.com
components of effective machine tool utilisation. The first involves finding ways to maximise the amount of time the machine is available to cut metal, and the second includes tactics to make the most productive, reliable, and profitable use of that time.
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F O C U S | M E TA L C U T T I N G T E C H N O L O G I E S
MACHINE TOOL UTILISATION k
k Production rate
Costs, k k
Rejections
Machine tool utilisation
Maximising available time Full utilisation of a machine tool must begin with maximising the time it is available to cut metal. Even though a machine is on the shop floor 365 days, its productive availability is much less. In the case of five-day, single shift work weeks, and counting time lost to holidays and other interruptions, there are approximately 1,300 or 1,400 machine hours per year available for production. Programming and setup consume a certain amount of time. To make that non-productive period as short as possible, manufacturers employ strategies that include offline programming and modular setup methods. Tool magazines and automatic tool changers expedite tool handing, another time-consuming necessity. Robotic work handling and pallet changers help reduce the time required to load raw workpieces and unload finished parts. Every hour saved via improved programming speed, faster setup methods, and streamlined tool handling and work handling is another hour that is available to machine parts.
Using time efficiently After implementing strategies to maximise the amount of time available to cut metal, manufacturers are challenged to use that time efficiently and produce as many parts as possible at the lowest cost. The key is to fully utilise the capabilities of the machine tool while the cutting edge is in contact with the workpiece material. Recognition of the machine tool’s limitations plays a role as well. When planning to best use the time available, it is clear that some elements of the machining process cannot be changed. The end application of the machined part determines the choice of workpiece material, and the material’s machinability dictates initial cutting parameters. For example, the poor thermal conductivity of titanium alloys demands use of low cutting speeds and feed rates to minimise build up of heat. Machine tool capabilities are also a given, because changing the machine
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Downtimes
Production costs are determined by productivity and machine tool utilisation (machine tool downtimes and wrongly produced workpieces).
is not usually an immediate option. Manufacturers recognise these factors when estimating production costs. However, significant differences between estimated and actual costs can result from inaccurate evaluation of machine tool characteristics and application of cutting conditions that cannot be sustained. There are common requirements when establishing initial cutting parameters for any machining operation. Depth of cut and feed rates must be chosen to avoid tool breakage, assure formation of desirable chips and limit generation of heat. Cutting speeds that are too high will cause tools to wear out too quickly, and speeds that are too low will not allow tools to function productively. Cutting faster generally will produce a workpiece in less time. But while the machining time is shorter, tool life also is shorter and tool costs will increase. More tools will be required to do the job and worn cutting edges must be indexed or replaced. The downtime resulting from tool changes boosts the costs of the operation overall. In effect, there is a trade off between faster and more expensive machining and slower and less costly operation. Consistent productivity and process stability lie in between the two approaches: insufficiently aggressive cutting parameters reduce costs until the tool no longer functions efficiently and productivity is lost, while increasingly higher parameters raise productivity until the tool wears too rapidly or breaks. In addition, the choice of cutting conditions depends not only on the characteristics of the cutting tools but also, in a large number of cases, on the capabilities of the machine tool. Different machine tools have differing limits of power, torque, rpm, and stability. The clearest limitation is power. Power ratings alone do not determine a machine’s capability for a specific application. A 60-kW machine tool would appear to offer more than adequate power, but if the intended manufacturing operation is, for example, producing 12 m-long, 3 m-diameter forging rolls, 60 kW is not as impressive. The power required to cut a specific workpiece depends on the workpiece material and size, the depth of cut, feed rate and
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M E TA L C U T T I N G T E C H N O L O G I E S | F O C U S
AVERAGE TIME SPENDINGS ON A MACHINE TOOL Tool handling Productive time Machine setup
Drilling
Milling
Workpiece handling
Problem solving
Turning
0
20
40
60
Tool breakage
Quality workpiece
Surfaces roughness
Chip forming
Safety
Others
cutting speed. Power demand rises as cutting forces are multiplied by higher cutting speeds. Accordingly, high cutting speeds may require power beyond a machine’s power rating. Additionally, extreme cutting parameters may have effects that exceed other machine tool capabilities. Excessively high depths of cut can create forces that are beyond a machine’s structural rigidity and vibration may degrade part quality. Similarly, overly high feed rates can produce large volumes of chips that may interfere with the cutting process or clog chip evacuation systems. To maximise the utilisation of a machine tool within the limits of its capabilities requires an intelligent, balanced approach in the development of cutting parameters. Generally, that involves reducing cutting speeds while proportionally increasing the feed rate and depth of cut. Utilising the largest depth of cut possible (recognising its effects on machine stability) reduces the number of cutting passes required and thereby reduces machining time. Depth of cut generally has little impact on tool life, but the effect of cutting speed is significant. Feed rate should be maximised as well, although extreme feeds rates can have negative effects on workpiece surface finish. When a manufacturer achieves a reliable combination of feed rate and depth of cut, cutting speeds can be used for final calibration of the operation. The goal is to utilise cutting conditions that offer both productive metal removal rates and process stability. The best combination of machine capabilities and cutting parameters provides a balance of tool costs, process reliability and productivity.
Future strategies While recognising that machine tool capabilities can impose limitations on the machining process, changing the machine is
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Tool wear
100
Average time spendings on a machine tool
not a simple, fast or inexpensive solution. It is quicker and easier to manipulate cutting tool application parameters to achieve optimum performance with the existing machine. And even if investment in a new machine tool is feasible, the relatively long operating lifetime of the equipment is an important consideration. A company may buy a machine tool with capabilities that match or exceed its present needs, but factors such as part workpiece material, size and volume can and will change significantly over the five, 10 or more years that the machine will be in operation. To cope with the changes it will be necessary to alter cutting conditions, but that must be done in an intelligent way. After finding ways to maximise the amount of time a machine tool is available to cut metal, the preferred path is to select tools with substrate material, coatings, and cutting edge geometries that are best for the workpiece materials and operations involved. The next step is to apply the minimum cutting speeds at which the tools will work well. Then, feed rates and depths of cut should be as high as possible, while recognising the power and stability characteristics of the machine tool. Mathematical formulas have been developed that can help determine the best match between machining parameters and machine capabilities. If possible, a shop may prefer to run practical tests to get similar results. Fairly often, the formulas only confirm reality. Probably more than 90 percent of time a simple, pragmatic approach of lower cutting speeds, with maximised feed rates and depth of cuts, accompanied by manipulation of cutting speeds as a calibration tool is most effective. That approach will be successful in providing reliable and productive machining as well as full utilisation of the capabilities of the machine tool at hand. �
> MORE@CLICK EM01566 | www.efficientmanufacturing.in
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HIGH SPEED MACHINING | TECHNOLOGY
Reducing machining time HSM is not just about high cutting speeds. It is a technology used to improve machining throughput. The article deals with the parameters considered for implementing a successful HSM, while discussing the application areas & benefits of machining technology
B P Poddar, Vice President - Sales & Marketing Fatty Tuna India bppoddar@femcoindia.com
High Speed Machining dates back to the 1920s. There are various ways to define HSM such as, High Cutting Speed Machining (Vc), High Spindle RPM Machining (n), High Feed Rate Machining (Vf), High Speed & High Feed Rate Machining (n + Vf) and High Productive Machining. One of the definitions of HSM was proposed by Dr Carl Saloman in 1931. He had assumed that at cutting speeds 5-10 times higher than in conventional machining, chip-tool interface temperature or chip removal temperature starts decreasing. Also, it sometimes gets confused and becomes a subject of discussion.
Improving machining throughput HSM is not just about high cutting speeds. It is a process, where operations are performed in specific methods and on particular machines designed for HSM. It is also very prominent in CNC machining methodology. It is used to improve machining throughput by adopting higher spindle rotational speeds in conjunction with higher feed rates with no compromise on output quality of finished parts. Various factors associated with it include machine tool construction, i.e. bed/ column/spindle/axes/motordrives, higher rotational speeds,
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CNC systems, CAM software, work-piece, material, tooling, cutter path, cutting tools, depth of cut, chip loading, width of chip and process knowledge. These factors contribute and have impact on implementation and success of HSM. In short, successful application of the technology can be seen as closely inter-related elements and an appropriate combination of CNC machine, CAM and tooling. A right combination leads to higher productivity, reduction in processing costs and much improved product quality. However, if a combination is wrong, it is certain to generate waste rapidly, due to tool breaking problems, chatters, vibrations in system, etc.
Constructing machines Design and construction of machines is of paramount importance for the success of HSM/HPM. Also, rigidity in every element of the machine is of critical importance. It is important for tool life, accuracy, surface roughness, especially in hardened materials. Stability and vibration damping of structure, head comes from weight distribution and reinforcement of machine bed, column, etc. Thermal dissipation
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TECHNOLOGY | HIGH SPEED MACHINING
and thermal growth & temperature stability are equally important aspects of the machine.
Stationary parts Whether cast iron or polymer concrete or granite is suitable depends on the design strategy and applications intended. Granite or polymer granite machine structures are far better than cast iron structures. They are inert materials and resistant to oil, chemicals, etc. They possess thermal stability and damping characteristics too. The stationary parts are especially strong and heavy to optimise damping and stiffness of structure.
Moving parts For all moving parts, the design strategy desired is to have minimum weight to maximum stiffness to ensure optimum dynamics of machine. The weight distribution and material selection will allow designing suitable HSM/HPM. The demands on machine tools include spindle RPM > 40,000, spindle power > 22 KW, programmable feed rate 40 – 60
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m/min, rapid travels = 60-90 m/min, axis acceleration/ deceleration > 1.5 ~2 g, block processing speed = 1~20 ms, high thermal stability, high rigidity, vibration damping, high stability under dynamic conditions, circular interpolation via NURBS, advanced look ahead functions, high thermal stability and rigidity in spindle – cooling of spindle bearings and different error compensations
Implementing successful HSM Spindle: It is the most critical element in HSM. It is important to ensure spindle run-out as small as possible to reach maximum productivity and accuracy. Highly efficient spindle & bearing cooling arrangements to minimise thermal growths are design philosophies. Refrigeration systems are used for cooling spindle and bearings. However, it is not sufficient. Additional measures are required to minimise the thermal effect. Tool holders: It is an important component for successful implementation of HSM. Tool holders with two plane fit between machine spindle & tool holder is the most appropriate holding system. At any speed, machine tool spindles are subjected to centrifugal forces. At higher speeds, centrifugal
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HIGH SPEED MACHINING | TECHNOLOGY
HSM is deployed mainly in machining of aluminium parts in automotive, computer and medical devices
forces become so evident that spindle bore grows slightly. If steep taper tools are used, spindle growth at higher speeds can cause stuck tool or constant pull of drawbar or dimensional inaccuracy in Z-axis. Two plane fit tool holders have contact on taper & face. During the spindle growth phenomena induced by heat generation at higher rotational speeds, face contact prevents tool from moving. Rigidity is another advantage of two plane fit tool holders. Supporting in both axial & radial planes makes connection between tool holders and spindle significantly rigid. Face contact reduces bending moment. This increased contact area gives better rigidity, allowing longer tools and side cutting tools to use more aggressively. HSK-E or HSK–F are most suitable tool holders for HPM/HSM applications. Cutter body gripping in tool holders is another important consideration in HSM. Some tool holders are asymmetric as a result of drive notches, side locking screws, etc. This can create more severe impact at high speeds. So, the HSM implementation must consider tool holders and cutter combinations, which are symmetrical, i.e. shrink fit, hydraulic clamping, etc. Symmetry is the key consideration. They are most suitable for spindle rpms 20000 and more. Balancing: Imbalance adversely affects a tool life, surface finish, more stress on spindle, which will result in untimely failure of spindle. Imbalance of a tool holder is one of the elements of rotating system including spindle, tool holder, cutting tool. Tool holders must meet balancing quality specified for the spindle. They are manufactured to G- 2.5 balancing quality.
CAM software Machine and parts can damage because of sudden changes in the strain on tool. The software must eliminate drastic variations in machining directions and chip load. It must also ensure constant MRR (material removal rate). Sharp corners,
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which are prone to drastic change in chip load, must be avoided and the CAM must generate round corners. Chip loads must be gradual, smooth minimising jerks and impacts. It must also generate tool path trajectory conducive for uniform chip load as far as possible and the system must change feed rates as required to have uniform chip load and MRR. The CAM selection is based on various factors, such as, review of possible applications, i.e. electrodes, die & mould, aerospace, injection moulding, complexity, number of axes, production demands, process optimisation requirements and the time taken for creating tool path, etc.
Application areas HSM has many applications. However, it is deployed mainly in machining of aluminium parts in automotive, computer and medical devices. This calls for fast material removal rate as the process involves many machining operations. It is also used in the aerospace industry, which involves machining of long and many times thin aluminium parts; die & mould manufacturing, which demands finishing of parts in hard materials; injection of moulds & blow moulds; graphite & copper electrodes. Also, forging dies are suitable for HSM because of the complex shapes.
Benefits HSM is useful in high metal removal rates and reducing throughput times, which has a shorter production time. It is efficient & economical in machining of hardened material and shortens process chains. It is beneficial in the elimination of manual finishing or polishing of die and has higher surface quality & increased accuracy of parts. � > MORE@CLICK EM01567 | www.efficientmanufacturing.in
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M A C H I N I N G | A P P L I C AT I O N
COST-EFFECTIVE CUTTING SOLUTION An application story on the high performance Haas CNC machine tools used by Telgelgo to cut complex parts in hard materials Telgelego is a precision machining subcontractor based around 40 km south of Stockholm, Sweden. The company has a shop full of old-style lathes and knee type milling machines, with just two employees. One of the machines that came with the purchase of the company was a 2001 Haas CNC MiniMill. Despite the small workforce and the preponderance of ageing equipment, customers included companies such as Alfa Laval and AstraZeneca and ubiquitous Scania.
