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Volume 03 No. 11 | April 2018 | ` 150

Pages 122 | RNI No. MAHENG/2015/64267

QUALITY CUTTING TOOLS

Automotive

AerospAce

Die & moulD

GenerAl enGineerinG


CEO CORNER GREEN MANUFACTURING - Are we ready ??? Manufacturers today need to be well-equipped to handle a variety of pressures to improve the effectiveness of their product while simultaneously looking for ways to cut costs. At face value, “going green” might seem like an impossible task for your business, but there are a surprising number of benefits. Going green has become more popular trend as of late, with more and more businesses opting to make the switch. While it can certainly seem overwhelming, manufacturers who embrace sustainable practices can recognize a positive impact on their bottom line. These benefits can help boost sales, lower operating costs, and more. A manufacturing business can see overall operating costs drop if the green changes are planned accordingly. Having access to solar and wind energy, along with applicable energy-efficient equipment and machinery, can drastically reduce energy and utility bills. Additionally, increasing recycling and going paperless for bills/documents can also save on supply costs. In the manufacturing world, it’s advantageous to focus on both green and sustainability. Although targeted improvements can be beneficial to your company, looking at the “bigger picture” maximizes the perks of an environmental focus. Sustainability improvements are a collaborative effort. When employees work together to identify and implement green and sustainable initiatives, it fosters a culture of teamwork and continuous improvement. Employees work harder when they are engaged and have a sense of pride in their company. By internally communicating the importance of changes and the effect they are having on the business and environment, manufacturers will positively influence their corporate culture.

CEO

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MACHINE TOOLS WORLD APRIL 2018


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


www.mtwmag.com

Publisher & Printer

Contents

Vol 3 Issue 11 | APRIL 2018

COVER STORY

Shirish Dongre

CEO Shekhar D.

Editor

FEMCO: Achieving the milestone with sustained growth

Shilpa Dongre

Assistant Editor Shweta Nanda

Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, Vinod Surve, Kamlesh Balkrishna, Kavita Chaudhari

Designer & Layout Arun P. Shinde, Nandan S. Moghe, Dinesh S. Gawade

B P Poddar Vice President – Sales & Marketing Fatty Tuna India Pvt. Ltd.

Online Division Ganesh Mahale

42

Circulation Executive Satish Kadam, Amol Ranshur Branch Offices (Zonal)

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

SOUTH (Chennai & Coimbatore) Y. V. Raghu : 09566141224 Bangalore Vaman : 09686721340

EAST (Kolkata & Other regions) Kamlesh B. - 09819464242

WEST (Maharashtra & Gujarat) Pune Shilpa K. - 09833373371 Gujarat Dinesh Shah - 09327344559 Rajkot (Saurashtra) Swapnil Bhatia: 09227909005

BUSINESS NEWS

18

Renishaw presents world leading metal 3D printing systems

18

Mastercam 2019 Released for Global Public Testing

20

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 APRIL 2018

44 The future will see a lot of penetration of automation...

46 Alex Machine Tools: The Grinding Experts

New control panel with built-in SD interface

24

Seco delivers high-pressure coolant

30 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

IN FOCUS

Walter s.r.o. celebrates launch of flow assembly line in Kuřim

48 Design & Manufacturing industry is slowly adapting...

50 Radius Engineering : Benchmarking the standards

32

Bosch launches first-ever ‘Service on Wheels’ initiative in India

36

Wohlhaupter India has launched GEN 3XT Pro drill

52 QVI : Smart Solutions with Quality & Precision

54 “Elesa+Ganter has carved a niche name for itself”


POWERING YEAR 10


Contents

Vol 3 Issue 11 | APRIL 2018

COMPANY PROFILE

58 We are for those, who are in Metal Cutting!

60 We give strategic advantages to our customers from diverse industries

62 Grob-Werke: Thrives on new technologies

66 Shavo Technologies offers high-tech tailor made solutions

PRODUCTS SHOWCASE

TECH TRENDS

70

YASDA Ultra-Precision Machining Solutions

114

KING CUT PRO – The Large Gantry Type CNC Cutting Machine

68

115

The new Gast 86/87R Series of oil-less rocking piston compressors & vacuum pumps

Mitsubishi Materials extends its Drilling Range by introducing MINI MVS DRILLS

84

116

Reliable testing technology for plastics processing

Steady Volt Servo Voltage Stabilizers

116

76

FLIR E53 – Thermal Imaging Camera for Electrical/ Mechanical Applications

Blasocut Bio Concept- A step towards a greener planet

117

Damping vibrations, shocks and noises

cables for flexible applications 94 Lapp

117

82 ADIRA leads the way in Metal Forming Solutions 10

MACHINE TOOLS WORLD APRIL 2018

100 Discover your power with 3D Simulation

Cooling Nut System for Ball Screws

118

Dished Heads production made easy with Faccin’s line


Most Authorized & Honorable Prize in European Machine Tool Market 2017 MM AWARD Grand Prize in MILLING Category

Machining Center for Impeller and Small-size Complex Shape Processing

Specifications

A-Axis

X-A

xis

xis

Z-A

B-Axis

Ram Type Moving (X/Z-Axis)

Ø200

mm Table Size

15

kg Workpiece Weight

40,000 (HSK-E40)

r/min Spindle Speed

20

EA No. of Tools

300/300/200

mm (X/Y/Z-Axis) Travel

50/50/50

m/min (X/Y/Z-Axis) Rapid Traverse

200/200

rpm (A/B-Axis) Rotary Table Speed

2G/2G/2G

G (X/Y/Z-Axis) Acc./Dec. Speed

SIEMENS 840D sl

CNC Controller

Rotary Tilting Table(A/B-Axis)

HYUNDAI WIA INDIA PVT. LTD. Address : #4/169 1st flr, LOTTE Bldg, Rajiv Gandhi Salai, (OMR), Kandanchavadi, Chennai - 600 096, Tamilnadu, India Office Tel. No. : (0)76049 03348, E-mail : sales@hyundai-wia.com


Editorial Board

Editorial Index A

M

Accusharp 58 Ador Welding 102, 114 Alex Machine Tools 46 ANSYS 100

MAC Machine Tools and Automation 82 Machining Software 48 Mastercam 18, 36 Micro-Epsilon 84 Mitsubishi 68

B

Mr. Arun Mahajan General Manager

Mr. A.P. Jayanthram Consultant

AMT- The Association For Manufacturing Technology

Grob Machine Tools India Pvt. Ltd.

Mr. GK Pillai Managing Director & CEO Walchandnagar Industries Ltd

Bettinelli Automation 60 Blaser Swisslube 76 Bosch Power Tools 32 D

Dahanukar Machine Tools Delta Electronics DOLD Electric Dormer Pramet DVS TECHNOLOGY

44 34 115 83 20

E

Elesa and Ganter 54, 117 F

Mr. Arjun Prakash Managing Director Effica Automation Ltd.

Ms.Samina Khalid Marketing Manager Renishaw Metrology Systems Ltd.

Mr. Rupesh Paparaju Director, Bettinelli Automation Components Pvt. Ltd.

Faccin Fatty Tuna India FLIR Systems India

118 42 116

G

Gala Precision Godrej Aerospace, GROB

98 32 62

H

HEIDENHAIN

72

L

N

NUM Precision Motion Industries (PMI)

QVI India 52 R Radius Engineering 50 Renishaw 18, 107 Rocklinizer 105 Rollon India 90 Rolls-Royce 34 S

Schmersal Group Seco Tools Shavo Technologies

Association of Ludhiana Machine Tool Industries

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

Mr. P.K. Balasubbramaniian President VBS Corporate Support

12

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

MACHINE TOOLS WORLD APRIL 2018

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

20 24 62, 115

U

United Grinding Unity Controls

30 116

W

Wohlhaupter

94

YASIDA machines

For editorial contribution contact E-mail: shweta@divyamediaonline.com

Manjit Singh Matharoo General Secretary

117

Q

36

Y

Lapp India

Mr. Dinesh Khambhayta President MTMA-RAJKOT

24

P

MTW Overseas Associates 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

70


BUSINESS NEWS

Renishaw presents world leading metal 3D printing systems Global engineering and healthcare technologies company, Renishaw, is attending LMT LABDAY, the largest dental laboratory event in North America. Renishaw will be exhibiting its worldleading metal additive manufacturing (AM) systems for the production of crowns and bridges and removable partial dentures (RPDs). Optimised for healthcare, Renishaw’s AM systems use metal powder bed fusion to build complex dental frameworks from 3D computeraided designs (CAD). The introduction of metal AM systems into the dental manufacturing process completes the digital workflow, bridging the gap in sophistication between advanced dental scanning technology and traditional casting techniques. “Renishaw is selling more than just machines, we are selling a digital process that is more efficient than traditional manufacturing methods, with more reliable results,” says Renishaw’s Chris Dimery, Sales Manager for medical AM solutions.

Dental CAD files can be prepared for additive manufacturing using QuantAM Dental, Renishaw’s dedicated dental build preparation software. QuantAM Dental allows you to import, automatically orientate, heal, support, and review dental CAD files in preparation for manufacture. The software even adds identification tags to be

Mastercam 2019 Released for Global Public Testing Mastercam 2019 Public Beta is now open to all currently maintained Mastercam customers. Shops all over the world, from small job shops to Fortune 100, get a chance to test-drive Mastercam 2019 before it is released and provide valuable feedback to help shape the final product. Participants in the Public Beta get an early look at dozens of powerful new tools for simple to complex jobs. New 2D/3D Milling Features improve toolpath efficiency and control. Automate 2D chamfering and multiaxis deburring operations. Accelerated

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MACHINE TOOLS WORLD APRIL 2018

Finishing™ is expanded with taper and lens-style tool support. Surface and Solid Modeling Improvements simplify CAD for CAM and deliver greater design and geometry editing tools for shop-floor programmers. Powerful Turning and Mill-Turn improve your productivity with new plunge/grooving strategies, additional PrimeTurning™ support, expanded 3D tool and holder support, plus bar feed and import/export operation improvements.

3D printed with the framework, making sure you never lose track. Conversion to a digital workflow can bring benefits to both process and product. Working with Renishaw’s AM systems removes labour intensive steps from the process, saving time and increasing productivity. Moving away from traditional casting equipment improves working conditions and can lower manufacturing costs. The resulting products demonstrate consistently good quality, with measurably improved mechanical characteristics compared to casting. The LMT LABDAY will be held at the Hyatt Regency, Chicago, from February 23rd-24th. The event is expected to host over 260 exhibitors and 3,700 laboratory owners, managers and technicians from 44 countries. To find out more about Renishaw’s AM systems for dental manufacturing, visit the Renishaw sales team on booth C-66 or visit www.renishaw.com/ lmtlabday2018.


BUSINESS NEWS

New control panel with built-in SD interface The Schmersal Group is extending its range of control panels with the new BDF 200-SD model. This product variant now has a built-in SD interface. The BDF 200-SD is also fitted with an EMERGENCY STOP function with electronic OSSD outputs and can be fitted with up to three operational command and alarm devices, such as illuminated push-buttons, illuminated alarms, selector switches and key switches. Using the built-in SD interface, the non-safe diagnostic signals from the command and alarm devices can be transferred via an SD gateway to the controller. In the safety circuit, different electronic safety switchgear devices, such as sensors and interlocks, can easily

be connected in series using the BDF 200-SD. The benefit for users: The devices are simpler, quicker and more cost-effective to install. This also reduces installation errors. Safety sensors and interlocks fitted with an SD interface can transfer extensive status and diagnostics data from individual devices connected in series via the SD gateway and different fieldbuses to the controller. This could be, for example, status data from the safety equipment or error messages from a device. This allows individual diagnostics for the safety switchgear devices connected. This means that a user can easily tell which switch in the series has triggered a signal. This helps

resolve problems quicker, enables preventative maintenance and thus increases machine availability. The BDF 200 product range was developed for installation on conventional aluminium profile systems in machine housings and is easy to install. The range is based on a slimline casing made of impact-resistant plastic. The positioning of the buttons on the control panel can be selected at will. Labelling fields allow the individual marking of functions. This means the machine constructor can show the normal operating functions (EMERGENCY STOP, On / Off, Forward / Back, mode selection, status display, error messages, etc.) on the BDF 200 range.

The Schmersal Group has extended its range of control panels to include the new BDF 200-SD model, which now incorporates a built-in SD interface.

DVS focuses on automation The DVS TECHNOLOGY GROUP is further extending its “Machine Tools & Automation” sector. As announced by the Board of the Company Group, DVS will be taking multiple stakes in rbc Fördertechnik GmbH backdated to January 1, 2018. The company, based in Bad Camberg, Hesse/Germany specialises in automation, including camera-guided robot systems for machine tools. With 35 employees, rbc Fördertechnik GmbH achieved a turnover of around 7 million EUR in the fiscal year 2017. “The collaboration with the DVS TECHNOLOGY GROUP will give us a very good basis for further continued growth,” commented Director Stefan Becker. Director Frank Götz continued: “Alongside project-specific synergies with the mechanical engineers at DVS, we will also be

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MACHINE TOOLS WORLD APRIL 2018

able to present ourselves better on an international level.” Certified as a system partner by well-known industrial robot manufacturers such as ABB and KUKA, the medium-sized company has been able to make a name for itself as a specialist for camera-supported automation solutions over the past few years and strengthen the house brand rbc robotics®.

“We are convinced that DVS and rbc Fördertechnik GmbH are a good strategic and operative match. In the mid-term, the automation solutions and robotic systems from rbc robotics® will play a decisive role in our system solutions for the series production of drive components,” explained Josef Preis, Chairman of the Board of the DVS TECHNOLOGY GROUP. rbc

Fördertechnik GmbH is the twelfth operative company within the company group. During the transaction, rbc Fördertechnik GmbH was advised by ALLBERA GmbH in terms of M&A and in legal matters by BRYAN CAVE LLP. The DVS TECHNOLOGY GROUP is a group of experienced companies with core competencies in the field of the metal cutting technologies turning, gear cutting, grinding and gear honing. In 2017, a turnover of around 245 million euros was achieved by more than 1,300 employees all over the world. The DVS TECHNOLOGY GROUP is one of the leading international system suppliers of machines, tools and production solutions for the soft and hard machining of powertrain components.


Good for the environment and good for you Skin friendly and 100% bactericide free Blasocut coolants are our area of expertise for over 40 years. Within this period of time we have continuously improved our Bio-Concept - for the benefit of our clients and the environment:

– Free of formaldehyde and boric acid – Years of stability without the addtion of additives or bactericides – Compliant with the latest EU regulations

Find out more about the Liquid Tool under blaser.com

Blaser Swisslube India Pvt. Ltd.

Gurgaon, Pin – 122002

Tel 0124 4994000

india@blaser.com

www.blaser.com


BUSINESS NEWS

NUM launches major new release of NUMROTO tool grinding software NUM has launched a major new release of its renowned NUMROTO tool grinding software. Offering numerous additional features and enhancements, Version 4.0 of the software is designed to increase the productivity of precision machine tools without the need for additional hardware. The ball nose and corner radius tools in NUMROTO now allow programming of a helix step on end mills. For the first time, it is now possible to program different helix angles for the end of the radius and the beginning of the cylindrical parts. NUMROTO Draw, the software’s drawing and documentation tool, automatically processes the geometry data used for grinding a tool to generate a basic drawing. Many NUMROTO users choose to provide this drawing together with the finished, ground tool to their customers, to show standards

compliance. The latest software release significantly extends this capability by automatically displaying the geometry of the grinding wheels and grinding wheel packages needed to make the tool in the drawing. Also all the important dimensions are automatically added to the

grinding wheels. The time-saving benefits of this approach are considerable: a grinding wheel assembly drawing can be printed out for the machine operator to help speed setup without having to involve the design department, which is especially beneficial for companies handling numerous

small production runs. The 3D simulation facilities of NUMROTO Version 4.0 have also been further enhanced. Coolant holes in the 3D blank are displayed automatically, and users can now add DXF comparison profiles. There is a new measurement mode which provides comparator functionality, and the programmed feed rate can be displayed during the 3D simulation. A new feature that is especially likely to appeal to users of high-end machine tools is support for adaptive grinding. By continuously monitoring the dynamic performance of the grinding spindle, the software enables the feed rate to be optimised automatically – without the need to install any additional hardware. This offers a very costeffective means of increasing the productivity of certain grinding processes.

Seco delivers high-pressure coolant Seco Tools has introduced Jetstream Tooling® high-pressure coolant technology for threading shank holders. The new range includes square shank holders for external applications, boring bars for internal applications and GL-heads for use with Steadyline bars. The Jetstream Tooling threading turning holders deliver a concentrated high-pressure jet of coolant – up to 150 bar/2,175 psi or hose connections for up to 275 bar/3,988 psi coolant inlets – to the optimum position close to the cutting edge making it possible to guide or steer chips a certain direction away from the cut. The toolholders are available in 22 external, 28 internal and 14 GL-heads types in insert pocket sizes 16, 22 and 27. For parts made from titanium or similar materials, Jetstream Tooling technology is capable

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MACHINE TOOLS WORLD APRIL 2018

of breaking the tough threading chips to increase tool life. When threading steel and stainless steel, the improved chip control of the new thread turning tools allow for potentially 30 percent to 60 percent higher cutting speeds without compromising thread surface quality.

The square shank holders also include the JETI and Duojet features. JETI delivers coolant through holders without using a hose connection, and DuoJet applies one or more additional coolant jets from a second direction. Incorporation of these features brings optimized heat removal, effective chip elimination, longer and more predictable tool life and enhanced thread surface quality to thread turning operations. Use of the JETI feature with square shank holders requires the use of adapters. The new range includes both face mount and star mount adapters for Seco-Capto™ C5, C6 and C8 turrets and star mount adapters for HSK-T 63 multi-tasking machine spindle interfaces. The adapters accommodate square shank sizes 20 mm and 25 mm.


