Machine Tools World - September 2016

Volume 02 No. 04 | September 2016 | ` 150

Pages 106 | RNI No. MAHENG/2015/64267

www.mtwmag.com

Global leadership through

COGNIZANCE & EXCELLENCE An interface with: Mr. Andreas Zieger Director EMAG India Pvt. Ltd. Pg. 42-44

Watch out for AUTODESK UNIVERSITY INDIA & SAARC 2016 coverage on Page : 40-41

www.mtwmag.com

Executive Publisher

Contents

Vol 2 Issue 04 | SEPTEMBER 2016

Shirish D.

BUSINESS NEWS

CEO Shekhar D.

12

Editor Shilpa Dongre

Mastercam 2017 mill brings speed & automation

Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, A.Purohit, Vinod Surve, Kavita Chaudhari

18

Designer & Layout

Renishaw launches FixtureBuilder 3D-modelling software

Arun P. Shinde, Nandan S. Moghe, Dinesh S. Gawade

Online Division Ganesh M., Pradeep M. Pillalamarri

Circulation Executive

18

Satish Kadam, Amol Ranshur Branch Offices (Zonal)

ExxonMobil launches Mobil Serv lubricant analysis in India

NORTH (Delhi & NCR regions) Sandesh Jain : 09810837877 / 09871602777

20

SOUTH (Chennai & Coimbatore) Y. V. Raghu : 09566141224 Bangalore Vaman : 09686721340 Kochi Sanjeev Nair : 09846249568

EAST (Kolkata & Other regions) S. Roy - 09433097806

WEST (Maharashtra & Gujarat) Pune Sandeep - 09822751645 Gujarat Dinesh Shah - 09327344559 Rajkot (Saurashtra) Swapnil Bhatia: 09227909005

COVER STORY

EMAG’s success story continues at AMB

42

EMAG : Global leadership through cognizance & excellence Mr. Andreas Zieger, Director EMAG India Pvt. Ltd.

INTERFACE

22

Castrol reinvents cutting fluids

24

DesignTech organizes one day tech seminar

REFLECTIONS

26

India Automotive Forum emphasises on innovation and design Head Office : Divya Media Publications Pvt. Ltd., 3rd Floor, Harmony Tower, N.S. Road, Thane-400 602. Maharashtra Tel: +91 22-25380574/75, Telefax: +91-22-25418254 E-mail: shekhar@divyamediaonline.com, Website: www.mtwmag.com.

Printed & Published by Shirish Dongre on behalf of DIVYA MEDIA PUBLICATIONS PVT LTD., Printed at Anitha Art Printers 29/30, Oasis, Next to Vakola Market, Santacruz(E), Mumbai-400055, published from 303/304, Harmony Tower, N.S.Road, Court Naka, Thane West, Thane-400601.

Editor : Shilpa Dongre

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MACHINE TOOLS WORLD SEPTEMBER 2016

28

Zimmermann offers FZ33 compact portal milling machine

46

48

“We are for those, who are in Metal Cutting”!

Preparing towards DIGITALIZATION STORY

30

Zeller+Gmelin to showcase range of lubricants at EuroBLECH 2016

ANCA Machine Tools Private Ltd 8/1 , Dr. M H Marigowda Road, Arekempanahalli , (Wilson Garden ), Bangalore - 560027, Karnataka, India T: +91 (80) 6759 2100, M: +91 96637 69911, E: indiainfo@anca.com, W: www.anca.com

Contents TECH PROFILE

Vol 2 Issue 04 | SEPTEMBER 2016

TECH TRENDS

70

Sparkonix’s customised EDMs to serve your specialized.......

10 Modern Drives Demand Innovative Tools

66

56

COMPANY PROFILE

52 32

74

Heavy duty machining But safe

CASE STUDY

Synetics in the forefront of Automation

The story of Europe’s largest 3D printed part...

36

80

82

Effects of multiple re-use of Ti6Al4V powder in AM

Gala’s Surface Engineering Solutions

90

PROJECTS

98

PRODUCTS 8

MACHINE TOOLS WORLD SEPTEMBER 2016

84

The special relationship between Formula 1 & Haas

86

Editorial Board

Editorial Index A

Haimer India

74

46

Hangsterfer

102

56, 100

Heidenhain

66

40

Hypertherm

12

Accusharp Cutting Tools Ador Welding Autodesk B

M

Birla Precision

101

C Mr. A.P. Jayanthram Managing Director Heidenhain Optics & Electronics India Pvt. Ltd

Mr. GK Pillai Managing Director & CEO

Walchandnagar Industries Ltd.

Mrs. Mohini Kelkar Managing Director Grind Master Machines Pvt. Ltd

Castrol

22

Concept Laser

80

D DesignTech Systems

24

DMG MORI

86

Dormer Pramet

49

E EMAG INDIA

20, 42

ExxonMobil Lubricants

18

F Mr. Arjun Prakash Managing Director Effica Automation Ltd.

Ms.Samina Khalid Marketing Manager

Renishaw Metrology Systems Ltd.

Mr. MIHIR Baxi President – Global Sales Jyoti CNC Automation LTD

MAPAL India

10

Mastercam

12

Mate Precision Tooling

102

R Renishaw

18, 82

S Siemens Ltd

48

Sparkonix

70

Synetics Automation

32

T TaeguTec

20

Thielenhaus Microfinish

76

F. Zimmermann

28

FARO Technologies

24

U

Firbimatic

52

Unity Controls

101

V

G Gala Precision

36

VoluMill

72

Z

H Haas Automation

84

Zeller+Gmelin

30

For editorial contribution contact editor@divyamediaonline.com

MTW Overseas Associates Mr. Dinesh Khambhayta President MTMA-RAJKOT

Mr. Ayaz Qazi Director

Precihole Machine Tools Pvt. Ltd.

Mr. Suhas Belapurkar Director - Sales & Marketing ( Industrial Products) Sanjay Tools & Adhesives

Mr. P.K. Balasubbramaniian President VBS Corporate Support

Mr. B.P. Poddar Vice President - Sales & Marketing FEMCO Fatty Tuna India Pvt. Ltd.

Mr. Jayant Vaidyanathan VP - Sales & Application Tsugami Precision Engineering India Pvt. Ltd.

USA Nancy TARTAGLIONE, Mepax USA n.tartaglione@mepax.com / usa@mepax.com

GERMANY Sebastian OLLIER Mepax Deutschland, Tel: +49 711 222 54 456, deutschland@mepax.com

FRANCE MEPAX SA, Romain CLASS Tel.: +33 1 39 02 77 78, FRANCE

SPAIN Sofiane JEDIDI Mepax España Tel : +34 963 255 886, spain@mepax.com

ITALY Valeria VILLANI Tel.: +39 339 8610117, Via Firenze, Milano, Italia

UK Liz Jones Tel: +44 (0)1227 276016 , l.jones@mepax.com

RUSSIA Garri ZALTS Mepax Russia Tel: +7 495 576-7666 / gizalec@yandex.ru

CHINA/South Korea/Taiwan Mepax - Konaxis Shanghai Julien PENARD Tel : (+86) 21 6252 2731/ china@mepax.com

SEPTEMBER 2016

MACHINE TOOLS WORLD

9

TECH PROFILE

As a single-pass solution, the PCD tool is suitable for the cost-effective machining of the main bore of a stator housing.

Modern Drives

Demand Innovative Tools The motor vehicle engine is changing. Electro mobility is on the advance, because vehicles with electric motor are a way of meeting the stricter emissions limits and slowing the depletion of fossil fuels. The percentage of electric cars will rise significantly from 2020, predicts the Center of Automotive Management in a study. In Germany, one million electric cars are expected to be on the roads by 2020. From 2025, only cars with electric motors will be allowed to be sold in Norway.

F

or MAPAL as a tool manufacturer, this development represents a challenge. Why? Many of the MAPAL tools are used for the machining of components for the powertrain of motor vehicles with internal combustion engine. But in electric motors, too, there are parts that have to be machined with high precision. One example of this is the stator housing of

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MACHINE TOOLS WORLD SEPTEMBAR 2016

the electric motor where in the main bore for the rotor has to be machined to within a few Âľm. MAPAL has developed a tool solution to allow this fine machining to be performed cost-effectively while meeting the demands on accuracy and cycle time.

Complex PCD tool for machining of the stator housing A complex PCD boring tool is used

to machine the main bore of a stator housing made from an aluminium alloy (AlSi9Cu3Fe) – and that in just one pass.

The tool with 2x6 fixed brazed PCD blades performs pre-machining and fine machining of the main bore of the housing at the same time. This single-pass solution is used particularly when the component tolerances are slightly larger and the housing is stable. Thanks to the

TECH PROFILE www.mtwmag.com

The innovative tool of lightweight construction with 2x6 PCD blades ensures optimum values with respect to machining time and quality.

short machining time, a single-pass solution is particularly suitable for industrial-scale production.

With less stable stator housings or with uncertain housing clamping, the machining operation is performed conventionally with a pre-machining and fine machining pass.

The lightweight tool is just as innovative as electric motors are modern.

An innovative welded design with a large inside diameter makes the tool particularly light – with a diameter of 220 mm it weighs only 24 kg. The moment of tilt is only 33.9 Nm. The tool thus satisfies all the demands for reliable use on the machining centre. It also has an internal coolant supply that ensures the optimum supply of cooling lubricant to the blades.

Thanks to the closed tool system, the noise is also very low despite the size.

High precision for optimum results The tool impresses with optimum values for diameter design, balancing quality and radial run-out accuracy as well as with the

short cycle times that are achieved due to the multi-cutting edge capability. As with all PCD tools from MAPAL, the ultimate quality statement is the quality of the PCD blades ground with µm precision.

Manufacturing tolerances of ≤ 3 µm for the tool diameter, multi-cutting edge capability and back taper are just a few of the high demands made on the blade.

The greatest care during production guarantees the full performance for both new tools and after reconditioning that allows the full potential of the tools to be utilised. Lasered chip breakers guarantee the optimum material removal from the cutting point. Interference with the running production caused by chip congestion is thus avoided.

Specifications fulfilled in practice With these properties, the tool satisfies all the customer’s demands for the production of the stator housing, both on the machining time and on the quality of the surface finish. The PCD tool reliably achieves Rz values of < 3 µm in series production – and that with a cutting depth of up to 3 mm that due to the taper of the casting increases conically from the bore entrance to the bottom of the bore. Even after reaching the end of the cutting edges’ tool life, the tool is still particularly cost-effective – it can continue to be reconditioned until mechanical wear occurs at the tool body.

For more information, you are requested to contact National Sales Manager – Mr Rajesh Kumar.K.G Phone: +91 9741499824 Email:rajeshkumar@in.mapal.com Website.: www.mapal.com

SEPTEMBER 2016

MACHINE TOOLS WORLD

11

BUSINESS NEWS

Mastercam 2017 mill brings speed & automation Mastercam 2017 Mill offers expanded machining flexibility and an increased emphasis on speed and automation. 2D High Speed Toolpaths, 3D enhancements, and Multiaxis features combine with dozens of additional new enhancements in a package intended to improve shop floor productivity.

In an effort to streamline and simplify workflow, Mastercam 2017 supports Region Chaining Preview which allows you to see your machining, air, and containment regions. Mastercam 2017 also builds on its already efficient and powerful Dynamic Motion engine, and introduces micro lifts which use a line-of-sight approach to move the tool where it needs to go through unobstructed areas.

Reposition moves are now more efficient, less complex, and travel a shorter distance which creates smaller file sizes and improves cycle times at the machine.

Maximum Stock Engagement allows you to select a previously made stock model and set the maximum depth so that you can limit how deeply the cutter engages uncut materials, especially useful when semi-finishing a part.

Perpendicular fill for the Raster toolpath allows you to limit raster passes and then fills in the limited area with perpendicular raster motion to create a more consistent finish. And, for quicker toolpath regeneration, the processing time for High Speed Scallop has been decreased.

To reduce confusion, the

Multiaxis toolpaths have been consolidated. They are now grouped by either a Pattern or Application toolpath to make them easier to find.

The new 4-axis toolpath, Rotary Axis, allows more control over the tool motion through the selection of walls, hubs, and shroud surfaces.

And, Multiaxis Drill has many new features including using a line length for the drill depth and recognition of the stock model for

depth and top of stock purposes.

Hypertherm introduces new technology for plasma cutting Hypertherm, a U.S. based manufacturer of plasma, laser, and waterjet cutting systems, is introducing SilverPlus electrodes for its HyPerformance HPR400XD plasma cutting systems.

Thorough laboratory testing shows SilverPlus electrodes last 50 percent longer than standard copper electrodes in most cutting applications.

Instead of replacing the electrode at a pit depth of 0.040 of an inch as recommended with standard copper electrodes, SilverPlus electrodes are designed to last to a pit depth of at least 0.080 of an inch. In addition, the electrode delivers a very consistent range 4 and 5 cut quality throughout its life. This allows owners to lower their operating cost with no impact on cut quality or speed.

Hypertherm’s SilverPlus electrodes are differentiated from other silver electrodes on the

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MACHINE TOOLS WORLD SEPTEMBER 2016

market in the way they are manufactured. By fusing the silver tip to a copper blank, using a patented process prior to electrode machining, Hypertherm electrodes have the best life and consistent performance. When used with an oxygen plasma gas on mild (carbon) steel,

SilverPlus electrodes can burn deeper than copper electrodes extending the life of the electrode.

Additionally, silver electrodes help to preserve the size and shape of the nozzle orifice increasing nozzle life as well.

“Our SilverPlus electrodes are proven to deliver performance benefits to owners and operators of our HyPerformance systems,” says Martin Geheran, a consumables product manager at Hypertherm. “At the same time, the increased electrode life also translates into double the nozzle life, helping owners lower their consumable costs.”

In addition to the new 400 amp electrode introduced today, Hypertherm also offers 130, 200 and 260 amp versions with similar performance. Please contact Hypertherm or an authorized partner to request samples of SilverPlus electrodes.

BE DYNAMIC!

THE FUTURE OF EFFICIENCY & SPEED IS HERE – MASTERCAM’S DYNAMIC MOTION TECHNOLOGY Since 2008, Mastercam has been building Dynamic Motion into our software. That means it has been shop-tested and proven in real-world environments. Dynamic Motion toolpaths carve out massive amounts of material quickly, reducing cycle times by up to 75% – while doubling and even tripling the tool life – immediately putting more money in your pocket. Sounds unbelievable, right? But as the market leader, we’ve had our Dynamic Motion toolpaths tested in most every conceivable work environment around the world. It works.

For more information, visit www.Mastercam.com 800-228-2877

BUSINESS NEWS

Renishaw launches FixtureBuilder 3D-modelling software FixtureBuilder is a 3D-modelling software package designed to allow the off-line creation and documentation of fixturing set-ups.

The software can be used with a CAD model of the part to be inspected, which is imported into FixtureBuilder, so that the fixture can be built around it. The entire set-up, along with the part, can then be exported into inspection programming software, using

universal file formats such as: IGES, SAT, STEP, etc.

FixtureBuilder offers a wide range of customer benefits, derived from Renishaw’s outstanding understanding of metrology best practice and part inspection.

FixtureBuilder offers unparalleled ease of use thanks to clear and well-organised component libraries; Intelligent ‘Drag and drop’

functionality; Quick manipulation of parts; and easy-to-use constraint mechanism.

User experience is further enhanced by the software’s full CAD compatibility and the availability of custom libraries.

The ‘Build it’ function is one of the key benefits available to all FixtureBuilder users. It automates the production of work instructions and Bill of Materials for every

fixture set-up, to help ensure compliance with quality standards and assist with product ordering.

The software is available to all existing and future Renishaw customers to complement and further improve the productivity of their Renishaw fixtures and other inspection equipment. It is available for purchase through the Renishaw distribution network as well as the Renishaw Web shop.

ExxonMobil launches Mobil Serv lubricant analysis in India ExxonMobil Lubricants Private Limited announces the launch of Mobil Serv Lubricant Analysis, its new mobile-enabled used oil analysis service, in India. The new service helps enhance efficiency and simplify the user experience by replacing a paperwork-heavy approach with a simple, intuitive mobileenabled service platform that reduces the number of steps in the used oil analysis process.

Specifically, the new service streamlines the entire process, from initial sample gathering to final reporting, with QR coded scan-andgo bottles that help customers easily deliver used oil samples to ExxonMobil’s oil analysis laboratory. Once samples are analyzed, customers can access results and customized equipment recommendations on their mobile or tablet device.

“Our discerning customers are looking for

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MACHINE TOOLS WORLD SEPTEMBER 2016

easy-to-use tools that can help them reduce costs, boost productivity and prioritize safety,” said Imtiaz Ahmed, Asia Pacific Mobil SHC Brand Manager, ExxonMobil Lubricants Pvt. Ltd. “Mobil Serv is an initiative in that direction and demonstrates ExxonMobil’s continuing commitment to providing best-in-class lubrication solutions, leveraging a combination of advanced lubricant technologies, expert technical services, and extensive industry expertise to help customers achieve their safety, sustainability and productivity goals,” he added.

The new service also offers applicationspecific analysis options – including hydraulic, gearbox, engine, compressor, powertrain and circulating analysis, among others – for a wide

range of industries, enabling companies to choose the option that best fits their specific needs.

Used oil analysis is essential for assessing equipment performance, as it can help provide crucial information to help you increase productivity, reduce unscheduled downtime, improve equipment durability and lessen lubricant consumption.

And, the launch of this new service builds on ExxonMobil’s long tradition of providing leading used oil analysis services to companies around the world. Mobil Serv Lubricant Analysis is the latest addition to the Mobil Serv family, ExxonMobil’s new lubricants services brand formalized in late 2015.

Mobil Serv Lubricant Analysis, which replaces ExxonMobil’s Signum Oil Analysis, will be rolled out globally in other markets later this year.

BUSINESS NEWS

EMAG’s success story continues at AMB Starting with a focus on the development of vertical turning machines, in recent years, we have witnessed the integration of the EMAG Group’s full technology portfolio into this new machine model. Now, in addition to vertical pick-up turning centers for chucked and shaft parts, there are also machines for gear cutting, induction hardening, and hard machining.

Combined with the TrackMotion automation solution, EMAG now offers these modular machines as building-blocks for entire production lines. EMAG will be introducing two new modular standard machines to the EMAG product line this year at AMB in hall 3, booth D32.

The modular machines are already optimized for maximum productivity due to its fully automatic manufacturing system which includes EMAG’s “pick-up” technology, self-loading working spindle and integrated parts

storage unit. In addition, there is a work turret with 12 tool positions, fully designed and manufactured

by EMAG, and considered one of the best on the market. When combined with the machine base made out of Mineralit® polymer concrete, the result is an extremely compact machine tool that ensures top quality results and maximum productivity. If these impressive features aren’t enough for you, EMAG is now introducing the new

The two work areas of the VL 3 DUO are each equipped with a 12-position tool turret.