Offering high-quality, low volume machining services These days, Telgelego has 7 Haas CNC machine tools, including SL-30 lathe and SL-40 lathe, ST-30Y y-axis lathe, the
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original MiniMill and the company’s latest investment, a UMC-750 universal machining centre. Equipped with everything, it needs to service its demanding, blue chip customer base. The strategy is to offer high-quality, low volume subcontract machining services, specialising in precision parts in stainless steel, tool steel and, occasionally titanium, as well as creating parts for mainstay clients, other short-run jobs are made for the paper and pulp industry, as well as shipping and marine engineering. Cutting tough materials has become the company’s USP. Many parts are hardened and ground to finish. “Our other biggest strength is the complexity of the parts we can machine,” said Karlsson, Owner, Telgelego. “The customer sends us the main drawing for a part and we make
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A P P L I C AT I O N | M A C H I N I N G
A P P L I C AT I O N | M A C H I N I N G
additional drawings to simplify manufacturing. Occasionally, we reverse engineer parts, if they’re spare or replacement components for a machine, for example,” he added.
Tooling machines A typical part for Alfa Laval, which the company is contractually required to keep under wraps, requires 32 hours of machining, 16 hours each side. The company usually makes 20-25 of these parts each year. “In the course of a typical 12 months, we machine Kr1.5 million worth of stainless steel. Most of the jobs are very small runs. One customer orders 2-300 of one particular part every month, but that’s unusual,” said Karlsson. He further added that many of the parts have a large diameter – typically around 400-500 mm. “The Haas lathes are excellent, high torque machines perfectly suited to cutting these large diameter stainless billets. The two-speed gearbox on the SL-30 is very useful. We take big rouging cuts and make a lot of chips,” he said. “We bought the SL-40 to replace a large German-built lathe, which was always letting us down. One of the parts we now machine on the Haas for Alfa Laval starts as a 500 kg, 420 mm diameter billet and ends-up as a 90 kg part!” Although the company does a lot of roughing, it also machines parts to tight tolerances. “For example,” points out Karlsson, “It’s common, we machine bearing housings to 0.0027 mm. As well as our expertise in hard materials and complex parts, customers often use us because of the speed with which we can turn a job. For example, before a Scania part goes into production, we’ll make 2-3 examples for development and testing. The customer isn’t set-up for this type of machining, but once they have finalised the design of the part, they can tool-up their own machines and make them in-house. Being close to their shop also helps keep delivery short.”
Machine more complex, turned & milled parts The company invested in the Haas ST-30Y to machine more complex, turned and milled parts in fewer set-ups. “We bought the ST-30Y when we had an employee who had good experience with Y-axis milling. Unfortunately, he left the
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M A C H I N I N G | A P P L I C AT I O N
Using a cellular machining configuration takes 12.6 shifts to finish 2000 components
company a little while later, which left us with a skills shortage. We had a deadline for the work on the machine at that time so we had to learn how to operate it very quickly. Thankfully, everyone in the workshop is familiar with the Haas control, so it was relatively easy to move someone to the ST-30Y and get them comfortable. The employee who left eventually came back. “We bought him a Haas VF-2 with a Haas rotary table 4th axis, which is now his responsibility,” added Karlsson. After the arrival of the VF-2, the company also bought a Haas VF-3 to replace an ageing Taiwanese machine. “For 3-years, this machine was dedicated to making a single part until the customer moved the job to a subcontractor in China. As it turned out, the machine was freed up to provide capacity we were desperate for, so things worked out just fine,” he said. The company buys all of its Haas CNC machine tools from Jönköping-based Edströms Maskin AB, one of the world’s most successful Haas Factory Outlets (HFOs). Like all HFOs, Edströms employs trained and factory certified technicians, runs a fleet of fully-stocked service vans and keeps an inventory of original Haas spare parts worth millions of dollars. As a result, Edströms can respond to problems and technical issues without delay, resolving even the most serious of events without having to send for parts or engineers from the USA. As Telgelego grows, as does its reputation for machining complex parts in hard materials, the company is committed to investing in the best, affordable CNC technology it can find. Around the time Karlsson and his colleagues began thinking about a 5-axis, universal machine, Haas launched its UMC750. “Ours was the first UMC-750 installed in Sweden. We placed an order as soon as we knew it was going to be available because we found we had more and more work that could be
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done better and quicker on a universal type machine. We looked at what we could buy from other manufacturers for the same money and they had smaller tables and smaller workenvelopes. To be honest, so far we’re not doing full five-axis cutting – we haven’t yet made the investment in the 5-axis Edgecam software. But, as a 3+2 machine cutting stainless and tool steel, it’s doing a great job. It’s currently making a large cylindrical part – a roller for steel production. We have great expectations for this machine.”
Conclusion Lots of similarly sized businesses in Sweden are finding it very difficult or impossible to survive. Often, the problem is simply finding suitably qualified people to run and manage them as owners grow older and retire. There are a few, young successors willing to enter manufacturing. It’s a problem common to almost all industrialised nations. “The longer Telgelego stays in business, the better,” said Karlsson. “As other companies fall away, we’re well placed to benefit. We have a big order coming next year, so we need more space and we have to find another 2-3 employees. We’re expecting to move premises in 2015. We’re also hoping to invest in some bigger Haas vertical mills; bigger and more complex parts are the future for us. “These are uncertain times, but increasingly, we have enough work that every machine in the shop is busy. Every day is a challenge, but those are definitely the days I feel happiest!,” he concluded. ☐ Courtesy: Haas Automation > MORE@CLICK EM01568 | www.efficientmanufacturing.in
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MACHINING | TECHNOLOGY
INNOVATION IN PRECISION BORING The article features an innovative asymmetric boring solution that accentuates the advantages of reaming and line boring, resulting in increased productivity & cost reduction Precision boring is a vital process in manufacturing many critical components. The accuracy and finish of a multi-journal crank bore in an engine block relates directly to power and fuel efficiency, and the time it takes relates directly to the engine company’s profits. Precision bores in numerous engineered components are essential to critical performance metrics. Such bores must meet critical tolerances; but the downside is that precision boring can be costly and time-consuming, with a small mistake or error resulting in the scrapping of expensive parts. The response from Kennametal is a geometric and asymmetric line boring bar solution being termed a revolution in the process by delighted users.
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By definition, boring, as opposed to drilling, is a machining process in which internal diameters are made in true relation to the spindle centreline. This process is most commonly performed with the workpiece held stationary and the cutting tool, both rotating and advancing into the workpiece, although boring is also done with the cutting tool and the workpiece being adjustable. Common applications for boring include the enlarging or finishing of cored, pierced, or drilled holes and contoured internal surfaces. Related operations sometimes performed simultaneously with boring include turning, facing, chamfering, grooving, and threading.
EM | Mar 2015
7:49:58 PM 3/13/2015 5:18:20
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MACHINING | TECHNOLOGY
MACHINING | TECHNOLOGY
How it is done? Envision a small engine block with five in-line journals requiring crank bores. Conventional thinking for a multijournal finishing assignment, for example, involves a multiblade guidepad reamer with the following suggested process (here designated as Option 1.0) that includes a pilot reamer finishing the first journal; the multi-blade reamer fed in and semi- and final-finishing journals 2 through 5. Finally the reamer is retracted. The advantage of such a process is that it lends itself to use on CNC horizontal or multi-axis machining centres and does not require a dedicated boring machine with dedicated fixtures. However, depending on the size of the workpiece, the machine tool must be of sufficient rigidity or quality can fall off dramatically. Also, feed-in and feed-out of the reaming tool over finished bores must be done slowly and precisely or retraction marks and damage to the cutting edges will occur. Another option for machining this kind of bore is line boring (Option 2.0). The basic issue to be solved at this option is how can the cutting blades and the tool’s guide pads pass through unfinished journals with smaller hole diameters? CNC machine tool builders have responded to this quandary using conventional line boring bars and “counter-bearing” capabilities on their equipment. The process includes the workpiece area of the machine tool lifting the cylinder block up. The line boring bar is fed through the component into a bearing at the opposite end; the cylinder block is adjusted down and clamped; crank bores are semi- and final-finished and the cylinder block is lifted up and the boring bar retracted. The process speeds up feed-in and feed-out, and because the tool is supported on both ends, the geometric quality of the finished bore is improved compared to Option 1.0. On the downside, lift functions require special fixturing and CNC control, and the required counter-bearing on the fixture makes any additional back-side machining impossible. Multi-axis machine tools with tilting worktables and/or tilting spindles together with more evolved boring bars contribute to a line boring Option 2.1, with expandable guide pads, where the process evolves in the following order: a pilot reamer is fed in and finishes journal 5; the component (or machine table) gets rotated 180o; the machining centre X-Y axis is adjusted to feed the boring bar in off-centre; the boring bar
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EM | Mar 2015
7:50:02 PM 3/13/2015 5:18:23
Now Launching in INDIA !
E-mail : info@kanefusa.co.in
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MACHINING | TECHNOLOGY
Asymmetric line-boring solution increases machining robustness, process speeds, and bore quality, and reduces tool maintenance and handling
with guide pads is centered into journal 5; guide pads are expanded; journals 1 through 4 are semi- and final-finished; guide pads are fed back in and finally the boring bar is retracted off-centre. Option 2.1 uses the multi-axis adjustability of the machine tool. It retains the advantages of Option 1.0 by eliminating the need for any lift function or counterbearing and Option 2.0 with support on both ends of the tool. The disadvantages are that the complex internal mechanics of this type of boring bar are costly and can be difficult to handle. Insufficient lubrication use can damage sensitive internal mechanics, and if not monitored exactly, the tool can jam or hook in the workpiece and cause damage to the machine, fixture, tool, and part.
An asymmetric solution In collaboration with a major automotive manufacturer’s engine block operations, the company’s engineering staff has advanced the boring function with Option3.0, asymmetric line boring. This is a geometric leap forward that accentuates the advantages of reaming and line boring while virtually eliminating the disadvantages of both. As with most advanced solutions, the principle at the foundation is quite basic. Normal guide diameters are of full material or build of 3 or more guide pads, providing no degree of freedom from the bore wall while feeding in and out. The asymmetric solution supports on guide pads in a setup similar to a typical guide pad reamer, but the guide pad, normally located 180° to the cutting edge, was rotated so the resulting design provides freedom to enter and exit the guide part even passing through the raw bores. This geometry allows feeding the bar through raw bores on an eccentric path. The process, then, looks like this: a pilot reamer is fed in and finishes journal 5; the component (or machine table) gets rotated 180o;
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the asymmetric boring bar is fed in off-centre using the machining centre’s X-Y axis; the tool is moved to the centre and finishes journals 1 through 4 simultaneously; the tool is retracted off-centre with fast feed out. Such asymmetric line boring retains all the advantages of previous line boring efforts-high-quality precision bores, support on both ends of the tool, while no expensive lift functions, obstructive counter bearings or critical mechanisms inside the tool are needed. It also adds the fact that complete feed-in and feed-out moves can be done at increased feed rates on conventional machining centres, adding efficiency to the process. Naturally, being an asymmetric solution, the indexable inserts offered with this eccentric boring bar solution are also advanced. High-precision RI8 inserts have eight cutting edges with pre-defined back taper, which allows for high feed rates. Diameter can be adjusted to the precision of 1 micron. The high clamping force provided by the conical clamp screw avoids any settling effects. Both inserts and the asymmetric boring bar are designed so the inserts clamp directly into the boring bar body. This eliminates the need for cartridges and the additional tolerances and space they require.
Conclusion In short, this asymmetric line-boring solution increases machining robustness, process speeds, and reduces tool maintenance and handling, all while being compatible with CNC machining centres – a solution any manufacturer in search of process improvements will find anything but boring. ☐ Courtesy: Kennametal > MORE@CLICK EM01572 | www.efficientmanufacturing.in
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M A C H I N E V I S I O N | A P P L I C AT I O N
Building monitoring & alarming system Setting up a machine vision system and making all the different parts work smoothly can be a tough job. This article highlights how Eigen Innovations with the help of FLIR has developed a smart hardware module that makes the integration Eigen Innovations, tries to make factories smarter by offering solutions that can capture real time data from the factory floor, apply advanced analytics to it, and automatically improve operating processes. This boosts factory productivity and ensures consistent quality, while reducing operating costs. “We started with building software control solutions for manufacturing systems in key markets, such as injection moulding, where a variety of sensors are used. Looking at the temperature profile of a part coming out of the machine is a good quality check. One of the issues of doing a quality measurement is that the product has to cool down first, which can take a while. With a thermal camera, being a non-contact
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sensor, one doesn’t have to wait anymore. He can monitor quality in real time. We discovered thermal imaging from FLIR at a trade show and we quickly realised that a thermal camera is so much more than a camera: it’s an intelligent feedback sensor for realtime processes,” said Scott Everett, CTO & CoFounder, Eigen Innovations.