BUSINESS NEWS

Walter s.r.o. celebrates launch of flow assembly line in Kuřim Walter s.r.o. in Kuřim recently celebrated the launch of its flow assembly line with numerous invited guests. Jürgen Schock, CEO of Walter Maschinenbau GmbH, welcomed the group of about forty invited guests followed by a short speech from project manager Markus Schulze about the flow assembly line project, before kicking off the official opening ceremony. Together, the entire project team pressed a start button to symbolize the official launch of the flow assembly line. Construction work for the new line at the Czech production facility took about 14 weeks after which the system was installed. The new flow assembly line is a multi-million euro investment

that represents an important milestone for Walter s.r.o. in Kuřim. A 90-meter-long, continuously moving conveyor belt now spans the assembly facility and runs directly into the shipping department. Once a machine has passed through the eighteen

assembly stations, it is immediately packed in the shipping facility and sent to the customer. Workflows have been streamlined thanks to this increase in process stability and customers benefit from shorter delivery times as a result of the shorter lead times. Currently,

the HELITRONIC POWER and HELITRONIC MINI POWER models are produced on the belt and it is planned that the HELITRONIC VISION 400 L will be added before the end of the year. Overall, the line will dramatically increase flexibility. Component assembly is also arranged according to a fishbone diagram in order to feed the line directly. The supply of materials to assembly was also reorganised and adjusted to suit the new flow assembly line. Various activities to improve the supply of materials to the flow assembly line, such as a pick-to-light system, were simultaneously implemented. Further measures are already in planning for the logistics area.

Consul launches technical guide for power conditioning Consul Neowatt recently launched a technical guide on power conditioning & power back solutions for consultants and electrical engineering professionals. The first copy of the kit was handed over to Pankaj Dharkar, President FSAI (Fire Safety Association of India) by Mr Sriram Ramakrishnan, MD & CEO, Consul Neowatt Power Solutions at theFSIE 2018 exhibition in Bangalore. The guide – PowerFULL Solutions has been developed by the technical team at Consul Neowatt keeping in mind the challenges faced by consultants and electrical engineering professionals in designing power back up and power conditioning solutions for their projects that meet customer, regulatory requirements in being reliable, efficient, safe and green. Speaking on the occasion Sriram Ramakrishnan, MD & CEO, Consul Neowatt said, “In our interactions over the years with the consultant fraternity and engineers

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MACHINE TOOLS WORLD APRIL 2018

involved in the design of low voltage power systems, we repeatedly saw a void in the availability of a comprehensive and reliable field tested guide on factors to consider in the design of power backup and power conditioning solutions. The guide – PowerFULL Solutions has been developed by the technical team at Consul Neowatt highlighting the various considerations and trade-offs in

designing the optimal power backup and power conditioning solution to meet specific customer project requirements.” with discussions on various UPS topologies and configurations along with the choice of right UPS and battery technology which can provide an optimal solution for a project. “ The technical guide - PowerFULL Solutions is a complete resource that contains information on power quality, the types of power problems that are seen due to power quality issues and also has extensive discussions on various UPS configurations and topologies along with the choices on UPS and battery technologies. It also has information on innovative products like Active Harmonic Filters, Static Transfer switches, Solar Inverter with energy storage, Isolated Power Supply (IPS) for Hospitals that is expected to see wider use with increasing awareness and regulatory changes.


Full Line Of Grinding Solutions... Machine Tools

ALEX - RA Series 00

RH5

R40

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R40

RH500

ALEX - R Series

ROTARY SURFACE GRINDING MACHINE WITH HORIZONTAL SPINDLE

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ALEX MACHINE TOOLS PVT. LTD.

8, Gaiwadi Industrial Estate, S. V. Road, Goregaon (West), Mumbai - 400 062, India.

  011-91-22-2874 3226 / 2874 3744 / 2872 8143,  011-91-22-2875 7319

 sales@alexmachinetools.com  www.alexmachinetools.com

(04/18) CROSSPOINT:28898194

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50


BUSINESS NEWS

Bosch launches first-ever ‘Service on Wheels’ initiative in India Bosch Power Tools India, one of the world’s leading manufacturer of power tools for construction, woodworking and metalworking industry, has launched its ‘Service on Wheels’ – a first-of-its-kind service initiative in India in association with its partners to visit users. The Bosch ‘Service on Wheels’ has been conceptualized to demonstrate the uncompromised and unparalleled Best-inClass service experience at our users’ doorstep coupled with a focus to reduce downtime. Two vans were unveiled at the event in Bangalore by Henning von Boxberg, President of the Bosch Power Tools GmbH. The services provided by the van include repair, training, routine maintenance, product demonstration, among others. Additional advantages of the ‘Service on Wheels’ are promotion of genuine Bosch parts and assured quality service by their skilled and trained technicians. Besides providing fast professional service to customers, these vans will help in enhancing productivity and improving brand

visibility for Bosch Power Tools. Henning von Boxberg, President of the Bosch Power Tools GmbH, said, “The sale of each product marks the beginning of a new relationship for our users with us. The ‘Service on Wheels’ initiative ensures that our relationships are strengthened at every touch point. The launch of the ‘Service on Wheels’ underlines this commitment and builds on our reputation for exceptional service. These vans will cater on ground service or onsite service particularly to ensure our users’ productivity.”

Commenting on the launch, Panish P K, Regional Sales Director and Business Head India and SAARC - Bosch Power Tools said, “We are in the process of making after sales service a very painless experience to their customers in terms of repair and warranty. Our focus is to provide quality service and repair the tool at the fastest possible with genuine spares. With this, we are empowering every customer of Bosch to experience Bosch’s trusted quality service in the hand of experts. This would help us further strengthen the trust of our customer in Bosch.”

Godrej Aerospace launches Aerospace ‘CoE’ Godrej Aerospace, a unit of Godrej & Boyce Mfg. Co. Ltd., inaugurated its Center of Excellence (CoE) located in Mumbai. This world-class facility further enhances Godrej’s manufacturing capabilities in aero engine industry. Recognizing Godrej’s technical expertise, Rolls-Royce had recently expanded its partnership and awarded contracts worth INR 2000 million (USD 30 million) spread over next five years. The contract is for manufacturing products like Unison Rings, Complex Fabrication and external brackets commodities which once in manufacturing, will result in shipment of 600 different parts spread across various Rolls-Royce Civil Aerospace Engine portfolio. The newly inaugurated CoE will be one of the best aerospace facilities in India for manufacturing of aerospace brackets. This

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MACHINE TOOLS WORLD APRIL 2018

facility’s metallurgy capability includes inconel, stainless steel and titanium. It will commence manufacturing in bulk to prove the production readiness within the next two-three months. With an investment of INR 500 million towards this facility, Godrej Aerospace opens itself to a global market size in excess of INR 15000 million. Emphasizing upon the importance of this partnership and the new CoE, Mr. Jamshyd Godrej, Chairman and Managing Director, Godrej & Boyce stated, “We have an integrated facility meeting diverse demanding requirements of Fabrication, Machining, Assembly and Testing with all associated capabilities for special processes for making

precision components and assemblies for Aerospace applications. In line with our vision to expand our foot print and partner with global majors we have established this center of Excellence. I am confident that this will strengthen and deepen our wonderful partnership with Rolls Royce and establish Godrej as their preferred partner.” Kishore Jayaraman, President, India and South Asia, Rolls-Royce, added, “The expansion of partnership with Godrej & Boyce for manufacturing of aero engine components showcases our commitment to developing an aerospace ecosystem in the country. We are constantly developing and rationalising strategic partnerships across our supply chain. With the expansion of this partnership with Godrej & Boyce, our focus will be to meet our customers’ strategic requirements in quality, cost and delivery.”


The Trusted Partner in Metal Forming Machines

PRODUCTIVITY RELIABILITY AUTOMATION


BUSINESS NEWS

Delta Electronics launches Electric Vehicle charging solutions In support of the government’s electric mobility drive, Delta Electronics India Pvt. Ltd., a leading Power and Energy management company, launched its complete range of energy efficient electric vehicle (EV) charging solutions in India. The advanced EV charging solution offerings from Delta will enable the ecosystem to keep pace with the growing demands for a robust electric automobile infrastructure. Exhibiting at Elecrama 2018, Delta showcased its diverse portfolio of EV solutions with DC Quick, AC Chargers and Site Management System. These

chargers can be conveniently installed in multiple applications such as parking spaces, highway service, as well as residential and commercial buildings. Hsieh Shen-Yen, President of Delta Electronics (Thailand) PCL. said, “The business climate in India offers Delta exciting opportunities to partner with the government to power India’s growing economy. In line with our vision to be a strong catalyst and partner in India’s growth story, we are also announcing our fourth manufacturing plant in the country today. This is testimony to our

commitment to the “Make In India” initiative. Delta’s goal is to develop sustainable and energy efficient integrated solution offerings in India, for India, that will offer immense employment opportunities across the geography.” Delta Electronics (Thailand) PCL. is the parent company of Delta Electronics India. The manufacturing plant in Krishnagiri, Tamil Nadu, will be operational in 2019 and is expected to generate employment for thousands in the state. Along with its state-of-the-art R&D Centre in Bengaluru, Delta is looking at

investments of over a US$150 million in India. The EV charging solutions launched by Delta will also be manufactured at this plant. “Driven by robust product engineering, R&D, service support infrastructure and most importantly domain knowledge, Delta in India has been successful in growing 35 times over in the past 14 years. Our India growth trajectory has been a resilient legacy of accomplishments in Telecom Power, Industrial Automation, Solar Inverters, Display Solutions, to name a few, ” said Dalip Sharma, Managing Director of Delta Electronics India Pvt. Ltd.

Rolls-Royce Power Systems & Force Motors Sign JV Rolls-Royce Power Systems and Pune-based vehicle manufacturer Force Motors signed an agreement on a Joint Venture in which Force Motors will hold a 51% and Rolls-Royce Power Systems a 49% stake. The new joint venture will be named ‘Force MTU Power Systems Pvt. Ltd.’ and is to produce MTU’s renowned 10 and 12-cylinder Series 1600 units. Besides manufacturing Series 1600 units, the JV will also build Series 1600 generator sets for the Indian and global markets. Generator sets built and supplied by the JV to customers in India, Nepal and Sri Lanka will carry the ‘Force – MTU’ brand while those destined for the rest of the world will be sold under the name ‘MTU Onsite Energy’. Overall, the parties are investing more than 40 million euros (300 Rs Crores) in the JV in proportion to their respective

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stakes. To meet Rolls-Royce Power System’s exacting standards, the JV is to build a state-of-the-art, dedicated manufacturing facility at Chakan near Pune. The facility will be equipped with nearly all core functions and is to operate as a stand-alone enterprise. The new factory is expected to launch serial production by the third quarter of 2019. The JV will use Force Motors’ expertise to lead

localization efforts and aims to achieve consistently high local content without compromising on quality. The JV will handle sales and service of Series 1600 generator sets for end users in India, Nepal and Sri Lanka territory, while Rolls-Royce Power Systems will handle sales and service in Rest of World territory. Andreas Schell, President

and CEO of Rolls-Royce Power Systems, said: “This Joint Venture opens new opportunities for a bright future with our Series 1600 products. In Force Motors we have found a reliable partner whose excellent production quality is proven by decades of experience in building engines for premium automotive brands. Once serial production capabilities for 1600 units have been established within the Joint Venture, we will have opportunities to add other applications, engines and power systems to the JV portfolio,” he added.


BUSINESS NEWS

Wohlhaupter India has launched GEN 3XT Pro drill High productivity drilling & fine boring are easy with Wohlhaupter India’s latest products GEN 3XT Pro and Variobore. Wohlhaupter India has launched GEN 3XT Pro drill from Allied Machine & Engineering, USA and Variobore boring head from Wohlhaupter GmbH, Germany in the Indian market. Allied Machine & Engineering and Wohlhaupter GmbH pioneers in field of drilling and boring are carrying out their Indian operations thru their subsidiary Wohlhaupter India. Allied Machine & Engineering, AMEC has indexable drills from 9.5mm to 142mm with deep L/ D ratios and Wohlhaupter has boring tools from 0.4mm to 3255mm diameter. New GEN3SYS® XT Pro line of high penetration drilling products, which features inserts and holders designed for three new geometries and introduces several new coatings. Combining specific geometries and coatings to create the optimal solution for different machining materials, this next level of the GEN3SYS® high penetration drilling product line delivers top results.

GEN3SYS XT Pro is available for steels (ISO material class P), cast irons (material class K), and non-ferrous materials (material class N). The drill inserts come in diameters ranging from 11 millimeters to 35 millimeters. Those in steel and cast iron will also have new AM400 coatings, while inserts for non-ferrous materials are coated with titanium nitride (TiN). Holders for the GEN3SYS XT Pro line are offered in numerous depth-to-diameter ratios, including 3xD, 5xD, 7xD, and the brand new 10xD. The new holder features an enhanced flute design that improves chip evacuation and an updated coolant configuration that increases coolant flow and directs coolant to the cutting zone. Available in imperial and metric shanks, the holders come in cylindrical and flanged with a flat. Variobore is a versatile and cost-effective tool that features a universal digital readout module. The VarioBore Precision Boring Head & System improves productivity through ease and accuracy of adjustment and virtually eliminates scrap because of its exact adjustments. A single module

can be used on a wide variety of tools fitted with docking ports. With a range of 0.4 to 152 millimeters, the boring head offers an accuracy of 0.002mm on diameter, and speeds of up to 30,000 revolutions per minute. A single Universal Digital Readout Module can be used to set any number of tools that have docking ports. The system uses selected Wohlhaupter 019, MiniDigi, PrimeBore, and DigiBore tooling. With an easy to read and use display that provides easy micron accurate settings, the module features an accuracy of 0.002mm on diameter with μ accurate ± setting. The battery allows up to 5,000 settings and is switched off after 30 seconds. The detachable module remembers the last setting, even when it is detached. The module is coolantsealed up to IP 65. Wohlhaupter India has the facility to repair its boring heads. For more information, E-mail: info.in@wohlhaupter.com, info.india@alliedmachine.com

Mastercam partners with NASA HUNCH program CNC Software, Inc., developers of Mastercam, the world’s leading CAD/CAM software, is partnering with NASA HUNCH. HUNCH, High Schools United with NASA to Create Hardware, is an effort to bring high school students new educational experiences with NASA projects. CNC Software, Inc. will be providing licenses of Mastercam to select schools to use, as long as they are participating in the NASA HUNCH program. While there are about 150 schools participating in NASA HUNCH, Mastercam is specifically working with those schools focused on Precision Machining. “CNC Software is proud to support HUNCH and its efforts to bring high school students new educational experiences with NASA projects,” says Peter Mancini, Education Product Owner, CNC Software, Inc. “This is a unique program.

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We are glad to be a part of students fabricating real-world products for NASA as they apply their science, technology, engineering, and mathematics skills, as well as learning to work in teams and think creatively.” HUNCH originally started 16 years ago with a handful of schools producing hardware training items for the International Space Station. Now, it has grown to over 150 schools across

the country, not only producing hardware for flight and training, but branching out to design projects, sewing flight and training articles, and an Astronaut Culinary Challenge. Over 20,000 students have participated, with 94% moving on to pursue undergraduate degrees. Says Blake Ratcliff, Program Manager, NASA HUNCH, “We are excited about the capability that Mastercam brings to our schools. This partnership will benefit both students in their academic pursuits and NASA in the products that will be generated as a result.” Mancini comments, “Some of our best customers, such as Lincoln Tech, Warren Tech, and Cypress-Fairbanks ISD are already a part of HUNCH, and we look forward to introducing Mastercam to other great schools involved with this innovate program.”


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COVER STORY

FEMCO: Achieving the milestone with sustained growth

Q. How do you see the market for CNC machines in India? Market potential for CNC Machine Tools is growing and will keep growing in future. This growth is fueled by certain industry segments aggressive growth plans. Infrastructure, Heavy Engineering, Railways, Aerospace and Defense sectors are high priority and high growth potential sectors. Of course, Automotive sector –which is largest machine tool consuming sector is also showing positive growth. White Goods sector is also growing rapidly. Particularly Tooling industry – Die & Mold is also growing phenomenally.

Q. Die mould industry / Tooling Industry is largely contributing to automotive industry. How do you see the future and your views on Die Mould / Tooling industry? It is undeniably right – Die + Mold industry is playing unquestionably critical role contributing to automotive sector and driving new developments in CNC Machine Tool industry. Die + Molds are becoming increasingly complex and demands increased functional & quality demands.The Dies and Molds market in India is experiencing increased demand from industries such as Automotive, Plastic, Electronics and Electrical, Healthcare, and Machine Tools, among others. Industry is growing about 15 ~ 20 % which is phenomenal growth.

Q. In your view, what Die & Mould industry should consider to enhance their Technological capabilities ..?

B P Poddar Vice President – Sales & Marketing Fatty Tuna India Pvt. Ltd.

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This sector must adopt high quality machine tools capable to produce high quality and critical dies & molds. Along with machine tools, right selection of software and hardware is also of utmost importance. In my view point, this segment is fragmented and needs consolidation and knowledge collaborative approach within


COVER STORY www.mtwmag.com

themselves in order to grow together and bring in and use technology. Die + Mold industry should consider : • High Speed Machining • Right CAD /CAM solutions • Right CNC features necessary for optimal speed control functions of machine • Right Tooling Along with this Die + Mold manufacturers must realign their short term and long term business strategies Future is potential and promising.

Q. Factors influencing the demand for dies moulds in India Dies & moulds are becoming increasingly

complex and demands increased functional and quality. The Dies and Molds market in India is experiencing increased demand from industries. such as Automotive, Plastic, Electronics and Electrical, Healthcare, and Machine Tools, among others. How Indian die mould providers can compete with the global players and reduce the dependence on import? This is question, our Die & Mould industry should address collectively and proactively.