The VL 3 DUO is the most compact high-performance manufacturing system for chucked components . Shown above in combination with the parts storage unit and the TrackMotion automation system.

VL 3 DUO, a dual-spindle machine that is redefining productivity.

When you see the VL 3 DUO for the first time, you’ll be immediately impressed by how compact the machine is. “Only 19 m2 (204.5 ft2) is required for the full setup of the VL 3 DUO,” explained Andreas Frank, Product Manager for Modular Machines at EMAG. “For a dual-spindle vertical pick-up turning center that’s an outstanding figure especially considering that the machine features a storage unit for up to 400 workpieces and is completely automatic.

These features make the VL 3 DUO one of the most compact and high-performance systems for chucked components in production,” Andreas Frank said.

With its range of parts up to 150 mm (5.9 in) in diameter, the VL 3 DUO is ideal for functions in transmission component manufacturing, for instance in the machining of blanks for gear production.

TaeguTec introduces new T-Burst holder TaeguTec has introduced a new addition, the T-Burst high pressure coolant holder for Swiss turning applications.

The T-Burst holder for Swiss turning applications, as with the current T-Burst holder, applies high pressure coolant from dual holes directly between the metal chip and the insert’s rake face; a feature that optimizes control, extends tool life as well as increases productivity through higher cutting speeds and feed rates.

It is capable of handling coolant pressure up to 140 bar maximum and is designed to machine miniature products generally found in the automotive, medical and aerospace sectors. The new T-Burst holder is ideally suited for machining difficult-to-cut materials such as stainless steel, titanium, Inconel and other heat

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MACHINE TOOLS WORLD SEPTEMBER 2016

resistant alloys.

For added convenience, a simple coupling (one-touch exchange) system has been

introduced. The hose connecting the machine to the holder can be easily and quickly attached or detached for replacement. The coupling system’s hoses are available in two lengths: 200 millimeter and 300 mm depending on the machine’s specifications.

During product testing, be it on medical parts or parts for the automotive sector, the new T-Burst for Swiss turning applications increased tool life by a minimum of 100 percent over the competition. In one test on a mission core workpiece made from steel magnetic iron, the new addition to the T-Burst line increased tool life by 300 percent over the competition.

In other tests on different materials such as steel magnetic iron and chrome cobalt molybden steel, the new T-Burst raised the bar by increasing tool life by 100 percent.

BUSINESS NEWS

Castrol reinvents cutting fluids Castrol, the leading global lubricants manufacturer, has reinvented cutting fluids with the launch of Castrol Alusol SL 51 XBB. Created to support the manufacturing of metal components, Castrol’s pioneering cutting fluid technology maintains constant pH levels (9-9.5) and stable conditions for longer than other standard cutting fluids. This reduces the need to add expensive treatment additives and biocides, as well as safeguarding against costly uncontrolled system changes.

Castrol’s Alusol XBB products do not rely on the use of boron or formaldehyde releasing agents or additional biocide and fungicide additive packs, but are still able to meet and exceed the lifetime expectations of the benchmark technology to date. In many cases, customers have been able to significantly reduce or completely eliminate the use of biocides from their management processes.

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MACHINE TOOLS WORLD SEPTEMBER 2016

Cutting fluids perform an essential role in the manufacturing of many types of metal components.

One of the main drawbacks of the traditional technology is that, over time, the fluid can suffer from bacterial growth and contamination resulting in the fluid ‘going off’. This leads to pH depletion, unpleasant odours, unstable emulsion and poor performance. From a breakthrough achieved by Castrol’s liquid engineering, these new Alusol XBB products redefine the properties of cutting fluids – they are resistant to acid attack from bacteria, proven to maintain pH at a constant level and are therefore inherently more resistant to bacterial growth.

Pawan Sabharwal, Vice President – Industrial & Heavy Duty, Castrol India said, “Our liquid engineers have reinvented the fundamentals of cutting fluid technology. By

having greater control of the pH, the reliance upon short-lived biocides to control bacteria is significantly reduced or eliminated. This ultimately translates into significant improvements for controlling manufacturing costs, increasing productivity, protecting the quality of end products and meeting HSSE requirements.”

As the lifetime of the cutting fluid is increased, costs associated with disposal of spent fluid are reduced and system stability minimises the requirement for costly maintenance regimes. Even at low concentrations, Castrol Alusol XBB products maintain machining performance and can help to protect against corrosion and staining. The excellent lubricating properties help prevent swarf build up, assuring high quality surface finish & low scrappage rates.

Castrol Alusol SL 51 XBB

improves precision performance in aluminium machining. It neutralises up to 33% more acidic material than standard aluminium cutting fluids* and reduces overall fluid top-up volumes by up to 30%** while ensuring maximum cutting precision. These products re-optimise the fluid in use and significantly reduce or can eliminate the need for biocide additives.

Castrol’s new cutting fluid technology also underpins products that positively impact an organisation’s HSE profile by significantly improving the factory environment and working conditions. By maintaining system stability, the unpleasant odours produced by an emulsion that is suffering from a large population of bacteria are minimised and the reduced need for testing pH levels reduces potential skin complaints for workers. Furthermore, the reduced need for biocide additives minimises the need for workers to handle dangerous chemicals.

Creating Tool Performance

A member of the UNITED GRINDING Group

HELITRONIC BASIC The entry level to the world of premium tools

Within the HELITRONIC family, the HELITRONIC BASIC system embodies the ideal resharpening machine for rotationally symmetrical tools with a diameter from 3 to 320 mm and a length of up to 350 mm. Items can weigh up to 50 kg. www.walter-machines.com

United Grinding GmbH – India Branch Office & Technology Center # 487, D1 & D2A, 4th Phase, KIADB Main Road, Peenya Industrial Area, Bangalore – 560058 Tel. +91 80 3025 7600 · Fax +91 80 3025 7603 · madabhavi@grinding.ch · www.grinding.ch

Creating Tool Performance

BUSINESS NEWS

FARO’s products used in Japanese Movie FARO recently announced that its 3D laser scanner, FARO Laser Scanner Focus3D, as well as its handheld scanner, FARO Scanner Freestyle3D, were used as cutting-edge crime investigation equipment in the movie “Himitsu – THE TOP SECRET”, which was recently released on 6 August 2016 in Japan.

The movie is a mystery flick based on the comic written by Reiko Shimizu and screenplay directed/written by Keishi Otomo.

Set in Japan in the year of 2060, the movie features the No. 9 forensic laboratory of National Research Institute of Police Science known as “Daiku (No. 9)”, where MRI investigation is conducted with images reproduced from a dead man’s memory. All the investigators suffer from severe distress as a result of the secrets revealed by the victims and perpetrators.

The movie begins with shocking images extracted from the “inner brain”, and it captures the

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MACHINE TOOLS WORLD SEPTEMBER 2016

audience with its plot filled with complex cases. It concludes with a shocking, surprise ending that reveals the biggest secret behind the case.

The FARO Laser Scanner Focus3D and the FARO Scanner Freestyle3D were featured in the investigation scenes as devices used to document the crime scenes. The Focus3D was used to scan the outdoor homicide scene and the Freestyle3D was used to scan the narrow space of the indoor homicide scene.

DesignTech organizes one day tech seminar

DesignTech Systems recently organized a one day technology seminar “Vision: Product Excellence through technology Impetus” at Hotel The Lalit – Great Eastern in Kolkata. The aim of this event was to showcase the latest and most advanced technologies in product design, analysis, validation and manufacturing to help companies build better products faster, cheaper and better than before. Using these technologies the companies can not only achieve their product design and manufacturing objectives, but through PLM solutions, they can also set-up well streamlined and optimized work processes to attain maximum efficiency.

DesignTech Systems ltd., being the strategic Business Partners with the world leaders and some of the biggest names in the product design and manufacturing industry, presented CAD/CAM, PLM and Digital Manufacturing solutions from Siemens PLM Software; Comprehensive CAE suite of solutions from Altair Engineering; 3D Printing technologies from Stratasys; MATLAB Technical Computing software from MathWorks; and Metal 3D Printing Solutions from SLM. Eminent Industry Speakers from L&T Constructions and MSME Tool Room Kolkata, shared their experiences and benefits they derived from using Altair CAE solutions and Siemens PLM

software respectively. Mukul Mandal, Bhaskar Sengupta, and Debiprasad Ghosh, from L&T Constructions highlighted how Altair CAE suite of solutions helped them in their Design and Analysis of Blast Furnace Steel Shell project.

At this event, DesignTech demonstrated technologies at every stage of product lifecycle starting from Concept development, 3D Modeling and Validation, Product Design analysis and simulation, Rapid prototyping, Alternative Production technologies, Digital manufacturing for Plant Simulation, to PLM for managing and optimizing the entire product design and development data and processes.

Vikas Khanvelkar, Managing Director, DesignTech Systems Ltd. expressed his happiness at the turn out of engineering fraternity for this event stating, “ I am extremely overwhelmed to see such a fantastic response to this event. It makes me happy to see the enthusiasm among the engineering industry to learn about, understand the advantages, and consider adopting new and advanced technologies to add more value to their engineering initiatives.

BUSINESS NEWS

India Automotive Forum emphasises on innovation & design The two-day high level conference - India Automotive Forum was held on 28 – 29 July, 2016 at Le Meridien, New Delhi powered by “Automechanika Academy”, Messe Frankfurt’s globally renowned series of conferences. The theme of the conference was Indian Auto-Component Industry – Transformation from “Build-to-Print” to culture of innovation and design, in line with the need for the Indian auto-component sector to invest in technology, nurture a culture of product development and innovation to remain relevant and competitive as a supplier base globally.

The conference was attended by over 104 automotive industry leaders, experts and consultants from leading companies. Notable presence at the forum includes speakers, panelists and senior delegations from Bosch, Federal-Mogul Motorparts, ZF India, Schaeffler India, Minda Automotive Solutions Ltd, Shriram Pistons & Rings Ltd, Bharat Gears Ltd, Setco Automotive Ltd, Delphi Automotive Systems Pvt Ltd, Varroc Engineering Pvt Ltd, Hella India, Rockman Industries Ltd, Tenneco Automotive India Pvt Ltd, Continental Automotive Component (India) Pvt Ltd, Mark Exhaust Systems Ltd, India Forge & Drop Stampings Ltd, Brake Parts India Pvt Ltd, Masu Brakes Pvt Ltd, Makino Automotive, Macas Automotive, National Engineering Industries Ltd, Emmbros Autocomp Ltd among others.

Leading solution providers in manufacturing technology, engineering design, ERP and IT solutions were also present at the forum including Siemens PLM, Satyam Venture Engineering Services, SAP India and Autodesk India, besides a delegation from

SNIPPETS

32%

In Past 3 years Machine Tools Industry Production increased in value terms at a 32 % Compounded Annual Growth Rate (CAGR)

58%

The consumption of metal working tools has increased considerably, at a CAGR of 58 %

Society of Indian Automobile Manufacturers (SIAM).

The inaugural session encompassed an overview of the Industry and featured presentations by Siemens, KPMG and Frost & Sullivan. Mr Sachin Sanghi from Siemens Industry Solutions talked about the global automotive technology trends and how the Indian auto-components sector could aspire to come at par with them.

This insightful presentation was followed by Mr Rajiv Singh from KPMG deliberating on “Overcoming challenges in the automotive sector to accelerate performance in the emerging markets”. Transitioning to how overcoming these challenges would help in better forecasting was well put by Kaushik Madhavan, Director – Automotive and Transportation, Frost & Sullivan.

$35 bn

(US$ 35 billion) The automotive industry is one of the largest consumers of machine tools in India

75%

75% of the Indian machine tool producers are ISO certified.

160

The Indian machine tools industry comprises of around 160 players in the organised sector.

13%

The production of machine tools in India to grow at a CAGR of 13% during the forecast period

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MACHINE TOOLS WORLD SEPTEMBER 2016

BUSINESS NEWS

Zimmermann offers FZ33 compact portal milling machine F. Zimmermann GmbH, based in Neuhausen auf den Fildern near Stuttgart, Germany, has extended the working area of its proven FZ33 compact portal milling machine. The Y-axis now travels up to 4,000 mm and the Z-axis up to 1,500 mm. This machine is used for the economical machining of small and medium-sized components for the aeronautical and automobile industries, tool and mould making, as well as for many special applications. This new version therefore enables users to process an even wider spectrum of workpieces.

The FZ33 compact has become established with users in various sectors since its launch in 2013.

The special feature of the range is its inherently rigid cast iron

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MACHINE TOOLS WORLD SEPTEMBER 2016

base with integrated table.

Mounted on this are side walls filled with special concrete, and a structurally rigid portal. This enables businesses to erect the machine on a solid industrial floor â&#x20AC;&#x201C; usually without special machine foundations. Its particularly high performance and stability enable aluminum components and components made from composite materials, for example, to be quickly and economically machined on 5 axes.

Users can also mill steel and castiron components with excellent dynamic performance. In doing so, the FZ33 compact achieves short throughput times, high availability and high precision. Workpieces therefore no longer have to be reworked after removing from the

machine. These characteristics, coupled with the increased working area, enable users to adjust even more flexibly and quickly to different component sizes, materials and complexity.

F. Zimmermannâ&#x20AC;&#x2122;s range features various innovative and patented milling head technologies for this

portal milling machine.

These include the VH30 milling head, which Zimmermann offers as an option with a more powerful spindle. The power was previously 60 kW and the torque 95 Nm. The user now also has 70 kW and a torque of 167 Nm at his disposal. The machine builder also provides a tool holder in the form of the HSK-A100. As a result, the new FZ33 compact is even more reliable when used for hard materials with difficult machining characteristics.

F. Zimmermann has also made design improvements to the new FZ33 compact. The machine is significantly easier and quicker to assemble thanks to modifications to the electrical and media cabinet.

BUSINESS NEWS

Zeller+Gmelin to showcase range of lubricants at EuroBLECH 2016 At the 24th international technology trade fair for sheet metal processing, the EuroBLECH 2016, Zeller+Gmelin presents its range of lubricants for sheet metal forming. The offer ranges from metal forming lubricants for the automotive industry to lubricants for roll forming and hydroforming. The new Multidraw product family for the automotive sector in its 2nd generation will also be introduced to the professional public.

The traditional company Zeller+Gmelin is celebrating its 150th anniversary this year.

Since its beginnings in 1866, the Eislingen expert has become one of the preferred solution partners in the industry for lubricants, printing inks and chemistry. At the EuroBLECH 2016, Zeller+Gmelin will now present a wide range of innovative forming lubricants

for a variety of processes and applications to professional visitors. “The EuroBLECH is the most important international fair for us as a manufacturer of forming lubricants for sheet metal forming”, according to Zeller+Gmelin Product Manager, Katrin Hommel. “We have supported the sheet metalworking industry for many decades with our products and the industry appreciates us as a reliable

supplier, innovator and solution provider.”

Thus, customers, partners and prospective customers can convince themselves of the innovatively advanced range of the lubricant expert. Zeller+Gmelin has developed ground-breaking products, in particular in the area of low-lubricant metal forming in cooperation with partners in the automotive industry. At Zeller+Gmelin fair booth (Hall 27,

Booth L42), customers can discover everything about the 2nd generation of low-lubricant sheet metal forming of the Multidraw series, which is used for the chipless forming of automotive parts made of steel for light, medium and difficult degrees of deformation.

A highlight of the fair is thus the new pre-lubricant Multidraw PL 61 SE which is primarily suitable for the basic oiling of all steel surfaces from the rolling mill and helps to reduce the zinc abrasion during the forming process of hot-dip galvanised surfaces. In addition, the product has optimal drainingoff inhibition, as well as excellent compatibility with all non-coated and coated sheet metal surfaces.

Zeller+Gmelin celebrates 150th anniversary As an independent family-owned company Zeller+Gmelin can look back on 150 years of history. Since the beginnings in 1866, the expert for speciality lubricants, printing inks and chemistry from Eislingen has emerged as the preferred partner of large and small companies.

With a two-day ceremony and an Open Day on September 24th, Zeller+Gmelin intend to celebrate this company anniversary.

As lubricant manufacturer Zeller+Gmelin offer individual and comprehensive solutions from one single source, from research and development to production. Numerous national and international companies such as for example Bosch benefit from the high innovative power of the supplier.

The lubricant specialist employs around 900 people worldwide, half of which work at the headquarters in Eislingen. As one of the largest employers in the region, Zeller+Gmelin celebrate

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their 150th anniversary with a two- day ceremony and an Open Day on September 24th.

“We are proud to be able to look back on a successful 150-year history as one of the few independent companies”, says Siegfried Müller, Director of Marketing and Sales at Zeller+Gmelin. “As an innovative solution provider and preferred partner of the industry, we want to continue to provide secure jobs for the people in the region of Eislingen -

an occasion that we will truly celebrate in September and to which we cordially invite everybody.”

On February 23rd, 1866, the company Zeller+Gmelin was registered as a general partnership and shale oil factory. Behind that were the ideas of the railway engineer Anton Zeller and the pharmacist Paul Gmelin to use the slate quarries of the so-called “plains” in Groß-Eislingen for the distillation and extraction of lamp oil and heating oil. When, however, coal advanced to be the preferred combustion material, the business gradually shifted to the production of lubricants which were in great demand in the course of the upcoming railway expansion.

COMPANY PROFILE

Synetics in the forefront of Automation

A turnkey project done involving robotic automation

Coimbatore-based Synetics Automation Solutions Pvt. Ltd. is in the forefront of automation, providing innovative and cost-effective solutions to the manufacturing sector. Six years down the line, the company has proven its engineering prowess and innovativeness in the areas of its core competence namely CNC auto-loading, assembly automation and robotic solutions, and added an impressive list of customers to its portfolio. Reduced dependence on labour, reduced overheads, increased throughput, increase in quality and consistency and ultimately increased customer satisfaction are some of the benefits of automation the user-industry should take advantage of, says the top brass of Synetics.

S

ynetics is the brainchild of two engineers –Vijayaram Balasundaram and Karthik Soundararajan, both having done their Masters in Automation & Robotics from the Rochester Institute of Technology, in the US. Synetics are primarily full-fledged

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system integrators and machine builders providing end-to-end solutions.

“We have a very strong mechanical design team with experience in 3D modeling and analysis, backed up by a controls team with vast PLC & robot programming knowledge. We do the entire assembly, integration and

“Government should encourage automation and provide loan subsidies for capital investment.”-

Vijayaram Balasundaram, Director, Synetics Automation Solutions Pvt Ltd

“We have to convince the customer on the tangible and intangible benefits of automation.”-

Karthik Soundararajan, Director, Synetics Automation Solutions Pvt Ltd

COMPANY PROFILE

testing in- house to achieve ultimate customer satisfaction,” says Vijayaram Balasundaram who has had a stint of 10 years with General Motors, US and has rich experience in automated car and truck body welding lines.