Cost-effective integration Building a monitoring and alarming system for fixed mounted automation applications can be a tough and expensive process. Since every application is different, custom
EM | Mar 2015
3/13/2015 8:32:35 7:50:05 PM 3/12/2015
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M A C H I N E V I S I O N | A P P L I C AT I O N
The Eigen Smart module has been designed to enable rapid deployment of fixed mounted thermal cameras for monitoring and alarming applications, eliminating the need for custom
software solutions are often needed, in addition to the sensor, in the cloud, and pushes it back into the module. In effect, the communications and computing hardware. Eigen’s Smart software writes itself. It can be used for a variety of automation Module (ESM) eliminates this costly step in the process. “If we applications, including parts manufacturing, pulp and paper, wanted to offer our customers a cost-effective monitoring food processing, fire prevention and condition monitoring. system, it was clear that we needed to find a way to make the integration of the cameras, hardware and software much Building around FLIR easier. That’s why we developed our Eigen Smart Module. In The first release of the module is completely geared addition, using FLIR cameras has made our job further easier. Sales cycles for industrial solutions like ours tend to be very towards GigE Vision standards and FLIR’s A-Series cameras. long, but when we can present a thermal image and show our “It doesn’t take much research to see the expertise, which FLIR customer what it says about a production process, it can get has built up. If one looks at the company’s portfolio and history, it made the most sense to choose FLIR cameras. Apart the ball rolling for us,” said Everett. from that, we have developed a great relationship with FLIR and the company has opened doors for us in the automation Eigen smart module market. So, it really has been a mutually beneficial relationship. Eigen’s Smart Module (ESM) is a robust GigE vision The great thing about thermal imaging cameras is that you thermal camera module, with monitoring and alarming can see the complete temperature distribution of an object, capabilities for fixed mounted automation applications. The not just one temperature point as thermocouples is showing. module allows for easy configuration of temperature This results in a huge amount of data, complemented with thresholds and enables PLC communications. The module other sensor information like pressure, speed or moisture has been designed to enable rapid deployment of fixed data. Our module combines the information of all of these mounted thermal cameras for monitoring and alarming sensors and tries to make sense of it,” said Everett. applications, eliminating the need for custom integration. It communicates with GigE Vision thermal cameras and Smart module for automotive customer performs temperature based calculations on designated Eigen Innovations has successfully deployed its smart regions-of-interest. It is also a self-learning system. The module can be used as a standalone solution, but as part of a module for an automotive customer. More specifically, the larger architecture and for more complex processing the same module and FLIR cameras are set up on a car assembly line to collects training data from the thermal camera, trains the data detect problems with the rear window defogger. In the
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LMW_210x273.pdf
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The module and FLIR cameras are set up on a car assembly line to detect problems with the rear window
assembly line, the defogger is turned on and a FLIR A-Series thermal imaging camera is used to check whether the heater bands are working fine. “Normally, in an automation setup, the parts that need to be controlled have a fixed position. In this case however, one needs to wait until the car comes into view. That’s why the algorithms integrated in our module need to determine the position of the car first,” said Everett. Another example from the company is outdoor monitoring of sulfur piles. In order to prevent self-combustion of sulfur, FLIR cameras are used to look for hot spots indicating a looming fire. The smart module is specifically useful here for improving the detection performance and to reduce the number of ‘false positives’, e.g. when heat is detected in case of birds flying by. The module can train the data to see whether the camera is looking at a bird, a loader truck, or an actual fire.
FLIR-A series: powerful and cost-effective Having installed multiple Smart Modules already, Scott Everett is very happy with its choice for FLIR, more specifically with FLIR’s A-Series cameras. He said, “We are especially fond of the FLIR A65 and its beautiful high resolution images. It is impressive how something so powerful can be built so small. With the current price level of the FLIR A35 and FLIR A65 for
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example, one can now easily include three to four cameras in an installation. Even though it is a cost-effective solution, the camera can replace a conventional line scanner application. The difference is that a FLIR camera is not only scanning one line, it is presenting a complete image.” The A-Series cameras use the GigE Vision standard, which allows for fast image transfer using low cost standard cables even over long distances. With GigE Vision, hardware and software from different vendors can interoperate seamlessly over GigE connections. The A-Series is also very robust and can be used for monitoring applications in harsh environments.
Promising future “In our line of work, there is much talk about the industrial internet, or the Internet of Things, where complex machinery is connected with networked sensors and software,” said Scott Everett. “Of course, when one wants to use all of this sensor data to its full potential, he needs to have qualitative sensors that deliver qualitative data in the first place. In that respect, I believe that FLIR and Eigen Innovations are facing a very exciting and promising future,” he concluded. ☐ Courtesy: FLIR > MORE@CLICK EM01570 | www.efficientmanufacturing.in
EM | Mar 2015
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A&D automotive AD_Jan15.pdf
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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
Saving time saves nine The article briefs on how Primo™ twin probe system, developed by Renishaw, has helped Victory Precisions to reduce part set-up time for the company from hours to seconds, thereby eliminating scrap & maintaining tight tolerances Pune-based Victory Precisions, manufacturers of aluminium die-castings and large machined engineering components for companies in the oil & gas, automobile, agricultural, infrastructure, and other sectors, found it challenging to maintain an accuracy of 15-20 microns on these components and reduce non-productive time while machining. The Primo™ twin probe system, developed by Renishaw, has helped Victory Precisions to achieve this accuracy, reduce part setting time and increase productivity. The company was established in 2006 and supplies components to well-known companies such as ABB, Alfa Laval, Atlas Copco, Cummins, and many others across the globe. With a workforce of 165 people consisting of engineers, designers, operators, and other staff, the company has registered a turnover of ` 250 million in the financial year 2013–2014. The well-
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equipped aluminium die-casting foundry has an E6 heat treatment plant, a drop quench facility, core shooters and shot blasting machines providing the capacity to produce 100 tonnes of castings every month. The machine shop has 14 twin pallet horizontal machining centres (HMCs), three vertical machining centres (VMCs), two CNC vertical turning lathe machines (VTLs), turning centres, co-ordinate measuring machines (CMMs) and comprehensive inspection facilities. It is an ISO-TS certified company and a proud Zero PPM supplier to all of its customers.
Primo system increases productivity & quality Victory Precisions was incurring huge losses in terms of time and material until it started using Renishaw’s Primo
EM | Mar 2015
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A P P L I C AT I O N | T E S T & M E A S U R E M E N T
CNC Machine-Tool Holders Supplying
A P P L I C AT I O N | T E S T & M E A S U R E M E N T
Since 1979
www.annwaytools.com.tw system. The Primo system, which consists of a radio part setter and a radio 3D tool setter, is available at a competitive price, and is aimed to deliver a fast return on investment. It enables automated on-machine part setting, part inspection and tool setting, helps to eliminate manual setting errors, and improve accuracy and part conformance, while reducing non-productive time and scrap. This also helps to increase productivity, improve quality, and increase profits. It is easy to use, simple to install and represents a low initial financial outlay. Additionally, its exclusive, enhanced warranty offers users peace of mind. The innovative Primo credit token system offers users the flexibility to ‘pay-as-you-probe’. Its six-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. Simple, single-line commands are used instead of multiple lines of code, which further eliminates the need for any special training.
GoProbe: making probe system easy to use According to Sagar Kaushik, Director, Victory Precisions, the company was introduced to Rensihaw in 2007, when it decided to install probes in the manufacturing unit. “The selection parameter was to go with the best supplier and Renishaw, being best in class and category, was a natural choice for us. Today, we have seven different probing systems from Renishaw,” he added. The company felt that the Primo system suited various applications and installed it on one of its HMCs. “While it is revolutionary, installing the Primo system is also very easy. Renishaw installed it within one and a half hours at our company and the operators were trained to operate the probe in just three hours using Go Probe. This combination of software, selflearning material and reference tools is standard with the Primo system. Requiring no previous experience of probing, GoProbe makes the probe system easy to understand and use,” said Kaushik.
Time saved is money earned At Victory Precisions, the Primo system has helped to save
EM | Mar 2015
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TAIPEI, TAIWAN
March 3rd ~ 8th , 2015
TWTC Hall 1, B0818
ANN WAY MACHINE TOOLS CO CO., LTD LTD. No. 63-3 Housheng Rd., Shengang Dist, Taichung City 42952, Taiwan Tel: 886-4-2563-1259 Fax : 886-4-2561-3712 67
E-mail: E il annway.tools@msa.hinet.net t l @ hi t t 3/13/2015 5:20:53 9:16:46 PM
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 bar geometry allows feeding the bar through raw bores on an eccentric path.
time and eliminate scrap. When machining a crankcase – a critical product for any engine – some casting process variations are often present. For the company, in order to get equal wall thickness and avoid future failures, the component would be set up on the machine and bore alignment would be performed manually using dial gauges. Before the Primo system was installed, this part setting process took two and a half hours and caused machine downtime. With this system, the onmachine alignment of a crankcase takes just 5 to 10 seconds, saving time & costs. In addition, scrap is eliminated – a saving of ` 45,000 per component – and precision is guaranteed. When machining a cylinder – an engine component and a high-performance part – concentricity is critical. Once the boring operation is performed, checking of concentricity is essential. Previously, it was necessary to take the product to another inspection facility, which led to a delay in the machining cycle. This entire process took one and a half hours. The Primo system enabled the inspection of this parameter to take place on the machine itself, and in just 30 seconds, without a gap in the machining cycle. A bonnet – an oil and gas industry component is very heavy and the cost of the raw forging is high. After machining the diameter and other operations are performed on a VTL, the component is set to within an accuracy of ±10 microns of the centre axis on an HMC, for middle hole boring, PCD holes and threading operations. This alignment was previously carried out by using a dial gauge and it took around two hours. After installing the Primo system, it took a minute to perform this alignment, resulting in a significant time-saving and confidence in the alignment. The Primo twin probe system also saves time when machining endbells, used in genset engines. The casting itself comes with a notch, which is used for locating positions of the holes for drilling and tapping operations. Failure by an operator
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to locate this particular notch for further machining can lead to many rejected parts. The Primo system has been useful to operators as it can correctly probe the notch and allows the machine to locate other features using this data. Previously, this process took 5 to 7 minutes and there was a possibility of rejections; now, it is a matter of just 20 seconds, with guaranteed results. Another critical component where the Primo system has helped in maintaining accuracy and reducing rejections is the air intake manifold that is used in automobile engines. This component comes in different sizes and can be very long. When a manifold is cast, there is normally a distortion of 1 mm to 2 mm. Correct alignment is very important when machining, so that bored and clamping holes are machined as per the drawing. The system probes port holes on the casting and aligns the component perfectly. It takes wall thickness variations into account, leading to a total time saving of ten minutes and the elimination of scrap.
Advantages The Primo system comes with Primo Premium Support cover, a comprehensive warranty scheme which safeguards the probes against any accidental damage. “The operators using the Primo system can be trained in 30 minutes and find it very easy to use this product. The advantage is its probe-on-probe calibration and the credit token system, which is a unique payment system that Renishaw has offered. We do not have to pay everything at one time and as such, higher initial investment is avoided. We can buy credit tokens as and when we want to use Primo. It is like a prepaid system that is a low cost solution for SMEs,” concludes Kaushik. ☐ Courtesy: Renishaw > MORE@CLICK EM01571 | www.efficientmanufacturing.in
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S P E C I A L F E AT U R E | W E L D I N G & A S S E M B LY
Sensor-based adaptive arc welding The article analyses how the use of emerging sensor technologies allow robotic automation to address the most difficult welding challenges In principle, the addition of sensors to robotic equipment will enable the automation technology to operate with remarkably human-like capabilities. When a sensor system is correctly selected, installed and trained (programmed) it will significantly extend the operational capability of the robotic arm and controller combination. In robotic welding systems the introduction of sensors provides the adaptive capability of touch and sight to address the challenges of a “moving” weld seam or component. Historically, the use of sensors with the ability to solve the problems of the moving target was not feasible for general industrial (non-automotive) type companies. The typical prohibiting factors were high initial investment costs; extended processing times; physical size of the sensor equipment; inability to achieve the desired accuracy of process; and the “stack-up” of tolerances that traditionally have precluded automated welding.
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In welding applications, recent and ongoing advances in sensor technology are enabling previously prohibited joint tolerances and configurations to be effectively produced with acceptable quality and weld integrity. Moreover, the technology has become performance and cost competitive for general industrial organisations, not just for the large dollar automotive and tier-one manufacturers.
Challenges There are three challenging phases of the welding process, where the introduction of sensors has enabled the use of robotic automation in the welding of inconsistent joints. They are: Joint Edge Detection - finding the edge or start of a weld seam; Joint Seam Tracking - maintaining the desired weld path; and finally measuring the width or profile of a joint. While there are a number of factors that influence the
EM | Mar 2015
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W E L D I N G & A S S E M B LY | S P E C I A L F E AT U R E
W E L D I N G & A S S E M B LY | S P E C I A L F E AT U R E
quality of a welded joint, the major sensing media capable of measuring joint width and geometry deviation have developed considerably over the last few years, greatly increasing their reliability and performance. The following methods outlines how the use of emerging sensor technologies allow robotic automation to address some of the most difficult welding challenges.