Q. There is lot of buzz around IIoT (Industrial Internet of Things) and smart factory. What do you think and what are your views ? IIoT, Smart Factory, Industry 4.0 are being heard very commonly in all industrial sectors be it Machine Tools , Automotive manufacturing

or general engineering sectors. Globally manufacturing industry is witnessing 4th Industrial Revolution and all these buzz words are coined to describe 4th Revolution. It is amalgamation / convergence of manufacturing and digital worldCyber-Physical-World. This is seamless integration through digitization of all connected industries. This is based on various technological pillars such as Big Data Analytics, AI, Cloud, Augmented Realities, Automation / Robotics, 3-D Printing etc. The Internet of Things (IoT) is a revolutionary manufacturing technology that allows electronic devices connected to each other, within the existing Internet infrastructure, to communicate with one another without human intervention. In my personal views, it will not happen so soon in India and it will take longer time that we are thinking. All stake holders must try to understand importance of IIOT in their particular industry and start taking baby steps as soon as possible and start learning and implementing. Software support system in India is almost ready to support this industrial revolution but other hardware parts are not yet ready to me implemented.

Brief info on company

F

EMCO is more than 70 years old Machine Tool Manufacturing company in Taiwan known and highly respected for manufacturing Machine Tools for various industry segments - Heavy Engineering, Oil & Gas and Aluminum Alloy Wheels. FEMCO realized the potential offered by Indian Industry and established own company in year -2011 with just 3 employees. In last seven years we have reached various milestones in our journey in Indian Market. FEMCO product overviews comprises – Horizontal Boring Machines, Horizontal Boring Machines with Integrated Facing Head & Automatic Tool Changer for Facing Head, Horizontal Lathe Machines, VTLs and Alloy Wheel Manufacturing Solutions. Femco is the 1st Taiwanese company to establish Technology Center in India which is located at Pune. This Technology cum Demo Center is spread over 40,000 square feet.

Through this Technological Center we are able to demonstrate our technical capabilities to our customers. We offer Test Cut trials to demanding customers. We are not only offering standalone machines but complete solutions which includes pre-sales, application engineering support, installation & commissioning through well qualified and factory trained engineers, support through warrantee and after warrantee, timely spare parts availability. After having into this market and understanding various industry segments and geographical regions, we have expanded our reach to various important industrial locations. To meet various requirements of market and various industrial segments, we have joined hands with few other Taiwanese Machine Tool Makers and started marketing different machines such as VTL, Double Column Machining Centers, Grinding Machines, EDM.

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MACHINE TOOLS WORLD

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IN FOCUS

“ The future will see a lot of penetration of automation in all the manufacturing activities� Q. What are the milestones your company has achieved till date ? Dahanukar Machine Tools since its inception in 1983, has always manufactured machine which offer huge value to the customers, The machine manufactured by us are in tune with the customer needs and requirements. Company has recently launched many new surface grinding machine models for catering to varied customer’s needs. Machine ranging from job sizes as small as 100 mm X 150 mm to job sizes 1200 mm X 600 mm are introduced in the market. Many new industry first grinding machine features are introduced with the launches of Linear Motion Series, Vfd Series, Adf series to suit customers requirement. Simple NC controlled machines and programmes are developed after long research keeping in mind ease of use for operators. Machines are sold as ready to use grinding machine, helping customers use the machine right away without losing valuable time of the shop floor. On many occasions, time study of components, making of jigs and fixtures and other background leg work is carried out on behalf of customer for giving them the best possible solution & helping them making an informed decision by our team. Company is recently renewed its focus on appointing Dealer network for sales & servicing of machine, across India for supporting past and new customers. Adding value to our customers through lowering the cost manufacturing and thus helping them achieve profitability.

Q. What product technology you represent ? Dahanukar Machine Tools manufactures Horizontal Spindle reciprocating table, Vertical Spindle Rotary Table type of surface grinders in India. All the machines are available in Manual, Semi-Automatic

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to have technical and/or commercial collaboration with foreign counterparts. This would not only secure the short term risk but also propel us into the future.

Q. What is your vision for forthcoming years ?

and Automatic versions to suit customers requirement. India being a cost conscious market, we have many cost effective grinding solutions for the customers without compromise in the quality.

Q. What is the future of your products in India ? The future will see a lot of penetration of automation in all the manufacturing activities done in India. Being in nascent stage there is a huge potential for International players to prosper in this vast market. Going forward a lot of foreign company would set shop here in India either via direct or via indirect route with tie-ups and collaborations, Indian companies would have brace for this influx and also shift there mind-set to embrace new technology for reducing the cost of manufacturing & delivering products that match global standards. The only downer is the availability of skill labour. This is where we at Dahanukar Machine Tools are investing our resources to upgrade in future technologies and are looking

The rapid growth of industries such as automobiles and auto components, defence, domestic appliances consumer electronics etc, has created a huge potential in India for manufacturing and tooling. With adoption of new technologies and manufacturing processes, companies would hugely benefit from this growth potential. With adverse effect of demonetisation and gst implementation behind, companies can now look forward to a fairly stable compliance scenario in coming years and positive changes in policy would further improve the outlook of manufacturing sector. All in all we foresee a upward market trend to continue in the near future. India is poised for growth because of lot of untapped potential in India.


IN FOCUS

Alex Machine Tools: The Grinding Experts Alex Machine Tools is the leading manufacturer of high precision Surface Grinding Solutions in India, with machines successfully operating in more than 20 countries.

E Nisha Lobo, Director, Alex Machine Tools Pvt. Ltd.

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stablished in 1964, Alex Machine Tools is the leading manufacturer of high precision Surface Grinding solutions in India, with machines successfully operating in more than 20 countries. Countries include India, U.S., Germany, U.K., Canada, Saudi Arabia, U.A.E., Oman, Kenya, Nigeria, Sri Lanka, Nepal, Bangladesh, Singapore, Thailand, Indonesia, Malaysia, Australia and New Zealand. Customers are leaders in major sectors of the Engineering Industry. Honda, Hero Motors, Tata Motors, INA, Timken, NRB, TVS Motors, L&T Valves to name a few. Several ALEX grinding solutions are in successful operation - the result of a continued development in design, quality, electronics and automation. ALEX offers a comprehensive range of Surface Grinding machines from the Reciprocating hydraulically operated Surface Grinder to high power Rotary Surface Grinder to precision Double Disk Grinding to Special Purpose Grinding Solutions. This range includes a wide variety of sophistication including computer numerical controls, automatic in-process gauging and other material handling automation, depending on the customer’s need and application. Director Nisha Lobo quotes her father and founder Alex Lobo, “We sell less to sell more - Our comprehensive range allows us to offer our Customer exactly what he needs, no more. This value keeps him coming back for more”. The Company is run by Vernon Pontes and Nisha Lobo. Both bring years of global experience to the business. Nisha has a Masters in Machine Tool Design from Cornell University, USA.

Vernon is a Business program graduate from Harvard University, USA. Both have grown multi-national companies before taking over the reins of the family business. With a 10X growth mantra, global vision, commitment to Technology, highly dedicated team they have come to know as family and a unique work culture - this family owned company is carving out its niche in the Global Grinding space. “Our Products, Tools, Design, Manufacturing and Service have to be ‘best in class’. Today, our Customers expect a grinding solution, Automation, Industry 4.0. Through FEA and the latest design technology we are able to provide optimum designs, reduce prototype iterations, and develop new models at a pace we have never done before. From robotic work piece handling to hands free pick and place, to in-process and post process gaging, our vision is to engineer grinding solutions that can scale globally. Our Double Disk product line is expanding fast. We are expanding the range and developing turnkey solutions for key markets. We believe this strategy will support our 10X plan as well as our global vision. We are very excited about the future of Alex Machine Tools, both domestically and globally. Today, Customers from Europe, USA, Japan are not only looking to India to set up operations for local supply and distribution, but also looking at equipment made in India that is able to be moved around their plants any where in the world. This has been a significant challenge and opportunity for us. It will make us a world class Company.


IN FOCUS

“Design & Manufacturing industry is slowly adapting cloud processing & solutions OnCreate3D eliminates user’s need to pay for onetime upfront purchase of desktop CAM software, AMC or upgrade charges for renewals and management of software installations, software/hardware lock maintenance and updates. OnCreate3D aims to bring down the cost of ownership of CAM software by 80% compared with desktop CAM softwares. MITCON, Pune provided us with the certification of innovative product in May 2016 and we subsequently registered our company as startup with DIPP, Govt. of India’s start up initiative in June 2016.

Abhijit Kumthekar, Co-founder & Director Machining Software Pvt. Ltd.

Q. Please brief us about your company. Machining Software Private Limited is a self-funded startup incorporated in May 2016 with the aim to design, develop and deploy “OnCreate3D”, world’s first CAM Centric Cloud CAM application. We are on a mission to create something useful in 3D and have been working towards the development from September 2015. We launched FREE public Beta release of OnCreate3D on 12th January 2017. Till date, we have more than 2500 subscribers and the number is steadily growing. OnCreate3D is a browser based offline CAM software package. Unlike a desktop CAM software that runs on a desktop/ laptop and is therefore tied to machine hardware including hardware/software locks; OnCreate3D runs in browser and so it is accessible from any device, anytime and anywhere. User only needs a standard browser and good internet connection to use OnCreate3D. Cloud infrastructure allows users to use 64GB or even 128GB RAM, multi-threading and built in concurrency to execute complex toolpath operations in minutes that could easily take half an hour on desktop CAM softwares.

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Q. Please highlight the latest initiatives in your domain. Design and Manufacturing industry is slowly adapting cloud processing and solutions in its mainstream workflows. Autodesk Fusion 360 and Onshape have already successfully deployed browser based cloud CAD products, so multiple users can collaborate across geographical boundaries. Serious users for Cloud CAD products and its consumption is steadily increasing. This trend is getting extended in manufacturing domain as well.

Q. What are Market opportunities for your company in India? Job shops and SMEs in India are our target customers. These set ups usually have a couple or more of CNC Machines or new set ups wanting to add a couple of CNC Machines. Buying a CNC Machine at huge investment is necessary, but they are left with very small budgets to buy desktop CAM software, trained machinists to program part for them etc. Typically they program 2 to 3 new components per month and therefore engage in utilizing CAM software for up to 10 days in a month. The rest of the time, CAM software is not utilized. But it still needs maintenance, AMC and/or upgrades every year. The cost of owning

CAM software is high for these set ups. OnCreate3D plans to help SMEs with ‘pay as you go’ option. Users can subscribe monthly for unlimited projects at ` 1800 per month or they can purchase credits for 3 or 5 projects at ` 975 or ` 1300 with no limit of time for consuming the credits.

Q. What is future prospect for your Industry? CIMData reports indicate good CAD/ CAM adaption over next few years. CIMData survey carried out in April 2017 shows 16% of CAD users to have already deployed Cloud CAD products, 14% taking decisions to implement the same in next one year and so on. Although, there is no specific data available for CAM adaption, it is safe to assume that it will follow trends of CAD users.

Q. What is the top line product range and is there any plan to add more products/Modules? OnCreate3D currently has implemented Milling module and Nesting module. As of today more than 2500 users have created more than 5000 projects and more than 25000 toolpath operations on OnCreate3D. We have subscribers from 34 countries, largest being users from USA, Indian user count ranks at 4. In coming months we plan to add Lathe, wire-EDM. Laser and punch module.

Q. What is your vision for your company? We want to be preferred partners in success stories of our customers, only then we can write our own success story. As SMEs, Tier2, Tier3 suppliers are constantly under pressure to either reduce prices by 2-3% year-on-year basis or improve efficiencies on yearly basis, we want to provide them with more economical solutions and customer support beyond expectations to achieve their targets.


IN FOCUS

Radius Engineering : Benchmarking the standards Q.What are the Mile stones your company has achieved till date? The company over the last few years has developed lot of customised machines and significantly moved to 2 areas. The Gun drilling machines with 6 axis CNC, for making pellet Dies used in the food processing industries for Fisheries, Poutry and cattle feed. We have indigenously developed state of the art machines other than Gun drilling machines, for manufacturing pellet dies which include OD and ID Grinding machines, Countersinking machines etc. We have offered Gun drilling machines for Die and Mould components, Orthopaedic Implants where the materials are quite challenging for drilling, Automotive components like fuel injection components which call for high accuracies. The other area is in the field of High tension Coil manufacturing for big generators and motors where we have indigenously designed and developed machines which can cut and buff the copper conductors, loop the copper conductors into coils, Form these coils into diamond shape and tape them with insulation using 6 axis CNC taping machines. The significant milestone is that all these products have been engineered to the minutest detail taking all the inputs of the customer and today we can proudly say that we are one of the top five companies in the world to have the expertise in these range of machines. Our machines are exported to countries like South Africa, Brazil, Peru, Thailand etc.

Q. What product Technology you represent? We represent a product technology that is cutting edge and futuristic. With the

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Gurushree Prasad. K.R., Director, Radius Engineering Solutions Pvt. Ltd.

world rapidly moving to automation, our products have intelligence built in so that the machines give consistently high quality output with minimum manual intervention...The machines are built with CNC system or PLC with scada systems, offering effective process control and include high end automation including robots

Q. What is the future of your products in India? We see a great future for our products both in India and abroad. With great degree of innovation and offering an excellent value proposition we are placed in a significantly better position... The food processing industry and the demand for various feeds right from fisheries , poultry to animal feed places us in a good position to capitalise on new requirements..With rapid thrust in energy requirements from windmills ,turbines and lots of power generation in an ever growing consumer driven

economy we see the future of our products very bright and look forward to an exciting future. The important fact of the matter here is we bridge the gap between China machines and highly expensive European / USA machines.

Q. What is you vision for forth coming years? Our vision in forthcoming years is to target and develop new solutions in the market to increase manufacturing and productivity of our customers. With the thrust given to Make in India by the current government we want to be the vehicles of change and contribute to manufacturing in our little capacity.


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IN FOCUS

QVI : Smart Solutions with Quality & Precision Q. Being the key player in the industry, Please brief us company’s journey from inception & share some of the milestones achieved? Quality Vision International (QVI) was founded in 1945 as Optical Gaging Products (OGP) with manufacturing of Profile Projectors. In 1980 we were the first to introduce Vision Measuring Systems to the Industry. In early 1990s we launched, our now worldfamous Model, Shreyansh B Hippargi, SMARTSCOPE Managing Director, QVI India Pvt. Ltd Vision Measuring Systems. We have sold thousands of SmartScope Systems across the world till date. Today QVI offers more than 70 models of dimensional measuring systems.

Q. Please brief us about company’s infrastructure & what are the technology alliances that has been made in order to out-front the competition? QVI has an installed base of more than 60,000 systems in over 75 countries. We have sales & service offices in different parts of the World. We have over 100 channel partners worldwide. The key is to be as close to customer as possible to give in time pre-& post-sales support.

Q. What are the products manufactured by your company? QVI is expert in optical technologies applied to non-contact dimensional measurement. Products range from optical comparators (profile projectors) to Vision Measurement Systems with multisensor capabilities. Vision systems forms the majority of the product range that we make. We also manufacture complimentary products including 3D Laser Scanning

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Systems and CMMs with unique touch, laser, and video sensor capabilities.

Q. What is your marketing strategy for India? Our marketing strategy for India is to make the QVI brand known to current and potential customers. We started in India in 2008 under the OGP brand which is now QVI. We have Channel Partners across the Country who play key role in promoting our Products. We are looking for additional channel partners in some of the key industrial hubs of India, where we don’t have any presence now. At the same time, we are strengthening our staff for Support activities. We also participate in key Trade Shows to boost our brand awareness & resulting Sales.

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? R&D is vital for any Organisation’s Growth, and we are no exception. QVI Inc’s focus has always been developing new technologies that will help manufacturers around the world to ease out their Inspection challenges. To that effect we have a dedicated R&D team at our Head Quarters in Rochester, New York, US. The company has numerous patents on its innovative technologies. QVI applies its R&D to its evolving product lines in order to meet the changing needs of advanced manufacturers worldwide.

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? QVI is ISO 9001:2015 certified for its manufacturing activities at Rochester, NY, US. Our state of the art calibration lab at HQ is ISO17025 qualified. QVI controls its quality through vertical integration. We do our own design of systems, hardware and software. We have multiple machining centers, a paint shop, optical and electron-

ics assembly – all to ensure highest quality. This helps us in having total Quality Control ensuring customer satisfaction. Our focus on customers is shown with our company tagline “Precision for People.”

Q. According you what are the factors affecting to your business? There are many factors like advanced manufacturing equipment that allows creation of parts with complex forms and tight tolerances, constantly changing competition, Price Pressures, changing Market Conditions, Government Policies and Customer needs. Throughout these dynamics our focus stays on meeting and exceeding our customers’ needs.

Q. What are the key technological trends that are driving the industry? Traditional metal machining and injection molding continue to evolve with greater capabilities to make complex parts; additive manufacturing is gaining traction; Industry 4.0 and IoT are becoming embraced by manufacturers. We stay tuned to technological developments so our products enable manufacturers to keep advancing their capabilities and quality.

Q. How do you perceive the future of the industry? Currently the Market particularly in India is looking good, and we feel that this growth, will continue until Q3 of this FY19, to see slight fall in Q4 due to General Elections in May 2019. Longer term, QVI believes India will become a dominant market in its global portfolio of satisfied customers.

Q. What is your vision for your company for near future? We are optimistic that the unique capabilities of QVI systems and software will meet the needs of ever more customers in India, even as our competitors recognize the opportunity that India represents. We’re sure your readers will become familiar with QVI if they need to reliably measure the parts they manufacture.


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IN FOCUS

Q. What are the milestones your company has achieved till date? ELESA+GANTER® is a commercial joint-venture between the two world leaders of plastic and metal manufacturers of standard machine elements: Elesa S.p.A (Italy) and Otto Ganter GmbH & Co. KG (Germany). In 1995, the two companies started setting up a common sales network under the trademark ELESA+GANTER. The joint venture made its first steps into the East-European market and today it covers more than 60 industrialised countries worldwide. Elesa+Ganter extensive product range & quality is result of the amalgamation in true sense of both the mother companies: high material quality combined with the best original design and accuracy in production. Across Industries and in the world of standard machine elements, Elesa+Ganter has carved a niche name for itself. We are well-known in the industry for offering the widest range of standard machine elements with a unique design, a perfect service and the ability to create special customized solutions in a very short time.