Synetics is highly creative and it applies its automation experience to come up with innovative solutions that address the customers’ problems.

It uses high quality and reliable automation components for its systems integration. “We focus on building operator-friendly systems also taking care of ergonomics. We have a thorough understanding of OSHA safety standards and lay greater emphasis on the safety of our systems.

Our systems are also designed with serviceability in mind and are quite maintenance-friendly. When it comes to aesthetics, our products are worldclass,” elucidates Vijayaram. “Hitherto the company has executed five robotic projects – one for machine tending, a large overhead gantry system for welding and two for painting. We have a steady stream of orders for our CNC Auto-loaders.”

“Our CNC Auto Loader needs special mention. With auto-loaders attached to 4 CNC’s, one operator can run four (4) machines. So across three 8 hour shifts, the auto-loaders can replace 9 operators. They are less expensive(40% less) when compared to robotic

solutions and can be easily retrofitted to existing machines,” reveals Karthik Soundararajan, who has experience in electrical design of machines, PLC and robot programming, having worked with Alliance Automation Systems and Assembly & Test Worldwide, USA. “Another revolutionary product is our Carbide Insert Vending Machine – ProCrib, which is a boon to machine shops.

Inserts are costly and hence their issue and proper usage should be monitored and controlled. “We have come up with two versions.

The smaller version is designed for single insert vending to be used for turning centers, while the larger one is meant for machine shops with vertical & horizontal machining centers which need supply of more inserts. Our prototypes are ready and are getting perfected. We shall be launching these machines in a couple of months.”

“The ASRS we have developed for food vending is also a novelty in retail outlets and public places. We have already supplied about 20 such systems. They are now being launched in Singapore,” explains Karthik,

elaborating on their innovations.

“When it comes to automation and calculating the return on investment, the customer should consider reduction in manpower, and also the improvement in productivity. With automation one can expect at least 15-30% improvement in productivity,” states Vijayaram. “ In order to reap the full benefits of Automation, the end-user should work very closely with the supplier and have a complete understanding of what they will get. Both should get involved and make things happen,“ he adds.

Synetics considers the development of its food vending machine as the most challenging one. “First we developed with pneumatic automation. Later it was switched to all electric. It is materials handling in a different form.

The development was quite exciting and satisfying,” says Karthik.

“Today everyone wants only CNC’s because they realize the benefits.

Similarly automation is also going through a transition phase in India and the country has to embrace it on a much larger scale so as to keep pace with the industrial growth envisaged,” opines Vijayaram.

Dwelling on his vision, Vijayaram says that they want Synetics to be one of the top 10 players in the automation industry in India by 2025.

– P.K. Balasubbramaniian

Assembly automation in progress

A carbide insert vending machine from the crucible of Synetics

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MACHINE TOOLS WORLD SEPTEMBER 2016

Synetics’ CNC autoloader

For a new era of manufacturing

Renishaw’s new metal powder bed fusion additive manufacturing system for industrial production, RenAM 500M, features increased emphasis on automation and reduced operator interaction. The system is the first to be designed and manufactured in-house by Renishaw, applying over 40 years of cross-sector engineering excellence that spans electrical, mechanical and optical technologies.

Highlights include: • Renishaw designed and engineered optical system with 500 W laser • Automated powder sieving and recirculation • Patented dual SafeChange™ filter system • Renishaw RESOLUTE™ linear encoder on Z-axis for precision and accuracy

Find out more at www.renishaw.com/additive

Renishaw India G K Archade, 3 floor, No 125/1-18 T Mariyappa Road, 1st block, Jayanagar Bangalore 560011 T +91(0)80 66236000 E india@renishaw.com

www.renishaw.com

COMPANY PROFILE

Gala’s Surface Engineering Solutions

T

he Gala Group, headed by Mr. Kirit Gala, believes that ‘Innovation is about challenging conventional wisdom and finding creative solutions, challenging the obvious and combining discipline and competency in precision engineering’. It proclaims that it is engaged in engineering next generation solutions for a world on the move.

The company is a technology leader in Springs, offering a wide array of Springs for applications in Automotive, Off Highway Vehicles and the Power Sector.

It also makes precision assemblies where Spring is the main component.

In Surface Engineering, it offers integrated solutions in the area of finishing and cleaning of metal parts.

It provides end-to-end solutions for Deburring, Polishing and Washing & Cleaning of parts. Moving one step ahead, it offers Finishing and Cleaning solutions using Robotics where safety, reliability and performance are of paramount importance. For deburring and polishing of parts, it offers Vibrators, Centrifugal Barreling and Disc Finishing machines with complete automation. For cleaning of parts, it provides different types of Spray cleaning, Multi-stage ultrasonic cleaning and Special purpose customized parts cleaning systems. In order to complete the spectrum, it also offers high quality media and compounds which are essential to achieve the required level of performance in finishing and cleaning processes.

Gala sees surface refinement as an art in engineering that it has developed with decades of experience and continuous innovations. Today it offers sophisticated, customized Surface Engineering solutions in the fields of Deburring, Finishing, Washing & Cleaning. Finishing is a proven, highly

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MACHINE TOOLS WORLD SEPTEMBER 2016

Gala’s Multi-Stage Ultrasonic Cleaning System revolutionizing cleaning

effective form of surface engineering.

It occupies an important place in the production process. The deburring & finishing solutions are tailored to suit the ever-increasing demands of modern manufacturing environment.

The company provides customized integrated solutions suitable for specific products and production requirements.

Precision Cleaning of Parts

The parts cleaning process which results in achieving stringent Millipore values and particle size and particle count is known as precision cleaning of parts.

This also calls for complete oil-free surfaces.

Precision cleaning of parts can be achieved with a combination of cleaning processes such as Spray, Deep Spray

Mr. Anand Kaundanya, COO – Surface Engineering, Gala Precision Engineering Pvt. Ltd.

Gala’s wide array of Vibratory Finishing, Washing & Auto Dosing Systems

COMPANY PROFILE and Ultrasonics. This is supported by basket dunking, basket rotation, basket tilting and agitation. Filtration at multiple levels is equally important. The company provides all cleaning solutions under one roof. This includes all types of spray cleaning machines such as conveyorised, rotary basket, indexing station and customized.

Tabletop ultrasonic to multistage ultrasonic cleaning systems up to 50,000 ltr work chamber with complete automated basket handling mechanisms are provided. It also offers: Single chamber multi-process aqueous cleaning machines; Rotary screw type Immersion and Spray cleaning machines up to a capacity of 1250 Kg/hr, Customized cleaning machines like Single piece flow ultrasonic cleaning, high pressure cleaning and Robotic cleaning, etc.

Modern Manufacturing Facilities

Some of the significant and recent milestones of the company include: • Export of finishing & cleaning systems of the company

Gala has its manufacturing facilities in Wada, Maharashtra, some 40 kms from its corporate office in Thane. The plant, spread across an area of 31,000 sq. mtrs, houses its Machine Manufacturing Division as well as R & D Centre. The R & D Centre conducts pre-sales trial to develop finishing & cleaning solutions to achieve the desired results. The Centre is equipped with a dozen machines for

Gala also offers Media & Compounds for Finishing and Cleaning

Screw type Rotary Washing System - A boon to the industry 38

pre-sales trials; 85 varieties of media and 20 varieties of chemicals, and a plethora of instruments to measure various parameters like surface finish, critical dimensions, Millipore values, etc.

In the Design Office, it has facilities like AutoCAD 3D modeling and modern work stations. It also has in-house facilities for SS & MS fabrication and machining.

Gala has a team of highly trained sales engineers stationed in Mumbai, Bangalore, Chennai, and Delhi. It also has an extensive service network covering major industrial belts across the country to attend to service calls.

“Service is crucial in our business,” says Mr. Anand Kaundanya, CEO.

MACHINE TOOLS WORLD SEPTEMBER 2016

A typical Disc Finishing System engineered by Gala

• Turnkey projects in defense sector • Manufacture of precision parts cleaning systems to achieve Millipore value of less than 1 mg • Successful completion of one of the world’s biggest Centrifugal finishing machines.

Thrust Areas

The company’s new thrust areas and new initiatives include: (a) Development of high technology Aqueous cleaning solutions for precision cleaning of parts at par with global standards; (b) Application based approach to offer customized precision cleaning systems; and (c) Building special purpose machines for defense sector for polishing of non-ferrous parts.

“Our vision is to be No.1 in every market we serve and build the sinews of this organization to have the strength of a big enterprise and at the same time the leanness and agility of a small company,” adds Mr. Anand.

The Group says it will be driven by entrepreneurship and professionalism and will offer great opportunities to deserving and dynamic individuals to make their mark in the world of scientific management.

ELECTROCHEMICAL DRILLING – MAKE QUICK WORK! SIMPLER

MORE STABLE

FASTER

MORE VARIABLE

LOWER COST

ELECTROCHEMICAL DRILLING PRODUCES ABSOLUTELY NO BURR OR DRILLING CAPS

HIGHLIGHTS +

Drilling produces no burr or drilling caps. This means no deburring – a crucial advantage for machining components which are difficult to access.

+

The material is not heated by the ECM process which means no negative effects on its microstructure and no micro-cracks.

+

A lot of ECM boreholes (20 or more) can be drilled at the same time; short cycle times and lean processes are a matter of fact. The feed rate can be up to 5 mm/min.

+

The process is suitable for hard and soft machining. The material hardness does not affect the feed rate.

+

The service life of the drilling cathodes is very long, even for hard materials.

The tools suffer almost no wear.

EMAG India Private Limited I “Technology Centre” I No. 17/G/46-3 · Industrial Suburb I 2nd Stage · Yeshwanthpur I Bangalore · 560022 I Karnataka · India Phone: +91 8050050140 I Fax: +91 8042544440 I E-mail: sales.india@emag.com I Website: www.emag.com

TECH UPDATE

Pioneers of Fusion 360 in Make In India Initiative

Autodesk University INDIA & SAARC 2016 draws 3800 Visitors

A

U INDIA & SAARC 2016 held at expansive CIDCO Exhibition Centre, Navi Mumbai on 1st Sept. 16 It was a 1 day mega convention that attracted nearly 3,800 professionals from Architectural , Engineering , Manufacturing , Media & Entertainment Industry.

Government of Maharashtra and few renowned technology vendors / Service providers were co- host of the convention.

Autodesk University is the premier learning destination for Autodesk software users where design and engineering professionals converge from around the world and attend classes, forums, and keynotes with product experts and thought leaders.

The attendees learn tips and tricks for working better, and explore how technology is changing the

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way we create. During the current fiscal, Autodesk is conducting such conferences in 15 countries including India.

The tag-line Insight - Innovation Inspiration was effusively delivered.

It discussed as many as 36 papers in plenary sessions, the key theme was Future of making.

Future of Making Things , Future of Making Movies ,Future of Making Things in AEC, Future of Architecture & BIM….

The Second half of the day was divided in different Industry Breakout Tracks • Architecture, Engineering and Construction – Buildings • Architecture, Engineering and Construction - Infrastructure GIS & Civil • Media & Entertainment • Manufacturing - Product Engineering

• Manufacturing - ID&V Concurrently an exhibition was also held at the venue wherein many Makers &Innovators showcased their designs & working Products.

Fusion 360 café was one of the big attraction for visitor, More than 1000 new users of the product stopped by & greeted the Fusion Force - a team of 70+ young engineers, enabling MSME in Maharashtra attain higher productivity & better design It was in May 2016 that Govt of Maharashtra Govt. & Autodesk signed the MOU to provide advanced design technology to local MSMEs in manufacturing sector. At the launch ceremony Chief Minister Devendra Fadnavis said: “This would enable our MSMEs to uniquely design and manufacture their products as per international standards.

This partnership of the Govt. of Maharashtra and Autodesk will create a potential for Maharashtra MSMEs

TECH UPDATE www.mtwmag.com

to become globally competitive and locally productive.”

We learned that around 2000 MSMEs in Maharashtra adopted Fusion 360 in this hort span of 4 month …10 of those SME industrialists were felicitated in the plenary session as Pioneers of Fusion 360 & for pioneering the Make in India Initiative.

- P.K. Balasubbramaniian

Holy shrine for SME manufacturers & designers of Maharashtra

SEPTEMBER 2016

MACHINE TOOLS WORLD

41

COVER STORY

EMAG :

Global leadership through cognizance & excellence

Mr. Andreas Zieger, Director, EMAG India Pvt. Ltd.

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MACHINE TOOLS WORLD SEPTEMBER 2016

COVER STORY www.mtwmag.com

Q. EMAG has gained substantial market share in machine tool industry worldwide , please elucidate the success story of the company?

The machine tool (MT) market is a cyclical market and to stay on top one has to face the daily challenges and reinvent oneself again and again. EMAG has been in MT business for more than 150 years. Our important milestone was the invention of vertical turning principle in the 90â&#x20AC;&#x2122;s.

Where lot of established manufactures had only a smile, but the vertical pick up machines are now a major concept with a lot of advantages and EMAG is market leader. Beside that core strength in turning we learned that in modern production the classical dividing lines between turning, milling and grinding will soon disappear.

Our R&D started to integrate more and more technologies in our machines, even literately in one machine, we offer grinding and turning or hobbing and deburring. Now a days success factors to increase the machines performance are the automation and the flexibility of the machines to adapt the processes. Here we developed a modular machine concept in which we can integrate more and more of our technologies, like turning, grinding, hobbing, hardening and also integrate them with full automation.

Q. Please brief us about the exports and overseas operations & what are the global alliances that has been made in order to out-front the competition?

EMAG is worldwide operative, coming from Germany, Europe is still the core market and important because of the partnership with the European car OEMs, who develop parts with us together.

But with our international network in sales and production, we cover all major production hubs in the world, can support our international customers with proven service solution anywhere in the world.

And like all international companies we use the various local benefits for the product optimization. Here we have production plants in Germany, France, Italy as well as in US and China. Sales and Service team are in more than 20 countries and the technology centers in 6 location around our HQ in Stuttgart.

Q. What are the market prospects for the EMAG products and How do you plan to position these products?

In general I would say that the MT market is not growing significant. Additional demand is partly compensated be increase in efficiency of the machines and longer life time of the machines. EMAG is well positioned with sturdy, high tech machines and with the combination of our various technologies plus the modular machine concept the machines are ready for the future. Also in India we realize a change in the manufacturing industry from a cheap job chopper to an international oriented quality partner.

And here we can provide proven solution or can develop new lines and concepts.

To achieve it we need a close partnership

with our customers over a well-trained sales organization as a bridge between the task of the customer and the expertise of our worldwide technology organization.

Thus we develop new solutions together with our customers, like PCL for build cam shafts or Graziano for laser welded differential casings or HAL for jet engine blades. In all our projects we target to get the extra benefit for our customers, not simple the cheapest my too product.

Q. Can you brief us about the marketing strategies that were applied in order to stand out in the competition of machine tool industry?

Because we are seeing ourselves as technology leaders our major task is to share the knowledge, technologies and solutions with our customers to allow them to start challenging there thinking and to initiate a spark of a new concept.

This is classical situation for a direct sales approach supported by informative marketing over web page, specialized magazines, Emailers. Of course we do use also the new media to share information,

SEPTEMBER 2016

MACHINE TOOLS WORLD

43

COVER STORY

like success stories over Facebook or videos over YouTube. But the classical discussion between an experienced sales engineer and the responsible teams in a production plant is the most fruitful base to create an improved solution.

Q. Please elucidate in brief about the companyâ&#x20AC;&#x2122;s infrastructure & What are the measure that are being taken from the product manufacturing to distribution?

In principle, we have worldwide three major machine production plants to produce the base machines. In our 6 technology plants we customize and tool up that machines or create complete lines, which we pretest with the customer before dispatch and finally with our worldwide service team we install and prove the machines at the customer place. The integration of various technologies to lines in combinations with additional equipment we do in our HQ. Beside turning, hobbing, grinding or laser welding we also add robot cells or central chip management systems to create complete production lines.

All that requires beside a strong own production, a well-organized supply

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MACHINE TOOLS WORLD SEPTEMBER 2016

chain management and project execution management.

Q. Brief us about the R&D and Quality policy for your business?

Quality management is the backbone for our daily improvement process and allows us to get stable results and learn each day. And our centralized R&D is driven by the international driven innovation process, where we collect the needs from the market, work with institutes about future processes and material together and finally the vision of the owner family to pushing us forward.

And the world is changing faster and faster, e-mobility, new materials, additive production, â&#x20AC;Ś.

Q. What are the key technological trends that are driving machine tool industry?

Trends from the market are the mass production to reduce costs, individualization of products with more product variances and faster life cycle time of product, fortunately the sustainability gets more importance and reduction on used resources. This requires high accurate and high efficient machines, with higher flexibility. Automation

becomes a more integral part, because here the quality and efficiency can be improved. Industry 4.0 is a big word, which in my eyes will bring machine technology and IT together, here sensor technology and big data can be added.

All that is to optimize the process and use underutilized capacity. Recourse saving like electricity, material, coolant in the production as well as during the machine manufacturing is gaining importance too.

Q. How do your perceive the future of the machine tool industry?

In future we will see more automated plants, where machines are linked, less manpower for stupid jobs. Technologies will come up new, like tool less electro chemical processes or additive productions. Sustainability I hope will play a more important role for the products as well as for the machines.

And maybe my kids will commute in driverless cars to worldwide connected offices to plan and control the production.

Q. What is your vision for your company?

At the moment our vision is to make manufacturing systems for precision metal components, this will still stand valid for the next years and behind the curtains we look into the future and work out our part of contribution and how we need to reinvent our machines.

Group GROB based y o n a rer f rm ufactu , offering The Ge g man es in d in a h is a le al mac epts univers g conc in in h 5-axis c a e and m v e ti v o ti innova Mold, Autom & for Die ustries. d allied in

G-Series

Horizontal 5 axis machining centers

Precision at the highest level

Contact: GROB-WERKE GmbH & Co. KG Mindelheim, GERMANY Phone: +49 8261 996-0 E-Mail: info@de.grobgroup.com GROB Machine Tools India Pvt. Ltd. Hyderabad, INDIA Phone: +91 40 4202-3336 E-Mail: info@in.grobgroup.com

GROB_Indien_Anzeige_Magazin_die_and_mould_April_2016_DINA4.indd 1

GROB 5-axis universal machining centers stand out due to their absolute precision and reliability in the automotive, medical and mechanical engineering industries, in tool and mold making as well as in the aviation industry.

The proven 5-axis simultaneous technology with horizontal spindle position enables you to machine parts of various sizes and materials in a flexible and failure-free way while offering maximum stability of the machine.

Fast chip-to-chip times and the innovative further development of our spindle technology guarantee a high economic efficiency and productivity.

The GROB G-series â&#x20AC;&#x201C; for the most versatile machining possibilities.

www.grobgroup.com

02.05.2016 08:11:57

INTERFACE

Mr. Ayaz Shaikh,

Director Marketing, Accusharp Cutting Tools Pvt. Ltd.