Joint Edge Detection In determining the start of a joint or the edge of a plate, the primary sensor tools now available to the manufacturing industry are tactile sensing and a proximity sensor. Tactile sensing: It is a well established solution. In principle, it is a voltage applied to the welding gas nozzle, welding wire or independent probe. The prominent welding power source manufacturers all have their versions with some variations. The principle of operation for a tactile sensing system is for the voltage to short out as it makes contact on the component via either the wire, gas nozzle or an independent probe. The short circuit is recognised by either the robot controller or welding power source, and resulting programming decisions are then made. An example of this type of sensor is SmarTac from ABB. Proximity sensor: It has existed for a number of years but recently the performance and reliability has become far more dependable. The sensor approach works in a similar manner as the tactile sensing system, providing an interrupt for the robot controller to make decisions. The proximity sensor, however, is non-contact and operates using an analogue inductive field. The advantage of this approach lies in the innovative skill of the robot programmer. A well conceived, strategic route of the robot traveling over the component will provide benefits of reduced sensing time and more reliable data received.
Joint Seam Tracking The use of vision and lasers to track and modify the welding criteria on the fly are now established and proven technologies. The initial and most primary consideration is that vision and laser systems are high performance options that demand a higher skill set and level of complexity than most other methods. There are three main methodologies that can facilitate seam tracking, each providing varying levels of investment, complexity and capability. They are vision solutions, laser scanning and through the arc sensors Vision solutions: Historically, most of the vision applications have been employed in situations, where the requirements of
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S P E C I A L F E AT U R E | W E L D I N G & A S S E M B LY
Examples of joint types more readily produced with enhanced sensors
Butt joint
6 mm Lap joint
Outside corner
3 mm Lap joint
quality were uncompromising, often with significant safety implications. A relevant example is the railroad industry producing undercarriage bogies for passenger carriages. The build-up of these types of structures uses large thick plate fabrications, forgings and castings. Such products have industry guarantee requirements of 30 years or more. The plates, castings and forgings when assembled inherently have tolerances in excess of the desired welding criteria. The introduction of a high end vision tracking solution enables these joint types to be produced with excellent results. This environment is clearly one where the higher cost threshold for such tools is much more acceptable. Laser scanning: It falls into the categories of 1D, 2D, 3D, spot, line and circle. While there are multiple uses of the various types of laser scanning options, there are some definite commonalities among them. All of the aforementioned laser types are normally combined with some form of CCD style camera to capture the images for processing with calculative algorithms. The system is usually managed by a host PC calculating the input data and producing the necessary output for the robot to execute its task. More recent vision solutions are combining the PC and camera to make smart space saving combination. Through-the-arc sensing: For various reasons vision and laser solutions are not the preferred choice. In these cases the “through-the-arc” approach may mean the difference between producing a repeatable, quality joint competitively through automation, or completely abandoning the automation option altogether. Through-the-arc-tracking has evolved considerably in recent years, as the reliable, fast, and accurate tracking of a
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weld joint is second nature to a robot today. A top performing through-the-arc seam tracking provides the combined benefits of economics, technical capability and physical geometry. While the ratio of investment to capability for this type of seam tracking solution has been well established over the years, recent process advancements have continued to push out the boundaries of capability in addressing the problems of the ever-changing joint configuration. One example of such a system is ABB WeldGuide III. The operating principle for through-the-arc sensing is to monitor the arc in order to track the seam. Through-the-arc sensing primarily uses “impedance” (not just simple volts or amps), which provides a more reliable value within the arc physics to determine accurate data.
Conclusion Today, sensor technology can be regarded as a mature methodology or procedure designed to meet the ever-changing demands of the low volume, inconsistent welded joint. For products that are low in volume and inconsistent by nature, there is now a high probability that they can be effectively produced by robotic means. The overall technology advances have lowered the threshold of when sensors can be safely and effectively deployed to achieve the ultimate goal of producing components that meet the demands of the required process tolerances. In short, they are capable, reliable and available to a much wider audience than previously possible. ☐ Courtesy: ABB Robotics > MORE@CLICK EM01572 | www.efficientmanufacturing.in
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I M A G E C O U RT E S Y: EMAG
COUNTRY FOCUS - CHINA | MARKET
Changing industry landscape After years of high-speed development, China’s economy has been entering into a developing stage, facing severe challenges to stride the middle-income trap and dissolve long-term accumulated contradictions of extensive growth. The article briefs on China’s new motive force of development, while highlighting the country’s changing ideological emancipation & concept innovation As per reports from RnR Market Research, China’s machine tool industry has witnessed a significant decline since 2011. In 2012-2013, the output of metal working machine tools in China dropped by 7.0% and 6.1% respectively. This is particularly true of metal cutting machine tools, whose output dropped by 7.3% and 8.9%, respectively. In the first half of 2014, China’s machine tool industry continued to present low growth, but the output rose considerably and the exports turned from negative to positive. However, amid sluggish recovery of the global economy and downturn of China’s machine tool market, many foreign companies are stepping up the layout in China. Moreover, a new motive force of development must be
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released from adjustment & reform, focussing on economic transformation. To achieve this, China’s economy needs to be at the cost of suffering from short-term pain and periodic slowdown growth. According to Chen Huiren, President & CEO, China Machine Tool & Tool Builders’ Association, the machine tool industry has slowed down in 2014 since the second half of 2011. “It is still in the downward trend, since the influence of growth continues to be slow in the country’s economy. The overall environment of the economic slow-down and transformation of development pattern has generated a comprehensive & persistent impact on the industry. The change of development environment also provides the optimum
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MARKET | COUNTRY FOCUS - CHINA
The Chinese industry has been comprehensively impacted by the global economic rebalance and slowdown of the country’s economic growth
opportunity for the industry’s adjustment & transformation, while bringing pressure and challenge,” he said.
Upgrading drive of industries The Chinese industry has been comprehensively impacted by the global economic rebalance and slowdown of the country’s economic growth. After high speed growth for consecutive ten years, the industry is facing & undergoing the ordeal of adjustment and transformation due to the significant change of market climate and other growth factors. Industry giants believe that the Chinese industry is in a conversion period of development phase coupled with growing transformation & upgrading. Commenting on the increasing drive of industries in the China market, Huiren said, “China is the biggest importer & consumer market of machine tools in the world with large inventory and excellent machining equipment. Therefore, it has a strong manufacturing ability and enough reserve of advanced technical worker. But, our structural adjustment requires the foundation of technical progress. So, there are more companies willing to establish R&D centre in the country to provide continuous drive to the development of the industry.”
How does the industry deal with the changes? Under the changing scenario of Chinese market, the current industry needs a new round of ideological emancipation and concept innovation, to conscientiously get rid of the path dependence of development model by scale expansion, to thoroughly abandon the blind pursuit of rapid growth, to adjust structure and to walk on the sustainable development road by
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means of technical progress, upgrade management and labour quality enhancement. Emphasising on this changing market, Huiren said that the machine tool association has been using two exhibitions— CCMT (China CNC Machine Tool Fair) & CIMT (China International Machine Tool Show) to hold docking activities & communications for various levels and different contents to provide a stage suitable for enterprises, both at home and abroad to demonstrate their adaptation to the changing market.
Recovery of the metal working industry According to reports, the metalworking industry of China has regained momentum in the market. In particular, the machine tool market has grown fast. It was estimated that by 2015, its annual consumption will reach 850 billion RMB and the CNC system demand will be about 4,00,000 units; the annual CNC machine tools production capacity will be 2,50,000 units, 70% of which will serve the domestic market and the exports of machine tools & their accessory products will reach $ 11 billion. It is also estimated that by 2020, high-end equipment will account for 25% of the equipment market and will be a major subsector in the Chinese manufacturing industry. By 2015, the intelligent equipment market will value over 1 trillion RMB with 25% growth YOY. As such, the implication of “Made in China” will cover the ideas of high-end and intelligent manufacturing too. In China, the strong growing industries, including automotive, die & mould, aerospace and medical are the major driving forces of the metalworking industry recovery. From 2018 to 2020, Chinese automotive market demand is expected
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COUNTRY FOCUS - CHINA | MARKET
It is estimated that the sales revenue of machine tool industry will continue to increase in China in 2014-2018, while the annual growth rate will decline to 10%
to meet its peak, over 50 million units, electric car sales exceeding the US in 2018. The mould production’s sale is expected to reach 350 billion RMB by 2015.
Contributing in the global output value China contributed 29.4% of the global output value and 45.1% of the global consumption of machine tools in 2012. The sales revenue of machine tool industry was CNY 802.63 billion in China in 2013, up by 13.7% YOY. The numerical control rate of machine tool production in China is lower than the US and Japan, though the rate increases in recent years. The numerical control rate of metal-cutting machine tools and metal-forming machine tools was 30% and 10% respectively. The import value of machine tools was $ 16.09 billion in China in 2013, down by 20.2% YOY. The import value of metal working machine tools was $ 10.1 billion, down by 26.0% YOY. The import value of numerically-controlled machine tools was $ 8.21 billion, down by 26.5% YOY. Among the metal working machine tools, the import value of metal-cutting machine tools was $ 7.99 billion, down by 28.4% YOY, while that of numericallycontrolled metal-cutting machine tools was $ 7.03 billion, down by 28.3% YOY. The import value of metal forming machine tools was $ 2.11 billion, down by 15.5% YOY while that of numerically-controlled metal forming machine tools was $ 1.18 billion, down by 13.9% YOY. After years of rapid growth in import, problems occurred as downstream industries raised the production capacity and adopted high-end products. The import of machine tools fell sharply in China in 2013, while downstream industries tried to solve the problems. Unlike the decline of import in 2009, the import of machine tools will not experience long-lasting and rapid growth in the future.
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The export value of machine tool products was $ 9.53 billion in China in 2013, up by 3.2% YOY. In fact, the prospering industrial robot market has become a trend for machine tool enterprises to enter robot manufacture field using manufacture advantages. Problems and risks exist in the machine tool industry though the market has huge potential in China in 2014-2018, including uncertainty of domestic and international economic environment, excess supply, decreasing demand in downstream, increasing costs of labours and raw materials, fluctuations of CNY exchange rate and insufficient technical innovation. It is estimated that the sales revenue of machine tool industry will continue to increase in China in 2014-2018, while the annual growth rate will decline to 10%. The industry upgrading and technical innovation of downstream industries stimulate a large demand for machine tool products with a trend toward high-end products. The import of high-end machine tools and moulds will continue to grow, though the overall import of machine tools suffers sluggish growth in China.
Structural adjustment is a necessity According to a report by Anhui Haian Machinery Manufacturing, the Chinese machine tool industry’s economic operation in the first half of 2014 showed low stabilisation. Although the government has increased from the second quarter of steady growth and policy efforts to deal with economic downturn; a structural adjustment in the domestic market demand, slow recovery in the international market demand, increased competition of imported goods, lack of liquidity and long-term deterioration of the financial, business difficulties and potential risks increase, the industry operating pressure is still great.
EM | Mar 2015
3/13/2015 11:50:59 9:16:53 PM 3/11/2015 AM
MARKET | COUNTRY FOCUS - CHINA
According to reports, the metalworking industry of China has regained momentum in the market. In particular, the machine tool market has grown fast
Overviewing the industry Analysing the industry reports, the following data highlights the ups-and-downs of the Chinese industry since last year. Industry-wide decline in growth rate: According to the National Bureau of Statistics in January-June 2014, the metal working machine tools’ business revenue increased by 8.7%, metal-cutting machine tools increased by 6.4% YOY, metal forming machine tools rose by 13.3% compared with the first quarter, a respective change of -0.5, -1.3 and 1 percentage point. The Machine Tool association statistics also show key contact network. From January to June 2014, sales revenue of all enterprises fell to 2.6%, while metal-cutting machine tools sales fell to 7.7% and metal forming machine tools sales revenue grew by 4.3%. Industry-wide decline in quality: The financial situation is not optimistic. According to the National Bureau of Economic Run from January to June 2014, the data estimated that the industry’s main business income margin, accounts receivable turnover ratio and asset-liability ratio was 5%, respectively, 4.6 and 54.1%; above three metal-cutting machine tools indicators were 3%, 2.7 and 62.6%; metal forming machine tools above three indices were 5.8%, 4.2 and 54.3%. Loss sustained, the situation is grim: National Bureau of Statistics in 2014 January-June economic data reflects the industry-wide loss-making enterprises accounts for 13.8%, including state-controlled enterprises accounting for 41.8% loss in eight sub-sectors. The biggest loss is the metal-cutting machine tools, where loss companies accounted for 24.7%, of which state-controlled enterprises accounted for 50.8 % loss. Steady growth in exports: According to customs statistics, from January to June 2014, the amount of machine tool exports $ 5.28 billion, an increase of 18.5%, representing an increase of
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7.4%. The domestic market demand continues to slump, falling production and operation of enterprises in the background, the first half of 2014 exports had shown steady growth. Therefore, opening up overseas markets and strengthening export resolve overcapacity is becoming an important breakthrough to achieve industrial transformation. From the export commodity structure, breakdown of the top three is a cutting tool ($ 1.24 billion), abrasives ($ 1.04 billion) and metal cutting machine tools ($ 970 million), its export value accounted for 23.5%, respectively, 19.7% and 18.4%. Market demand stabilisation: Due to China’s economic slowdown development pattern, the machine tool consumption market and industry is also experiencing profound structural adjustments to significantly reduce the amount and structure, characterised by accelerating changes in the market to upgrade. Given that China’s economic development has entered a new satge, changes in consumer demand for machine tool market is expected to stabilise.