“Elesa+Ganter has carved a niche name for itself”

Mr. Ram Grover, Managing Director Elesa and Ganter India Pvt Ltd

Points of strength • Technological prowess of the two established mother companies. • Innovation in combination with decades of experience. • Unique design. • Optimised and widest product range of standard machine elements, driven by the market • Worldwide distribution network • Full stock availability with fastest delivery times • Customized solutions • Perfect service including technical assistance.

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Q. What product technology you represent? Elesa+Ganter offers a wide range of 50,000 standard machine elements worldwide. Our products contribute to improve the quality of the machines and equipment they are destined to. Our product portfolio is comprised of: • Operating elements, Machine elements, Indexing Elements • Clamping knobs , Clamping Levers


IN FOCUS

• U-handles, Fixed, revolving, fold-away handles • Control elements, Rotary controls , Levelling elements, • Joints, Hinges, Latches, Hook, toggle and power clamps • Accessories for hydraulic systems, • Tube clamp connectors, Castors and Wheels, Retaining magnets etc.

Our high performing items are marked with their own icons, allowing standard parts to be selected specifically in terms of certain requirements. Also, Customized solutions are part of Elesa+Ganter’s core competence. Our products are protected and by more than 150 international patents. We believe in continuously searching for

better ways of doing things.

Q. What is the future of your products in India ? India is a growing market with extensive scope for our products. As growth rides on increased industrial production and international trade, demands on machine elements have become more intense and sophisticated. Within India, increasing penetration of organized trade and preferences for branded products has added fuel to the increasing demand. Machines and advanced technologies in most of the industrial sectors has come up to meet this rising requirement. Another factor is the rapid growth of exports, which involves superior quality standards for the international market. With this the need for adopting better technology, materials & machinery to ensure quality has become very important for Indian businesses. Our range of standard machine elements are well suited to the machines of almost all the sectors. Elesa+Ganter’s standard machine elements are widely

used in these industries i.e. Construction and material handling machines, Hydraulic Equipment, Metalworking Machines, Machines for Building Materials, Plastic/Rubber molding machines, Agriculture and Gardening, Woodworking Machines, Textile Machines, Pharma Machines, Medical and Laboratory Equipment Dairy Industry Machines, Packaging Bottling and Labelling Machines, Paper Processing and Printing Machines etc. to name a few. Despite being price sensitive, the market is improving in a phased manner. Customers today are lot more aware and since we are the most prominent players in this segment, we can easily gauge this fact from the response that we have been receiving.

Q. What is your vision for forthcoming years? Elesa+Ganter is currently investing into the Indian market by expanding team of Sales and service professionals in all the regions. We are also investing heavy to build our brand – Industry magazines, Exhibitions, Digital Marketing etc. Our focus is to expand our customer base and foray into different industry lines for which we plan to participate in various industry exhibitions spanning different sectors. On the other hand, we are also investing in our sales & service staffs. We have regular visits from headquarters and our team members often travel for advanced training and to understand new product launches. Additionally, our well-established Channel Partners Network across India ensures easy availability of our Products and on time deliveries. We are very bullish towards Indian market and with initiatives and programs like ‘Make In India’ our resolve to make big in India has only got stronger.

Visit us at TAGMA Hall: 1, Stall C-83 For more information, Website: www.elesa-ganter.in

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COMPANY PROFILE

We are for those, who are in Metal Cutting!

S

tarted in 1999 at Pune, Accusharp Cutting Tools Pvt. Ltd; stands today as a leading company, in design, manufacture & supply of special cutting tools in HSS and Tungsten carbide for Automobile, Engineering, Textile, Energy Sector, Machine Tools Industries, etc. Our business objective is to assist customers for their productivity 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.

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People: With competence and passion for the organisional objectives. Professional team of competent application engineers provide unmitigated solutions for metal cutting processes for customers. Manufacturing setup consists of modern equipment, like, 5-Axes CNC Tool & Cutter Grinders - ANCA, WIDMA, Rollomatic, Strausak-, and Zoller Geninus3, & Rapid-I, as Q.C. equipment. We strongly believe, that customer is our first concern. For a number of MNC’s & OEM, as well as other satisfied customers, we have established strong support teams across India, and logistic network, a step closer to customers.

Accusharp Cutting Tools Pvt. Ltd. is a company certified for ISO: 9001-2008 for QMS. 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, Supplier Code of Conduct aspects. And this remains as our work culture.

For more information, Website: www.accusharp.co.in


NC4 non-contact tool setting system Non-contact tool measuring and broken tool detection on a variety of machining centres

Key benefits:

Specification:

• Reduce tool setting times by up to 90% and reduce scrap caused by setting errors

• ± 0.1 µm 2σ repeatability

• Improve setting accuracy

• Measures and detects tools of Ø0.03 mm or larger

• Broken tool detection cycles enable reliable unmanned machining

• Flexible systems – fixed or separate

• Increase productivity, improve quality and increase profits.

• Ultra-compact systems – just 30 mm wide and 35 mm high • Environmental protection – features patented MicroHole™ and PassiveSeal™ technology • Easy installation – ideal for retrofitting offering fast set-up

call +91

20 6674 6200 or visit www.renishaw.co.in/nc4

Renishaw India [Pune] S.No.282, Hissa No.3, Raisoni Industrial Estate, Village Mann, Tal:Mulshi, Pune 411057 T +91 20 6674 6200 F +91 20 6674 6211 E india@renishaw.com

www.renishaw.co.in

NC4Advert A4(EN).indd 1

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COMPANY PROFILE

We give strategic advantages to our customers from diverse industries

Rupesh Paparaju, Director, Bettinelli Automation Components, India

B

ettinelli S.p.A, established in 1953, specializes in the development and manufacturing of precision motion control components and systems. In 1996 a separate division named CDS Cam Driven Systems was created for engineering solutions in automation and motion technology. CDS produces the widest range of mechanical Cam Driven Units, commonly known as rotary / indexing tables for precision motion control applications, requiring rotary or linear transfer, positioning and handling. The products range includes, cam indexing and servodriven tables, ring positioning drives, intermittent and oscillating drives with parallel or right angle configuration, rotary & linear part handlers, precision link transfer systems, and epicycloidal servo reducers.

Wide ranging products

The broa4d product spectrum covers IP parallel shaft indexers, IT roller dial indexing tables, TR roller dial indexing tables, HP roller dial indexing tables, IG/ IGA roller gear indexer, TL precision link conveyors, MHP/LHP part handlers, FTHT open center ring tables and packages of rotary indexing tables. Bettinelli has a wide range of standard products. These are delivered in 3 weeks. When it comes to customized products, these are designed,

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manufactured and shipped in 6-8 weeks. The manufacturing takes place centrally in Italy. The regimen starts with design & engineering, CNC induction hardening, CNC milling, grinding, quality check and then assembly, painting and shipment. In order to ensure quality, all components are machined internally, including the cam hardening by a proprietary CNC controlled induction hardening equipment. For better finish, the products are also subjected to chemical nickel plating, blasting and painting. The manufacturing process is constantly controlled to conform to international standards. The company’s quality systems are ISO-9001-2008 certified.

are used in pallet transfer tables, assembly machines, painting applications and test rigs, just to mention a few. In machining industry, they are used with advantage in deburring, lapping and pressing machines and in transfer lines. In SPM & robotics, they find applications in transfer lines, station loading, sequential operations and so on. Inwelding, these indexers are inevitable in positioners, synchronous welding, robotic welding and component transfer. Packaging too is a major application area. Cam systems are used in box filling machines, wrapping machines, cartoning and capping machines. Indexers are also used in casting, printing and cosmetics industries.

Strategic advantages

Over the years, Bettinelli Group and CDS Indexers have become synonymous with high quality automation products and technologies. “Our design and manufacturing systems have furnished competitive and strategic advantages to numerous industries in pharmaceutical, automobile, manufacturing, packaging and a plethora of other sectors. And for automation functions, our solutions are invariably preferred by companies,” says Rupesh Paparaju, Director, Bettinelli Automation Components, India. The Indian subsidiary, headquartered in Pune, serves its customers in India by providing installation, commissioning, and after-sales support. It also offers technical consultation. In the pharmaceutical industry cam driven systems are used in filling, blister pack, tablet making and packaging machines. In automobile industry, they

Parallel Shaft Indexer

Rotary Indexing Tables, TR Series Closer to the customer

The Indian arm of Bettinelli, based in Pune, Bettinelli Automation Components Pvt. Ltd., is highly customer-centric. “Our presence in India means quite something in fostering a symbiotic relationship with our customers. It helps us to match our world-class products with our eminent customer support,” underlines Paparaju, Director, who has built up a team to improve Bettinelli’s response time. “CDS are high-tech products which lend themselves to enhance the operational efficiency and productivity at the customer’s end. We stay close to the customer to understand his needs and offer customized solutions within the shortest possible time to ensure peak uptime of his equipment and operations”, he adds. - P.K. Balasubbramaniian


COMPANY PROFILE

Grob-Werke: Thrives on new technologies

G

robe-Werke, with a standing of over 90 years, is one of the global players in the development and manufacturing of machines and production lines. Its customers include the world’s most prestigious car manufacturers, their suppliers and many other renowned companies from various industries. With production plants in Mindelheim (Germany), Bluffton, Ohio (USA), São Paulo (Brazil) and Dalian (China), and worldwide service and sales subsidiaries, the company is represented around the globe. The GROB Group, with a workforce of about 6,600 employees, generates worldwide revenue of over 1.3 billion euros. Its portfolio ranges from universal machining centers to highly-complex manufacturing systems with own automation function through to manual assembly stations and to fullyautomated assembly lines. Furthermore, production plants for electric motors and assembly lines for battery and fuel cell technology are part of its product range. GROB engineers are delivering solutions for the technology involved in spraying engine components, in cutting high-strength turbine housings and machining structural and chassis components. By developing GROBNET4Industry, its proprietary industrial software for the digitalization and networking of production systems, GROB is taking a giant leap into the digital future. Glorious past

The success story of GROB-WERKE began back in 1926 when the company was founded by Ernst Grob, who was

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producing folding boats, weaving machines and stationary combustion engines at that time. In 1952, Burkhart Grob, the son of the founder, assumed responsibility for the company almost completely destroyed during the war and was able to forge the link to the emerging automotive industry with high-quality and technologically-convincing production machines. In 1968, the Mindelheim plant was built and the company’s headquarters was relocated from Munich to Mindelheim. Besides the parent plant in Mindelheim, the plants in Bluffton (USA), São Paulo (Brazil) and Dalian (People’s Republic of China) are part of the production network of GROBWERKE. This production network is expanded through thirteen sales and service branches in South Korea, China, India, Russia, Great Britain, Hungary, Mexico, Italy, Poland, Switzerland, the Netherlands and the USA to guarantee the best service quality.

Even after Dr. Burkhart Grob passed away in May 2016, the future of the family company has been strictly set out. Christian Grob takes the company into the third generation as the new Supervisory Board Chairman. Even at this early stage, the next generation is being prepared for future tasks. By purchasing DMG meccanica in January 2017, GROB has acquired a strong partner in the field of electromobility. GROB now also acts as a developer of system concepts for electromobility, which is a future-facing step for expanding the existing product range of highly-efficient manufacturing and assembly plants. In January 2018, DMG meccanica was renamed GROB Italy S.r.l. Product and service spectrum

The product range of GROB-WERKE GmbH & Co. KG can be divided into the following areas: System solutions and special-purpose machines: Machining centers or flexible


COMPANY PROFILE manufacturing systems are designed specifically for the customer’s part. Offering so-called turn-key solutions, GROB provides the required planning, engineering, manufacturing and commissioning on site at customers’ facilities – everything from a single source. In most cases, these systems consist of modular machining centers and special-purpose machines that are interlinked with the latest automation solutions. Typical parts are for example cylinder heads, crankcases, transmission case and housings for auxiliary units of the engine. Universal machining centers: The machining centers are mainly operated as stand-alone machines but are also available with automation solutions. They are typically used in the aerospace, automotive and medical industries, in tool and mold industries and in case of felxible contract manufacturers. Assembly technology: All assembly stations and assembly lines for the

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automotive industry are individually planned, designed and custombuilt according to specific customer requirements. The systems are used for semi-automatic or fully automatic assembly of assemblies equipped with a variety of robot cells and measuring and test stations. They are typically used for example for the assembly of engines or manual transmissions for passenger cars and trucks. Assembly systems for electromobility: As a general contractor, GROB offers machines, automation systems and purchase components for electromobility as well as the required management expertise. From stator and rotor assembly through to final assembly, we deliver a modular and reliable plant concept for high-output electric motor manufacture. Into the Future

At GROB-WERKE, the development

of new technologies has been a key element of the company’s success since the very beginning. New technologies that set benchmarks in the mechanical engineering sector are continuously emerging. The G550TS thermal spraying system developed by GROB thus expands the production chain for cylinder crankcases. GROB has also developed a motorized spindle with cross-feed – an outstanding concept for the complete machining of turbine housings on the machining center. The company is taking a giant leap into the digital future with the proprietary software GROB-NET4Industry, developed for the digitalization and networking of production processes.

For more information, Website: www.grobgroup.com


MEASUREMENT ERROR

MEASUREMENT PRECISION

The non-contact Mida ML75P laser tool pre-setting and verification system is the key to maintaining the micrometric accuracy required by the most demanding machining applications, as in the aerospace field. You get consistent quality, less waste and more profit. Marposs means precision.

www.marposs.com

Y O U R G L O B A L M E T R O L O G Y PA R T N E R

MARPOSS INDIA Pvt. Ltd. 147, Sector 7, IMT Manesar 122 050 - Tel. +91 124 4735700 | sales@in.marposs.com


COMPANY PROFILE

Shavo Technologies offers high-tech tailor made solutions

Rushil Shah, Managing Director, Shavo Technologies Pvt. Ltd.

S

havo Technologies Pvt. Ltd., a part of the Shavo Group founded by Mr. H.K Shah, a pioneer in the pneumatics field in 1960, is in the frontiers of niche high technologies cutting across diverse disciplines. The company headquartered in Pune and headed by Mr. Rushil Shah, Managing Director, represents some of the world leaders in their respective fields for technology solutions like static elimination, precision air movement, high quality instrumentation, high purity gas delivery, corrosive gas handling, energy absorption and so on. With a vast portfolio, the company serves over a thousand customers from diverse key sectors including semiconductor, aerospace, defense, chemical, oil & gas, automobile and so on.

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“Over the years, we have gone from selling components to systems and solutions and turnkey capability in an effort to keep offering better value by leveraging the technologies we provide,” says Mr. Rushil Shah. All its principals have specific technologies that would be classified ‘cutting edge’ considering the fact that all of them are world leaders in their fields. Following are brief details of their principals and business areas: TESCOM is a recognized leader in the manufacture of high-pressure regulators up to 20,000 psig designed to work with all types of fluids, both corrosive. Tescom range covers over 70 standard models of highpressure regulators to meet almost any requirement. HAM-LET specializes in the design, development and production of high quality instrumentation valves and fittings in a wide variety of materials for high, pressure, temperature and

vacuum applications. These products are used in diverse industries like petrochemical, semiconductor, energy, food, biotechnology, pharmaceutical, defense, pulp & paper and mining. CLASSIC FILTERS brings you filter elements to filter housings to complete filter systems for almost any function. It delivers some of the most robust high quality, coalescing filters and particulate filters in the world. In order to manufacture high tech devices such as semiconductor devices, flat panel displays and even photo voltaic or solar cells, precise fluid control is a must. HORIBA is the established world leader in offering a full line-up of gas, liquid, and vapor delivery products. Applied Energy System Inc. is one of the world leaders in the field of ultra high purity gas delivery systems like gas cabinets and panel for solar, semiconductor, nano technology and other high purity industries. Gas specializes in design and

High pressure regulators


COMPANY PROFILE www.mtwmag.com

Applied gas delivery systems

manufacture of air moving products including vacuum pumps, compressors, air motors, gear motors, vacuum generators and regenerative blowers. “As a matter of fact, our journey of working with high technology industries started with Gast which today remains one of the world leaders in air motors and fractional horse pumps,” reveals Mr. Shah. Meech’s forte is industrial electrostatics. With a standing of over 40 years, Meech has developed a wide range of products like ionizing bars, hand-held ionizing air curtains, etc. for effective static neutralization and dust removal. With the experience gained from more than 200 successful web cleaning installations, Meech can offer both non-contact and contact web cleaning systems. ITT Enidine is again a world leader in energy absorption and vibration isolation products, providing solutions to a wide range of industrial markets. ITT Corporation is a high-technology engineering and manufacturing company operating on all seven continents in three vital markets viz. water & fluid management, global defense & security, and motion & flow control. Shavo feels fortunate to work with

High quality instrumentation valves

Electrostatics for effective static neutralization

some of India’s top companies and institutions like Reliance, Tata’s,, Biocon, GE, Department of Space, Ministry of Defense and many more. It has in excess of 1000 live accounts. The company has a full service capability at its Pune office and is in the process of building a world-class

service center in its Bangalore factory. “Our service support is the key pillar of the value we provide,” says Mr. Shah. – P.K. Balasubbramaniian

For more information Web: www.shavogroup.com

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TECH TRENDS

Mitsubishi Materials extends its Drilling Range by introducing MINI MVS DRILLS New Generation Solid Carbide Drills The extensive drilling range from Mitsubishi Materials has now been extended with the introduction of a new series, Mini-MVS drills. They are designed for high precision drilling of small diameter holes and provide impeccable hole quality, swarf clearance and productivity levels. The Mini-MVS series is available in diameters from 1 to 2.9 mm in increments of 0.1 mm with a drilling depth of up to 30XD. This next generation of solid carbide drills is a multi-purpose range that can be applied to a diverse range of materials and applications. The wide application range is credited to Mitsubishi’s Miracle Sigma coating technology that provides outstanding tool life on all material types. The stability of the Mini-MVS enables it to at least double tool life over conventional solid carbide drills when creating holes in materials such as mild, carbon and alloy steels, ductile cast iron, grey cast iron, stainless steels, aluminium alloys and heat resistant alloys. Enhanced performance Mini-MVS generates process security and precision when deep hole drilling with its straight cutting edge geometry that enhances edge strength and improves chip evacuation. Adding to the remarkable swarf removal characteristics is a new flute geometry with a chip breaker that creates compact and fine chips that eliminates stringy swarf when cutting at high speeds. The removal of chips is also enhanced with a through coolant facility that supplies high pressure coolant direct to the cutting edge. The coolant delivery dissipates heat from the cutting edge whilst rapidly removing chips to prevent build-up.