“We are for those, who are in

Metal Cutting”!

Q. Being the key player in the industry, Please brief us company’s journey from inception & share some of the milestones achieved?

Our business journey is an interesting story of how we processed our technocommercial experiences around us and reached at this growth level, 30 Cr. INR turnovers.

A highly skilled and experienced young technocrat, Mr. Ilyas Shaikh, started initially tool grinding activities, with one secondhand Tool & Cutter Grinder, for resharpening of used tools for engineering industry at Pune, in 1999.

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MACHINE TOOLS WORLD SEPTEMBER 2016

After 17 years, Accusharp Cutting Tools Pvt. Ltd; stands today, as a leading company, in design, manufacture & supply of special cutting tools in Tungsten Carbide, for Automobile, Engineering, Textile, Energy Sector, Machine Tools Industries, etc.

Under the dynamic leadership of Mr. Ilyas Shaikh, our Managing Director, with the strength of product quality, and service reliability, the company has grown today with 120+ employees. The company stands proud on a setup of 15,000 sq. ft. with ongoing expansion.

Q. Please brief us about company’s business objectives & what are the technology alliances that has been made in order to out-front the competition?

Our business objective is to assist customers for their productivity

INTERFACE www.mtwmag.com

improvement coupled with reduced tooling cost.

Our business strength lies in 3-‘P’s - i.e.

Products, Process, & People.

Products: Having quality to meet customers’ expectations.

Processes: With modern equipment of high efficiency.

People: With competence and passion for the organisional objectives.

For customer desired technology alliance, we have installed latest design software for tool designing, and manufacturing setup with modern equipment, like, 5-Axes CNC Tool & Cutter Grinders - ANCA, WIDMA, Rollomatic, Strausak-, and Zoller Geninus’3, & Rapid-I, as Q.C. equipment.

MIS and entire business processes are supported by SAP.

Q. What are the products manufactured by your company?

I would like to say that “We are for those, who are in Metal Cutting.” Our Product cluster consists of Drills, Step-Drills, Endmills, Reamers, Cutters, Centre-Drills, Form-Tools, Profile-Tools and Customised tooling solution in Solid Carbide and H.S.S. Tool applications are for machining of Engine Heads, Cylinder Heads, Connecting Rods, Wheels, Crank-Shafts, Gears, Crank-Case, Axles, Nozzle Rings, Wind-Mill- Blades, etc. This covers Industry Sectors like Automotive, Energy, Engineering, Die & Mould, Aerospace, etc.

Q. What is your marketing strategy for India?

I strongly believe, that customer is our first concern.

As I have said earlier, our business objective is to assist customers for their productivity improvement coupled with reduced tooling cost. We provide not only cutting tools, but also, the entire solution for the customer for their product development and manufacturing process.

For a number of MNC’s & OEM, as well as, other customers, we have established strong support teams of competent and professional engineers across India, and logistic network, a step closer to customers.

‘ISO:9001-2008’ for QMS. Moreover, Environment, Industrial Safety, Health of employees and Social Responsibility hold an integral part of all our business operations. We have been approved by a number of MNCs for their audits of Safety, Environment, and Supplier Code of Conduct aspects. And I would like to add - This remains as our work culture.

Q. Product innovation through R&D is vital to be a leader in the competition, as per your opinion, how does R&D plays the role of catalyst in the success process?

Cutting Tools, what we make, are ‘consumables’ for manufacturing industry; and our business activity is dependent on the manufacturing industry operations and their growth. As I have said, our products are key consumables for manufacturing industry; therefore, we need to stand as a ‘Productivity Partner’ for customers. Our assistance for customers for faster metal removal rates at their lowest possible operational cost remain the driving business factors, for us.

I believe that we have now reached the stage that we need to have a separate R&D activity for further technical developments; and we are on the way to set up the same, soon.

Q. Quality standards are benchmarked by the product performance; please brief us how do you maintain the quality norms since from solution development to implementation?

Our concept for ‘Quality’ is to make products that meet customers’ expectations. It includes product specification, performance reliability, supported by our service quality.

We are a Company certified for

Q. According you what are the factors affecting to your business? And what is the key ‘Driving Factor’ for your business growth?

Q. How do you perceive the future of the industry?

Auto Industry, Energy sector, and Construction industry are steadily growing in India. And I strongly believe, we shall have business future and a sizable market share to support them accordingly.

Q. What is your vision for your company for near future?

Our Vision is “To stand as a model organization, becoming the first preferred choice company in the Indian engineering industry, for designing, developing, manufacturing and supplying metal cutting tools; along with strong technical support to customers. Acquiring the highest local market share, our further ambition is to be the leader in export sector, for metal cutting tools.”

And let me tell you, my people on the job, with professional competence and passion for the organizational objectives, shall make this company vision to happen.

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REFLECTIONS

Preparing towards

DIGITALIZATION STORY Q. Whatâ&#x20AC;&#x2122;s your area of specialization in Automation?

Factory Automation

Q. What are the latest trends in Automation in your domain?

Preparing towards digitalization story

Q. What are the benefits of automation to the end-user?

Flexibility in manufacturing, ability to have a management dash board with consistently cohesive data such as Production Data, Process data and Product Data, and Remote access through mobile technology/ web technology

Q. What are the challenges faced by the industry in adapting to new technologies?

Instead of larger landscape, industry (mainly SMEs) are taking investment decisions based on absolute investments and not on the basis of total cost of ownership. This results in to island automation which is surely going to become a bottleneck as far as taking next steps towards digitalization is concerned.

Q. Whatâ&#x20AC;&#x2122;s the shape of things to come in Automation in the near future?

Totally integrated automation at plant with increasing usage of IoT as an enabler for digitalization.

Mr. Milind Kulkarni,

Chief Manager- Business Development (Factory Automation), Siemens Ltd.

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TECH TRENDS www.mtwmag.com

Keeping reliability & quality on track for rail industry More and more travelers use modern train services because of their ease, cost effectiveness, comfort and safety

I

t is therefore a matter of course for manufacturers of rail and train components to ensure that quality products and services continue to be delivered to the industry every day.

Increasing reliability through new tools, materials and machining techniques, as well as supporting productive and cost effective maintenance of existing infrastructure, is crucial.

The railway segment has been a focus for Dormer Pramet for many years, with the company offering customers a wide range of cutting tools to help with both production and maintenance. TomĂĄĹĄ Hantek is International Application

Manager for Railway at Dormer Pramet.

Railway wheels and rails are the most important components in any railway operation, as they represent the interface between vehicle and track.

Therefore, both rail and wheel surfaces must always be of the highest quality.

Any roughness or irregularity in surface quality can create undesirable forces,

friction, vibrations and wear, developing unwanted effects on the vehicle and infrastructure. In the case of passenger vehicles, this can influence not only the comfort of the occupants, but also their safety.

As an established partner to the rail industry in many locations around the world, Dormer Pramet supports the manufacture and re-profiling of wheels, as well as machining of axles, chassis, rail profiles and renovation, switches, base plates, mounted axles, junctions and other rolling stock components.

With any contact between the vehicle wheels and rail surfaces, the materials

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TECH TRENDS must be strong enough to resist the normal (vertical) forces exerted by regular and heavy loads. The forces in the contact zone must be low enough to allow heavy loads to move at speed with little resistance and also large enough to generate acceleration, braking, & guidance of vehicles.

Rail treatment The most common mechanical noise from a train is generated between the wheel and rail contact. These ‘vibrations’ are transmitted through the ground and can even be felt in nearby buildings.

Vibrations (in the range of 4 to 80Hz), or low frequency rumbling noises (between 30 and 250Hz), can also be transmitted into the vehicle itself affecting passenger comfort and vehicle life.

To combat against this constant force between track and vehicle, there is a need to make sure the rail remains in a good condition. There are several reasons for rail treatment, but primarily it is an issue of operational safety. With the mechanical stresses in wheel and rail contact, cracks can appear on the surface of the rail. These have to be removed quickly before they spread and destroy the track area. A regular assessment of the rail profile is important for limiting damage to the track and rolling stock.

Also, another objective is to enable modern high speed trains to use existing

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lines, while maintaining reliability and safety standards.

Rail treatment can be performed in several ways. The most time-consuming involves the use of track relaying machines, which replace old rails with new.

It is also possible to subject the existing rails to grinding operation, however, the disadvantage with this is that it offers a small depth of cut and can create sparks, presenting a potential fire hazard.

However, an alternative option is dynamic rail milling. The re-profiling of a railway line without removing the tracks represents significant time and financial savings. It is therefore no surprise that dynamic milling of rails has become one of the most popular methods. But this ‘on the-move’ application requires specialised equipment to achieve optimum results.

Dynamic milling can be performed by specially designed trains, operating at a constant speed of 700 meters per hour.

Rails made of R350HT steel have good abrasion resistance, with a hardness of between 900 and 1,200 MPa. Sometimes the passage of trains results in the rail head being hardened up to 1,500 MPa. To re-profile the rails, two milling units are used. The first roughens the surface, the second one finishes it, and the two units act on both rails simultaneously.

The final rail profile and high quality surface finish are ensured by the grinding

units, while metal chips produced during milling are transferred to a nearby container, making sure no debris or swarf is left on the track. Another option is the use of a truck which can switch between road and rail by changing its wheel type. This uses only one milling unit on each side, so the cutters perform only a finishing operation.

Safety It is standard practice that during the re-profiling of rails, insert indexing due to wear is done on board the train performing the milling. To reduce down time, operators often change the whole milling cutter, and to do this, they must leave the train.

However, renovation of railway infrastructure is usually done at night when there is less traffic. To improve safety it is advisable to avoid changing the cutter during a shift, especially at night. The normal distance covered when milling during a standard shift is between 3,000 and 3,500m. Dormer Pramet’s rail milling inserts and cutters have a durability of more than 3,700m, meaning staff can stay on the train for the whole shift.

“Our range for the rail industry includes disk mills, cartridges and indexable inserts for dynamic rail milling.

Pramet’s rail milling cutters, for example, have a diameter of 600mm, a cutting speed of between 220 and 280m/min, and each cutting tooth can deal with between 3.5 - 5mm of rail length, cutting to a depth of between 0.5 and 1.5mm,” states Tomáš Hantek.

These cassettes are also used for different rail profiles - the AHC (Anti-HeadCheck, for rails used by trains operating at speeds up to 160 km/h) and the UIC 60E2 profile for high speed lines. When the profile needs to be changed it is only necessary to replace two out of the eleven inserts in each cassette. This delivery of cutting tools specifically for dynamic rail milling applications & the firm’s aim to continuously develop new products for the industry, has allowed it to develop strong partnerships with some of the world’s leading railway companies.

Every chip tells a story

Compact system for in-process tool breakage and tool wear monitoring on cutting machines

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TECH TRENDS

The advantages of Solvent Cleaning Machine Among many choices, one process stands out for its ability to produce a clean, dry part at a reasonable price: solvent metal degreasing machines

T

oday manufacturing engineers and plant managers face a difficult challenge when choosing among the many surface cleaning options available. Aqueous, semi-aqueous, hydrocarbon solvents, HCFCs, new fluorinated and brominated solvents are just a few of the possibilities. Among these many choices, however, one process stands out for its ability to produce a clean, dry part at a reasonable price: solvent metal degreasing machines.

Principles of hermetically sealed metal degreasing The hermetically sealed metal degreasing process is the ideal technology for high quality parts cleaning. It is able to remove the most stubborn soils. It reaches into

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small crevices in parts with convoluted shapes. Parts degreased by solvent with cleaning, immersion and vapour come out of the process perfectly cleaned.

An additional drying stage under deep vacuum recovers almost all solvent present on parts surface and in the system, reducing the consumption close to â&#x20AC;&#x153;0â&#x20AC;? (Zero Emission).

Hermetically sealed solvent cleaning machines are particularly effective with parts that contain recesses, blind holes, perforations, crevices, and welded seams. Solvent vapours readily penetrate complicated assemblies as well. Solid particles such as buffing compounds, metal dust, chips, or inorganic salts contained in the soil are effectively removed by the washing mechanical

action of the machine. Firbimatic solvent cleaning machines can also be equipped with ultrasonic cleaning, which is an option, in order to remove heavy oil deposits and solid soil, by installing transducers in the treatment chamber.

The process When ultrasonic energy is transmitted to a solution, it imparts a scrubbing action to the surface of soiled parts through cavitation â&#x20AC;&#x201C; with quick build up and collapse of thousands of tiny bubbles.

Typically these modern vacuum degreasers perform the cleaning operation in a sealed chamber into which solvent is introduced after the chamber is closed.

Solvent vapour then performs the final cleaning stage, and all vapours are

TECH TRENDS

recovered through the drying circuit at the end of each cycle.

If needed, residual solvent vapours are driven through an activated carbon recovery system, in order to reduce even further the already negligible fugitive emission. With the vacuum sealed chamber, solvent loss is reduced by more than 99,9 %. Operation is programmed and fully automated, allowing a variety of cleaning programmes, including hot solvent high pressure spraying in conjunction with mechanical action through rotating, oscillating and swinging movements of the basket.

Although Firbimatic hermetically sealed units can be more sophisticated, the superior cleaning results and the significant savings in solvent consumption have determined their undisputed success in full compliance with safety and environmental regulations.

No component has ever failed because it was too clean!

The reasons for failure A research made by the Massachusetts Institute of Technology of Boston by Dr. E. Rabinowicz showed that 70 % of failure reasons of lower performance of components is to be motivated by the degradation of the surfaces and that the most of such failures take origin from mechanical wearing (50 %) and corrosion (20 %).

The Firbimatic cleaning systems, are in total compliance with the international standards protecting operators and safeguarding the environment, capable to successfully treat both metal and nonmetal surfaces.

These cleaning units must completely remove both organic and inorganic

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Reasons Of Failure â&#x20AC;˘ Obsolescence of component (15%) â&#x20AC;˘ Accidental causes (15%) â&#x20AC;˘ Surface degradation (70%) contaminants from the treated pieces, pinpointing from time to time the cleaning cycle most suitable for the type of component and pollutant and they must be specially effective with parts of complicated shape.

The solid dirt particles such as powders, swarfs, shavings and inorganic salts must be successfully removed as well as layers of burnt oil and other solid contaminants (oxides and lapping and polishing pastes) deposited on the component which often require on the other hand the action of ultrasonics.

Architectural features of Firbimatic modified alcohol machines Closing system of the washing chamber: dual seal technology and commissioning tests under-vacuum at the beginning of each cycle. This allows a high level of safety (with the category of AIII solvents).

The dimensioning of the distiller is to avoid additional heaters in the tanks.

Thermal energy recycling of the distiller and in this way the power consumption is lower (- 30%). The heating in the distiller is indirect and electronic temperature control, this avoids pasting oil residue on the bottom of the device. The resistive elements for the heating of the distiller can be disassembled easily for cleaning.

Possibility of double distillation to evacuate the distilling oils in bypass to avoid manual intervention or stop the

production consisted. Firbimatic uses only a very powerful vacuum pump for the vacuum system and drying (Multisolvent). Automatic defrosting of the cooling unit is installed on the machine. All tanks are heated through vapor distillation (tanks 1 and 2), this allows excellent cleaning and a low energy consumption. Integration of a high flow circulation pump to create turbulence in the bath of the first tank in the washing chamber.

Tanks and piping can be completely insulated. The machines are designed for use with modified alcohol and nonhalogenated hydrocarbons, without modifications. versions are available DUAL SOLVENT (perc and alcohol).

Circulations forced under pressure and the size of the still allow you to wash from 4 to 8 baskets / hour.

Consumption of solvent cleaning machines For solvent cleaning machines, we can estimate an average consumption of very few liters of solvent per year if the following conditions are met: 1. Correct choice of the treatment program; that is by using only the preloaded programs in the machine by our technicians during commissioning and start-up of production.

2. Proper management of the distillation of the solvent; that is by performing the steps of distillation according to the amount of contaminant brought to machine and not manually forcing the procedure of distillation.

3. Regular maintenance and cleaning; operating according to the appropriate time period indicated in the user manual.

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TECH TRENDS

Automation in sheet metal

cutting and welding The paper examines welding and cutting process trends in the sheet metal and plates used in various industries like automobiles, infrastructure, ship building, aerospace industries, wind tower manufacturing etc. Productivity gains in arc welding are reviewed, and the increasing use of laser cutting and welding, as well as laser-arc hybrid welding, particularly in Europe, is discussed and explained. Some friction technologies are already widely adopted, but they could make more impact with further development. Electron beam welding could also be used with economic benefit in some situations, but as with all non-arc processes, it will only be adopted if significant gains in productivity and cost reduction can be created to justify the more specialist welding equipment required. Many productivity improvements can come fromw non-welding activities in the fabrication process.

1. INTRODUCTION Leadership in manufacturing (welding and Cutting) can come from addressing the factors of QUALITY, COST, PRODUCTIVITY, SAFETY and CONTINUAL UPGRADATION OF TECHNOLOGY. Inflection in Metal Fabrication Technology has taken place in the Manual / Semi-Automatic Welding Power Sources - (Digital control inverters), Welding Automation - (Developments in HNG SAW, HNG MIG, Tandem MIG / SAW, Friction Stir, Electron Beam, Saddle Welding Automation, Robotics, Laser spot welding, Hot wire TIG, Orbital systems, automation with hybrid welding systems like Plasma â&#x20AC;&#x201C; MIG, Laser - MIG) and major advances in the cutting processes (Precision Plasma, Laser Cutting, Waterjet cutting etc.).

This paper reviews current trends in arc welding and cutting processes used for Sheet metal processing and will discuss some of the newer processes which are beginning to replace arc welding for such steels, or have potential to do so in the next 10 years.

2. ADVANTAGES OF AUTOMATION a. Consistency in weld result - Error Proofing: A welding supervisor can limit the amount of changes an

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b.

c.

d.

e.

operator can make during a program, preventing him from accessing the override screen through the use of a key switch or password.

Multiple parameters for multiple weld-run: In addition to the ability to adjust parameters between weld passes, operators of microprocessorbased welding machines can also program changes to weld parameters during each pass, which offers distinct advantages for certain applications.

Store parameter for sharing on other machines with same applications: A microprocessor-based power source can store programmed welding procedures on data cards. This allows the operator to easily transfer programs developed on one machine to other machines being used either in the same facility doing the same type of work.

Quality control: Microprocessorbased machines can immediately alert the operator if weld parameters fall outside pre-selected limits. Parameters can be directly to a quality-control computer program for storage or statistical analysis. This eliminates time-consuming radiography in many applications.

Date storage and records: It is now

very easy to display a set of welding parameters and operator or supervisor can observe the welding procedure.