For a better tomorrow According to Huiren, there has been both competition and a certain degree of complement in the machine tool industries between China & India. “The percentage of export to the Indian market has increased from 1.4% to 1.9% in the metalworking machine category. For imports, the percentage has increased from 1.5% to 2.3%. However, the proportion in each market of both countries is still not high enough. We are looking forward to co-operation between Chinese & Indian enterprises,” he concluded. ☐ Compiled by EM > MORE@CLICK EM01573 | www.efficientmanufacturing.in
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COUNTRY FOCUS - CHINA | INTERVIEW
“Looking forward to co-operation between Indian & Chinese enterprises” Chen Huiren, President & CEO, China Machine Tool & Tool Builders’ Association, in this interaction with Megha Roy, highlights on the strong manufacturing ability of the Chinese machine tool industry, while discussing the highs and lows of the global industry. How do you look at the Chinese machine tool industry ability and enough reserve of advanced technical worker. Also, in terms of its strength, capabilities, export potential, our structural adjustment requires the foundation of technical technological advances & innovations? progress. So, there are more companies willing to establish China is the biggest country in producing machine tools R&D centre in the country to provide continuous drive to the worldwide, not only in quantity but also in category ranging development of the industry. from household general-purpose machine tool to 5-axis CNC machine tool needed by aerospace field; from ordinary How are you planning to promote the ‘Made in China’ brand punch to press production line for auto’s covering parts; from globally? grinder with nanometre grade to planer type milling machine The best channel to promote our brand is through over 10-metre in width; from non-traditional machining to international professional exhibitions. The exhibitions help additive material manufacturing and 3D printer; from robot to make demonstrations and expand the publicity effect via to automotive various links and the like. technical forum, magazine and website. CMTBA owns two China is the biggest importer and consumer market of exhibitions, namely, CIMT and CCMT. We invite machine tool machine tools in the world with large inventory and excellent buyers across the world to visit these events. They display the machining equipment. Therefore, it has a strong manufacturing strength of enterprises of the Chinese machine tool industry. It
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EM | Mar 2015
3/13/2015 5:35:15 9:16:54 PM
INTERVIEW | COUNTRY FOCUS- CHINA
“The overall environment of the economic slow-down and transformation of development pattern has generated a comprehensive & persistent impact on the industry” Chen Huiren
organises the Chinese enterprises to attend overseas exhibition. We are also organising a delegation to attend the forthcoming exhibition of EMO in Milano, Italy. Can you highlight on the performance of the China’s machine tool industry in the year 2013-14? The Chinese machine tool industry has been in the slow-down trend in 2014 since the second half of 2011. Currently, it is still in the downward trend since the influence of growth continues to slow in the country’s economy. The overall environment of the economic slow-down and transformation of development pattern has generated a comprehensive & persistent impact on the industry. The change of development environment also provides the optimum opportunity for the industry’s adjustment & transformation, while bringing pressure and challenge. The reserve mechanism it has formed provided strong external power for the transformation of the industry. Which are the various exhibitions – domestic and international, in which your organisation is representing the Chinese industry? China’s huge potential market and production capacity lay a solid foundation for CCMT and CIMT to push various global trade opportunities. Currently, we are using the two exhibitions in the changing times to hold docking activities and communications for various levels and different contents to provide a stage suitable for enterprises, both at home and abroad to demonstrate their adaptation to the changing market. How are you planning to promote the Chinese machine tools in India? Any specific initiatives?
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India is the third largest export market of the Chinese metal-working machine tool. Members from CMTBA have participated in exhibitions such as IMTEX for several years. It has been observed that the Chinese enterprises have strong desire to exploit the Indian market. Seen from the present, the most efficient path to tap the Indian market is to attend the exhibition there. We hope having an opportunity to get in touch with the representatives from the industries of autoparts and military to discuss deep cooperation, if possible. Currently, integration between machine tool companies is a key benefit to the industry. What is your take on this? Integration of enterprises exerts co-operation benefits but not every co-operated project is successful. I’ve observed some enterprises that club mutual understanding & trust as the foundation of the integration and management & technical fields as complementary. I’m looking forward to cooperation between Chinese and Indian enterprises with an open attitude. How has been the performance of industrial trade activities with India this year? There has been both competition and a certain degree of complement in the machine tool industries between China and India. The percentage of export to the Indian market has increased from 1.4% to 1.9% in the metalworking machine category. As far as the import is concerned, the percentage has increased from 1.5% to 2.3%. However, the proportion in each market of both the countries is still not high enough. I believe that both countries can exert more potentiality on each other markets. ☐ > MORE@CLICK EM01574 | www.efficientmanufacturing.in
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MARKET | INTERVIEW
“Establishing our brand in India is a major challenge...” ...says Dilip A Chauhan, Director — Business Development, Henfux India. He briefs on the company’s recent innovations, and elaborates on the future expansion plans for the Indian market in an interview with EM. Excerpts… What are the current trends in the machine tool industry of China? China’s local machine tool demand was huge in the last 20 years because of the “Made in China” trend. This brand has resulted in a rapid growth of many Taiwanese, Korean & Japanese machine tool suppliers. The huge market requirement also drove local machine tool manufacturers to produce qualified machines with competitive prices. The China made machines have also been improving manufacturing in the terms of precision, automation and operability. High quality and costeffective machine tools will play a vital role in the international market in future. What is the USP of “Made in China” products? “Made in China” machine tools & metal working machines are most economically driven with state-of-the-art-technology. The competitiveness of the machines in terms of quality & price is mainly due to integrated efforts by the local machine manufacturers, who have almost all the features offered by Japanese, Taiwanese & European equivalent product range with competitive price & shortest delivery period. How does R&D work in your domain? We have R&D teams in 5 manufacturing plants for continuous improvement in the existing design & manufacturing process. For new products, there are independent R&D centres in Taichung, Taiwan. We present budget for new development & continuous improvement, which is more than 5% of the total sales turnover. Our company aims at 8% R&D investment of the business turnover by 2018. Brief us on your company’s innovations… Our company has established an integrated manufacturing facility at Guizhou, China, having an annual capacity to build more than 2000 machines. The main innovation is the high technology products designed & developed in-house. We are the only company in China & Taiwan with the design of hydrostatic spindle housing arrangement for centreless grinding machine. This design makes us at par with the Japanese &
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European machine builders. The CNC turning centres, turn mill centres, vertical CNC lathes, vertical machining centres & CNC drill tape centres also offer high speed machining centres & customised automation. How has been the industrial trade activities with India? We are entering the Indian market with the concept of commissioning & more specifically offering innovative turnkey solution from our highly experienced technical team & wide manufacturing product range. Offering machine with optimised solution will provide a better platform to the Indian customers. What are the challenges in the Indian market? Establishing our brand in India is a major challenge. Our company is committed to provide high quality CNC machines with best package prices for customised solution. What are the changes witnessed in your sector? With the changing demand scenario, how do you plan to align your market strategy to business growth? Currently, we are focussing on the overseas market, i.e. US, Europe, Russia, Turkey, UAE, besides India. We offer world class CNC machines equivalent to the Japan & Europe made-machines with competitive price and turnkey solution. In 2015, our company targeted 35% of the total production for export market. The present level of export is nearly 20% of the total turnover. Our overseas teams & business partners are geared up to this growth-oriented target. What are your future expansion plans? We will establish our after-sales services in India soon. The company also plans to appoint localised dealership/ distributor’s network all over India. A technical application centre will be established to support the Indian customers & sales/service team for better services on Henfux products. The company’s top management may study the feasibility of putting up manufacturing plants in India based on the business development in coming years, i.e supply & demand pattern. ☐ > MORE@CLICK EM01575 | www.efficientmanufacturing.in
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COUNTRY SPECIAL - CHINA | TECH NEWS
NC series standing die spotting machine
Engraving & milling spindles
Dongguan Nice Machine Building’s new series of products include NC standing die spotting machine, NCW horizontal die spotting machine, NCF die-overturning machine and NCS deep-hole drilling machine. The company’s main products are NC series of standing die spotting machines. Two kinds of standing die spotting machine—the magneto electric-typed & the press-typed, are mainly used in repairing and replacement of various kinds of plastic die, hardware die and thin-trip tensile die. The company has cooperative relations with Skyworth, TCL, BYD, Zhongxin Plastic, CHIGO, etc. It sells products to Brazil, Turkey, Malaysia, among others. Other products NC150-1511 from the company are die rolling machine, NCF-5 die turnover machine, NCF-30 die turnover machine and NCW-120 horizontal die spotting machine that has a strong applicability, quicker & greater return of investment and quick installation. The company’s products have high quality, high request and high efficiency.
Guangzhou Haozhi Industrial is specialised in designing, manufacturing, sales and repairing high speed electric spindles & spare parts. Engraving and milling spindles are a series of products from the company, which are specifically designed for high-precisions and are efficient of all types of metal, nonmetallic materials. These spindles are mainly used in various types of CNC milling machines, and are suitable for DGZX-0840I2 machining all non-ferrous metals & non-metallic materials. The company’s product line has polishing glass spindle, including DQFX-100A, used for high speed engraving and DGZ-60E, used for high speed grinding non-ferrous metals. There are also PCB machine spindles, which include DQF-125C, used for high speed and high precision routing and DGZ-60C, used for high speed and high precision routing. The high precision grinding spindle includes DGZM-0840H, used for machining in non-ferrous metals and DGZM-1006H2, used for high speed engraving and grinding non-ferrous metal, such as copper and aluminium, nonmetals such as acrylic, glass, graphite material, etc.
Dongguan Nice Machine Building | China Email: nice@nicemachine.net | Tel: +86-769-22707026
Guangzhou Haozhi Industrial | China Email: sales@haozhihs.com | Tel: +86-20-6225-7588
> MORE@CLICK EM01576 | www.efficientmanufacturing.in
> MORE@CLICK EM01577 | www.efficientmanufacturing.in
Machine tools for compressor & rolling components
Centreless grinding machine
Guangzhou Min Jia Manufacturing Technology’s main products are all special automation equipment, including numerical control lathe, car milling compound centre, vertical/horizontal/gantry machining centre, multi-master vehicle processing centre, CNC grinding machine, special machine tools for the compressor and rolling components industry. The company mainly services industries, such as air-condition compressor, refrigerator compressor, auto air-condition compressor, ball screw, linear guide, plumbing equipment and electronic industries. The main SMK 204 processing and testing equipment in the company are gantry machining centre, vertical machining centre, car milling compound machining centre, numerical control lathe, precision guide rail grinder, three-coordinates measuring instrument, laser detector, ballbar, dynamic balancing instrument and electronic leveling instrument, etc. All products & technology of the company completely rely on the independent research and development, which grant the company to have 100% of the intellectual property rights. Besides, the company makes product research on elected manufacturing technology, compound processing, high-speed processing and multi-axis machining.
Henfux offers a wide range of centreless grinding machine, including manual version, PLC, CNC and the customised one for special applications. Model HFC-1808HCNC-17A has 7 axes control for customised solution including parts loading/unloading, yielding high productivity and reduced operator intervention. It has hydrostatic spindle (patented technology) manufactured using Japanese high grade alloy steel SNCM-220H. This helps to achieve high spindle RPM (up 7 axis CNC centreless grinder to 2000), spindle run-out less than 1.5 micron and enhanced life cycle. It is a rigid & stable frame made out of meehanite cast iron with natural aging of 18 months. With CNC control in-feed, compensation and dressing can be put in auto mode. The servo motor is used for in-feed drive and linear encoder, ensuring positioning accuracy within 1 micron. The company’s main innovation is the high technology products designed & developed in-house. The CNC turning centres, turn mill centres, vertical CNC lathes, vertical machining centres & CNC drill tape centres offer high speed machining centres & customised automation.
Guangzhou Min Jia Manufacturing Technology | China Email: agile-machine@163.com | Tel: +86-020-34908006
Henfux India | Pune Email: dilip@henfux.com | Tel: +91- 9371053281
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> MORE@CLICK EM01579 | www.efficientmanufacturing.in
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EM | Mar 2015
9:16:55 PM 3/13/2015 5:30:22
TECH NEWS | COUNTRY SPECIAL - CHINA
Volumetric lubrication systems
Vertical machining centre
Herg (Foshan) Automotive Lubrication System Manufacture produces inspecting volumetric lubrication systems, which comes from Japanese technology with patented protection. Here, the system can accurately distribute the required oil volume to each lubrication point, the working pressure is 12-15 kgf/ cm2. It is of reasonable fabrication cost & quality product, which is widely used for lathe, plastic injection moulding machines, Volumetric lubrication systems weaving machines and wood-working machines. Some new lubrication equipment from the company includes NKHY-8, with a discharge capacity of 8 cc/st and a maximum discharge pressure of 15 kgf/cm2. Here, the discharge bore is M10 X1 (dia 6) and is resist-type. Another model is PH-1600, with a discharge capacity of 16 cc/st and a maximum discharge pressure of 25 kgf/cm2. It has a tank capacity of 1.6 L, with a discharge bore of M10 X1 ( DIA 6) and has pressure take-off type. There is also the HL type motor-driven lubrication pump, which is a gear pump with rational structure, complete functions and suitable for many applications.