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Precision small hole drilling To create unparalleled precision and balance, the Mini-MVS also incorporates a double-margin on its periphery to generate excellent surface roughness levels inside the hole. This double-margin also optimises the balance of the drills, so high speed precision drilling is improved. The Mini-MVS is available with four variants whereby type one and two are stub length drills for enhanced rigidity and performance with a 145 degree point angle. Type three and four drills have extra flute length and a 140 degree point angle for precision deep hole drilling up to 30xD. The four variants provide a total of six different geometry options for each of the 0.1 mm increment drills, providing a comprehensive solution for all materials and small hole making applications.

For more information, Email: sales@mitsubishicarbide.co.uk Website: www.mitsubishicarbide.com


TNC 640 – The new High-End Control for Milling and Turning Operations The new TNC 640: for the first time, milling and turning are combined in one TNC. Now users can switch as desired between milling and turning—within the same NC program. Switchover is independent of the machine kinematics. It automatically takes the respective operating mode into account and without any additional action.This new simplicity is complemented by dialog-guided plain language programming, the optimized user interface, powerful programming aids as well as comprehensive cycle packets taken from amply field-proven HEIDENHAIN controls into the new TNC 640.

HEIDENHAIN OPTICS & ELECTRONICS INDIA PRIVATE LIMITED

Angle Encoders

Linear Encoders

Chennai 600031, India

Contouring Controls

phone +91 44 3023 4000

Position Displays

Length Gauges

www.heidenhain.in

Rotary Encoders


TECH TRENDS

YASDA Ultra-Precision Machining Solutions Aiming for World’s Top Quality Die & Mould Applications

Y

ASDA is World’s leading manufacturer in Ultra-Precision Jig Borer machines. Global renowned customers when need super precision machines in applications of Die & Mould, Aviation, Medical Electronics, Mobile Phone Dies, Optical products Dies, Electric Cars Battery/ Interior dies development prefer to have YASDA machines as first choice! YASDA aims to become World’s Top Quality Machine Manufacturer! YASDA manufacture a complete range of Vertical CNC Jig Borer, Horizontal Precision Center, 5-Axis Precision Center, Micro-Center (for IT Parts manufacturing). These machines are manufactured and assembled in strict temperature control of 0.5 degrees. The Vertical CNC Jig Borer YBM Series is available in models YBM640V (Table 600x400), YBM950V (900 x 500), YBM9150V (1500x900), YBM1218V (1800x1200). YASDA’s 5-Axis CNC Jig borer has achieved highest accuracy with outstanding total performance at Japanese Die manufacturing industries. The demand for Ultra precision 5-axis machining of complicated shape components and high hardness/ high surface quality moulds

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is increasing. The 5-Axis Jig Borer is available in models YBM Vi40 (Table 400), YBM7Ti (Table 500x500), YBM8T-63TT (630x630), YBM10T-TH/ TT (1000x1000). YASDA use unique structured framework in highly rigid symmetric bridge construction with minimum temperature expansion effect, optimized spindle head and saddle construction, minimum weight difference in movable bodies of each axis. Machines are supplied with YASDA original bridge, saddle and spindle cooling design and Thermal distortion stabilizing system. A Unique YASDA spindle construction with thermal distortion stabilizing system is considered as

top quality in machine tools industry. This Spindle has lowest vibrations at cutting tool edge and superior rigidity. Spindle does not get heated and allows heavy duty cutting with this unique feature! All YASDA machines employ through hardened box guide ways combined with roller pack bearings for smooth and high response. YASDA machines are popular in complicated shape, cold forging die machining for a combination of high hardness material and difficult shapes. YASDA offers most advanced Software system for machining, management systems and latest tool geometry measurement systems and a unique feature of CMM in built in machine to measure parts after machining and keep records. YASDA has unprecedented technology, machine features, superior machining capabilities and an edge over all competitors! YASDA Welcome Indian Customers to see these technologies, and have a World’s manufacturing in India to meet Global needs and support, “Make in India” program. For more information YASIDA machines E-mail: contact@arhan.co.in


G-SERIES

Precision at the highest level 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.

Contact: GROB MACHINE TOOLS INDIA Pvt. Ltd. I Hyderabad, INDIA Phone: +91 40 4202-3336 I E-mail: info@in.grobgroup.com

01_MTW_Monthly_Magazine_190x250mm.indd 1

www.grobgroup.com

15.02.2018 10:20:47


TECH TRENDS

HEIDENHAIN Encoders for industrial robots Significant accuracy improvement at the tool center point Speed, power and durability are key characteristics of industrial robots. These robots are typically used in applications such as welding or in lifting heavy components for vehicle assembly. Yet despite advanced calibration methods, the position accuracy of industrial robots has been inadequate for certain tasks. This is now changing thanks in part to highly accurate, output-side encoders from HEIDENHAIN and AMO.

T

he main driver behind this development has been the aerospace industry because it must perform highly accurate machining operations on very large components. Machine tools would achieve the required level of accuracy with ease but are either too inflexible or too expensive as special-purpose machines for the job sites and working spaces involved. A robot, however, can easily reach any position on a very large component, such as the fuselage of an aircraft, and can perform tasks on it such as drilling and milling.

• In order to achieve the desired level of maneuverability, robots with serial kinematics are required, such as articulated robots with six axes. • Each one of these axes is driven by a servo motor with a gear train. Zero position error, backlash, and joint elasticities are the main sources of inaccuracy. • Applied forces and dynamic effects during the machining process affect the rigidity of the robot’s mechanics and negatively influence the absolute position accuracy.

Accuracy is impaired by many factors For these kinds of applications, however, the tool center point (i.e., the tool at the end of the robot’s arm) must be positioned and guided with sufficient accuracy. This is where the classic industrial robot runs up against its limits. Deviations result from a variety of factors:

Thanks to advanced calibration methods, it is already possible to move a tool center point to a certain position repeatedly to within several hundredths of a millimeter. Depending on the manufacturer, the repeatability of articulated robots as per ISO 9283 is ±0.1 mm or better. However, when compared with

Figure 1: Classic HEIDENHAIN rotary encoder for motor feedback

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repeatability, the absolute position accuracy that can be achieved within the robot’s coordinate system is worse by a factor of ten. Depending on their design, maximum range, and maximum load capacity, articulated robots currently achieve an absolute position accuracy of ±1 mm. This is insufficient for meeting the accuracy requirements of industries such as the aerospace sector. Yet robot manufacturers have been responding to this problem. Step 1: highly dynamic motor control Classic rotary encoders continue to provide the servo motor feedback at the robot’s axes. Because servo motors require high control dynamics, the robust inductive rotary encoders from HEIDENHAIN, such as those of the ECI 1100 and 1300 series, or multiturn models of the EQI 110 and 1300 series, are ideal for this type of application. These encoders deliver high control quality and system accuracy, and they are resistant to strong vibrations. Since these encoders feature a purely serial EnDat interface, even applications exposed to strong electromagnetic interference do not impair data transfer quality or safety. These inductive rotary encoders support safety integrity level SIL 2, category 3 PL d. They can even attain SIL 3, or category 4 PL e, if additional measures are taken on the control. These encoders also provided the added safety advantage of mechanical fault exclusion against the loosening of the shaft and stator connection. With this safety package, these inductive rotary encoders can also be used in systems designed for human-robot collaboration.


TECH TRENDS Step 2: secondary encoders for highly accurate position measurement Robotics manufacturers can significantly improve the absolute position accuracy of their robots by using additional, high-accuracy angle encoders or rotary encoders at every robot axis. These socalled secondary encoders, which are

Figure 2: Improvement of the absolute position accuracy through the use of socalled secondary encoders on every axis

Figure 3: High-accuracy HEIDENHAIN and AMO encoders for absolute position measurement on robots

mounted after each gear train, capture the actual position of every robot joint. This allows the encoders to account for zero position error and backlash. The retroactive forces on each axis resulting from the machining task are measured as well. All of this results in a 70 to 80 percent improvement of the absolute position accuracy at the tool center point. Modular angle encoders, such as the HEIDENHAIN ECA 4000 with optical scanning, the HEIDENHAIN ECI 4000 rotary encoder with inductive scanning, and the AMO WMR angle encoder, are well-suited for these applications. Thanks to their modular design with a scale drum or scale tape and a separate scanning unit, these encoders are well suited for large hollow-shaft diameters and for the challenging installation requirements often encountered in robots due to space constraints. The signal quality of these secondary encoders is considerably better than that of the rotary encoders on the servo motor, meaning that the returned position values are significantly more accurate—even for highly dynamic movements. Step 3: accurate position measurement for movable robots In order to reach all of the machining positions on very large or long components, such as an aircraft fuselage or for manufacturing large composite fiber components, robots can be moved along the length of the component on linear axes. For the highly accurate

ECA 4000

ECI 4000

WMR

Scanning principle

Absolute, Optical

Absolute, Inductive

Incremental, inductive

Inside diameter

70 mm to 512 mm

90 mm / 180 mm 60 mm to 10 000 mm

Resolution

29 bits

20 bits

Depends on the subsequent electronics

System accuracy

±2“

±25“ / ±40“

±3“ per meter of arc length

Resistance to contamination

+

++

++

Mounting tolerances

+

++

+

Table 1: Comparison of the most important specifications for typical secondary encoders

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positioning of robots with a linear drive, enclosed linear encoders from HEIDENHAIN are available in lengths of up to 30 m. Position measurement from a linear encoder compensates for thermal errors and other factors that influence the feed mechanisms. These factors cannot be captured by means of conventional position detection methods based on the pitch of the recirculating ball screw and the angular position of the rotary encoder on the motor.

Figure 4 : HEIDENHAIN linear encoders

Conclusion: highly-accurate position measurement improves accuracy at the tool center point The use of secondary encoders on all of a robot’s axes, as well as the use of linear encoders for positioning the robot relative to the workpiece, enables a level of accuracy at the tool center point that allows appropriately equipped industrial robots to perform positionally accurate machining and handling tasks on components. Angle and linear encoders from HEIDENHAIN and AMO offer not only the required system accuracy but also the necessary flexibility for installation in complex and compact robot mechanisms. The suitability of these encoders for safety-related applications also makes it possible to implement human-robot collaboration systems.

For more information Web: www.heidenhain.com


TECH TRENDS

Blasocut Bio Concept- A step towards a greener planet Skin friendly 40 years of experience

No additives necessary

Punit Gupta, Managing Director, Blaser Swisslube India Pvt Ltd

I

t is becoming a global requirement for all Manufacturing organizations to contribute towards a greener planet. These initiatives are either due to global regulations or selfconsciousness towards the environment. Blaser Swisslube has designed Blasocut, a concept that works in perfect harmony with nature. It enables colonization by stable primary bacteria that eliminate all other bacteria by taking over the available nutrition, thus limiting their own growth as well. The result is longterm emulsion stability and one of the safest formulations to use across the world.

Free of boric acid and formaldehyde

Environmentally friendly

Blasocut – 100% bactericide free Water-miscible metalworking fluids based on the well established term Bio-concept have been Blaser Swisslube‘s

Blasocut basics Water-miscible Blasocut emulsions stay biologically stable inherently, without needing any bactericides – a concept Blaser Swisslube introduced 40 years ago. The harmless environmental primary bacteria commonly found in drinking water are deliberately fostered to keep Blasocut emulsions stable. Mixing the emulsion concentrate with water propagates a natural biological equilibrium. By incorporating the primary bacteria, the Blasocut system

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strength for over 40 years.

uses a well-proven law of nature to eliminate the use of tank side addition of allergenic bactericides. Blasocut benefits Apart from successful technical performance of Blaser Swisslube metalworking fluids, one of the

company’s top priorities has always been its human and environmental compatibility. Blasocut emulsions based on the primary bacteria principle enables optimal process reliability, extremely long service life and make it as one of the safest formulations in the world.


TECH TRENDS the ultra-modern Technology Centre in Hasle-Rüegsau, a range of tests were started with the goal of optimising the tool life during pocket machining. The specialists at Blaser reconstructed the partner’s machining environment and employed the same machining parameters and data using a DMG Mori DMU 65 mono block machining centre, and began comprehensive tests employing trochoidal milling strategies. The tests compared machining performance (specifically tool wear) when using a conventional metalworking fluid against an optimal metalworking fluid specifically adapted to the partner’s needs. The series of width of wear tests were conducted up to 0.30 mm. The results were excellent. Using the optimally adapted coolant from Blaser Swisslube, eleven (11) instead of just five (5) pockets could be milled until the wear on the tool forced the processing to be stopped. The result achieved was confirmed in various series of tests, and corresponds to a doubling of the tool life.

Leveraging effect of Blaser Swisslube Liquid Tool It is fascinating to see the large positive impact which can be brought by little investment in this area of metalworking fluids. Blaser Swisslube has been able to demonstrate this dimension very well. In many closely held studies at customer places, Blaser has been able to achieve productivity improvements in the range of 8-15 per cent by working together with customers. In terms of tool cost, the effect can be approximately 20-40 per cent reduction. Doubling of the tool life In a recent project, Blaser experts in the Technology Centre impressively

Machining data Operation: Pocket milling Material: high-strength titanium alloy for aircraft construction Tool: End mill with a diameter of 12 mm Cut parameters: Vc 80 m/min, fz 0.075 mm, ae 0.9 mm, ap 19 mm Coolant pressure: 75 bar.

optimised the tool life. A renowned partner filled the role of international supplier and manufactured aircraft parts from a high-strength titanium alloy. In

pocket machining in high-strength titanium alloy – after three tests

tool wear overview pocket machining

(tool wear of 0.30 mm)

0.30

Liquid Tool Blaser Swisslube

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11

average tool wear of all cutting edges in mm

conventional coolant

Liquid Tool Blaser Swisslube

conventional coolant

number of machined pockets per tool

0.25 0.20 0.15 0.10 0.05

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number of machined pockets

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TECH TRENDS

ADIRA leads the way in Metal Forming Solutions

Prathik Shetty, Dy Manager - Sales

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eing in the market for over 25 years, MAC Machine Tools and Automation is one of leading Machine Tools distributor in India. Having partnerships with over 15 Machine Tool Manufacturers, MAC brings to you the best machine tools having the latest technology. In its pursuit to bring to its customers the best CNC Machines from across the globe, MAC Machine Tools and Automation has partnered with ‘ADIRA’, a Portuguese Company which has been the industry leader in Metal Forming industry for the past 60 years. Known for its expertise in developing highly complex machine tools built in with latest technology, ADIRA has introduced Shears, Laser Machines and Press Brake Machines to cut & bend sheet metals

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with at most precision. Portfolio of ADIRA Being the world leader in sheet metal forming technology, ADIRA is operating in over 60 markets worldwide and has an install base of over 5000 machines in USA alone. Its global customers include, NASA, Arcelor Mittal, Boeing, Siemens, SSAB, Airbus, Caterpillar, Bombardier, Bosch, TyssenKrupp etc. Known for its capability to produce highly complex and customized solutions based on customer’s requirements, ADIRA is committed to continuous innovation and improvement of its machines by adopting technology. Having an exhaustive range of machines catering to the all-round requirements of customers, ADIRA has introduced Electric, Hydraulic and Hybrid Press Brake Machines, Hydraulic Shears and CO2 Laser or Fibre Laser Cutting Machines. Leading the way by Innovation – ‘C-Frames’ Standing true to its principle of providing customised innovative solutions to customers, ADIRA recently

patented “C-Frames”, a unique concept of frames for Press Break Machines. Called “HEXA-C”, this frame ensures that the ‘Beams’ (movable & fixed) remain aligned and intact with any load condition in contrary to what occurs in conventional C-Structures. The harmonious alignment between the fixed beam and movable beam makes way for improved and increased bending accuracy which is the most important feature of the HEXA-C Frame. Not only alignment, but the HEXA-C Frame also provides the largest immunity to the structure torsion effects in case of off-centre bending. HEXA-C eliminates the need of extra devices for reading the correction of the movable beam position encoders. Maintaining the throat depth on the frames is an advantage comparing with H-frames as this feature is important for many applications: it simplifies the removal of parts, the execution of box type parts and makes it easier for tooling setup. The HEXA-C philosophy presents advantages in terms of sturdiness resulting on a lighter frame and consequently, lower environmental impact.


TECH TRENDS

Achieving the best of both worlds

www.mtwmag.com

The challenge today is to achieve versatility, while also meeting the dimensional and finish demands that were once only placed on tools designed for a specific operation & material type

V

ersatility has become a necessity for modern cutting tools, but should this requirement compromise a quality end product? Milling cutters, for example, which can support roughing to finishing applications in all materials are not uncommon in the marketplace. The challenge today is to achieve versatility, while also meeting the dimensional and finish demands that were once only placed on tools designed for a specific operation and material type. Dormer Pramet’s Econ LN is a highly costeffective, versatile milling option, capable of supporting numerous operations in most materials and still producing an excellent surface finish. Benefits The positive axial geometry on the universal 90° cutter allows for lower cutting forces and smoother machining in steel, cast iron, stainless steel, non-ferrous metals and hardened materials. With an internal cooling system close to the cutting edges, a combination of wiper inserts, secure clamping and reduced power consumption, the Econ LN delivers fast chip-evacuation and a consistently high quality surface finish. Compatible with the Econ LN are the LNGX 12 and LNMU 16 inserts with four-cutting edges. The LNGX 12 inserts

support helical interpolation, ramping and progressive plunging, while the LNMU 16 inserts are strong and robust for long tool life when machining steel and cast iron. Case in point In a recent example in North America, an end user was face milling gas turbine end caps made of stainless steel using a large horizontal mill. The Econ LN 80mm face mill with LNGX 120508ER-MF M6330 insert allowed the customer to use a feed rate that was 44 percent higher than the previous option. It meant they ran the equivalent of three finished parts on the

first edge, with the insert showing little to no wear. The Econ LN reduced cycle time by 18 minutes just in this single operation & achieved five pieces per edge over the original competitor’s one piece per edge.