Moreover, the data can be printed in the form of reports, which can be presented to the customer as quality assurance procedure. f. Quicker Weld-Fault diagnostics lower repair time: The system can be stopped if the measured values cross a certain preset variation limit. It is possible to stop the machine in out-oftolerance conditions. This enables the operator to perform timely functions and take necessary steps to prevent the deposit of faulty welds.

3. TANDEM MIG AND ROBOTIC WELDING Significant improvements in productivity are nowadays hard to gain in this mature process. In gas-shielded MIG/MAG processes, the growth of tubular wire over solid wire is still slow despite the deposition and bead shape benefits of the former although tubular wire usage is higher in the USA and Japan compared to other parts of the world. The lower price of solid filler wire, particularly in Europe, is still a dominant factor that continues to favour their use. Self-shielded cored wires are still widely used in the USA

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TECH TRENDS but less so in Europe because of the fall-off in fabrication of large offshore installations. Care is always needed in selecting self-shielded wires if weld metal toughness is a critical design factor.

Schematic of Equipment for TANDEM MIG

installations per annum, but generally robot take-up for welding is still majorly for the automobile sectors. Robots are being employed in situations where product repetition and/or tonnage throughput are high, combined with relatively standardised designs. Robot profile cutting is increasing in usage and in Japan, some building frames are now being welded on robot lines and agile robots are also used for site welding building column joints at height.

The applications most suited to robot use involve butt and fillet welds in the fabrication of beams, welding of stiffeners to beams, welding of end plates and the assembly of panels or decking.

A likely trend is to ‘take robots to the work’ and use them for large part and sub-assembly manufacture in cells which house autonomous vehicular robots. These robots, mounted on moving platforms are manoeuvred around the parts to be welded and are capable of all-positional welding using the MAG process with tubular wires, (Fig.2).

Fig. 1: TANDEM MIG Advantages of TANDEM MIG: • Exceptional welding speeds • High weld metal deposition rate • Superior weld quality: ◊ Reduced heat input ◊ Resists burn-through on thin materials ◊ Maintains low spatter levels ◊ Produces good penetration on thick materials ◊ Improves bead wetting at weld toes ◊ Resists undercut • Bead profile control • Lowers production costs • Increases productivity The greatest potential for productivity improvements comes from using robots.

Japan still leads the work in new robot

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Fig.2. Schematic diagram showing autonomous robot vehicle navigated by vision system, being used for all positional MIG / MAG welding 4.NARROW GAP SAW In submerged arc welding, multi-wire, iron powder additions and narrow gaps are common ways to increase productivity. However, the use of tubular wires is increasing in popularity and can offer better weld quality compared to solid wires in some situations, e.g. when submerged arc welding of primed plate.

In building and bridge construction MIG/MAG welding is more suited to automation and is now beginning to replace submerged arc welding, reducing costs and distortion significantly.

5 . LASER – IN CUTTING AND WELDING Low power CO 2 lasers were originally developed in the late 60s for cutting and welding operations, while Nd: YAG lasers entered the market only in the early 1980s. In the shipbuilding and off-road vehicle sectors, higher power lasers (3-10kW CO 2 and 2-4kW Nd:YAG) have become popular in the last decade because their use brings more precision in dimensional control, and greater accuracy in assembly, as well as the additional advantages of high cutting and welding speeds, and cleaner working.

Laser cutting is now an essential route to accurate assembly in steel fabrication.

Parts can be cut to a precision of ±0.3mm in 10 metres compared to ±1-2mm for conventional plasma cutting. Sub assemblies can then be arc welded to tolerances of a few millimetres in 15 metres, with the same lasers being used for marking and hole drilling on the cutting table. Even though arc welding is still regularly used for assembly of laser cut parts, cost reductions can be dramatic because of the improved accuracy of assembly and the potential for eliminating distortion correction and other processing operations downstream from welding. Direct costs have been cut by up to 50% using lasers for cutting in many shipyards, and this shows the extent of benefit which could follow from more widespread use of laser cutting in building, bridge and public infrastructure construction.

Fig.3. A typical laser welded sandwich panel and advantages over conventionally stiffened panels 6. LASER-ARC HYBRID WELDING There is tremendous interest in the use of CO 2 laser-arc or Nd: YAG laser-arc for steel construction at the present time.

The concept has been around since 1978 and was actively developed in Aachen in the late 90s using high power CO 2

TECH TRENDS

Fig. 5. Schematic diagram of the FSW process: (A) Two discrete metal work-pieces butted together, along with the tool (with a probe). (B) The progress of the tool through the joint, also showing the weld zone and the region affected by the tool shoulder.

Fig.4a. Nd:YAG laser - MAG hybrid process being developed for land pipeline girth welding. Picture of the welding head

Fig.4b. macro section showing MAG root and cap beads & central hybrid weld bead lasers in combination with one or two MAG torches directed into the same weld pool in series with the laser. Already one shipyard in Germany has such a system in production on a panel line, the process replacing submerged arc welding. The advantages of moving from simple arc processes to a hybrid laser-arc system include higher joint completion rates and associated control of distortion. As noted above, laser systems alone are usually not sufficient to cope with variations in joint gap in large structures. However, where plates are thin, it is possible to produce stiffened panels successfully by laser welding.

7. FRICTION TECHNOLOGIES There have been many exciting

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developments in friction welding and probably more process innovation in the last decade than in the previous 40 years when friction welding first came on the scene. In the context of metal joining and construction, friction stud, radial friction and friction stir welding are good examples of more recent approaches, with friction stud already being used in the production of sandwich structures comprising steel skins and a concrete core and for welding attachments in high volume such as shear connectors and reinforcing bars to end plates.

Attachment of anodes under water to offshore installations using steel studs and electrical connections to railway lines are other applications of friction stud welding.

APPLICATIONS Shipbuilding and Offshore, Aerospace, Automotive, Railway Rolling Stock, Fabrication

8. ELECTRON BEAM TECHNOLOGY There have been several key improvements in this process in the last decade which have made EB welding increasingly attractive for large-scale fabrication of steel structures such as buildings and

bridges. The two main areas of improvement are in gun development and reduced pressure technology.

Reduced pressure electron beam welding system Reduced pressure EB welding using chamber pressures of around 1mbar has been another major step forward in simplifying EB welding operations.

The beam shape and beam penetration at, say 5mbar, is identical to that at the more conventional pressure for EB welding of 5 x 10 -3 mbar. This reduced

TECH TRENDS

pressure option does away with the need for large vacuum chambers and worries about leaks and seals. Simple mechanical pumps and local seals are sufficient to achieve ~1 mbar. These systems are also more tolerant to fluctuations in working vacuum pressure, gun to work distance and work-piece cleanliness.

9. WIND TOWER MANUFACTURING – SPECIALIZED CUTTING AND WELDING PROCESS APPLICATIONS Wind Tower fabrication employs extremely precision applications of metal cutting and welding processes like gas cutting triple torch, with Single pass three torch cutting Automatic setup which provides High accuracy, Capacitive height adjustment, Infinite rotation of cutting head, Automatic angle adjustment 20 - 50° (Option for 30 - 60°). In addition, plasma cutting system is used with Automatic Setup, Highest Accuracy, and Bevel angle adjustment: +/- 52°, Initial height setting with tactile sensor, Cutting height adjustment via automatic arc voltage sensing process.

Precision High end CNC Plasma cutting process is utilized with high degree of automation needed to guarantee consistent quality. Programming software, Numerical control and Automatic rotating bevel tools are used to dispense with manual tasks. Automated SAW systems with Twin Wire, Tandem, Tandem – Twin and Multi – wire systems are used along with customized welding heads, wire feed systems, joint tracking systems, Column and Booms, TELBO systems,

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Rotators and Positioners. In addition, Tractors and Fit – up units are all used for this application and also for many other welding applications.

10. CONCLUDING REMARKS Where will engineering construction be in five years time? Productivity improvements can come from many different areas in the total fabrication process, e.g. general design, detailed design, contract drawings, CNC instructions, cutting and profiling, welding, inspection, finishing etc. It needs to be realised that optimising the welding process and procedure in isolation may have only a small effect on overall productivity. As an example, fabricators in the bridge and building sector continue to make big improvements in reducing the cost per tonne of steel fabricated by focussing on efficiency improvements in non-welding operations.

These non-welding areas will continue to receive much attention in the next few years. For example, 3D solid model-

ling is expected to be at the heart of the improvement process enabling virtual assembly, direct instruction of cutting and welding machines, computer modelling of metal processing and welding operations and optimising of welding sequences. In addition automated inspection and data gathering will increase in usage to give more comprehensive Quality Assurance. Productivity improvements could also come from greater standardisation in steel specifications and in joint details and from modularisation of large structures to reduce the time spent on site fabrication and erection.

Use of new welding processes and an increased use of automation and robots will take place slowly and gradually, only being justified where the introduction creates significant gains in productivity or cost reduction. As such, these changes can be expected particularly in situations where skilled labour is short, where welding cells can be kept fully occupied or where customised, made to order components are needed.

(Contributed by Ador Welding Ltd.)

For more information Web: www.adorwelding.com

Taming power quality is now child's play

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These silent sentinels protect your sophisticated, high precision production equipment from the ill-effects of voltage, spikes, surges, transients, sags, noise and harmonics affecting AC power lines. Thus ensuring continuous uptime and enhanced productivity and consistent quality.

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TECH TRENDS

The Diversity of Tactile Measurements The number of metrology applications is almost infinite—automated testing, multipoint measuring stations and individual test stations are just a few of the variants, and each application demands specific properties of the encoders and evaluation electronics used. HEIDENHAIN provides a wide spectrum of solutions for such purposes which, thanks to photoelectric scanning, benefit from high accuracy across the complete measuring range.

The four HEIDENHAIN length gauge product ranges: From online device monitoring and 0.1 µm accuracy to almost zero Newton gauging force

T

he diversity of uses for HEIDENHAIN length gauges is hardly less than the number of applications. For measuring rooms, the monitoring of measuring equipment or for manually operated measuring stations, the CERTO and METRO series are ideal, with accuracy of better than 1 µm. ACANTO and SPECTO length gauges, on the other hand, are suitable for automated test equipment and multipoint measuring stations because of their specific construction designs.

High accuracy over the complete measuring range means that several different components of various sizes can be measured with identical accuracy levels by all length gauge models. The result is that supplementary devices are not needed. All variants also feature special characteristics targeted at the wide diversity of applications. Together with suitable evaluation electronics, HEIDENHAIN solutions meet the highly specific demands of metrological tasks.

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HEIDENHAIN ACANTO: Absolute length gauge with online device monitoring In dynamic measuring tasks such as on test stands, counting errors can occur in the subsequent electronics when using incremental encoders. These are often caused by excessive speeds or vibrations.

The absolute length gauges from the HEIDENHAIN ACANTO series avoid such counting errors by continuously determining the absolute position value for each request without needing a reference run, thus immediately providing a measured value. Measuring errors caused by excessive plunger speeds (e.g. from bounce) belong to the past.

HEIDENHAIN ACANTO length gauges also supply analyzable data about the measurements, providing

information about the specific rating with each machining step or quality testing step. This is made possible with the bidirectional EnDat 2.2 interface, which in addition to the position value provides further information about the length gauge: • Valuation numbers supply data about the current state of the encoder.

Continuous monitoring of the functional quality of scanning is therefore possible.

• Warnings and alarms allow conclusions to be drawn about components affected by failure, e.g. the light unit.

• Upon switch-on, the electronic ID plate immediately displays all technical parameters for the encoder. This avoids erroneous configuring of the evaluation electronics.

TECH TRENDS www.mtwmag.com

An important aspect of the Industry 4.0 topic is supporting people via technology, for example with self-configuration and self-diagnosis. The subsequent electronics can independently configure the signal period or measuring step with the transmitted information. Also, the EnDat 2.2 interface enables information to be written back to the length gauge. Two different corporate divisions directly benefit from this added value: • Quality Assurance can determine the quality of measurements with the diagnostics information.

• Machine maintenance can avoid unnecessary idle times during production via advance inspections thanks to the valuation numbers.

The valuation numbers are dynamically generated in a similar way to the maintenance intervals for modern automobiles according to their driving conditions, with the encoder detecting whether a light source is aging, for example, or the scanning equipment is contaminated. The measuring range of ACANTO length gauges is 12 mm or 30 mm according to specific version, with IP67 protection. The compact station width of 15 mm means they are also especially suitable for multipoint measuring stations.

Multipoint measuring equipment is gaining in popularity Multipoint measuring stations are becoming ever more important in the field of industrial measuring technology. Electronics control the simultaneous measurement of several measured values on a test component in such applications, and often as part of a predetermined testing procedure with complex measuring tasks.

The SPECTO series features a station width of just 13 mm for such applications, enabling several length gauges to be positioned in tight spaces. To keep space requirements in the system low, cables can be either axially or radially connected.

HEIDENHAIN SPECTO length gauges are also ideal for in-process measurements thanks to protection classes to IP67.

Accuracy of ±1 µm is ensured over measuring strokes of 12 mm or 30 mm. The short-range accuracy (measurement error in a measuring range of 200 µm) is typically less than 0.3 µm, and

Online device monitoring for all machining steps and quality inspection steps providing information for quality assurance and machine maintenance

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TECH TRENDS repeatability has the same low value.

These values are possible among other factors due to the highly precise ball guide, designed for a life of more than 60 million measuring cycles.

To ensure that data from multipoint measuring stations is reliably and quickly evaluated, HEIDENHAIN offers the MSE 1000 modular subsequent electronics, enabling the simultaneous measurement of up to 250 measurement channels over a wide variety of interfaces. When designing the MSE 1000, HEIDENHAIN placed an emphasis on simplicity for installation of the modules and connection to the encoder. Modules can be mounted to DIN rails to achieve tidy and compact measuring stations. The selected system configuration of the modules is detected automatically and unnoticed by the user, who only needs to define and set the specific channels.

The MSE 1000 also of course allows EnDat encoders to be connected in their entire functionality, enabling all the benefits provided by the ACANTO length gauges to be used for example. Valuation numbers, warnings, alarms and the ID plate can be displayed and queried via the unit.

In addition to support for the EnDat HEIDENHAIN protocol for absolute encoders, all common incremental encoders, further connection options for analog sensors and LVDT and HBT displacement sensors from well-known producers are also supported. Modules with switching inputs and outputs enable interaction with other actuators in the encoder. A Compressed air switching module for direct control of e.g. pneumatically actuated length gauges is also available. Data transmission is via standard Ethernet.

The scope of supply of the MSE 1000 includes, in addition to a system configuration program, a DLL library that allows users to develop their own testing programs. With testing processes requiring further actions (depending on the measuring results), complex sequences can thus be stored.

The ND 2100G GAGE-CHEK evaluation electronics are ideal for up to eight measurement channels, displaying

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the values of the single channels or directly evaluating these. The ND 2100G GAGE-CHEK can also carry out complex calculations via equations and comparisons, with the software and hardware enabling the saving of processes and responses and the controlling of switching inputs and outputs. In this way, PLC functionality can be integrated into the evaluation electronics.

HEIDENHAIN METRO and HEIDENHAIN CERTO: Measuring below 1 µm With an accuracy of ±0.1 µm and repeatability of 0.03 µm, the HEIDENHAIN CERTO length gauge gives you the most exact tactile measurement over a range of up to 60 mm that the market has to offer. HEIDENHEIN measures repeatability with five measurements across the complete measuring range near to the lower plunger stop. Repeatability specifies the difference between the initial measurement and the settled condition of the encoder after five measurements.

The advantages of photoelectric sampling are exploited to the full, with the finest lines being sampled without contact and therefore without wear, thus enabling such outstanding technical parameters.

The calibration chart also indicates a value for linear error compensation. In combination with an ND 287 evaluation unit, the achievable accuracy improves to ±0.03 µm.

Using the recommended CS 200 gauge stand even results in a thermally invariable measuring loop. Since the gauge stand and the HEIDENHAIN CERTO mechanism both consist of Invar (expansion 1 ppm/K) and the scale with 2 µm signal period is manufactured from ZERODUR (expansion 0.1 ppm/K), small variations in temperature, which generally cannot be avoided, do not affect the accuracy. Length gauge accuracy is specified in the range of 19 °C to 21 °C for this reason. For high-accuracy measurements, such as stations where the finished dimensions are checked, the optional analog module of the ND 287 can be used to compensate for deviations in the temperature of the workpiece or the entire system. The electrical motor of the

length gauge offers three gauging forces and a constant probing force over the entire measuring range.

A further series in the accuracy grade below 1 µm is the METRO product range, and just like CERTO length gauges, these feature a precision graduation with a 2 µm signal period. This ensures system accuracy of ±0.2 µm over the entire measuring range of 12 mm or 25 mm. The interplay of ball bearing guides and highprecision photoelectric scanning achieves repeatability below 0.03 µm, and shortrange accuracy with a measuring range of 12 mm is typically less than 0.03 µm.

Tactile length gauge with a measuring force of almost zero Newton Continued progress in the field of materials technology is leading to increased use of flexible materials such as elastomers in industry. The desire to produce ever more compactly also presents new challenges for the measuring of delicate workpieces.

The undesired deformation of elastic parts caused by the encoder may distort measurement results, and workpieces made of highly sensitive materials can also damage or destroy the encoder.

The MT 1281 MW length gauge from HEIDENHAIN’s METRO range now enables a test object to be measured tactilely with minimum risk from deformation or damage. This is due to the unusually low measuring force of between 0.01 N and 0.07 N manifested by the length gauge over its complete 12 mm measuring path.

The ND 287 evaluation unit is suitable as a subsequent electronics unit for standalone measuring stations. When combined with the METRO series, a measuring step of 1 nm is possible. It also offers many possibilities for capturing and classifying measurement series as well as creating histograms. The ND 287 thus makes it easier to evaluate the manufacturing process.

Contributed by

TECH TRENDS

Sparkonix’s

customised EDMs to serve your specialized applications!

S

parkonix is a leading manufacturer of Electric Discharge or Spark Erosion Machines and has been leading the way in multiple applications across industries. One of Sparkonix’s highly innovative solutions in this domain is fully customised EDMs for specialised applications.

The customers asked for it!

Sparkonix offers a full range of EDMs

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catering to a variety of needs and applications. However, post 2000, many companies, especially MNCs, began manufacturing highly complex dies and moulds in India. Several companies approached Sparkonix with their specialised needs, which were highly difficult to perform on the standard EDM models available in the market.

Customers trusted Sparkonix’s deep expertise in the spark erosion technology

and commissioned the team to develop custom-made EDMs to serve their specific applications.

Advantages of Customised EDMs Customised EDMs from Sparkonix offer several unique advantages to the users: Lower cycle time Custom EDMs come with specially designed fixtures/holding tables, di

TECH TRENDS www.mtwmag.com

electric tanks and sparking systems that significantly reduce the set-up time and cycle time as compared to standard models.

Better finish and accuracy Custom EDMs are specially designed keeping all the unique needs of the process, and include provisions to place, hold and shape the job as required.