Shenzhen Joint Industry’s joint VMC-650L3 machining centre has spindle servo motor, dynamic balancing system accuracy and a prolong life of spindle. It has high rigidity structure, which is applicable for processing complicated workparts. The main components, such as spindle, bearing, limit switch and tool magazine are imported to assure stable and accurate performance of the machine. It has the standard accessories, like control system, electronic hand wheel, cutting fluid and filter system, auto VMC-650L3 lubrication of slide way, coolant system, cover, hammer balance, alarming light, stainless steel covers of slide way, tool and tool box and operation manual. The optional accessories include milling chuck and tool unlock, arm type or umbrella type tool magazine, auto chip conveyor, oil coolant, heat exchanger and the fourth axis NC dividing head or rotary table. The optional system used is Mitsubishi system M70B, Fanuc system OI MATE or OI MD and KND2000M-H. The company’s main products include CNC milling machine, CNC lathe, CNC engraving machine, milling machine and grinding machine.
Herg (Foshan) Automotive Lubrication System Manufacture | China Email: info@herg.com.cn | Tel: +86-757-82011888-8032
Shenzhen Joint Industry | China Email: jointcathy@126.com | Tel: +86-755-84678998
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> MORE@CLICK EM01581 | www.efficientmanufacturing.in
6-axis coordinate advance milling & drilling machine
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Worldwide Industrial Machinery’s 6-axis coordinate advance milling and drilling machine (CAMDER) has been patented as a new application machine in China. It is most suitable for automobile mould and complex machine component. It uses an advance 6-axis CNC control with milling and deep hole drilling functions, in one machine and is specially designed for large automobile mould and machine component. On the other hand, 5-axis coordinate advance milling & drilling machine is based on horizontal deep hole drilling machine with CNC rotary table and spindle tilting function design concept. With the advance CADMER design, it can interchange from a milling function to a drilling function in a very short time. X, Y, Z, & W axis are all using a high precision linear guide and ball screw, with high rigidity and accuracy. The maximum loading capacity is 30 tonnes, with a dual servo motor to eliminate the backlash. The spindle power is 22 kw and can be used in gun drilling and a more efficient ejector drilling system.
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EFFICIENT MANUFACTURING
EM | APRIL 2015 COUNTRY
FOCUS
USA XXXXXXXXX
The next issue will highlight the industry & market developments in the US machine tool sector, with interviews & technology write-ups from the industry
Worldwide Industrial Machinery | China Email: info@wim.hk | Tel: +852-3188-2554
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EM | Mar 2015
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EVENT | REPORT
Innovative grinding technologies Motion Meeting 2015, organised by United Grinding was held recently in Thun, Switzerland. The conference featured the latest development & innovations in grinding technology and also took this occasion to deliver its prestigious Fritz Studer Award for innovative research in machine tool and grinding technology. A report… With the theme of “The Cylindrical Grinding Universe”, Motion Meeting 2015 was recently organised by United Grinding amid the beautiful countryside of Thun in Switzerland. The company, every year hosts this conference for its sales partners from all over the world and international trade press editors to showcase its latest technology advancements. This year around 150 sales partners from all over the world and around 60 representatives from the international trade press had attended the conference. The purpose of this annual ‘Motion Meeting” was to highlight the group’s latest offerings in grinding technology, particularly in the area of cylindrical grinding, which includes Studer, Schaudt and Mikrosa brands.
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Srimoyee Lahiri Sub-editor & Correspondent srimoyee.lahiri@publish-industry.net
The Group positioning The United Grinding Group is the world’s leading supplier of machines for hard fine machining. With its eight strong corporate brands - Studer, Schaudt, Mikrosa, Walter, Ewag, Mägerle, Blohm, Jung - the group has the most extensive application knowledge, product portfolio and range of services in the market. “We have the broadest application know-how, machines and services portfolio in the grinding machine industry and all our activities are focused on customers’ success,” said Stephan Nell, CEO, United Grinding. These business units provide cylindrical, surface and profile, and tool grinding
EM | Mar 2015
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REPORT | EVENT
United Grinding used this occasion to deliver its prestigious Fritz Studer Award for innovative research in machine tool or grinding technology
machinery for metal and wood applications. The group’s innovative technologies are used in diverse industries such as the automotive industry and its suppliers, the tool industry, power plant turbine manufacture, tool and die makers, medical technology, machine tools, clock and watch manufacturers as well as the turbine industry.
Market growth After 2012, the Cylindrical Grinding Technology Group witnessed a comparatively weaker market growth. This was primarily due to the relevant industries delaying or taking a cautious approach to investment projects. In 2015, Studer, Schaudt and Mikrosa brands planned a high to moderate the growth rate. Growth rates can only be achieved by winning market shares. The markets are largely saturated and production capacities are not fully utilised in the target segments. In such times, a strategy of displacing the competition must be pursued. It is a question of providing or further developing the capabilities, capacities and also the products, to facilitate market entry for the sales organisation to win further market shares. The company continues to make investments in 2015, with the focus on increasing the efficiency of its production processes. Also, Lean Six Sigma has been introduced as standard throughout the group and will be used to increase efficiency in all areas. “We’re expecting a growing grinding market worldwide in 2015, including India. The geographical distribution of the machine orders shows an improvement in the situation in Germany. The Latin countries of Europe are showing signs of recovery. Eastern Europe is growing constantly and Northern Europe is also starting to become more active again. Investments should now have bottomed out in Asia (and particularly China). North America is likely to remain at a very strong level”, affirmed Nell.
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Manufacturing facility United Grinding’s Mägerle brand, part of the company’s surface and profile grinding group, offered a tour in the manufacturing facility, where Mägerle builds large custom multiaxis CNC machines in a modular fashion, primarily for export. On the other hand Mägerle AG Maschinenfabrik, established in 1929, builds high-performance grinding systems for simple & complex flat and profile grinding tasks based on standard modular components. The technology-leading company, thus, covers the grinding machine range for super-productive special applications such as the turbine industry, the automotive industry and the pump and hydraulics industry, as well as electronic and medical technology. With its cutting-edge developments, Mägerle AG increasingly acts as a turn-key supplier of complex grinding cells, which include grinding machine, tool changer, washing station and measuring machine, for example. With 150 employees, including professional handscrapers, the facility aligns with the company’s aim of developing the infrastructure so as to ensure that a high availability of new methods in production and supply chain would already be in place for new developments in future.
Technology innovations A wide range of new products were introduced at the event. This included the Studer S131 and S151 cylindrical grinding machines, which are built on the innovative S141 cylindrical grinding platform. The S141 platform is distinguished by ID and OD grinding capability enabled by a grinding spindle turret that accommodates as many as four grinding spindles. Both internal and external grinding operations can be completed in one setup to enhance accuracy and reduce non-cut times. No matter whether its a flange component that is required or
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“We’re expecting a growing grinding market worldwide in 2015, including India. The geographical distribution of the machine orders shows an improvement in the situation in Germany. The Latin countries of Europe are showing signs of recovery”, Stephan Nell, CEO, United Grinding
spindles up to 1300 mm, the S141 CNC universal internal projects concerned with energy efficiency, also in collaboration cylindrical grinding machine can meet any challenge. The with universities. In these projects, improvements to grinding machine’s ergonomic design and user friendliness are evident at machines have been developed, which once implemented will the first glance. Two generously-sized sliding doors provide the lead to a reduction in the energy consumed by machines. best accessibility, not only to the workpiece, but also when changing the grinding wheel. Short changeover times and fast Award for innovative research in machine tool reprogramming of the controls helps to keep downtime to a United Grinding also used this occasion to deliver its minimum. This makes the machine very interesting for the production of single pieces, small and large series. The S141 is prestigious Fritz Studer Award for innovative research in available in a variety of model lengths for workpieces up to machine tool or grinding technology. The 2014 Fritz Studer maximum lengths of 300, 700 and 1300 mm (11.8”, 27.5” and Award was presented to Dr Eduardo Weingärtner, Swiss Federal 51.1”). In all models, the swing diameter over the table is Ø 400 Institute of Technology, , Institute of Machine Tools and mm (15.7”) and the maximum grinding length is 250 mm (9.8”) Manufacturing, Zürich, who pioneered the application of the for internal and 150 mm (5.9”) for external grinding. The S141 wire EDM process for on-machine dressing of metal bonded is the ideal machine for grinding spindle shafts, spindle casings, grinding wheels. This research was instrumental in the introduction of the Studer WireDress system. With the rotor shafts, axes or flange parts. The S131 is much smaller and more compact than the S141, presentation on-machine wire electrical discharge dressing of with a swing diameter over the table of Ø 250 mm (9.8”) and a metal bonded grinding wheels, he also won a sum of CHF maximum grinding length of 175 mm (6.9”) for internal and 10,000 along with the award. The jury comprised of Prof Dr Konrad Wegener, Institute of 125 mm (4.9”) for external grinding. It is available for workpieces with a maximum length of 300 mm (11.8”). The S151 is Machine Tools and Manufacturing, Swiss Federal Institute of somewhat larger than the S141 - it has a swing diameter over Technology Zurich, Dr Heinrich Mushardt, United Grinding the table of Ø 550 (21.6”) mm and a maximum grinding length Group AG and Dr Frank Fiebelkorn, Head of Product of 400 mm (15.7”)for internal and 150 mm (5.9”) for external Development, Research and Technology, Fritz Studer AG. The grinding. It is available for workpieces with a maximum length decision criteria for assessment included, for example, the ease of implementing the findings in the machine industry, novelty of 700 mm (27.5”). Another recent product is the CrankGrind, a crankshaft and idea of the research work, scientific content, form and grinding machine from Schaudt. Cosmetically, this grinder correctness of statements and results. Dr Weingärtner is sports the ‘new look’ that represents the unified corporate involved not only in the development of a wire erosion dressing identity within the Cylindrical Grinding Group as well as the unit and its integration into a grinding machine but also in company-wide emphasis on functionality and ergonomics. modeling, simulation and optimisation of the wire erosion More important is its capability. The CrankGrind is designed to dressing process. In his dissertation, he developed a special do rough- and finish-grinding of both main and pin bearings wire guide, which is key to the feasibility of a reliable dressing on automotive crankshafts, all in one setup on one machine. process, as the precision and efficiency of the process were thus The new crankshaft grinding machine is aimed largely at the able to be increased considerably. With the thermo-electric automotive industry. With this machine, main and pin bearings model developed by Dr Weingärtner, the performance of are both rough- and finish-ground in what the company calls a material removal by erosion can be predicted; the influence of relative speed on the erosion process is more easily ‘superproductive’ machine. Another program presented during the conference in energy comprehended and graphitisation of the diamonds can efficiency was BluePlus label, which indicates that its machine be analysed. ☐ offers rigorous energy efficiency, in its construction as well as > MORE@CLICK EM01584 | www.efficientmanufacturing.in future production. Studer is a major player in state-funded
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Showcasing latest technology standards Enabling the “Make in Indiaâ€? campaign and reflecting a positive vibe among the crowd, this year’s IMTEX showcased a wide range of innovations and technological refinements in the complete product segment of metalcutting machine tools and manufacturing solutions category. A post event report‌ The Indian Machine Tool Manufacturers’ Association (IMTMA) recently organised the 17th edition of South East Asia’s largest industrial show, IMTEX 2015 and the concurrent Tooltech 2015 from January 22 to 28, 2015, at the Bangalore International Exhibition Centre (BIEC) in Bangalore. Sprawling over an area of 50,000 sq mts, the machine tool expo witnessed about 1,000 exhibitors displaying over 1,500 ‘live’ machines from 24 countries at BIEC with a footfall of around 89,000
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Srimoyee Lahiri Sub-editor & Correspondent srimoyee.lahiri@publish-industry.net
industry professionals. The event was inaugurated in the presence of G M Siddeshwara, Hon’ble Minister of State for Heavy Industries & Public Enterprises, Government of India; R V Deshpande, Hon’ble Minister for Higher Education and Tourism, Government of Karnataka; Jamshyd N Godrej, Chairman, Exhibitions, IMTMA; L Krishnan, President, IMTMA and P G Jadeja, Vice President, IMTMA. Highlighting the ‘Make in India’, Krishnan opined that
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Seminars & conferences The exhibition witnessed a milieu of concurrent events which included technical conferences, association level interactions, industrial visits and demonstrations of the IMTMA Technology Centre. One of the events organised by IMTMA was the 6th International Seminar on machining technologies, with the theme “Powering Manufacturing Growth and Competitiveness”. The seminar began with an inaugural & keynote session, wherein Fraunhofer IWU Chemnitz, Germany, gave an overview of the latest developments in machining technologies. International experts from Germany, Israel, Sweden, UK and USA as well as from India facilitated concurrent technical sessions on machine tools & machining; work-holding, tools & tooling and CAD/CAM & automation. The seminar brought together individuals from varied segments of the Indian manufacturing industry such as automotive & auto components, tool-rooms, aerospace, defence & railway establishments, pumps & valves, consumer durables, general engineering, machine tools and other capital goods industries. IMTEX 2015 is a great enabler of ‘Make in India’ project and the exhibition would propel Indian manufacturing towards productivity and quality and help in making Indian manufactured products globally acceptable. “The event has the ability to galvanise and motivate the entire manufacturing industry. Even at the time of recession, IMTEX helped industry leaders to connect with the customers. With current improved sentiments, the exhibition would further be a catalyst to spur investment and modernisation of the manufacturing industry. Speaking on the latest developments, Godrej said, “IMTEX has showcased the latest technologies and solutions from the global manufacturing industry. Visitors have witnessed some of the emerging trends in 5-axis machines, multi-task machines, new gear cutting tools, force controlled robots, etc.” This year, the event witnessed an increase in the number of industry and association delegations participating along with country pavilions. It also involved other important events like an international seminar on machining technologies, academia and industry interface, UDAAN delegation, etc.