APRIL 2018

MACHINE TOOLS WORLD

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TECH TRENDS

Reliable testing technology for plastics processing

In plastics processing, only precise temperature control ensures high, consistent product quality. The process is monitored using non-contact, infrared temperature measurement methods based on pyrometers for pinpoint measurements and infrared cameras for overall measurements.

In plastics processing where thermal processes play a particularly important role, temperature is the crucial measurement parameter. Only precise temperature control ensures high, consistent product quality. Micro-Epsilon provides suitable measurement technology from a single source for almost any material or polymer.

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he process is monitored using non-contact, infrared temperature measurement methods based on pyrometers for pinpoint measurements and infrared cameras for overall measurements. Non-contact measurement technology in the plastics processing industry based on modern, infrared measurement systems offers many advantages. Very hot measurement objects, as well as difficult-to-access or rapidly moving objects can be easily detected at extremely fast measurement and response times. Modern, infrared measurement systems

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from Micro-Epsilon are suitable for a wide range of applications, from frozen foods to molten metals. Depending on the product series, they detect a temperature range from -40 °C to +2200 °C. These values have to be determined in real-time and enable, if required, the immediate adaption of process parameters in order to ensure high product quality and to avoid unnecessary rejects. Infrared cameras enable the documentation of temperature behavior over the whole material surface, while pyrometers measure a point. Their advantage is that they are available with

different wavelengths, which means temperatures of even very thin plastic films can be determined, where for example, long-wave thermal imaging cameras are operating at their limits due to the material’s transmissivity. The measuring principle Every body with a temperature above absolute zero of -273.15 °C (= 0 Kelvin) emits electromagnetic radiation proportional to its own temperature on the surface which is the so-called “intrinsic radiation” regardless of whether the object is ice or


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TECH TRENDS hot steel. Part of this radiation is infrared radiation and can be used for temperature measurements. This radiation penetrates the atmosphere and is focused by a lens (input optics) in the infrared measurement system onto a detector element, which in turn generates an electrical signal proportional to the radiation. The signal is amplified, digitally processed and converted into an output size proportional to the object temperature. The measured value can be shown on a display or output as an analog signal, which enables easy connection to process control systems. The three most important factors in IR temperature measurement are emissivity, transmissivity and reflection. The emissivity of a body indicates how much radiation it emits compared with an ideal heat radiator which is a black body. The transmissivity is relevant for thin plastic films and varies with the wavelength. It is inversely proportional to the thickness whereas thin material is more permeable than thick plastic films. Optimal temperature measurement is possible at wavelengths where the transmissivity is independent of the thickness, close to zero. Polyethylene, polypropylene, nylon and polystyrene are, for example, IRimpermeable at 3.43µm. The temperatures of these measurement objects can be determined using the thermoMETER CTP-3. The temperature range of the thermoMETER CTP-3 extends from 50°C to 400°C. However, polyester, polyurethane, Teflon, FEP and polyamide are impermeable at 7.9µm. Here, the thermoMETER CTP-7 is used, which operates precisely within this wavelength range. Without cooling, this robust thermoMETER provides precise measurement values in ambient temperatures up to 85 °C. With thicker (> 0.4mm)

and pigmented films, a wavelength between 8 and 14µm can be selected for temperature measurements. The emissivity is between 0.9 and 0.95. IR temperature sensors of the thermoMETER CT series have a modular design and can be used for a wide variety of applications in non-contact temperature measurement. From low temperatures prevalent in cooling chains or laboratories, to the highest temperatures in hot molten metals and blast furnaces, these IR sensors measure precisely and reliably. Due to their compact design, the temperature sensors can be integrated in applications where installation space is restricted, for example, in machine building, manufacturing of extremely small devices or OEM applications with multiple infrared measuring positions. Fast response times, high precision and high resolution are distinctive features of the thermoMETER product group. Particularly with temperature-critical applications, IR sensors from Micro-Epsilon are the preferred choice in order to achieve reliable measurements. A diverse range of applications are possible for temperature monitoring in production processes: Injection molding In the production of injection-molded plastic parts, thermal imaging cameras enable the monitoring of product quality, particularly with regards to stability and accuracy of fit. The inspection of the cooling process is a critical factor that ensures the material densities within the injectionmolded parts are consistent. Inhomogeneous cooling can cause different material densities and can have adverse effects on the material characteristics. Also, incomplete molded parts that remain

In production of injection-molded plastic parts, thermal imaging cameras enable the monitoring of product quality, particularly with regards to stability and accuracy of fit.

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With blown film extrusion, the temperature of the tubular film must be measured precisely at different points in order to ensure high product quality, consistency and to minimize waste.

undetected by a visual inspection are immediately recognized. For monitoring, a component is conveyed directly in front of the thermal imaging camera during the production process using an automatic handling system for removal and storage of components, which modern injection molding systems are normally equipped with. The inline thermography system which is used for component testing is the moldCONTROL thermal imager, which enables fast, continuous and cost-effective quality inspection of molded plastic parts directly in the processing line. This system solution includes a thermoIMAGER infrared camera, a ready-for-use industrial PC, the moldCONTROL software and a communication interface for machines. The moldCONTROL thermal imager can be installed into existing removal systems and machine control systems at moderate cost. The primary advantages of this inline thermography system are the early recognition of quality fluctuations and, based on the measured values, faster production start-up along with optimal tool temperature adjustment in order to reduce waste. Blown film extrusion With blown film extrusion, the temperature of the tubular film must be measured


2018_04 Engineering Review (Hannover Messe).pdf 1 05/04/2018 14:39:25

Linear solutions global provider.

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CM

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CMY

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Linear Line

Actuator Line

Telescopic Line

Actuator System Line

Rollon is a global provider of linear motion solutions for several industrial sectors, such as: industrial machines, railway, automation, packaging and logistics, aerospace.

Hannover, Germany April 23-27, 2018 Hall 17, Stand C32 ROLLON India Pvt. Ltd. - INDIA 1st oor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA www.rollonindia.in - info@rollonindia.in


TECH TRENDS precisely at different points in order to ensure high product quality, consistency and to minimize waste. The position of the frost line is a decisive factor, which if detected precisely, avoids blocking of the take-off rollers. Thermoforming In thermoforming of plastic sheets and films made from thermoplastics, the material is heated in the molding machine until the material is plasticized. When a predefined temperature is achieved, the material is sucked into a predefined mold via a vacuum. The heating time depends both on the material itself and on the material surface. Dark plastics, for example, can be heated more quickly than light-colored plastics, which means reliable temperature control is critical. Otherwise, the temperature would have to be detected in diverse, expensive test runs, which can be avoided using non-contact temperature monitoring. (Injection)Stretch blow-molding This technique is intended for thermoplastics such as PET, PVC and PP, which are often processed into bottles. Hollow plastic parts are used for the production of PET bottles. The preforms are first heated to temperatures between 80°C and 120°C. The plastic material becomes viscous and is clamped into a mold. During the so-called compensation times, the preforms are not heated further and their temperature is compensated for across the entire wall thickness. In the second stage, the actual molding process takes place in a blowing wheel of the stretch blow molder. Finally, the finished molded bottle is cooled with water. In particular,

In the extrusion process of flat films and sheets, molten material is pressed through large, slotted nozzles and further processed in a calendar, where the extruded parts are cooled down in stages.

the process where the bottles are heated to a suitable processing temperate must be controlled in order to ensure high quality molding of the preforms. Infrared cameras enable the monitoring of temperature across the entire preform surface. Flat film and sheet extrusion In the extrusion process of flat film and sheets, molten material is pressed through large, slotted nozzles and further processed in a calender, where the extruded parts are cooled down in several steps. Infrared measurement is required at several points in order to control the film temperature and to ensure smooth processing. Therefore overheating, cracks and surface defects become visible. Fast defect detection is an indispensable instrument that helps to prevent high rejection rates and costs. Summary As decisive factors for quality and smooth production, temperature measurements are vitally important, particularly in plastics processing. Depending on the respective application, temperature can be determined point by point using pyrom-

In thermoforming of plastic sheets and films made from thermoplastics, the material is heated in the molding machine until the material is plasticized. When the predefined temperature is achieved, the material is sucked into a predefined mold via a vacuum.

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(Injection)Stretch blow molding is intended for thermoplastics such as PET, PVC and PP, which are often processed into bottles.

eters or covering the whole surface area using an infrared camera. The advantages of these systems are fast response times and high precision temperature detection directly in the processing line. This is how infrared temperature measurement helps to minimize waste and its associated high costs. Possible system control errors are determined in real time, enabling fast intervention measures. Micro-Epsilon is a full-service provider that offers suitable measurement technology for almost any material used in the plastics industry. The infrared temperature sensor product range includes both pyrometers and infrared cameras. Depending on the application, these point sensors and infrared cameras can be combined, which enables high standards of quality in the production process. MicroEpsilon offers cross-product consulting, sales and support services from a single source. Author: Dipl.-Ing. Manfred Pfadt Product Manager Micro-Epsilon Messtechnik GmbH & Co.KG


Value Selling Techniques for Major Sales at

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TECH TRENDS

ROLLON at HANNOVER MESSE 2018: New solutions for industrial automation The Italian company ROLLON (Hall 17, Stand C42) will be presenting its linear and telescopic rails, & actuators for linear motion, at the international trade fair scheduled from 23 to 27 April.

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ollon Group, present in India with a direct branch in Bangalore, is not limited to offering linear and telescopic guides and linear actuators, but has specialized in the production of mechanical systems integrated with the Actuator System Line. Emblematic is the example of the “Seventh Axis”, a shuttle system available in seven solutions to increase the range of anthropomorphic robots up to 2,000 kg in

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applications such as painting and welding in the automotive industry. Rollon products represent the ideal solution in the industrial machinery sector - from the assumption of cartesian robots and multistation presses to sheet metal processing, from pick and place in contained spaces - packaging and logistics, as well as transport and medical sector. Seventh Axis System Technical Features Seventh Axis is designed to offer maximum solidity and precision, thanks to a system of profiles in high rigidity extruded aluminum and other connecting

crosspieces. The sliding system was designed with rails with recirculating rollers, and the drive system uses a pinion and tempered rack with inclined teeth. Seventh Axis also has adjustable feet to obtain alignment also on surfaces that are not flush, and is complete with a cable-holder chain and end of stroke shock absorbers. The system can easily be integrated and assembled on any robot through a specific system of customizable connection plates and very long strokes. The entire system has several components like the lubrication system for the rack and rubber or gas activated decelerators, depending on the client’s needs. Seventh Axis guarantees maximum reliability for every work environment, also with applications involving residue from work processes, such as welding or painting. In fact, it is available in three different protection configurations: with a protected rack, with a light cover for


TECH TRENDS

the rails and rack, and with a completely pedestrian trafficable cover. Advantages - Simplified mounting and alignment Thanks to a system of steel crosspieces and feet with two different adjustment systems - New technology with aluminum profiles Aluminum profiles are resistant, light and easy to assemble. - Potentially infinite strokes Thanks to precise jointed versions that are easy to build with self-centering inserts. - Free-standing, wall-mounted or ceilingmounted assembly Each type of solution comes in three different configurations The Rollon Group The Rollon Group is based in Vimercate (MB-Italy) and has branches in Germany, France, the United States, China, India and Japan. It produces linear and telescopic rails, and actuators for linear motion in many sectors: industrial machines, packaging, railways, aerospace,

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logistics, medical and special vehicles. Numerous end markets and a vast clientèle are Rollon’s strong points. The company is known for high quality standards in its products, attentive pre-sales support and precise product customization. Today, Rollon offers one of the most complete ranges of actuators in the world. The company is evolving to offer industrial automation solutions and integrated mechanical systems. Seventh Axis falls into this strategic context: as it provides the market with the most complete range of solutions for integrated automation, the company presents itself as a “global provider” for linear motion solutions.

You can find Rollon India Pvt. Ltd. and its solutions for linear motion systems at: Hannover Messe 2018 Hall 17 - Stand C42 April 23-27 Hannover, Germany.

For more information: ROLLON INDIA Pvt. Ltd. 1st floor, Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA Tel: +91 80 67027066, Fax: +91 80 67027004 Email: info@rollonindia.in Website: www.rollonindia.in


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TECH TRENDS

Lapp cables for flexible applications The ETHERLINE® FD Cat. 6 A Ethernet cable is suitable for robot monitoring or for use in camera systems.

Does a cable break if it is bent or twisted too much? Not if you choose the right cable for the required application. This article explains where the challenges lie and the technical ideas that Lapp is using to overcome these issues as the leading supplier of connection solutions.

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ables have long been high-tech products. There is now a wide range of options when it comes to the material, processing methods and preassembly. This variety is necessary as the demands placed on cables, particularly regarding flexibility, have risen sharply over the last few years. One of the most gruelling places to install a cable is in a power chain. Here servo cables such as the ÖLFLEX® SERVO FD 796 CP and the ETHERLINE® or HITRONIC® fibre optical data cables are placed very close to one another. They move to and fro during a machine’s power cycle, sometimes faster than 5 m/s with accelerations over 50 m/s2. “In highly dynamic applications, several things must be borne in mind in order to accommodate the demand for increased service life while guaranteeing lower space requirements, reduced weight and a small minimum bending radius,” explained Lucas Kehl, Product Manager at U.I. Lapp GmbH. Three types of movement There are three different types of movement in cables: • Torsion: the cable is twisted about a longitudinal axis. Pure torsional movements are found in wind turbines

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Polyurethane is the first choice for cables in highly dynamic applications, e.g. the ÖLFLEX® Servo FD 796 CP cable

where the cables run from the rotating nacelle down to the tower; • Drag chain: the cable is bent, sometimes millions of times, in the drag chain; • Winding and unwinding: this is where cables are unreeled from drums, for instance in stage applications or on live TV, then reeled back onto them and stored after the event. The material, particularly that used

in the sheath, determines whether a cable can withstand movements over long periods of time and most combine several properties, e.g. fire behaviour or resistance to oil, chemicals and cleaning agents. PVC continues to dominate the market for sheath materials, but there are other materials such as thermoplastic elastomers (TPE) or polyurethane, which is the first choice for highly dynamic applications, e.g. in the ÖLFLEX® Servo FD 796 CP servo cable. Polypropylene


TECH TRENDS

Lapp bundles its solutions under the name of ÖLFLEX® CONNECT. All components are perfectly matched, which is a definite plus in terms of safety, especially when it comes to flexible applications.

excellent shielding. Suitable for use in power chains, the ETHERLINE® TORSION Cat. 6A can even be used in applications where the cable is twisted. Until now, cables in accordance with Cat. 6A with data transmission rates of up to 10 Gbit/s were only possible in fixed or slightly flexible installations. Data transmission rates of up to 10 Gbit/s can be achieved with the ETHERLINE® TORSION Cat. 6A Ethernet cable for use in power chains.

is particularly good at insulating the core in flexible applications as it features excellent electrical insulation properties while also being very strong with a low density. Flexible braiding The screening braid plays an important role in a cable’s flexibility. It blocks out interference from other cables, e.g. from motors or live cables. It is important that most of the screening braid is covered; no gaps should appear, even when the cable is bent. The braiding angle is the decisive factor here: the steeper it is when measured agains the cable’s axis, the more turns are made in the wires in the braided shield per metre of cable, the thicker the braiding. Unfortunately, this also makes the cable more expensive as more material is needed. The ETHERLINE® FD Cat. 6A Ethernet cable, which is used for robot monitoring or inspecting finished products using camera systems, is an example of

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plastics their exceptional properties, are often used here. If the cable is stretched, the textile sheath absorbs the tensile force and prevents the fibre optic cable from also being stretched. Each cable type undergoes rigorous testing at Lapp before being recommended for a particular application. In these tests, Lapp engineers test the torsion of cables for wind power plants in an old lift shaft by twisting the cables over a total length of 12 metres. This process is extraordinary in the cable industry. Other manufacturers test shorter cable lengths twisted at more acute angles and extrapolate this data to estimate the figures for longer cable lengths. “We don’t just rely on what’s written on paper. We check every cable in realistic conditions,” promised Werner Körner, Head of Development and Technology at the U.I. Lapp GmbH.

Glass fibres can also bend Fibre optic cables are the only option if you want even higher data rates. Users can choose between three fibre types: plastic optical fibres (POF) for shorter distances of up to 70 metres, plastic cladded fibres (PCF) for distances of up to 100 metres and glass fibres for even larger distances and applications requiring the highest data rates. In principle, all fibre types are suitable for flexible applications as long as the recommended bending radii are observed. However, in order to achieve the highest possible transmission performance, the bending radius in fibre optic cables should be at least 15 times greater than the diameter. While a lower bending radius will not cause it to break, it will lead to increased attenuation, meaning that light is lost in the tight curve and the signal quality will drop.

Everything from one supplier Customers are increasingly requesting preassembled cables, i.e. cables with mounted connectors that are often already built into the energy chain. Lapp Systems, a subsidiary of the Lapp Group, has long provided these kinds of preassembled integrated systems. Customers like to be safe in the knowledge that all components are perfectly matched, particularly in flexible applications. Under the new name of ÖLFLEX® CONNECT, Lapp is now bundling all global preassembly activities for customers, including consultation. To this end, the company is expanding its corresponding production and preassembly capacities in America, Europe and Asia. The customers thus benefit from customised solutions, high quality thanks to the optimum interaction of all components and expert on-site consultation.