Higher productivity Additional automation and customised programming in the EDMs means better productivity for the customers For the love of technology “The challenges in customised EDMs are totally different as compared to standard

EDMs”, says Shailesh Patwardhan of Sparkonix.

Customising the EDMs opens-up many new possibilities in terms of innovative features that create unique advantages for the customers. “At Sparkonix, we just love taking up these new technical challenges and that has been the driving force in building the customised EDMs, year on year”, adds Shailesh.

Some examples of customised EDMs by Sparkonix include: • Special purpose EDM developed for one

of India’s largest pump manufacturer to machine through almost inaccessible places in stainless steel components • A Custom EDM for a highly specialised machine tools company to manufacture twin screw extruders, critical to the operation of the machine. The screws, measuring several meters in length, had to match tolerances in microns.

• Customised EDM for India’s leading Plastic Mould manufacturer to machine Ribs in cavities as deep as 600 mm.

• Specialised EDM for Diamond Wheel manufacturer to make grooves on wheels used in the glass grinding application For more information, Email: sparkedm@vsnl.net

Specialised Job manufactured on Customised EDM

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TECH TRENDS

How Toolpath Machining Technology is making manufacturers more competitive Manufacturers are improving machining performance 50 to 300 percent without the need to make changes to existing equipment and infrastructure. Thousands of manufacturers worldwide have transformed their machine shops into highly cost-efficient operations, enabling them to successfully compete in world markets – many for the first time in decades.

By Jim McMahon

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anufacturers in North America must balance a multitude of issues to stay profitable.

Increased competition from overseas manufacturing with its access to cheap labor, the reduced availability of qualified workers in the manufacturing trades, and tightening employee and environmental regulatory requirements, are but a few of the key issues challenging the wits of manufacturing executives today. Because of this increased level of change and instability in the manufacturing sector, the costs of traditional growth initiatives – such as adding floor space, capital equipment, personnel and overhead – present more of a significant risk today than in early times when the manufacturing environment was more stable and predictable.

Underutilization of existing machining resources One key area of poor capacity planning within manufacturing is the failure to fully realize the capability of existing machining resources. Instead, for many machine shops, the solution to increased capacity has been to add more equipment and workers, and extend valuable floor space. But, the true production capacity of a machine tool is seldom fully realized by those responsible for assessing production volumes. This factor is so important that it can make or break the profitability of a machine shop. At the very center of

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this issue is the inefficiency of computeraided manufacturing (CAM) toolpath generation, which plays a critical role in fully influencing machine production capacity. Also, a high level of inefficiency exists in conventional toolpath generation, despite the otherwise high-performance levels of modern CAM systems.

“Millions of manufacturers believe that the toolpaths native to their CAM systems are designed for optimum performance,” said Gregory M. Saisselin, Vice President of Worldwide Sales for Celertitive Technologies, a leading developer of toolpath generation software. “In the vast majority of cases, they are running, at best, at 50 percent of their productivity potential.”

The importance of science-based Toolpath Technology For many manufacturers, using more efficient toolpaths to drive their existing machining equipment has proven to be a much more cost-efficient and workable solution to managing the variables of order size and improving production throughput, compared to

investing capital into new machinery and the labor requirements to support it. Groundbreaking toolpath technology has helped manufacturers reduce costs, produce more parts, and lower project bids, while utilizing their existing equipment and infrastructure.

This machine-efficiency transformation is being played out in thousands of machine shops within manufacturing facilities in the United States and throughout the world. Spearheading this change is a science-based toolpath, called VoluMill, developed by Celeritive Technologies, Inc. (Celeritive), for highefficiency, rough-milling operations.

VoluMill is a true science-based toolpath technology that enables machine tools and cutting tools to operate at peak performance. It performs all of the complex calculations required to determine the best cutting strategy for any part. Its toolpaths drive cutting tools along a path that maintains a consistent tool load, has no sharp corners or sharp directional changes – the toolpath is smooth and flowing with no repeated

TECH TRENDS www.mtwmag.com

stopping and starting. VoluMill keeps a constant step-over whenever possible, resulting in shorter path lengths than other approaches. This produces even machining loads with uniform chip formation, and excellent heat evacuation. By avoiding sharp directional changes and controlling the rate of material removal, the toolpath enables the tools to cut faster and deeper, while greatly reducing stress. The toolpath evens the loads on machine tools and cutting tools, significantly extending tool life.

“This toolpath solution increases the productivity for any twoaxis, three-axis or two-plus-three-axis rough-milling application” continued Saisselin. “It dramatically reduces machine c ycle times, enabling the production of more parts per hour. This means increased profitability and increased asset utilization for the shop.”

What is driving widespread manufacturer acceptance Released in 2008, VoluMill has gained international acceptance within dozens of various manufacturing industries such as aerospace, automotive, medical equipment, heavy industrial, oil & gas, and consumer products. Manufacturers are improving machining performance from 50 to 300 percent without the need to make changes to existing equipment and infrastructure.

“The toolpath solution can easily blend into any machining environment, without having to change CAM systems,” explained Saisselin. It is integrated into seven of the world’s leading CAM systems, and consistently performs better than the native toolpaths.

“We use Siemens NX with the VoluMill plug-in,” said Chuck Shannon, with General Tool Company in Cincinnati, Ohio. “Tool life is dramatically increased due to the reduced load and heat on the cutter. We obtain higher metal removal rates than traditional cutter paths.”

The recognition that streamlining toolpath performance can significantly improve machine efficiency and production capacity has prompted a number of CAM software offerings following in the footsteps of VoluMill. None, however, have been able to keep pace with its market acceptance or its toolpath performance.

“The introduction and industry acceptance of VoluMill is nothing short of revolutionary,” said Saisselin. “It has completely changed the way metal is cut. It throws out everything that has been done in the past, and has introduced a better system of toolpath generation.”

Game-changer for manufacturers Although toolpath generation is but a component within complicated CAM systems, it is a very critical one that plays a vital role in machining.

The benefits of an intelligently engineered toolpath technology in use within a manufacturing facility can have extensive implications. Increased machine capacity means a greater volume of finished parts can be produced in less time, which provides for greater flexibility to meet just-in-time delivery schedules.

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Heavy duty machining - But safe The importance of the tool holder is still understated, especially when it comes to roughing and heavy duty machining. Metal removal rates in these types of processes are absolutely crucial for the productivity of the machining operation. By using special shrink fit chucks with drive pins and spiral grooves in the tool shank it is now possible to perform high-feed full slotting of up to 2 x D (50 mm) or more in difficult to machine materials. Application studies conducted by the machine tool manufacturer Heller have proven the effect of the HAIMER Safe-Lock system

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specially within the aerospace, energy and mechanical engineering sector, production managers have to bridge the gap between economic efficiency and high process reliability when working with materials that are difficult to machine.

Fortunately there is peace of mind in knowing that the machine technology innovations continue to develop to meet the ongoing demands of manufacturing.

Heller machine tools is known as a source of inspiration for these kinds of innovations. The company, located in Nuertingen, Germany, is known for its high quality 4 and 5-axis CNC machining centres, CNC mill/turning centres, CNC machines for crankshaft and camshaft machining as well as flexible manufacturing systems. Customers value their availability of products and their competency in managing special processing demands. Both qualities stem from Heller’s in-house manufacturing, which relies on closer collaboration with customers, suppliers and researchinstitutes to remain on the forefront of innovation.

Roughing is a highly promising process Werner Kirsten, who is working in the Technology Development Department at Heller and is responsible for the area of “difficult to machine materials“, explains: “our service includes optimizing the machining processes together with our customers and suppliers. To support such services with practical trials, our

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Technology Center is equipped with a variety of machines”. In most cases the aim is to increase the prod-uctivity without compromising the process reliability. Technologist Kirsten adds, “We often achieve this aim with an optimized roughing operation which ultimately results in a reduced finishing process. By maintaining the same technological values, but shortening the finishing depth of cut by 50%, the overall machining time is reduced to half. However, this requires process reliable and controllable systems during roughing.” In this regard,all machining components in the process chain have to be considered in order to improve productivity. The machine tool is the most evident component of the machining process, however the tool holding system, the coolant supply and other elements are also essential for a successful operation. “In the end the weakest link of the process chain limits the success,” Werner Kirsten emphasizes.

In his opinion most machine shops don’t pay attention to the tool holder even though it is especially significant for high performance cutting. “Many of the trials which we carried out during the last few years have proven this point”, Werner Kirsten explains. We realized that the tool holder hasan incredible influence on the machining process. In the case of reinforced shrink fit chucks, for example, the vibration node is closer to the bearing point (due to the larger mass). The

result is a smoother machining process with less vibration and a better surface finish quality while using the same tool, machine, process parameters and fixturing technology.”

Tool holding - an important factor for productivity By selecting the right tool holder you can even achieve good productivity and surface quality results using basic standard cutting tools. Werner Kirsten refers to comparative tests with basic four-edge cutting tools without an inner coolant supply. As an alternative to a standard shrink fit chuck he selected a HAIMER Power Shrink Chuck with Cool Flash which ensures that the coolant is transported directly to the cutting edges.

“Compared to using a normal shrink fit chuck and external coolant, we were able to achieve significantly better results.”

When a group of representatives from the aerospace industry, the Technical University of Dortmund and Technical University of Hamburg-Harburg visited Heller,an especially extensive milling application study was conducted in Titanium Ti-6AI-4V. Gaining new insights from difficult cases The available machining center was a four axis Heller H 5000 with a gear unit and HSK-A100 spindle, which yields torques up to 2.290 Nm. In order to demonstrate the machining potential, different 25mm diameter end mills were used to mill full slots into a titanium plate. To simulate holder conditions used in the aerospace industry, the tools

TECH TRENDS www.mtwmag.com

were clamped into reinforced shrink fit chucks. At an axial cutting depth of0.5 to 1.0x D the machining process was found to be very reliable. Since the spindle was not running at full capacity, the trial participants agreed to increase full slotting depth to 2 x D. Werner Kirsten explains: “Under these conditions the tool pulled out of the shrink fit chuck during the machining operation, creating a slot closer to 2.5xD as it progressed through the part. Towards the end of the slot the tool finally broke as a result of increased cutting forces.”

The milling specialists all agreed that the clamping force of the chuck was the limiting factor in this process. As

soon as the axial pressure and process related vibrations are too high the tool moves out of the chuck and further into the workpiece. At the same time the cutting pressure increases such thatin the end the tool breaks and the workpiece is irreversibly damaged. Reasons and possible countermeasures were discussed intensively. In the end, Werner Kirsten developed the idea that the tools are forced to navigate towards the spindle when the holding forces are exceeded.

This is how he ultimately noticed the patented HAIMER Safe-Lock™ system which in addition to frictional clamping forces, has the same helix pattern as the tool. Theoretically, he realized that even if the tool got loose while using Safe Lock™, it would be pulled into the holder through the helical drive keys and not into the part. A movement that can be easily prevented through the use of length presetting screws.

Prevent tool pull-out Werner Kirsten got in contact with

HAIMER, the European market leader for tool holding technology, in order to test the Safe-Lock™system: “we wanted to know if our ideas could be put into practice using the HAIMER system in an even less forgiving environment.” The Heller technology developer repeated the described trial,with a few major changes.

HAIMER Safe-Lock™ grooves were subsequently added on similar solid carbide tools, but the application would be run again with a reduced spindle taper interface (HSK 63 instead of HSK 100), with a less rigid 5-axis gear driven spindle and a less stable diagonally fixtured workpiece. The result: Despite these additional limiting factors, the tool was able to process a full slot of 2 x D = 50mm with complete process reliability.

Werner Kirsten says: “this way we were able to indirectly prove that Safe-Lock™ works and that the shrinking technology has even more potential with HSK-A100, especially on 5-axis machining centers with gear spindles.”

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Thielenhaus’s cost-efficient machining solutions For the large-scale production of flat precision components Thielenhaus Microfinish has launched a cost-efficient and compact machining solution

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n close collaboration with the Japanese mechanical engineers Nissei, the ultraprecision machine tool producers offer a double-disc grinding machine characterised by four advantages: Precision, cost-effectiveness, ease of use and compactness.

During production, any expensive extra that wasn’t necessary for achieving the stipulated goal was foregone. Instead, it was precision that was of paramount importance: The focus of the design has therefore been laid on a high degree of rigidity: closed box frames instead of a C-frame, forged instead of turned tool spindles, clever positioning of spindle tilting mechanisms and a doublewalled frame design for temperature insensitivity. Indeed, the all-important dressing process requires such rigidity to create the appropriate tool geometries.

Other highlights include the spindle sleeve feed system in conjunction with a worm gear, the associated patented pneumatic compensation for thread play and high-precision ABEC-7 class bearings. Furthermore, effective standard features, such as an automatic tool-wear compensation system for the lower grinding disc by means of in-process measurement, are also included.

Exceptional machining results With steel precision discs with a diameter of 68 mm, for example, parallelism below 3 µm and surface results of Ra 3.2 µm can be achieved with a cycle time of 0.6 seconds. In another application, the machine achieves a

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removal of up to 0.6 mm per pass.

Ease of use is a further crucial advantage. A patented swivel transport disc bracket allows the operator to change the grinding discs easily through the large front opening just a few seconds after the spindles have come to a stop. With an adaptable tool-changing aid this can be done in just a few minutes. Depending on the tolerances to be achieved, workpieces can be machined using a flow, flow/ plunge or oscillation process. For the highest component specifications, the workpieces can also be propelled in the grinding gap with the appropriate transport disc designs.

Minimum footprint Nissei has managed to compress this vertical machining solution into a footprint of just 2 x 2.5 m including the

Conditioning of the upper grinding disc with the NC-controlled dressing unit

With the Thielenhaus-Nissei doublesided grinding machine control cabinet, which also makes it suitable for compact production lines.

There are various automatic loading options for feeding and removing workpieces, ranging from stack magazines to robots.

The vertical double-sided grinding machines are available in eight models with different grinding disc sizes up to a diameter of 760 mm. Depending on the machine model and process, rotationally symmetrical workpieces from a thickness of 0.8 mm and up to a diameter of 220 mm can be machined.

Whilst Nissei is responsible for the construction, installation and runningin of the client’s workpieces, all service aspects, including dealing with enquiries, advice, quotations and sample processing, through to commissioning, training, warranties and after-sales, are provided by the Thielenhaus team for Europe and North America. As a result, operators have the advantage of a local contact who can be reached quickly throughout the whole life cycle via the 24/7 service hotline. With this support, even small and medium-sized companies are able to purchase and operate a high-quality Japanese machine with a long service life and outstanding cost-effectiveness.

An exhibition on technologies for automotive manufacturing 21 â&#x20AC;&#x201C; 23 March 2017

Pragati Maidan, New Delhi, India www.aes-show.com

Contact us to book your booth now: Divya Lad +91 22 6103 8435 | +91 99200 18008 divya.lad@india.messefrankfurt.com Abhishek Kumar +91 22 6103 8434 | +91 98198 34900 abhishek.kumar@india.messefrankfurt.com

CASE STUDY

The story of Europe’s largest

3D printed part for satellites How Thales Alenia Space & Poly-Shape SAS built Europe’s largest qualified 3D metal printed part for satellites

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dditive manufacturing makes more than just headlines. The industrial revolution of 3D metal printing is pointing the way to a change in manufacturing strategies. And facts are being established which will herald a fundamental paradigm shift for the manufacture of metal parts. AM is really pointing the way forward when it comes to substitution or as a hybrid strategy in combination with conventional machining methods.

Once again, the aerospace industry is driving forward innovation and acting as the spearhead for digital manufacturing.

The most recent signal comes from Thales Alenia Space. Working in collaboration with the 3D printing service company Poly-Shape, it has produced additively manufactured parts for the new South Korean communications satellites Koreasat-5A and Koreasat-7. Koreasat-7 is set to go into orbit in 2017 at position 116º East in order to provide coverage for South Korea, the Philippines, Indonesia and India. Koreasat-5A will cater for Korea, Japan, Indochina and the Middle East from the position 113° East. Koreasat5A should be launched before 2017 second quarter.

XXL component produced in collaborative working relationship

The Koreasat-5A and Koreasat-7 antenna supports will be the largest volume parts

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so far produced by powder-bed-based laser melting of metals from Europe to be in orbit. With dimensions of 447 x 204.5 x 391 mm3– and weighing just 1.13 kg – they really can be referred to as lightweight components. The additively manufactured 3D components are used as basic antenna supports for the communication with ground base of the Koreasat-5A and Koreasat-7 satellites.

An identical part was installed in both satellites. The dimensions presented a real challenge for ThalesAlenia Space.

Lightweight construction and reduction in costs as crucial advantages

Aluminum (Al) is the metallic material most commonly used for satellites due to its weight and thermal conductivity. The less weight that needs to be put into orbit, the better. Florence Montredon, Head of AM at ThalesAlenia Space, says: “As a rule of thumb, the actual costs of putting 1 kg into orbit are around EUR 20,000. So every gram really does count. The starting weight of the two new satellites is around 3,500 kg.” AM’s potential for lightweight design was therefore a key reason to

move away from the traditional methods.

For these AM parts Thales Alenia Space chose an AISi7Mg alloy. Applications in space demand high strength, rigidity and resistance to corrosion from the materials that are used. The component validation process also revealed a low porosity rate on the finished component of < 1%. The tests of tensile and shear strengths also produced pleasing results. For example, the tests in relation to symptoms of fatigue according to Wöhler yielded values that significantly exceeded the required specifications.

Minor deviations in the geometry were corrected with simple reworking, as was a small crack which was revealed by the CT. Fairly small pores inside the geometry were accepted following localized mechanical analysis. Ultimately, the parts successfully passed the dynamic tests carried out at Thales. Florence Montredon: “The effects were huge: A 22% weight saving for the bionic AM structure compared to a conventional structure. Not forgetting a reduction in costs of around 30% with the finished part being available very much faster.” The cost reduction

CASE STUDY www.mtwmag.com

time to market. In this sector, it is referred to as time to fly.

Machine and plant technology from Concept Laser on XXL scale

of 30% is attributable to various factors.

First there is the reduction in outlay on assembly: The redesign as an additive, bionic part replaced the number of parts that were previously produced from nine to one. And this was done through oneshot manufacturing, without the previous outlay on assembly. Secondly there was no need for mold construction, as casting would have needed to make the same part. Thirdly the temporal aspects are interesting when it comes to completing the ambitious stages of a project such as this on time. This is known in industry as

Poly-Shapehas 28 3D metal printing machines which have different sizes of build envelope. The largest build envelope dimension for 3D printing with aluminum at Poly-Shape is currently an X line 1000R from Concept Laser. It offers a build envelope of 630 x 400 x 500 mm3 and has a closed system for reliable process and powder management in accordance with the ATEX directives.