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National & international participation Overseas participation: Around 493 exhibitors from all over the globe had set up stalls at IMTEX 2015 and Tooltech 2015 covering a total area of around 12,724 sq mts. The exhibitors participated from Switzerland, Austria, Belgium, China, Czech Republic, France, Germany, Hong Kong, Ireland, Israel, Italy, Japan, Korea, the USA, etc. In total, there were eight country pavilions from China, Czech Republic, Germany, Italy, Japan, Spain, Taiwan and USA, hosting multiple companies and institutions under the same banner. The largest overseas participation was from Germany with over 130 exhibitors. Discussing the show, Junya Tashior, Director General, JETRO, said, “Indians are becoming conscious about durable quality and are ready to spend money for the same. Due to this, Japanese companies are looking at the Indian market with a positive attitude. With FDI being allowed in many key sectors, we can see more and more Japanese companies entering the Indian market.”
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“IMTEX 2015 is a great enabler of ‘Make in India’ project and the exhibition would propel Indian manufacturing towards productivity and quality and help in making Indian manufactured products globally acceptable” L Krishnan, President, IMTMA
The show had witnessed a very positive sentiment amongst the crowd. Speaking on this, Jeffery S Foregard, General Manager—Asia & Europe and Executive Director, ANCA Machine Tool, said, “The first three days witnessed a very good number of footfall of visitors. We have tailored specific packages for specific customers. We specialise in CNC tooling cutting and grinding, so we work with the customers to tailor the supply of the product and we target the specific market”. All these delegations had participated in the exhibition with a clear agenda of attracting investments from Indian companies for their country, and vice versa. National participation: Around 486 exhibitors from India displayed their technology solutions in a total area of around 18,182 sq mts. The machines and accessories on display focused on key industries like aerospace, defence, railways, automotive & auto components, medical engineering, construction equipment, IT and electronics, etc. Addressing the mega event, Rajesh Khanna, Chief Executive, Wendt India, said, “IMTEX 2015 lived up to the expectations in displaying the Indian manufacturing capabilities and technology possibilities in metal cutting industry. It is clear that India’s aspirations of being one of the top 5 players in machine tool manufacturing in the backdrop of ‘Make in India’ initiative, no longer seems to be distant dream. The main highlights of the exhibition is the focus on innovations in technology, design, and product development in order to achieve competitiveness and excellence in machine tool making which are vital for growth of manufacturing sector. It is not just the products displayed by the indigenous machine tool producers, but also the enthusiastic participants from 24 countries, that reinforces that the Indian machine tool industry is fast approaching to realise its Vision 2020. With fast closing of the gap between technology and productivity, the marriage between these two is already in the sight”. The Indian machine tool industry is currently matching the global standards. Emphasising on this, Sameer Kelkar, Executive Director, GrindMaster, said that IMTEX 2015 has shown that the Indian machine tool industry is reaching the edge. “Machine build quality and aesthetics have improved drastically across the industry. Our company has developed
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“IMTEX has showcased latest technologies and solutions from the global manufacturing industry. Visitors have witnessed some of the emerging trends in 5-axis machines, multi task machines, new gear cutting tools, force controlled robots, etc” Jamshyd N Godrej, Chairman, Exhibitions, IMTMA
around five machines over the past one year. This includes product launches of crankshaft dynamic balancing machine and gear deburring and chamfering machine, and new generation microfinishing and superfinishing machines. Indian machine builders are creating products, which were hitherto mostly imported. Crankshaft measurement system from Octagon and crankshaft grinding machine from Bestek are two such technologies that are displayed during the exhibition,” he added.
Tooltech 2015 Tooltech 2015, a concurrent event, was organised alongside the flagship event IMTEX 2015 to showcase the latest trends and technological refinements in metal cutting from within the country and overseas. The exhibiton showcased machine tool accessories, metrology and CAD/CAM cutting tools, tooling systems and current trends in the tooling industry. It unveiled the explicit range of cutting tools from the stable of the world’s leading brands. A total of 261 Indian exhibitors displayed their products in an area of 6,072 sq mts, while a total of 109 foreign exhibitors displayed their products in an area of 2,340 sq mts in the Tooltech 2015 exhibition.
New initiatives A host of new initiatives were introduced at the exhibition, including ‘Job Connect’, Souvenir Kiosks, single window clearance system, safe drive initiative, etc. All were well received
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INDUSTRY SPEAK “Indians are becoming conscious about durable quality and are ready to spend money for the same. Due to this Japanese companies are looking at the Indian market with a positive attitude” Junya Tashior, Director General, JETRO
“IMTEX 2015 has shown that the Indian machine tool industry is reaching the age. Machine build quality and aesthetics have improved drastically across the industry” Sameer Kelkar, Executive Director, GrindMaster
“It is clear that India’s aspirations of being one of the top 5 players in machine tool manufacturing in the back drop of Make in India initiative, no longer seems to be distant dream” Rajesh Khanna, Chief Executive, Wendt India
“IMTMA envisages developing ‘Job Connect’ into an ideal forum to source talent for the machine tool industry” P J Mohanram, Sr Advisor, IMTMA
“IMTEX has always been a good brand and provides a platform for both the solution provider and end user to come under one roof and witness the recent developments in the Indian manufacturing industry. The visitors' inflow this year includes many Asian distributers as well as global end users. The exhibition also makes way for the export of machine tool services in design, part manufacturing, commissioning and application engineering” T K Ramesh, CEO, Micromatic Machine tools
by the exhibitors as well as the visitors. A total of 25 engineering and technical institutions showcased their innovative research projects related to metal working at the Academia Pavilion. Job Connect witnessed experts from leading machine tool industries like ACE Designers, BFW, CADEM, FANUC, Grind Master, Jyoti CNC, Kennametal, LMW, Makino, and Taegutec, organising orientation sessions, engaged with the budding engineers. About 600 students from both mechanical and electrical engineering streams participated in the seminar. It was divided in two oriental sessions — the CEO Connect and the Industry Talk. The CEO Connect session had CEOs talking about the manufacturing industry, how machine tool technology helps in industry growth, and the role of an engineer in manufacturing industry. The Industry Talk had senior personnel from various companies making a presentation of their company, speaking about their recruitment process, the career growth in their companies, available job profiles, etc. Rajashekhara, Director, IMTMA, gave an overview on the training initiatives of IMTMA. To bridge the knowledge gap between the academia and the industry, the organisation has instituted a technology centre in Bangalore and another one in Pune for providing comprehensive training in production technology and machine tool design and making the students attending these programmes industry ready. It has established the Design Institute and the Productivity Institute at these centres for imparting training in all aspects of machine tool design and production technology. The classes are conducted by industry experts. Students attending the training programmes get
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hands-on training and an opportunity to interact with industry experts. Students after undergoing the training programmes at these institutes are ready to serve the industry from day one. Trained engineers are placed in member companies and industries successfully and effectively. According to P J Mohanram, Sr Advisor, IMTMA, there are now about 25 academic institution, and the association is also working on various projects for the machine tool manufacturing industry. “IMTMA envisages developing ‘Job Connect’ into an ideal forum to source talent for the machine tool industry. From now on, this will be a regular feature in subsequent IMTEX”, he said.
Looking forward The phenomenal success of IMTEX 2015 and Tooltech 2015 was made possible by the strong presence of business visitors and decision makers from India and abroad, making it a truly pan-global event. It served as a platform to mirror the positive sentiments of the industry as evident from the number of enquiries generated and the volume of orders received by the participating exhibitors. Being exclaimed as one of the best shows both by visitors and exhibitors alike, IMTEX 2015 has raised the bar on the fronts of service and customer satisfaction. IMTEX (cutting technologies) will return in 2017 after a gap in 2016 when IMTEX Forming will take the centre stage. ☐ > MORE@CLICK EM01585 | www.efficientmanufacturing.in
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CNC grinding machine with turning function
Right-angle precision gearbox
Owing to excessive deformation after heat treatment and too much tolerance left, the workpieces require more time for grinding. With Benign Enterprise’s newly developed BMT-D320GT, a CNC grinding machine with turning function, complicated machining can be accomplished within one setup of work piece, 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. The grinding spindles on the Y and Z-axes can perform coarse and fine BMT-D320GT grinding. With turning and grinding operations accomplished on this machine, work pieces concentricity and accuracy are also assured. Moreover, both spindles can do grinding processes, one for internal grinding and one for external grinding or any combination. As such, many more complex grinding procedures can be completed on this machine, accelerating the process and improving the accuracy.
Bonfiglioli’s new TQK series—a right-angle precision gearbox version is complementary to the TQ series and has maximum power density, allowing top performance and offering space-saving installation solution. Due to its cutting-edge design and stellar performance, it covers a wide area of application where dynamic, high-speed, and TQK series top precision actions are required as well for reverse operations and a high number of starts & stops. It is particularly suitable for dynamic positioning applications for packaging & machine tooling and for flat-bed machinery for wood working. In addition, it can carry out continuous running applications necessary for printing and paper converting. It provides a maximum power density and features a versatile design in 5 sizes (060, 070, 090, 130 and 160), ratios from 6 up to 200, thanks to its design based on one and two reduction sizes, all this with a nominal torque from 30-800 Nm. It is also equipped with a standard and reduced backlash lower than 4 arcmin and a smooth/keyed shaft.
Benign Enterprise | Taiwan Email: bematoco@ms11.hinet.net | Tel: +886-4-2323-3016
Bonfiglioli | Chennai Email: salesindia.mws@bonfiglioli.com | Tel: +91-44-2478-1035
> MORE@CLICK EM01585 | www.efficientmanufacturing.in
> MORE@CLICK EM01586 | www.efficientmanufacturing.in
Hydraulic press machine
Non-clog sewage submersible pump
Dees Hydraulic Industrial’s HD Series has computerised optimism frame design by Finite Element Analysis. It is maintenance-free and has adjustable eight-point oil less guiding plates. It has a smooth operation at high speed, with overload protection valves. Efficiently designed in hydraulic circuit block with less pipes and connection, it has programmable logic controller and European standard electric components. It HD Series has an accessible open side-frame, suitable for automation equipment, front to back or left to right. With a slide and cushion position controlled by limit switch, it has a front side T-stand and front side safety light curtain. It also has pressure switch, T-slotted slide & bolster table, ram lock device, central lubrication system and cushion pin supplied (if cushion system is selected). The optional accessories of the series include colour NC touch screen with linear transducer, hydraulic ejector in slide, quick die change system (Q.D.C), moving bolster, punching damper, auto load and unload system, along with a fully compliance with CE standard.
Kirloskar Brothers has announced the launch of i-NS pump, which has been developed entirely with domestic technology. The pump’s new innovative features make it ideal for dewatering function in the water & wastewater treatment industries, sewage, building & construction and other allied segments. It is an innovative non-clog sewage submersible pump designed for customers by taking into consideration the end-user’s views. The compact size of the pump helps in minimising submergence, and it comes with an aesthetically-improved design for maintenance-free work. The pump’s stationary installation arrangement is simplified with single guide pipe system. It introduces the i-NS pump innovative modular concept for interchangeability of components. Its cable bracket design for wrapping the cable around the body helps in avoiding cable damage, and its potting cup design helps in restricting the entry of water inside the pump. Its integrated design also eliminates most of the potential leakage and short circuit issues, typically faced by the end-users in all the industries.
Dees Hydraulic Industrial | Taiwan Email: sales@spc.com.tw | Tel: +886-2-2601-8936
Kirloskar Brothers Limited | Pune Email: | Tel: +91-20-2721-4444
> MORE@CLICK EM01587 | www.efficientmanufacturing.in
> MORE@CLICK EM01588 | www.efficientmanufacturing.in
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Digital process planning application Kennametal’s NOVO™ digital process planning application has continued growing by supplying complete tool data and process knowledge electronically, saving process planners, cost estimators and manufacturing engineers countless hours of catalogue lookups and process guesswork since its launch in 2013. The same intelligence for driving new efficiencies is now available on PC and tablet devices in the new Version 1.6. By entering basic information for the shop’s machine tools, such as hourly cost, maximum spindle speed, NOVO™ digital process and maximum torque, for example, a new “My planning application Machines” button will take NOVO tooling recommendations and optimise them for specific machine conditions. Such virtual machine libraries can also be shared across multiple users. Also, new to V1.6 is a turning cut-off advisor. When the tool advisor searches for cut-off applications, NOVO’s powerful rules-based engine will return and rank the most appropriate cut-off tool based on the job conditions. For an extra level of efficiency, the application for PCs and tablets now has a customer part-number capability.
Visualisation solution Open Mind Technologies AG has released hyperMILL® ShopViewer, a proprietary visualisation solution for the workshop. It provides machine operators with a complete overview of the upcoming NC program right through to simulation and ensures that only safe, checked NC programs run on the machine. Generally, the actual programs are forwarded to the hyperMILL® ShopViewer controller via the network, but the associated information is not normally transferred. The machine operator can usually only take advantage of static aids like drawings, tool reports, screenshots, PDFs, etc. It is a different picture with a viewing system. Here, the system provides the specialist operating the machine with all information related to manufacturing data, as well as geometry and component structure. The ShopViewer makes it possible to view and examine data from hyperMILL® and hyperCAD®-S in more detail, directly next to the machine. The information visible on the hyperMILL® ShopViewer workspace includes a 3D model with the ability to measure features, CAM program, 3D clamping plans and tool data.