Textile fabric as strain relief The material enveloping the fibres largely determines whether a fibre optic cable can withstand movements. Aramide fibres, i.e. synthetic fibres that give bulletproof vests or fibre-reinforced

For more information, Website: www.lappgroup.com


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

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MGM brake motor main features

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• TEFC 3-ph asynchronous brake motor (0.09kW-130kW) • AC 3-ph brake (no rectifier) or DC brake on request • Oversized brake disc for higher brake torque, longer life and reduced maintenance • Fine and easy brake torque adjustment (as standard) • Very quick brake reaction time • Frequent START/STOP cycle applications • Manual brake release (as standard) • Hexagonal hole on non drive end of the shaft for manual rotation • Single speed or two speeds motors • All motors designed for inverter duty

• RS-RT worm gearboxes: 28 to 150 mm centres. One stage worm, helical/worm and double worm. • RD helical gearboxes: 50 to 2300 Nm. Two and three stages. • RN parallel shaft gearboxes: 180 to 3300 Nm. Two and three stages. • RO-RV bevel/helical gearboxes: 180 to 3300 Nm. Three stages. • RG precision planetary gearboxes: 10 to 230 Nm. One and two stages. • VR dry friction speed variators: IEC63 to IEC90 1 to 5 stepless speed range, 300 to 1500 rpm. • VS planetary speed variators: IEC71 to IEC112 1 to 5 stepless speed range, 200 to 1000 rpm.

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A new generation of electric motors and gearboxes for power transmission quality from the alliance of two dynamic italian companies. For those who want quality.

MGM-VARVEL Power Transmission Pvt Ltd Ware House No. G3 and G4 • Ground Floor • Indus Valley's Logistic Park • Unit 3 • Mel Ayanambakkam • Vellala Street Chennai - 600 095 • Tamil Nadu, INDIA • Phone: +91 44 64627008 • info@mgmvarvelindia.com • www.mgmvarvelindia.com REGIONAL OFFICE: KOHLI TOWERS • 4th Floor, Dapodi • Near Bharat Petrol Pump • Pune - 411012


TECH TRENDS

Profound & pervasive: Gala Precision’s Cleaning & Finishing Solutions

Gala’s Multistage Ultrasonic Cleaning System

for its standing and reputation for over 25 years, offers one stop solutions for deburring, finishing, washing & cleaning of machinery parts on a mass scale. “When you switch over to machine cleaning, you save up to 40% on expenses incurred on account of parts cleaning,” says Anand Kaundanya, Chief Operating Officer, Gala Precision. Gala, known for its profound domain knowledge and vast experience, conceptualizes, designs and builds cleaning machines, most of them customized to suit specific requirements.

C

Mr. Anand Kaundanya, COO, Gala Precision

leaning of contaminated parts and components is an absolute must to bring the parts to their original working condition. It increases the operational efficiency. If the volume of cleaning required is massive, manual cleaning is ruled out. One has to opt for mechanized cleaning so as to avoid downtime and enhance productivity. Gala Precision Engineering, known

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Steps to optimize savings Gala recommends the following four steps to optimize savings in the industry: 1. Switch over from manual process to mechanized cleaning: In case of multi-stage cleaning, one can achieve substantial reduction in labour cost. This also enables improving productivity of the cleaning operation and consistency of the cleaning process. 2. Regular preventive maintenance of machines: With this simple step,

expensive breakdowns and downtime can be avoided. This results in lower maintenance costs. Regular maintenance also saves on investments on inventory of spares. 3. Optimum consumption of compounds: With regular cleaning of filter bag and systematic maintenance of oil separation mechanism, the bath life can be enhanced drastically, thus resulting in reduced chemical usage. Maintaining specified process parameters like temperature, cleaning consistency can be achieved over a long period of time. 4. Controlling power consumption: Gala offers special compounds which work on low temperature / room temperature. This leads to substantial reduction in heating load. Optimum design of heater banks will enable savings in electricity and the power cost. Perfect remedies Gala has a number of case studies


TECH TRENDS www.mtwmag.com

quantifying the savings achieved in specific applications at customers’ places. One such case is the solution it provided to a customer for removing oil, loose chips and burr from mine hammer assembly parts where the input contamination was 10 mg Millipore and the output cleaning requirement was 2mg Millipore. The client was using manual wash involving high labour, improper cleaning, lower productivity, and high cleaning cost. Gala studied this problem and recommended a Multistage Ultrasonic Cleaning System using the Alkaline degreasing compound as the cleaning media. The process involved ultrasonic cleaning in the first stage, rinsing in the second stage and hot air drying in the final stage. The result was excellent. The client acknowledged the three tangible benefits viz. (a) Uniform cleaning (b) No manual intervention, and (c) 70% Reduction in labour cost. In the 2nd case, the component was a Brake pad which had to be cleaned from dirt, dust and oil, achieving an output of 2.8 mg Millipore. The client was using cloth and manual cleaning. Gala supplied a Conveyorised Spray Washing Machine and an Alkline degreasing compound for spray wash, rinsing and hot air drying. This enhanced the productivity by 80%. In the 3rd case, the components involved were Aerosol Aluminium parts

Gala’s Vibratory Finishing System

Gala’s Phosphating Plant

which needed to be kept free from heavy drawing oil, dust, dirt and dull finish inside. The party was already using Vibratory finishing and manual cleaning. Gala recommended switch over to Two Stage Ultrasonic Cleaning and Steel ball vibratory finishing. The degreasing, was done using Alkaline compound as the media. With this the customer could achieve 100% oil removal without any manual intervention. The finish turned out to be consistent and the productivity also improved substantially. In yet another case, the problem posed was removal of heavy grease, oil and dirt from bearings. The client was using spray wash up to 10 bar resulting in insufficient and inconsistent cleaning. Gala offered them a Conveyorised Multistage High

Pressure Spray Washing Machine involving processes like high pressure spray wash up to 10-12 bar, rinsing and hot air drying. This resulted in 100% removal of grease and oil, and uniform cleaning. Delighting the customer The above are only some recent examples of Gala’s comprehensive solutions that delight the customer. As of now, the company has over 5000 systems installed in India and abroad which are giving peak performance at customers’ places. Gala’s product range includes Multistage Ultrasonic Cleaning System, Cylindrical Rotary Screw Spray Cleaning System, Single Chamber Multi-Process Cleaning Equipment, Phosphating Plant, Vibratory Finishing & Washing System, Vibratory De-scaling, Degreasing & Drying System, etc. Gala provides surface engineering solutions to sectors as diverse as aerospace & defence, automotive, precision engineering, consumer products and so on. It has an ever-growing customer base. “At least 40% of our business comes from repeat orders. That’s proof enough of the high quality of our products and services endorsed by our customers,” remarks Anand Kaundanya . - P.K. Balasubbramaniian

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TECH TRENDS

Discover your power with 3D Simulation

Mr. Harshad Karve, Technical Director Asia, ANSYS

T

here is an increasing demand for smarter, faster, simpler, smaller and more economical products today. Creation of such products poses significant challenges. IoT has brought the digital world and the real world together enabling the creation of ‘Smart’ products. Such extraordinary product innovations have substantially increased the complexity of the design. Testing these complex products is costly and time-consuming. These trends are true across the product lifecycle. Innovation leaders worldwide are using simulation for manufacturing of every day products like chocolates, to manufacturing of very complex

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products such as aircraft engines. But in most organizations, simulation today is still mostly restricted to the final validation studies. At this stage, often 80% of design costs are already locked in, and there is very little room for design changes. This often results in over-engineered products. Time-tomarket constraints, unavailability of “simulation experts” and high learning curves for traditional simulation tools prevent organizations from adopting simulations upfront in the design cycle. Thus, innovative ideas do not even get evaluated. An ability to easily make a design change and get real time simulation results will help overcome these challenges. ANSYS Discovery Live does exactly that! It empowers engineers to pose ‘what-if’ questions upfront in the design process. It also allows to explore thousands of design options rapidly and to receive immediate feedback. It provides engineers with the flexibility to test and creatively solve design trials without risking a product delay or setback. Discovery Live is a tool intended for the conceptual design phase. Focus on interactive design exploration and upfront simulation helps to find the right

design direction and insights. Knowing the most optimum design options early, helps reduce number of expensive physical prototypes, reduces the design cost and brings the products to the market faster. This also helps freeing up the analysts’ time to focus on more challenging simulation problems for their future product needs. Its instant simulation, tightly coupled with direct geometry modeling in a real-time and intuitive design environment, delivers rapid product innovation. Its intuitive UI makes it easy for even someone who is not too familiar with it to utilize its tools and restructure the solution process. Discovery Live is powered by NVIDIA graphics processing units (GPUs) and CUDA parallel computing that provides supercomputing capabilities to deliver results thousands of times faster than the more traditional methods. The real-time design environment revolutionizes the way innovative products are designed and created. ANSYS first unveiled Discovery Live’s capabilities for instantaneous solving of major physics during a five-month technology preview. From students to start-ups to Formula One racing teams, thousands of users downloaded


TECH TRENDS www.mtwmag.com

Discovery Live during the technology preview. It has been gratifying to see users tackle designs of almost every type of product with varying complexities and validating the need for rapid simulation in the early concept

development phase. It allows users to navigate multiple physics present in their design problem by exposing powerful fluids, structural and thermal capabilities. Increasingly, simulation will start

from the requirements and generating the design, instead of being applied after most of the design choices have been made. This is the only way to tame the complexity inherent in modern product design, and to capitalize on the opportunities created by the rapid innovation required to be successful today. Discovery Live, together with ANSYS AIM® and ANSYS SpaceClaim® is now part of the Discovery product family geared towards all engineers. The introduction of the Discovery product family is a milestone in ANSYS’ commitment to Pervasive Engineering Simulation and enabling every engineer to benefit from incorporating high fidelity insight into their design. Discovery Live and the entire Discovery product family is available for commercial use today. Visit ANSYS. com/Discovery for more details.

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TECH TRENDS

WELD SURFACING Surfacing minimizes downtime required for replacement of worn-out components, Reduces inventory by reducing the amount of replacements needed, and Saves money. For worn-out components, surfacing can save up to 75 percent of the cost of replacing worn parts.

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oday’s industry is required to manufacture components with superior properties for longer service life and in an economical manner. The aim is to achieve an improvement in surface properties by altering surface characteristics in a component. Components often fail their intended service not only because of fracture, but because of additional factors such as wear, abrasion and corrosion which cause them to lose dimension and functionality. The service conditions most commonly experienced by components are: • Abrasion • Metal to metal wear • Impact • Erosion • Oxidation • Corrosion Out of the above modes of wear, Abrasion occurs in about 50% of cases. Then impact, metal to metal wear, corrosion and others in decreasing order. Most of the components fail from a combination of modes, such as abrasion and impact. For example, a mining bucket tooth is subjected to abrasion and impact, and depending on the type of material mined, one mode may be more dominant than another. This decides the welding product/s to be used. SURFACING Surfacing involves deposition of filler metal on a base metal to obtain desired properties or dimensions. This broad definition can include processes like electroplating and metal spraying. In metallurgical terms, surfacing is depositing a filler metal on base metal to build up wear resistant or corrosion resistant overlayby welding or spraying.

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It is composed of one or more stringer or weave beads, on a surface to obtain desired properties or dimensions. Welding consumables designed for wear-resistant applications are commonly referred to as hardfacing consumables, in spite of the fact that hardness is not always a true measure of wear resistance. It is apparent that surfacing consumables are meant to be used as much in the design of new components as in the reclamation of used and or wornout components in order to reduce their wear and tear in service. Based on application requirements surfacing can be classified as: I. Hardfacing Overlay II. Corrosion Resistant Overlay I HARDFACING OVERLAY Hardfacing is the process of the deposition of thick coatings of hard, wearresistant materials on a worn-out or a new component surface that is subject to wear in service. Welding and Thermal Spraying are the processes generally used to apply hardfacing layers. Thermal spraying is preferred for applications requiring minimal thermal distortion of the component and good process control. Cermets such as WC-Co and alumina-based ceramics are deposited by thermal spraying. These coatings are applied to a thickness of about 0.3mm and

Fig. 2 - Hardfacing on Pipe

have limited usage. Weld hard facing by conventional welding processes is used to deposit very thick up to 10mm dense layers of wear resistant material with a good metallurgical bond. Most commonly used alloy system for hardfacing is iron based chromium carbide alloy with Cr>17% and C>3%. This type of alloy can resist wear upto 350OC. With various proportion of chromium carbides in combination with refractory metals such as Nb, W, V can achieve high temperature hardness and wear resistance upto 750OC.

Fig. 3 - Microstructure of Iron based Chromium Carbide alloy

Typical hardness data: Bulk hardness : 55-60 HRc Carbide hardness : 900-1200 VPN Matrix hardness : 500-700 VPN

Fig.1 - Hard-facing on Screw feeder

Apart from bulk hardness, the volume fraction of carbides, its shape and distribution in a matrix decides wear resistance of an alloy. The bulk hardness requirements for wear resistant applications


TECH TRENDS www.mtwmag.com

generally vary from 50 to 68 HRc. For hard facing applications, weld deposits are normally restricted to up to two to three layers. Limited-layer products usually are in the metal carbide families such as chromium carbide, complex alloy carbides and tungsten carbide. For multi layer applications there are austenitic alloys and some martensitic alloys too are used. STRESS RELIEF CRACKS The brittle nature of the metal carbides leads to stress relief cracking, and as multiple layers are applied, stress continues to build which concentrates at the root of the cracks, until separation or spalling occurs between the parent metal and the hardfacing deposit. These are the result of high stresses induced by the contraction of weld metal as it cools. These cracks always occur perpendicular to the bead length (Fig.4).

Welding Techniques Various welding techniques used for surfacing are listed in order of popularity. The major factor which affects the economics of hardfacing is deposition rate. Below table shows the estimated deposition rate for each process. Process

Fig. 5 - Corrosion resistant overlay cladding

recommended for use of one layer only. However, for certain applications of wear areas of pump linings a second layer of surfacing is applied. In this process, weld metal dilution is very important to control and affect ferrite percentage in especially in case of stainless steel overlays. Overlay Patterns: Depending on the type of wear, there are several types of surfacing patterns can be used viz.; stringer, weave, zigzag, dot or a combination of all.

Fig. 4 - Stress relief cracks on hardfacing weld

The cracks propagate through the thickness of the weld bead and stop at the parent metal, as long as it’s not brittle. In the cases where the parent metal is hard or brittle, there is need to apply a buffer layer of a softer, tougher weld metal. The austenitic family is a good choice for a buffer deposit. Many metal carbide alloys show stress relief cracks when cooled to moderate temperatures; this is normal. Alloys from austenitic and martensitic families do not show this phenomenon when applied with proper welding procedures. II. CORROSION RESISTANT OVERLAY These overlays are used to improve the service life of components made with an otherwise corrosion-prone material. Surfacing for corrosion resistance is

Fig. Straight bead with weaving

Deposition Rate, Kg/Hr

Flux cored arc welding (FCAW)

3.5 to 11

Gas metal arc welding (GMAW)

2.3 to 5.5

Shielded metal arc welding (SMAW)

1.3 to 2.3

Submerged arc welding (SAW)

3.5 to 11

Gas tungsten arc welding (GTAW)

1.3 to 2.3

Strip Cladding (ESSC or SASC) is another technique for corrosion resistance overlaying of Stainless steel and Nickel based alloys. The other special surfacing processes are Plasma transferred arc welding (PTA), Laser cladding, Thermal spraying, and Brazing. With the Oxy-fuel welding (OFW) process too surfacing can be done but this technique is less popular. Welding Filler Metals Surfacing filler metals can be in the form of bare rods for Gas welding, GTAW, GMAW, SAW process to be used with agglomerated flux, coated electrode for the SMAW process, strips for ESSC and SASC process. List of Ador Welding make surfacing welding alloys: Sr. No. I

Application/Hardness

a. Austenitic type

Corrosion resistance, Impact resistance, Work hardening characteristics

b. Martensitic type

Metal to metal wear resistance, Abrasion & Impact resistance, Hardness: 20 to 60 HRc

II

Carbides

Severe abrasion resistance, Hardness: 40 to 65 HRc

III

Nickel Base

High temperature OxidationAbrasion resistance

IV

Cobalt Base

High temperature OxidationImpact-Corrosion resistance, Hardness: 25 to 55 HRc

V

Copper Base

Corrosion resistance and low frictional wear resistance

Fig. Zigzag pattern

Base Metals Carbon and low alloy steels, Stainless steels, Mn steels, Cast irons, Nickel and Copperbase alloys can be hard-faced. For steels with carbon content above 1% a suitable buffer layer is required. For corrosion resistant applications, Carbon and low-alloy steels are most popularly used.

Alloy Base Iron Base

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TECH TRENDS ADOR WELDING SURFACING CONSUMABLES HARDFACING OVERLAY Application Moderate Abrasion Impact

SMAW

FCAW

Zedalloy 250, Zedalloy 350, Zedalloy350 LH

High Abrasion-Moderate Impact

Zedalloy 550, Zedalloy 550 LH, Zedalloy 600

Work Hardening High Impact

Zedalloy 12Mn/16Mn

Severe Abrasion

Super Zedalloy, Zedalloy VB, Zedalloy 16

Abrasion-Corrosion

Zedalloy Bell, Zedalloy K, Zedalloy 17Cr NS Plus

High Temperature Metal-Metal Wear

Nimoten Plus 535 A, Nimoten Plus 535 B, Nimoten HFD

Sugar Mill Rollers

Maganacane

SAW (Automelt H25 & Automelt H35) + Automelt EL8

Automig FC 580

Automelt H55 + Automelt EL8

Automig FC 400

CORROSION RESISTANT OVERLAY Base Material/ Application

SMAW

MIG/TIG

SAW

Stainless Steel Dissimilar Joining, Buffer Layer

Betanox D, Betanox DL, Superinox 312

Miginox-Tiginox 309/309L

Automelt S76+Subinox 309/309L

High temperature Corrosion Resistance

Betanox C

Miginox-Tiginox 310

Automelt S76+Subinox 310

Martensitic Alloy

Betachrome 13Cr, Betachrome 13/4, Betachrome 13/4 LB

Miginox-Tiginox 410/410NiMo

Automelt S76+Subinox 410

Ferritic-Martensitic Alloy

Betachrome 17Cr

Miginox-Tiginox 430

Automelt S76+Subinox 430

Mn steel

Betachrome N/ND

Automotive Exhaust System

Miginox 430LNb Nickel based

Nickel 200/201

Nicalloy 1

Automig-Tigfil Ni-1

Inconel 600

Nicalloy Fe-2, Nicalloy Fe-3

Automig-Tigfil NiCr3

Inconel 625, Inconel 825

Nicalloy Mo-3

Automig-Tigfil NiCrMo-3 Automig-Tigfil NiCrMo-4

Alloy C-276

Nicalloy Mo-4

Inconel 625, Inconel 800

Nicalloy Mo-5

LNG storage system for cryogenic application

Nicalloy Mo-6, Nicalloy M0-12

C-22

Nicalloy Mo-10

Monel

Supermonel

Automelt S76+Automelt NiCrMo-3

Automig-Tigfil NiCu-7

Cobalt Based Elevated Temperature OxidationAbrasion

Zedalloy CoCr-A Copper Based

Copper-Steel joining

Bronze

Corrosion, Erosion, Cavitation

Super CuNi

Automig-TigfilCuNi

Brazing Copper-Steel-Cast Iron

Bracc 2211

Cu & Ni based alloy, Steel, SS, CI, CuZn20Al, CuNi10Fe, CuNi30Fe

Bracs 3343

Surfacing of steel, bronze, CI

Bracc 7700

BENEFITS: For saving time and money on equipment maintenance and repair, surfacing is best available option. The benefits of surfacing are: • Minimizes downtime required for

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replacement of worn-out components • Reduces inventory by reducing the amount of replacements needed. • Saves money For worn-out components, surfacing can save up to 75 percent of the cost of replacing worn parts.