The X line 1000R also has a rotating mechanism which allows two build modules to be used reciprocally, thus guaranteeing constant production with no downtimes. This unique machine design not only results in greater availability, but also simple and above all secure handling when arming and disarming the machine.

The LaserCUSING process technology from Concept Laser was very important for the project: What makes systems from Concept Laser unique is stochastic navigation of the slice segments (also referred to as “islands”) which are processed successively. This patented process ensures a significant reduction in stresses when manufacturing very large parts.

With huge dimensions of 447 x 204.5 x 391 mm3, it is obvious to want to control warping to the maximum extent possible.

The X line 1000R offers balanced temperature regulation of the build envelope in order to prevent warping in the “oversized” parts. The large, bionic and intricate geometry takes a great deal of time to assemble: It took only a few days to print it.

Design to suit the process

The transition over to AM also means rethinking the design. To make full use of the potential offered by laser melting, it makes no sense to replicate a geometry 1:1. Lightweight design and bionics demand a design to suit the process. CAECAD-based methods are used to trim the 3D components to a performance-focused geometry, bionics, and lightweight

design. The design was optimized in several transitions at Thales Alenia Space (AM design optimization), for example in respect of the various joining and mounting techniques. In addition, there was fine-tuning in the area surrounding the satellite in order to guarantee a maximum precision fit. The topology was optimized in 2-3 passages.

The CAD data then underwent a redesign and smoothing before a mechanical analysis and simulation took place. Furthermore, the design was optimized to suit the process-related circumstances in the build envelope with Poly-Shape. This involved the orientation of the part in the build envelope and the necessary support structures. Thales Alenia Space also incorporated methods of LBM (Layer-Based Manufacturing).

Florence Montredon: “It is clear that we have identified AM as a good prospect for further projects. In the future, we would also like to incorporate thermal control technology or radio functions directly on or within the 3D structures. So functional integration is the next task. This is also a logical consequence of the potential offered by AM.” The benefits

In the Koreasat-5A and 7 project, the feasibility of highly sophisticated and very large AM parts for applications in space was highlighted. The redesign as an additive, bionic part made it possible to reduce the number of parts from nine to just one part. Thanks to this method, the manufacturing process was carried out in one shot, so without the previous outlay that was needed for assembly. There was also significantly enhanced potential for a lightweight design. 22%of the mass was saved with this AM solution.

This resulted in a final weight of just 1.3 kg. This was a huge leap because in these applications every gram really does count.

The 3D geometry was optimally trimmed for use in orbit. The project’s impressive results highlighted the potential that additive manufacturing offers in space travel and this project will undoubtedly not be the last of this type.

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CASE STUDY

Effects of multiple re-use of Ti6Al4V powder in AM

Renishaw AM250 systems at the Stone, Staffordshire, UK facility

Metal powder re-use in additive manufacturing (AM) has been investigated using a Renishaw AM250 system and titanium alloy Ti6Al4V ELI (extra low interstitial) powder.

This study is a follow-on from the encouraging results obtained in a previous study in which the chemical and physical effects of re-using metal powder through the AM250 twenty times was investigated

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enishaw additive manufacturing systems use metal powder bed fusion to build complex components directly from CAD data. Objects are built layer-by-layer by spreading out fine metal powders and selectively melting areas with a highpower laser. Any un-melted powder remaining after a component has been built can then be re-used for another build. There is a question mark over whether there is a limited number of times that metal powders can be cycled around an AM process because chemical and physical properties are bound be changed, but to what extent?

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Multiple factors

The importance of economics

There are multiple factors which contribute to consistent, repeatable, and reliable AM builds, such as laser focus, filter condition, and z-axis movement â&#x20AC;&#x201C; for this study we looked at feedstock (metal powder). The properties of the powder and the machine parameters that are used to process it are closely related, so the chemical and physical properties of the powder are critical.

Manufacturers are naturally concerned that the condition of the powder they are processing is predictable and stable in order to have confidence in the quality of the manufactured components.

Economics is also an issue; the fine metal powder used in laser melting can be costly, so waste should be avoided.

In most cases, only a small proportion of the powder that is laid down in a build process is actually melted into a component - most is left un-melted and is therefore available for re-use.

Some of the benefits of near-net-shape manufacturing depend on such recycling.

If we are forced to consider un-melted powder as contaminated and therefore unfit for re-use, then the cost of additive manufactured parts is likely to be prohibitive for many industries.

CASE STUDY www.mtwmag.com

In order to increase the robustness of the study, more tensile bars were built for each run; three to be tested with an ‘as built’ surface and three machined. Powder capture capsules and density blocks were also built.

A single batch of powder was cycled through Renishaw’s additive manufacturing process for a total of 38 builds until there was no longer enough powder remaining for a test sample height. Powder was analysed for oxygen and nitrogen content, Hall flow, particle size distribution (PSD) and density. There was found to be a small but steady increase of both oxygen and nitrogen concentrations in the powder as the build number increased. At around 16 builds the oxygen level started to fluctuate around the upper limit for the specification.

Nitrogen stayed within the material specification maximum limit as well as the more stringent lower allowable 300 ppm stated for some other grades.

It is likely that under normal running conditions with regular topping up of the silo with virgin powder these levels will remain within the boundaries of the ELI specification.

Both levels stayed well within the boundaries of the grade 5 specification.

PSD values shifted very slightly upwards due to gradual loss of smaller particles resulting in an increase in Hall flow speed. Upper tensile strength was found to be higher for the machined, compared to the rougher ‘as built’ tensile bars.

An example of a build setup with 1. powder capture capsule, 2. tensile bars (×6) and 3. density block General conclusions

The changes observed over the period of the two studies do not seem to affect the way that the AM system functions with the powder, therefore the material parameters are still valid for the powder from start to end.

There was a general increase in oxygen and nitrogen levels observed over both studies. These impurities are most likely picked up by particles close to the weld pool which are heated but not melted. The levels of both impurities do eventually reach the maximum allowable for ELI grade Ti6Al4V, however they stay well within the specifications for the more widely used grade 5 Ti6Al4V.

It is likely that under a normal running scenario in which the silo is topped up with virgin powder at regular intervals the levels of oxygen and nitrogen would stay within acceptable boundaries as the new powder blends with the used. This however will require backing up with data.

Flow improves as the number of builds increases, this is most likely due to narrowing of the PSD by gradual removal of smaller particles. Powder morphology does not significantly change over the entirety of the study. Occasional misshapen and agglomerated particles occur within the bulk but at a very low occurrence, and the effect does not seem to be cumulative.

Observations

The observations gained from this study suggest that there is no requirement to dispose of un-melted Ti6Al4V after it has been cycled around the AM250 system after a limited number of times. This does however depend on the specific requirements of the component material properties, in which case a stringent blending regime may be required for traceability.

The effects of powder re-use will potentially be different for other materials in terms of physical property effects, however because titanium has a high propensity to pick up interstitial impurities, the pickup rates observed can be thought of as a ‘worst case’ for commonly used metal AM powders.

A re-use cycle 1. Build, 2. Remove build plate, 3. Sieve un-melted powder, 4. Replace sieved powder into silo at the top of the machine.

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CASE STUDY

The special relationship between

Formula 1 & Haas Here’s something all Haas customers know: Wherever there’s a Formula One race, there’s almost definitely a Haas Factory Outlet (HFO) nearby

F

or the 2016 Formula One season, national HFOs, local to many of the 21 circuits around the world, are holding open houses, screening events and race visits, allowing their customers to share in the excitement of Haas F1 Team’s inaugural year.

The HFO network provides Haas customers with local sales and technical support to a very high standard, as if they were dealing directly with

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Haas Automation itself. Each of the 170 facilities worldwide is staffed and equipped to requirements set by the U.S.-based company, with comprehensive spare parts, next-day delivery, service vans and factorytrained technicians; all helping to ensure Haas CNC products are the best supported machines in the world.

Although the HFO network is not officially a technical resource of Haas F1 Team, there’s no doubt that having such

capable engineering expertise close by, during testing or on a race weekend, can bring the team a little extra peace of mind.

Jens Thing, managing director at Haas Automation Europe: “Back in February, when the Haas VF-16 car was being tested at the Circuit de Barcelona-Catalunya, the team found some modifications were necessary to the wheel-gun sockets and other pit equipment. The HFO in Barcelona,

CASE STUDY www.mtwmag.com

located just 30 minutes from the track, used a Haas UMC-750 5-axis vertical machining center, a Haas ST-30 CNC lathe and a Haas VF-2 vertical machining center to modify and produce the required components, which were then immediately delivered to the race circuit so the team was able to complete its test sessions.”

A few weeks later, in May, the Barcelona HFO held an open house to coincide with the Spanish Grand Prix race weekend. Managing director Andreas Le Noir welcomed almost 200 special guests to the event.

“We have worked with Haas for a long time and a lot of our customers are big fans of motor racing – especially Haas motor racing,” he said. “This was a great opportunity for them to share Haas’ involvement in F1 and to meet the teamdrivers, Romain Grosjean and Esteban Gutiérrez, along with Gene Haas and team principal Gunther Steiner.

“Of course, it was also a great opportunity for us to show our

customers the latest Haas machine tools.

Usually, during a normal working week, it’s difficult for customers to find the time to come to get away.

This is different, though. Our race weekend open house was held on a Saturday after qualifying. Also, it was a more relaxed atmosphere. People were here as our special guests. They could enjoy the race and they could visit the HFO without having to think about work.”

Spending time with our customers over F1 race weekends is great fun.

Machinists and engineers love racing, and F1 in particular.

- Jens Thing, Managing Director, Haas Automation Europe

Barcelona sets the tone

The Barcelona open house event proved to be so successful that many other HFOs have similar events planned throughout 2016. “Spending time with our customers over F1 race weekends is great fun,” says Jens Thing. “Machinists and engineers love racing, and F1 in particular. Some customers bring their colleagues and their families to these events. It’s a pleasure for us to get to know them better and it makes for a memorable event.”

On the subject of whether an HFO

might be called upon to provide technical assistance – like the Spanish HFO did during pre-season testing – Thing thinks it’s only a matter of time: “In the event, other F1 teams would probably have to make-do or ship parts from their own machine shops. Haas F1 Team, on the other hand, knows that just like Haas customers around the world, they’re only ever an hour or so from the nearest HFO. That’s got to be reassuring.”

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CASE STUDY

How automation helped

SPECK

boost its productivity Since 2010 SPECK has consistently relied on automated machine tools from DMG MORI Systems in order to boost capacity in its production

S

PECK PUMPEN Walter Speck GmbH & Co. KG from Roth produces more than 250,000 pumps and pumping systems for industrial applications a year. The company has been supplying customers in over 40 countries for more than 100 years. SPECK produces its specialised products primarily for customers from the medical technology, chemicals and pharmaceutical industries, for cooling and temperature control equipment and for the plastics industry. The high level of specialist expertise of its more than 450 employees worldwide is supported in mechanical production by state-of-the-art machine tools. Automated systems from DMG MORI have played a significant role here since 2010, as the latest investment proves. For this DMG MORI Systems linked a MILLTAP 700 and a CTV 160 using an automation solution.

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When asked about the core competences and the differentiation features of his company, the CEO Wolfgang Krüger mentioned especially its innovative and application-orientated capability. “We unite this with a high level of flexibility in production and assembly in the manufacturing of our many different components and with short delivery times.”

To appreciate the importance of this statement it is worth taking a look at the product programme. The company’s website mentions no less than 26 or rather 33 areas of application in its fluid and vacuum pump divisions. Its list of references includes standard applications in machine tool manufacture, in laser and welding technology or in

agricultural and rail vehicle manufacture as well as the proverbial exotic use of special pumps for tobacco moistening.

To accommodate this multitude of applications SPECK in Roth offers a total of 18,000 different pump versions in over 80 series – and often in different performance classes as well. So it is no surprise that there are no standard parts in the production halls. “The average batch size in mechanical production is just 50 to 100 parts.”

In view of the outlined requirements profile, the question as to the importance of its own production is easy to answer.

Wolfgang Krüger points out the close interaction between machine tool, tool and cutting material and stresses: “The autonomous development of new or alternative manufacturing strategies and continuous further development in all

CASE STUDY www.mtwmag.com

the sectors mentioned are what boost the productivity of our manufacturing processes.” The company would lose a big portion of relevant expertise if it purchased workpieces from outside.

“Added to this is the extremely high demand placed on the quality of the pumps.” In order to maintain a high degree of efficiency, the gap dimensions of the SPECK pumps are often in the range of a few hundredths of a millimetre. Such quality pressure is further intensified by the trend towards ever smaller pumps with an ever higher degree of efficiency.

But in the last instance, it is not just economic and qualitative issues that are decisive for Wolfgang Krüger. “Demands for ecological and humane compatible production are growing in importance.”

One example of this is efficient dry processing or at least a reduction in the amount of coolant lubricant needed. Another example at SPECK are automated manufacturing systems.

DMG MORI Systems‘ first automated machine tool

This productive form of manufacturing has grown dramatically in importance

since 2010 when DMG MORI Systems installed the first automated machine tool – a CTV 160. A highly complex system comprising a CTX alpha 500 with stations for measuring, truing and pressing followed in 2011. A shaft and a rotor are connected to an armature shaft that SPECK produces for pump motors on this system within about a minute.

“The original procedure involving several machining steps and a manual pressing process took far, far longer”, recalls Dieter Meier, Head of Mechanical Production. Nowadays all that is needed is to feed the automation solution with the orders for the different component variants and load the respective blanks.

“The high level of precision achieved in machining is also of great benefit. Automated production scores points in this respect due to its high repeat accuracy.”

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CASE STUDY

Such automation drastically reduces throughput times and boosts quality while at the same time gaining time for the specialist workers to perform other tasks, as Dieter Meier goes on to tell us: “Our workers can operate several machines simultaneously during the autonomous machining cycles.”

It was this same motivation that lay behind the investment in meanwhile two such linked systems for the manufacture of motor bearing shields. Turning is carried out by a CTV 160 in both systems, while a MILLTAP 700 handles boring in the case of the newest automation. As DMG MORI did not have the compact machining centre in its programme in 2012, the older investment uses a DMC 635 V for this purpose. “The output of the two systems is enormous”, says Dieter Meier. SPECK produces over 250,000 motor bearing shields a year on the two respective linked machine tool systems.

Achieving diversity in components

However, the high quantity does not mean that the actual batch sizes do not remain relatively small, as the Head of Production goes on to explain: “We need the components in a number of different diameters and variations, so both systems had to be set up to be extremely flexible.” DMG MORI Systems achieved such diversity in components by incorporating flexible chuck jaws.

The equipment in the rotary magazine can be adjusted to the right diameter in

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no time at all.

DMG MORI Systems designed and implemented the two linked systems on the basis of the components. “We were able to start production within three months”, says Dieter Meier looking back at the fast realisation of the first system.

Installation of the second system was even less complicated: “Apart from the MILLTAP 700 this system was identical in design to the first one, because we were more than satisfied with that first investment.”

Dieter Meier believes that automation is the future of manufacturing: “With their short throughput times, higher capacity and considerable boost to productivity, due not least to multiple machine operation, automated manufacturing systems pay for themselves extremely quickly.” Such machining solutions also simplifies the work of our employees enormously.

“Our workers can operate several machines simultaneously during the autonomous machining cycles.”

- Dieter Meier, Head of Mechanical Production, SPECK PUMPEN Walter Speck GmbH & Co

MGM-Pubblicità(210x297)_Layout 1 08/04/13 10.33 Pagina 1

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PROJECTS

Airport / Aviation Airports Authority of India (AAI)

Airport / Aviation Automotive Hydro Power

PROJECT

Ports & Shipping Power Railways Renewable Energy

UPDATE

Transport

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MACHINE TOOLS WORLD SEPTEMBER 2016

Plans to construct a new terminal at Leh airport which will increase the passenger handling capacity. Indian Air Force (IAF) is likely to hand over 11.8 acre of land for the construction of this terminal.

The work is likely to start in 6 months.

Airport Authority of India (AAI) AAI is implementing the construction of 1,200-metrelong additional taxiway at the Mangaluru airport since August 2014 at a cost of `40 crore. The work is expected to get over in the next two months. AAI has recently approved the extension of taxiway by further 1200 metre. The work is likely to start in 6 months and take 24 months to complete.

Place: Jammu & Kashmir Place: Karnataka Contact: M N N Rao, GM (Civil), Airports Authority of India, Rajiv Gandhi Bhawan, Safdarjung Airport, New Delhi-110003, T: 011-24693495, M: 9420689180, E: mnnrao@aai.aero

Ministry of Civil Aviation A greenfield airport is planned near Bhiwadi in Alwar district, Rajasthan.

Site clearance was accorded subject to certain conditions, was given in November 2015. Detailed Project Report (DPR) would lead to further development once the economic viability is established.

Place: Rajasthan Contact: Venkat Raman Hegde, Director, Rajiv Gandhi Bhavan Block 1st Floor, Sub Division, New Delhi-110003, T: 011-24643246, E: v.hegde@nic.in

Contact: Rajiv Gupta, Deputy GM, (Civil), Mangalore Airport, Kenjar, Ba- jpe-574142, Karnataka.

T: 0824-2220421, 2220400, F: 2254175, E: rajivkgupta@aai.aero

Karnataka Public Works Department Plans to assign the completion of the balance work at the upcoming airport at Kalaburagi in Karnataka.

The work includes passenger terminal building works including interior, electrical substation cum CCR room, ATC tower cum technical block, fire station, pump room, external development and service and external electrification or electrical equipment.

Place: Karnataka Contact: Maruthi Gokhale, Executive Engineer, Bijapur/1 Street Station Road, Bijapur, Gulbarga-585102,

PROJECTS www.mtwmag.com

Karnataka, T: 08472-256465, M: 9449267411, E: eeglb2014@gmail.com

Seocho-gu, Seoul, Korea, 82-2-3464-1114

Boeing International Corporation India Pvt Ltd

Narmada Water Resources

US based aircraft manufacturer has tied up with Tata Advanced Systems Ltd (TASL) to set up a facility at the aerospace Special Economic Zone (SEZ), Adibatla.

Tata Boeing Aero- space Ltd (TBAL) is the joint venture firm that will produce Boeing AH-64 Apache helicopter fuselages and other aerostructures. The foundation stone was recently laid.

Place: Telangana

Hydro Power Setting up small hydro power projects at Karjan Dam, Gujarat on Design, Build, Finance, Operate & maintain and Transfer basis.

Place: Karjan Gujarat

Dy Executive Engineer, Vadodara Irrigation Circle, Vadodara, Guajarat, T: 02640-222899, M:9998246494

Ports & Shipping Paradip Port Trust (PPT)

Manager (Communi- cations), 3rd Floor, DLF Center, Sansad Marg, New Delhi-110001, Delhi.

T: 011-46566000, M: 9654606067, E : ashmita.sethi@boeing.com

Plans to take up outer harbour project under Sagarmala Programme. The outer harbour would have cargo handling capacity of 150 million tonne per annum.