Kennametal India | Bangalore Email: sathyamunish.venkitakrishnan@kennametal.com | Tel: +91-080-2839-4708
Open Mind Technologies | Bangalore Email: Info.India@openmind-tech.com | Tel: +91- 80-3232-4647
> MORE@CLICK EM01589 | www.efficientmanufacturing.in
> MORE@CLICK EM01590 | www.efficientmanufacturing.in
Automatic 3D design tool
Highfeed milling cutter
SCHUNK eGrip is the world’s first fully automatic 3D design tool for additively manufactured gripper fingers, and is now available for free on the company website. Minimal data is required for the fully automatic calculation of the optimal 3D contour, pricing, and delivery time. The license-free, browser-based web tool from the competence leader for clamping technology and gripping systems, the company reduces the design and ordering time for customised gripper fingers to 15 minutes. With the intelligent software, which is available around the clock and doesn’t require a separate CAD program, the user has to upload the workpiece or component as a STEP or STL file and enter eGrip additional specific information, such as the weight, installation position of the gripper and finger length. In a few seconds, the user receives a detailed offer containing the 3D contour, delivery time and price. It can quickly calculate complex geometries. Users can either order the top jaws right away or save the offer or retrieve it later.
Seco Tools has expanded its highfeed milling cutter lineup with the introduction of the new Highfeed 2 small-diameter and Highfeed 4 with double-sided inserts. Both families incorporate new insert designs, combined with more teeth per diameter for higher productivity. Both Highfeed 2 and Highfeed 4 cutters excel in high-velocity, high-speed cutting of hard and tough materials, especially when performed on smaller machines equipped with high-speed/low-torque spindles. Highfeed 2 LP05 inserts feature two cutting edges in cutter diameters down to 12 mm. The inserts effectively machine sticky Highfeed 2 materials, such as stainless steels, titanium and superalloys. Designed with four cutting edge, the Highfeed 4 LO06 insert provides up to four cutting edges for cost-effective, efficient and high-performance machining of common workpiece materials when using cutter body diameters from 20 mm to 63 mm. Both the Highfeed 2 and Highfeed 4 cutters significantly reduce vibration for smooth, stable cutting and increased productivity. Their innovative designs also efficiently evacuate chips for worry-free operation.
SCHUNK Intec India | Bangalore Email: info@in.schunk.com | Tel: +91-80-40538999
Seco Tools India | Pune Email: seco.india@secotools.com | Tel: +91-2137-667300
> MORE@CLICK EM01591 | www.efficientmanufacturing.in
> MORE@CLICK EM01592 | www.efficientmanufacturing.in
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CNC solution with software version 4.7
Digital control of spindle speed & power-stroke speed
Siemens has extended the scope of functions of SINUMERIK 828D with new hardware and software. The compact CNC is now equipped with the new software version 4.7 and the powerful PPU 2xx.3, and can control up to ten axes/spindles. It offers a second machining channel for simultaneous machining with two tools. The update also widens the range of use of the solution, which, for the first time, can control turning, milling machines and grinding machines. The standardised SINUMERIK Integrate RunMyRobot / EasyConnect interface also allows SINUMERIK 828D robots to be connected to machine tools quickly and easily via the CNC. It provides the option of running two machining channels in turning and circular grinding machines. Users can execute two NC programs simultaneously in independent channels, or synchronise them in the simplest way with Program Sync. In this way, two workpieces can be machined at the same time in one machine, e.g, for the simultaneous machining of their rear sides in the counter spindles.
Sunnen Products Company has recently introduced digital control of spindle speed, power-stroke speed and extra strokes on its new SH-2000 job-shop honing machine, designed as an affordable and flexible tool for bore sizing/finishing on a wide variety of parts. It is ideal for medium to high production of parts with bore diameters from 1.5 to 102 mm (0.060” - 4”) in power-stroke mode. It is capable of processing a variety of part sizes, configurations and weights with its standard universal honing fixture or optional applicationspecific fixtures. The 2.25-kW (3 hp) spindle drive SH-2000 job-shop delivers 200 to 3,000 rpm, adjustable in fine honing machine increments. The 0.75-kW (1 hp) stroker drive produces stroke rates of 60 to 350 SPM, with stroke lengths of 6.8 to 170 mm (0.236” to 6.7”). Power stroking ensures constant stroke length and stroke rate, and the machine’s standard zero-shutoff and optional automatic size control (ASC) allow high production rates with precise control of bore size, finish and geometry.
Siemens | Mumbai Email: motioncontrol.india@siemens.com | Tel: +91-92230-11000
Sunnen Poducts Company | Mumbai Email: sales@sunnen.com |Tel: +91-223-913-6055
> MORE@CLICK EM01593 | www.efficientmanufacturing.in
> MORE@CLICK EM01594 | www.efficientmanufacturing.in
Compact four corners double-sided insert TaeguTec has launched a compact four corners double-sided insert for multiple applications – the 4NKT 6 millimetre insert for end mills, face mills and modular cutters. The 90 degree entering angle insert, despite the double sided design, is suitable for high ramp down angle applications. Its high positive geometry generates low cutting force, while the cross edge insert geometry prevents unexpected insert failure. The increased insert thickness and high strength, combined with the cutter’s wide bottom for 4NKT 6 millimetre insert improved clamping, enables excellent high stability and productive machining. Its smaller 6 mm size compared to the 11 mm and 16 mm sizes increases the number of teeth on the cutter, which is not only good for machining small components, but also makes it a finer pitch tool that increases productivity. The new line of cutters is offered as end mills (D16-40 mm), modular types (D16-40 mm) and face mill types (D32- 63 mm). All cutters include an internal coolant delivery system for efficient chip evacuation that prevents built-up-edges. TaeguTec India| Bangalore Email: sales@taegutec-india.com| Tel: +91-80-2783911
Statement about ownership & other particulars about EM, as required to be published in the first issue every year after the last day of February 1. Place of Publication: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 2. Periodicity of Publication: Monthly 3. Printer’s Name: Kala Jyothi Process Pvt Ltd Address: S.No. 185, Kondapur, R R District, AP 500 133 4. Publisher’s Name: Shekhar Jitkar Nationality: Indian Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 5. Editor’s Name: Shekhar Jitkar Nationality: Indian Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 6. Names & addresses of individuals who own EM and partners or shareholders holding more than 1% of total capital of publish-industry India Pvt Ltd, 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 Details of the shareholders of publish-industry India Pvt Ltd who are holding more than 1% of the paid up equity share capital of the company as on 10-03-2015: a) publish-industry Verlag GmbH, NymphenburgerStrasse 86, 80636 Munich, Germany b) Kilian Mueller, NymphenburgerStrasse 86, 80636 Munich, Germany I, Shekhar Jitkar, hereby declare that all the particulars given above are true to the best of my knowledge and belief.
Dated: 10th March 2015 Sd/SHEKHAR JITKAR Signature of the Publisher
> MORE@CLICK EM01595 | 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 | I M P R I N T
Highlights - April 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
» Casting & Forging Basic technologies in casting & forging have not undergone much change, but the emphasis has changed. The world has become more environmentally conscious and technologies have to conform to more and more stringent environment norms. A The next issue will highlight some of the trends in the casting & forging sector.
» Industrial Robotics There are new factory robotic trends emerging every day, like the addition of vision and sensors to make robots easier and safer to work with in a human-populated environment. The next issue of EM will discuss these advanced technologies incorporated in robotics. » Geometric Dimensioning and Tolerancing The proper use of Geometric Dimensioning and Tolerancing within a well-defined product development effort can identify a bad design before it results in a lot of needlessly expensive parts. EM will feature the articles on importance of GD&T in manufacturing.
» Green Machining Practices The demand for sustainability is growing stronger every day, and manufacturers are looking for ways to comply to reduce their impact on the environment and increase profitability. The concept of Green Manufacturing aims at design and implementation of processes that will eliminate waste and reduce environmental impacts in work practices and plant operations. The Special Feature in the next issue will talk on this concept in detail.
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Name . . . . . . . . . . . . . . . . . . . . . . . . . Page GE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 GF MachiningSolutions . . . . . . . . . . . . . . . . 15 Gifu Enterprises . . . . . . . . . . . . . . . . . . . . . . 4 Grindmaster Machines . . . . . . . . . . . . . 21, 28 Guangzhou Min Jia Manufacturing Technology . . 82 Haas Automation . . . . . . . . . . . . . . . . . . 1, 50 Hannover Milano Fairs India . . . . . . . . . . . . . 17 Henfux . . . . . . . . . . . . . . . . . . . . . . . . 80, 82 Herg (Foshan) Automotive Lubrication System Manufacture. . . . . . . . . . . . . . . . . . . . . . . . 83 Hyundai WIA India. . . . . . . . . . . . . . . . . . . . 49 igus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 IIT-Delhi. . . . . . . . . . . . . . . . . . . . . . . . . . . 24 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . 53, 88 Jainnher Machine Co . . . . . . . . . . . . . . . . . 30 Jyoti CNC Automation . . . . . . . . . . . . . . 5, 21 Kaifeng Machinery Co . . . . . . . . . . . . . . . . 51 KamiKaze B2B Media . . . . . . . . . . . . . . . . . 12 Kanefusa India . . . . . . . . . . . . . . . . . . . . . . 57 Kennametal . . . . . . . . . . . . . . . . . . . . . . . . 93 Kirloskar Brothers . . . . . . . . . . . . . . . . . 14, 92 Lakshmi Machine Works . . . . . . . . . . . . . . . 63 LK Machinery Corp ( Taiwan ) . . . . . . . . . . . 39 Marox Tools Industrial . . . . . . . . . . . . . . . . . 71 Micromatic Grinding Technologies . . . . . . . . 24 Micromatic Machine Tools . . . . . . . . . . . . . . 28
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
COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . . . . Page ABB Robotics . . . . . . . . . . . . . . . . . . . . . . 70 Ace Manufacturing Systems . . . . . . . . . . . . . 26 Ace Micromatic Group. . . . . . . . . . . . . . . . . 69 Ador Welding Limited . . . . . . . . . . . . . . . . . 73 Altair Engineering India . . . . . . . . . . . . . . . . . 3 ANCA Machine Tool . . . . . . . . . . . . . . . . . . 16 Ann Way Machine Tools. . . . . . . . . . . . . . . . 67 Benign Enterprises . . . . . . . . . . . . . 40, 41, 92 Bharat Forge . . . . . . . . . . . . . . . . . . . . . . . 10 Bharat Fritz Werner . . . . . . . . . . . . . . . . 22, 28 Blaser Swisslube . . . . . . . . . . . . . . . . . . . . 35 CII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 CMTBA. . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Dees Hydraulic Industrial . . . . . . . . . . . . . . . 92 DMG MORI . . . . . . . . . . . . . . . . . . . . . . . . 24 Dongguan Nice Machine Building . . . . . . . . . 82 ElectroMech . . . . . . . . . . . . . . . . . . . . . . . 59 EMAG India . . . . . . . . . . . . . .Back Inside Cover Epicor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Ervin Junker Maschinenfabrik . . . . . Back Cover Everising Machine Co . . . . . . . . . . . . . . . . . 56 ExxonMobil . . . . . . . . . . . . . . . . . . . . . . . . 12 Femco . . . . . . . . . . . . . . . . . . . . . . . . 55, 46 Festo Controls . . . . . . . . . . . . . . . . . . . . . .31, Flir Systems. . . . . . . . . . . . . . . . . . . . . 13, 60 Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . 87
Features Writer Maria Jerin maria.jerin@publish-industry.net
Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Mitsubishi Electric . . . . . . . . . . . . . . . . . . . . 65 Mitsubishi Heavy Industries. . . . . . . . . . . . . . . 2 MMC Hardmetal . . . . . . . . . . . . . . . . . . . . 23 Motul Tech India . . . . . . . . . . . . . . . . . . . . 25 Omron Automation . . . . . . . . . . . . . . . . . . . 11 Open Mind Technologies . . . . . . . . . . . . . . . 93 Renishaw 24, 66 Ricoh India . . . . . . . . . . . . . . . . . . . . . . . . 45 Rollomatic India . . . . . . . . . . . . . . . . . . . . . 37 Saint Gobain . . . . . . . . . . . . . . . . . . . . . . . 10 Schunk Intec India . . . . . . . . Front Inside Cover Seco Tools . . . . . . . . . . . . . . . 24, 33, 42, 93 Shenzhen Joint Industry . . . . . . . . . . . . . . . 83 Shuter Enterprise . . . . . . . . . . . . . . . . . . . . 81 Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Stratasys India . . . . . . . . . . . . . . . . . . . . . . . 6 Suhner India . . . . . . . . . . . . . . . . . . . . . . . 47 Sunnen Products . . . . . . . . . . . . . . . . . . . . 94 TaeguTec . . . . . . . . . . . . . . . . . . . 24, 28, 94 UCAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 United Grinding. . . . . . . . . . . . . . . . . . . . . . 84 Worldwide Industry Machinery . . . . . . . . . . . 83 Yamazaki Mazak . . . . . . . . . . . . . . . . . . . . 24 YG Cutting Tools Corporation . . . . . . . . . 18,19 ZF Friedrichshafen . . . . . . . . . . . . . . . . . . . 16
Design & Layout Sovan Lal Tudu (Senior Designer) sovan.tudu@publish-industry.net Editorial & Business Office publish-industry India Pvt Ltd 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Tel: + 91 - 20 - 6451 5752 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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