The port trust is looking for appointing a consultant to prepare the detailed project report (DPR).

Kia Motors Corp South Korean company plans to set up its first factory in India. The company is scouting for suitable location and likely to finalise by August, 2016. The plant would have a capacity to make 3,00,000 Kia vehicles and production is likely to commence by 2019.

Place: NA Contact: 2, Heolleung-ro,

Place: Odisha Contact: K.Ramchandra Rao, Paradip-754142, Odisha.

T: 06722-222026, E: ceppt@paradipport.gov.in

Contact: A V Mahale,

Contact: Amrita Dhindsa,

Automotive

International Cargo Terminal Pvt Ltd (PICT). PICT is a special purpose vehicle (SPV) set up by United Liner Agencies India Pvt Ltd to implement this project in PPP mode.

Place: Odisha Contact: K.Ramchandra Rao, Paradip-754142, Odisha.

T: 06722-222026, E: ceppt@paradipport.gov.in Paradip Port Trust (PPT) In order to cater to the container traffic and clean cargo at Paradip Port, the port authorities have already inked a concession agreement in March 2015 with Paradip

Power East Central Railway Plans to assign the design, supply, erection, testing and commissioning of 132 Kv, 3-Phase double circuits transmission line (Approximate 146 Km) including Pile Foundation In Sone river between Jeonathpur to Sonena- gar via Kudra, Karamnasa & Sasaram over Mughalsarai Division Of East Central Railway.

Place: Bihar Contact: V K Shukla, Chief Engineer, (Con/South) Mahendrughat 2Nd Floor Cao/Con/South Office Complex, Patna-800004.

State: Bihar M: 9771425256 Karnataka Power Transmission Corporation Ltd. (KPTCL) Plans to assign the design, manufac- ture, supply and installation of 12.1kV, 2.9 MVAR and 12.1kV, 5.8 MVAR Capacitor Banks in

existing 220 kV and 66 kV sub-stations in Bengaluru transmission zone limits on partial turnkey basis including supply of all matching materials/ equipments and erection (including civil works) of all materials/equipments, testing and commissioning.

Place: Karnataka Contact: M S Prabhakar, Superintendent Engineer, Kaveri Bhavan, 3rd Floor, K.G.Road, Bangalore-560009, T: 080-22238154, M: 9448375176, E: seepandp@gmail.com Madhya Pradesh Poorv Kshetra Vidyut Vitaran Company Ltd Plans to assign the installation and commissioning of SCADA equipment 1. 33kV and 11kV Ring Mam Unit (RMU). The work is likely to start in one month and completion is targeted in 18 months.

Place: Madhya Pradesh Contact: Ajay Sharma, CGM (RAPDRP)COF Block, Shakti Bhavan, Rampur, Jabalpur, Madhya Pradesh, Tel: 0761-2666399, 2702478, 2702456, F: 2666080, E: mpczapdrp@gmail.com Ajmer Vidyut Vitaran Nigam Limited Plans to assign the strengthening of subtransmission and distribution network for bringing down

SEPTEMBER 2016

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PROJECTS

AT&C losses and providing 24X7 power supply in urban areas including provisioning of solar panels on Govt. buildings and metering of feeders/ distribution transformers/ consumers in the urban towns of twelve circles of Ajmer Discom under IPDS scheme for Turnkey Contract.

Place: Rajasthan Contact: Ashok Kumar, SE, Office of the Superintending Engineer (TW), Vidyut Bhawan, Panchsheel Nagar, Makarwali Road, Ajmer, Rajasthan T: 0145-2644507 F: 2644507, M: 9414004258, E: setwavvnl@gmail.com Government of Sikkim Plans to assign the construction of 11Kv switching substation including rearrangement and drawing of 11Kv transmission line at Kongri along with modernisation of tashiding Bazar in West Sikkim.

Place: Sikkim Contact: K.K Pradhan, CE (West), Power & Transmission Dept, Annexe 1, Top Floor, Kazi Road, Gangtok , Sikkim-737101, M: 9434318288

Railways South East Central Railway Plans to undertake the electrification of 4th line between Raigarah - Lajkura

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MACHINE TOOLS WORLD SEPTEMBER 2016

by 25 Kv, 50Hz, Single Phase, AC Ohe In-Connection with 4th line between bilaspur - Jharsuguda Including remodeling of yards En-Route, in Bilaspur division.

Place: Chhattisgarh Contact: DC Pattanayak , Chief Elect. Engineer (Con-HQ), Bilaspur, Chhattisgarh.

T: 07752-410305, M: 9752475300 E: cee@secr.railnet.gov.in

South East Central Railway Plans to assign the construction of Limited Height Subway by open cut method at unmanned LC No.GJ- 04,GJ-05,GJ-06,GJ07,GJ-12 and GJ-15 between Gondia-Hatta Road section under the jurisdiction of Aden/ Nainpur. The work is likely to start by September 1, 2016 and complete in a year.

Place: Maharashtra Contact: Mohan.J.Chaudahry Divisional Office, Kingsway, Nagpur-440001, Maharashtra.

M: 8600027439, E: dycebrcr@gmail.com

Renewable Energy

20 units of G114-2.0 MW T106 turbines. The commissioning is targeted by March 2017.

Place: Gujarat Contact: Madhu Kumar Boppana, Head (Corp Comm), Redhills, Chennai-600066, Tamil Nadu.

T: 044-39242424, 30989898 E: bmadhukumar@gamesacorp.com Gamesa India The company has received turnkey order from Orange Renewable for its upcoming wind projects in Gurmitkal, Karnataka. Gamesa will deliver complete turnkey solutions for a 60 MW project in Karnataka with the supply of 30 units of G972.0MW T104 turbines. The commissioning is targeted by March 2017.

Place: Gujarat Contact: Madhu Kumar Boppana, Head (Corp Comm), Redhills, Chennai-600066, Tamil Nadu.

T: 044-39242424, 30989898 E: bmadhukumar@gamesacorp.com,

Transport

Gamesa India

Delhi Metro Rail Corporation Ltd (DMRC)

Bagged turnkey order from Orange Renewable for its upcoming wind projects in Maliya, Gujarat. Gamesa will deliver complete turnkey solutions for a 40 MW project in Gujarat with the supply of

Plans to assign the construction of elevated viaduct, three stations viz: Ernakulum South, Thaikoodam and Petta (from Ch: 18180.058m to Ch: 19329.685m & from Ch:

23532.771m to Ch: 25119.278m excluding Chamb- akkara bridge from Ch: 24157.754m to Ch: 24452.271m) including architec- tural finishing, plumbing and electrical works on Alwaye-Petta Line of Kochi Metro Rail Project.

Place: Kochi Kerala Contact: Dani Thomas, Project Director (Contracts), 2nd floor, GCDA Eastern Entry Tower Karshaka Road, Ernakulum South Railway Station, Kochi-682016 Kerala.

T: 0484-2311113, F:2321112, M: 9400000150, E: dmrckochi@gmail.com, Delhi Metro Rail Corporation Ltd (DMRC) Plans to assign the construction of elevated viaduct, two stations viz alliance junction, and SN junction (from Ch: - 25119.278m to Ch: 27040.000m) including architectural finishing, plumbing and electrical works on Alwaye- SN Junction Line of Kochi Metro Rail Project.

Place: Kerala Contact: Dani Thomas, Project Director (Contracts), 2nd floor, GCDA Eastern Entry Tower Karshaka Road, Ernakulum South Railway Station, Kochi-682016 Kerala.

T: 0484-2311113, F:2321112, M: 9400000150, E: dmrckochi@gmail.com,

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PRODUCT SHOWCASE KING CUT PRO – The Large Gantry Type CNC Cutting Machine Ador’s KING CUT PRO is a CNC portal cutting machine which is very precise and reliable. The machine has one head for plasma sheet metal cutting and one head for flame cutting of sheet metal with a dual side longitudinal drive with AC motors.

The standard equipment comes with a basic machine package with CNC controller, one torch, central gas diffusion with manometers and a remote flame ignition.

The following equipment are supplied as required by the customer: Additional Equipment: • Plasma power source KJELBERG with machine torch • Programming software MOST 2D • Support table for sheet metal with segment extraction system • Extraction-filter system • Laser position indicator for determining the cutting point Optional : • Extension of the longitudinal rail • Additional cutting head

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The Phantom brings you the performance of a cutting edge CNC that is built on more than 40 years of experience in the motion control and cutting industries. This controller is designed for multiple axis cutting machines and features the latest advances in CNC technology on a proven platform engineered to increase productivity, reduce costs and enhance profitability. The software provides flexibility, ease of operation and technologies that put Ador’s experience and expertise in your operator’s hands, resulting in extremely good cut quality and high productivity.

The Phantom can operate any cutting machine and interface with virtually all plasma systems. Following are its standard features: Bright touch screen interface, Touch screen interactive display, Expandable shape library, True multi-tasking environment, Fast Dxt file conversion, Go to(Job interrupt), Quick plate alignment, and Monitor & track consumables. Advanced Plasma Process Control (Plasma Process Wizard) is available as optional extra. Ador offers cost-saving height control unit for simple plasma cutting applications. The KHC1 system provides all the essential functions that are needed for good cuts and optimum utilization of work-piece.

PRODUCTS www.mtwmag.com

Steady Volt Servo Voltage Stabilizers Frequent voltage variations are a menace that can damage electronic components like power supplies, drives, PLCs, controllers, etc. Their effects are widely felt in CNC, printing and textile machines as well as laboratory, data processing, medical & telecommunication equipment. Frequent breakdowns of such machines are costly to repair.

This apart, the downtime and frequent interruptions in operation brings substantial loss of revenue. Steady Volt from Unity Controls is a state-of-the-art Voltage Stabilizer designed to protect such equipment from voltage variations and its ill-effects.

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For Product Enquiry Contact Unity Controls Pvt. Ltd 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E), Mumbai 400 077 Phone: 022- 2501 3832 / 33 E-mail: sales@unitycontrols.in Web: www.unitycontrols.in

• • • • • • •

Intelligent microprocessor-based system(available in new digital models) Digital interface with large LCD display and keypad Auto re-start, adjustable output voltage, trip bypass, fault list No hunting, oscillation and noise generation Innovative transformer design to minimize power loss Constant output voltage across a wide input voltage range Single phasing prevention, surge suppressor and EMI / RFI filter

With the best-in-class response time and correction rates, Steady Volt offers improved power quality and greater energy efficiency, thereby saving the cost of breakdowns and energy utilization. Apart from protecting your equipment from damage, Steady Volt also saves energy during continuous operations.

Spindles with Back Tapers Birla Precision Technologies Limited offers a wide range of Taps quick change for Transfer machines and machining centers.

Our production develops adaptors with the following categories: • Tapping to Double Compensation • Rigid tapping • Tapping with Axial displacement.

Our company offers spindles with back tapers such as BT-MAS403, ISO 30/40/50 (DIN 69871) HSK (DIN 69893), the tap adaptors formers are available in sizes 0 - 1 - 2 - 3 - 4- 7.

All items are also available with the following attachments:

For Product Enquiry Contact Birla Precision Technologies 206 Dalamal House, 1st Floor, Jamnalal Bajaj Marg, Nariman Point, Mumbai - 400 021 Web: www.birlaprecision.org Email: itmth@indiantool.com.

• Chuck Weldon according to DIN 1835, mainly used for control machines and transfer machines • Chuck Morse taper, according to DIN 228A and 228B, mainly used for machining centres and boring • Spindle Keystone, according to DIN 6327, mainly used for transfer machines and threading • Cylindrical and chuck VDI, DIN 69880, mainly used for control machines • Spindle with conical “B” according to DIN 238, mainly used for traditional machines such as drill presses or threading With the aim to provide better quality and longer life, the we use the best grades of steels and subject all products to rigorous quality assurance during each stages of manufacturing , assembly and testing.

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PRODUCTS

Grinding Oil 1- Straight Grinding Oil for Gear Grinding Features of Grinding Oil No.1

• • • • • • • •

Translucent and low odor Superior cooling properties Non irritating / Non corrosive Produces excellent surface finishes Excellent filter-ability All grinding wheel compatible Superior lubricity package Excellent oxidation Stability / Long sump life

Grinding Oil 1 is compatible with all types of grinding wheels. It can be used for grinding high-speed steel, cobalt, carbide, ceramics and hardened steel. Grinding Oil 1 can also be used in grinders that require the same oil for both lubricating the machine and the wheel / work-piece interface. Unique advanced synthetic and natural lubricity additives in Grinding Oil 1 help keep the grinding wheels clean and free cutting allowing them to function properly.

Conventional oils can allow build-up and packing of the wheel. This can lead to burned parts, smoke and scrap parts. Grinding Oil 1 helps maintain part integrity, surface finish and an overall great working environment.

Grinding Application:

For Product Enquiry Contact Hangsterfer’s Laboratories, Inc. USA Sanjay Tools & Adhesives Mobile : +91 9822028518, +91 9892516810 E-mail: hangsterfers@sanjaytoolsnsk.com Web : www.hangsterfers.com

• • • • • • • •

Creep feed Grinding Gear Grinding - Profile & Warm Crush Grinding ID and OD Grinding Center-less Grinding Cylindrical Grinding Diamond & CBN Wheel Grinding Tool & Cutter Grinding

New Mate Ultra® QCT™ Is Quick Change – Tool Less – Revolutionary Tooling

For Product Enquiry Contact Mate Precision Tooling call 1-763-421-0230.

Fax 1-800-541-0285.

Website: www.mate.com Email: marketing@mate.com

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Mate’s greatly expanded one source fabricating solutions include the new Ultra QCT Quick Change Tooling, CleanBend Press Brake Tooling and the One-Micron Fiber Laser Lenses Mate Ultra QCT tooling is simple and intuitive to setup, and fully compatible with Mate’s Ultra® family of guides and standard canisters. To setup, flip the latch to remove and snap the new insert into place; it’s that easy!

The punch is keyed at the perimeter of the tool – not the center – providing superior angularity control. The shoulder of the punch remains securely guided by the guide when punching. Another nice feature – only one punch driver is needed for rounds or shapes.

Made from M4PM™ tool steel, Mate Ultra QCT is proven to be the most durable, longest lasting tool steel in the industry. And it’s coated with SuperMax™, Mate’s next generation coating, to minimize wear and preserve fits. Mate Ultra QCT truly revolutionizes punch press tooling.

ADVERTISERS INDEX COMPANY NAME

PG. NO.

COMPANY NAME

PG. NO.

COMPANY NAME

PG. NO.

A

ELECTROTHERM (INDIA) LTD.

13

MGM-VARVEL POWER TRANSMISSION PVT. LTD.

89

ACCUSHARP CUTTING TOOLS PVT. LTD.

29

EMAG INDIA PVT. LTD.

39

ENGIMACH - 2017

93

MMC HARDMETAL INDIA PVT. LTD.

INSIDE FRONT COVER

ACE MICROMATIC GROUP

BACK PAGE

ACTCAD ENGINEERING SOLUTIONS PVT. LTD.

49

ADOR WELDING LIMITED

59

ANCA MACHINE TOOLS PRIVATE LTD

7

ASIAMOLD - 2016

94

AUTOMOTIVE ENGINEERING SHOW - 2017

78

B BIRLA PRECISION TECHNOLOGIES LIMITED

31

R

GALA PRECISION ENGINEERING PVT. LTD.

53

RADIUS ENGINEERING SOLUTIONS PVT. LTD.

19

GLOBAL INDUSTRIAL EXPO - 2016

96

RAJKOT MACHINE TOOLS SHOW - 2016

99

GROB MACHINE TOOLS INDIA PVT. LTD.

45

RENISHAW INDIA (PUNE)

35

S

H HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED

57

HTS - 2016

79

CAPITAL FIRST

75

CNC SERVICING & SOLUTIONS (I) PVT. LTD.

27

CNC SOFTWARE, INC.

15

IMTOS 2017

98

J JYOTI CNC AUTOMATION LTD.

INSIDE BACK COVER

L

D

LAPP INDIA PVT. LTD.

DELTA ELECTRONICS INDIA PVT. LTD.

37

DOWEL ENGINEERING WORKS

69

E 61

SANJAY TOOLS & ADHESIVES

67 & 73

SHAVO TECHNOLOGIES PVT. LTD.

77

SPARKONIX (INDIA) PVT LTD

17

U

I

C

EFFICA AUTOMATION LIMITED

G

UCAM PRIVATE LIMITED

25

UNITED GRINDING GMBH

23

UNITY CONTROLS PVT. LTD.

65

U-TECH ASSOCIATES

21

W 62-63 WIN INDIA - 2016

M

97

Y

MACHAUTO EXPO - 2017

95

MAPAL INDIA PRIVATE LIMITED

33

MARPOSS INDIA PVT. LTD.

51

YASKAWA INDIA PVT. LTD.

55

YG CUTTING TOOLS CORPORATION PVT. LTD.

FRONT GATEFOLD

SEPTEMBER 2016

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Inside Story

Mr.

Andreas

Zieger

Director, EMAG India Pvt. Ltd.

My Life’s Goals

Aim & Ambition: Enjoying the moment, do things with passion, being interested in new things and varieties. Accept diversity and keep the global topics in mind, that is beside the world as a whole the small world like the family and the kids around me.

Vision: Do something meaningful and do it successful, use the given time and try to improve a little the world we touch.

Social Goal: Not complaining, start doing something around you, respecting others, permanent learning. If I do a little bit for betterment and other follows, the impact will be visible Business Goal: Achieve the given goal. But contribute to a better team work, help others to develop. Find solutions with win win effect for employees and customer.

My Leisure Choices Favourite Tourist Spot: Europe’s diversity in history, architecture, culture and food, just now spend wonderful days in Italy and can recommend the Tuscany. In addition Asia as rich cultural influence for me, from big India over SEA countries up to East India.

Music I like : No specific preference. Open for all from classic to pop, sometimes also world music, has to fit to the mood and bring enjoyment.

Sports I Love : Team sports I liked to play for the spirit, now I do watch more. Paddling in wonderful nature is for me a retreat and reminds me that we need to protect nature, also hiking and cycling goes in same direction.

Ask my Taste Buds Favorite food: I´m addicted to bread I have to confess, all the varieties in a good German bakery drive me mad. And that together with a good Mediterranean antipasti.

Favorite Drink: And a good glass of wine.

In Awe of I Admire: Diversity of live, people with own opinion, authentic in themselves and not showing of. Deeper discussions of the world and our contribution, new thought’s outside of the daily repetition.

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MACHINE TOOLS WORLD SEPTEMBER 2016

RNI No. MAHENG/2015/64267 Postal Reg. No. THC/173/2015-2017. Posted at Mumbai Patrika Channel Sorting Office G.P.O. Mumbai 400 001 on 15th of every month and Published on 10th of every month

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