[Contributed by Ador Weding Ltd.]


TECH TRENDS www.mtwmag.com

Fighting Wear & Thermal Fatigue in Die Casting Dies With today’ s emphasis on productivity, ways must be found to lengthen the life of die casting dies

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eat checking is probably the most frequent cause of failure of a die casting die. It is caused by thermal fatigue, which results from the stresses created by the alternate heating and cooling of the die surface during the casting process. When hot metal strikes the surface of the die, the die expands ... and it contracts during cooling. Heat checks start as tiny pits which eventually line up to form a closed network of fine cracks. Eventually the cracks enlarge until they are deep enough for the casting metal to flow into the steel below the surface of the die during casting procedures. It is important not to let heat checks get too deep, as these deep cracks sometimes become too costly to remove, and the die may have to be resunk or remade entirely. As an example, a complex die was about to be replaced at the request of a customer of a California die caster, due to severe heat checking. The castings produced had been so rough from the thermal fatigue heat checking of the die that they could cut a person’s hand. In an

attempt to salvage the die, the die caster used a sanding drum to remove the heat checks in the area of the gale. Tungsten carbide was electronically applied to three different die cavity areas. First, the die area of heavy heat checking was polished and then tungsten carbide was deposited, as was the die area where car bonaceous compound had formed on the die or die sprayed areas. In the third area, the die was impregnated with tungsten carbide in an area where the die had an exceptionally heavy wall, approximately 0.375 in. or more, where the aluminum adhered to the die on the surface. The tungs ten carbide treatment was applied with a Rocklinizer, a gun-type metal impregnalor. The desire was to provide a test to determine if the process would be successful in alleviating these three different conditions on the same die. The die was successfully salvaged and has run approximately 35,000 pieces, and the parts are still useable. The die ca n be Rocklinized again without any surface preparation, to further extend its useable

life. It is possible to reduce the tendency for heat checking to occur on a new die by treating it on a preventive maintenance basis. Also, dies can have extended overall life as well as longer runs without maintenance if the tung s ten carbide is applied before heat checking exceeds acceptable limits. The gun electronically impregnates and deposits wear resistant material both on and within the metal surfaces. Manufactured by Rocklin Mfg. Co., Sioux City, Iowa, the units offer deposit capabilities, ranging from 0.0001 in. to approximately 0.004 in. in a single application, controllable within 0.0001 in. by machine dial setting. The electrode is placed in light contact with the workpiece to genera te time-released arcs throughout the area to be protected without stress or distortion. No appreciable heat is generated, and the deposited electrode material will not separate or flake off. No subsequent grinding, honing, or lapping is necessary after Rocklinizing. There are other die areas that can benefit by treating with tungsten carbide,

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TECH TRENDS

including runners, overflows, and vents. The vents on a die stay much cleaner when they have been car bided. Minor cracks in a die can be covered with tungsten carbide as long as they have not been allowed to progress to a width greater than 0.001-0.002 in. Galling and seizing of cores is another problem. The thermal expansion of zinc and aluminum die cast metals is much greater than that of the s teel core. The metal shrinks onto the cores, thus resulting in extreme pressure at the core section. When treating with wear-resistant material, it will appear that the core is too

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rough to release the casting. However, this roughness is so shallow that the core actually makes the casting smoother because the aluminum will not adhere as much as it does to a core that has been stoned to a high polish. The cores with a carbided surface make the lubricant or die release agent adhere better to the steel, thereby providing a nicer finish on the cast parts . The Rocklinizer has dial settings which can control the amount of tungsten carbide deposit in increments of 0.0001 in. On small cores lower dial settings ar e used; higher dial settings and, accordingly, a greater deposit, are available for larger cores. Some experimentation with depth of deposit is necessary to maximize the benefits of appl ying tungsten car bide. Tungsten carbide has also been successfully applied to rework areas of fits on slides to reduce galling. Soldering of the zinc or aluminum casting material to the die surface also is a cause for rejection of many castings. Carbiding prior to a production run has

eliminated soldering at gates, vents, parting lines, and the die cavity, where molten metal has a tendency to solder to the cavity. Ejector pin flash can be eliminated if the die is in fair condition before treating. (Of course, a completely worn out hole cannot be repaired.) Tungsten carbide applied to the ejector pin about 1 in. back from the face of the cavity has been used success fully. Users report needing less lubrication, which results in a better finish on the die casting. They also find such treatment valuable in building up fixture locators on close-tolerance automatic equipment. The end result of applying wearresisting materials to tooling in the die casting industry will be less of the following: machine downtime, idle time for the operator, die removal and reinsertion time, inspection time, and die maintenance. The bottom line of this surface treatment: increased productivity and reduced production costs.


CASE STUDY www.mtwmag.com

PAL Robotics integrates magnetic encoder technology into robots to achieve balance This case study focuses on REEM-C, PAL Robotics’ full-size biped humanoid robotics research platform. It is one of a family of robots that are used for many applications. REEM-C provides a fully customisable basis for research into exciting areas such as navigation, machine vision, human-robot interaction, artificial intelligence, grasping, walking and speech recognition.

I

magine a world where robot companions improve your productivity at work, carry your bags at the airport or even provide assistive living to the elderly. This is the reality that PAL Robotics SL in Barcelona, Spain, hope to create. Located in the heart of Barcelona’s technology district and only a short walk from the world-famous Las Ramblas promenade, this innovative company is pioneering the development of such robots. The design, programming and assembly of the robots all take place in PAL Robotics’ bustling Barcelona offices where a team of engineers work to constantly advance the capabilities of their robots. Challenge

Luca Marchionni (pictured right), Chief Technology Officer at PAL Robotics, notes that one of the most difficult challenges is maintaining balance while walking, which humans take for granted. Walking involves the generation and execution of trajectories for many degrees of freedom simultaneously while the feet interact with the environment. The

control system of a biped robot has to deal with transitions between two phases: the double support, with both feet on the ground and the single support when only one foot is planted. Designing control laws to enable this is difficult due to the non-linearities associated with robot dynamics. Often, this cannot be done analytically and is too complex to accomplish by mere trial and error. Instead, a numerical approach is applied called trajectory optimisation, where an ‘ideal path’ of the robot is prescribed and a numerical method calculates the best possible approximation to this path, where the criterion for ‘best’ is determined by a specially chosen cost-function which accounts for both the ideal path and the physical limitations of the robot. There are strict space and weight constraints in the design of joints for humanoid robots to keep robot volumes and inertias as low as possible; many of PAL Robotics’ robots are human-sized and exhibit up to 40 degrees of freedom. Solution

REEM-C and other humanoid robots

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CASE STUDY from PAL Robotics have fully articulated joints capable of performing a range of complex movements depending on the task. High-quality encoder feedback is required for the servo-control of each joint in terms of applied torque, velocity and position. Renishaw advised PAL Robotics on encoder selection for each application and leveraged a deep understanding of their business needs and products. Non-contact magnetic encoders by Renishaw associate company RLS were chosen as the solution. These included rotary encoders such as AksIM™ and Orbis™ which are integrated into knee (pictured above), wrist and elbow joints and the component-level incremental RoLin™ system. For balance control, a feedback-force system at each robot’s foot is implemented to calculate the zero-moment point (ZMP), a metric that can be used to assess the stability of robots like REEM-C. The measured ZMP is then fed into a ‘fuzzy logic’ PD controller to track the desired ZMP, achieving balance and disturbance rejection. The controller’s goal is to adjust the robot’s centre of mass (CoM) position to always maintain the ZMP point inside of the support region (under the feet).

Successful biped dynamic walking requires precise control of the legs’ joint angles in terms of position, velocity and acceleration via rotary encoder feedback. Results

Balance control is particularly vital for

stable biped locomotion and encoder outputs enable the estimation of robot posture and the generation of position, speed and acceleration references that every joint should follow. Magnetic encoders provide PAL Robotics with a flexible position measurement solution and are capable of meeting stringent space and performance requirements. The selected encoders have an impressive range of capabilities enabling significant design freedom. Balance control is achieved by controlling the instantaneous torque acting on each joint, which enables correct positioning of each robot limb for stable walking motion. High encoder accuracy ensures that errors in the control signal are minimised, thereby enabling the controller to quickly adjust robot positions to always maintain the ZMP within the support region of the feet.

For more information, Website: www.renishaw.com

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A GLOBAL DISPLAY OF IN

Organised by

Supported by

Awards by

Registered Office: 3rd Floor, Kailash-A, Sumangalam Society, Above HDFC Bank, Opp. Drive-In Cinema, Bodakdev, Ahmedabad-380054, Gujarat. M +91-98795 66567 admin@imtos.com +91-79-40048594, 40305602 www.kdclglobal.com


PRODUCTS SHOWCASE

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

The CNC Controller – Phantom:

For Product Enquiry Contact Ador Welding Limited Akurdi Chowk, Chinchwad, Pune 411 019 Tel.: 020- 4070 6000 Email: cmo@adorians.com Web: www.adorwelding.com

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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 & optimum utilization of work-piece.


PRODUCTS SHOWCASE www.mtwmag.com

The new Gast 86/87R Series of oil-less rocking piston compressors and vacuum pumps While other manufacturers have been busy selling rocking piston compressors that produce a lot of noise and less-than-ideal pressure, Gast has been quietly setting the new standard by re-engineering our oil-less rocking piston from the ground up. The result is a unit that delivers quieter performance, higher pressure, a longer life and greater application flexibility. The sleek, new 86/87R Series is not just another pretty product. It’s beauty runs deep as it performs in ways not yet seen in the industry. The patented crossover chamber design regulates and controls airflow to dampen sound and optimize performance, while delivering a wide range of pressure level options. Because the 86/87R Series can easily retrofit into an existing footprint, it’s also a smart, flexible solution for a wide range of markets and applications, viz. Environmental, General industrial, medical, printing & packaging, food and beverage, transportation, laboratory, and material handling.

Designed to performs

For Product Enquiry Contact Shavo Technologies Pvt. Ltd. Shavo House, S.No.21A/10B, Plot No,394 South Main Road, Hotel Cozy Inn Chowk Koregaon Park, Pune - 4112 001 Phoned: 020-2615 9641 Email: shavogroup@vsnl.com

“When we set out to re-engineer our rocking piston compressor, we aimed to do more than just increase pressure. We set out to dramatically reduce sound, enhance flow, create a standard footprint for easy retrofit anywhere in the world and improve the compressor’s aesthetics,” says Gast. The inherent design of rocking piston technology makes it the optimal choice for applications requiring high pressure or vacuum and air flow in a small package. The flexible cup is made with superior materials and mounted on top of the connecting rod, creating vacuum or pressure while maintaining a tight seal against the cylinder walls in a rocking motion. The forgiving design has fewer components, causes less friction and has a low exhaust temperature, for greater reliability and durability for the life of the product. Despite it’s small size, the versatility of 86/87R means this is the right product to deliver quality air solutions.

Electrical Safety for Power Supplies! Reliable Insulation Surveillance in IT Networks

For Product Enquiry Contact DOLD Electric India Pvt Ltd (100% Subsidiary of E.DOLD & Sohne Kg - Germany)

B – 3 Vishranti Heritage, Gotri Road, Vadodara – 390 021 Call: +91 990 9001585 Website: www.dold.in

The demand for the availability of machines and plants in the region of factory machinery and process technology is constantly increasing. The requirement for this is a functioning and reliable power supply. Unexpected insulation faults in the plants can lead to unwanted supply disruptions culminating in damages to persons and property. Therefore, insulation surveillance equipment in IT systems is required. The insulation monitor RN 5897 from the VARIMETER IMD series from DOLD was specifically developed for use in modern power supplies. These are often comprised of converters, thyristor regulators, and direct current components. Through EMV interference suppression measures, high leakage capacitance onto the ground is present. The RN 5897 is suitable for system leakage capacitance up to 1000 µF as well as for voltages up to DC/AC 300 V. Using an additional ballast unit, it is possible to use the system with voltages reaching up to AC 760 V and DC 1000 V. As well as an adjustable alarm threshold, the insulation monitors also enable a configurable warning signal. A multicoloured LCD screen constantly updates stating the current insulation value. The insulation monitors guarantee additional surveillance over current-free networks. A selective earth fault detection of L+ and L- enables quick fault localisation. The insulation monitors will also be used in USV facilities, photovoltaic facilities, mobile generators and so forth.

APRIL 2018

MACHINE TOOLS WORLD

115


PRODUCTS SHOWCASE

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.

Following are some of its unique features: • 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 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

• 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.

FLIR E53 – Thermal Imaging Camera for Electrical/Mechanical Applications The entry-level E53 Advanced Thermal Imaging Cameras offer the superior resolution and range performance needed to quickly identify hot spots and discover potential points of failure in electrical distribution and mechanical systems. With 43,200 pixels resolution and a more vibrant LCD screen than any other pistol-grip camera, the E53 makes it easier than ever to diagnose problems—even at a distance. Avoid costly shutdowns and lost production time through regular predictive maintenance routines with these rugged, intuitive cameras and improve plant reliability & safety and make your work easier. For Product Enquiry Contact FLIR Systems India Pvt. Ltd 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034, INDIA Tel: +91-11-4560 3555 | Fax: +91-11-4721 2006 Email: flirindia@flir.com.hk Webiste: www.flir.in

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MACHINE TOOLS WORLD APRIL 2018

• Temperature range is -20°C to 120°C with FOV of 24° × 18° & 5MP digital camera. • Detect temperature differences as small as <0.04°C (24° lens) for immediate identification of failing components. • MSX® image enhancement adds the depth and detail to image • Rapid-response touchscreen with intuitive new user interface


PRODUCTS SHOWCASE www.mtwmag.com

Damping vibrations, shocks and noises

For Product Enquiry Contact Elesa and Ganter India Pvt. Ltd. A-54, Sector - 83, Noida 201 305 (U.P.) INDIA Tel. +91 120 472 6666, Fax +91 120 472 6600 E-mail: info@elesaganter-india.com Website: www.elesa-ganter.in

Elesa+Ganter vibration-damping elements represent an easy and effective solution to damp unfavourable vibrations produced by moving bodies or non-balanced vibrating masses which can also affect adjacent equipment improving operator safety and comfort. They are ideal for use with compressors, fans, vibrating feeders, rotary pumps or electric motors. Manufactured with natural rubber NR, hardness 40, 55, 60 or 70, combined with zinc-plated steel or AISI 304 stainless steel threaded inserts, Elesa+Ganter damping elements are from now available in a wide range of dimensions and shapes. In addition to the already well-known series with cylindrical (DVA.1, DVA.2, DVA.3 – DVA.4, DVA.5) or parabolic shape (DVA.6, DVA.7), Elesa+Ganter has recently introduced on the market new solutions. DVB.6 and DVB.7 rubber bushes with conical shape, which are generally used as bumpers or limit stops for the absorption of vibrations. Standard executions are available with Ø from 20 to 60 mm and stiffness from 49 N/mm to 975 N/mm. New DVC.1, DVC.2, DVC.3 vibration-damping elements with bobbin shape. Under pressure, they allow more lateral movement as well as vertical dampening. Available with Ø from 10 to 95 mm, they provide stiffness from 15 N/mm to 903 N/mm. In addition, DVE series bell-shaped mounts, composed of two metallic elements joined together by a rubber anti-vibration body. A round element with a boss and a threaded pass-through hole constitutes the base for fixing to the vibrating machine. Another element, oval or square shaped, constitutes the flange for fastening to the floor. Suitable for applications with rotary machines that do not present big dynamic imbalances, where elasticity is required both vertically and transversely. These damping elements provide stiffness from 13 N/ mm to 448 N/mm. Elesa+Ganter buffers GN 454 are used as end-stop buffers, e.g. conveyor trolleys. They can be fixed on the damping side with socket head cap screws DIN 912. They absorb most of the kinetic energy development on impact. They act as dampers & prevent damaging shock and rebound. They also act as sound dampers. These buffers are also used as levelling feet. Last, but not least, LW.A vibration-damping levelling elements, composed of base, plate, stem & washer in zinc-plated steel, NR rubber damping element with NBR synthetic rubber packing ring. Their max. limit static load is up to 40,000 N & contributes to the stability of the machinery even in the presence of strong vibrations.

Cooling Nut System for Ball Screws

For Product Enquiry Contact Precision Motion Industries, INC. (PMI) No.71, PRECISION Ln. 20, Dafu MOTION Rd., Shengang INDUSTRIES, Dist., INC. Taichung City 42946, Taiwan TEL: +886-4-25282984, FAX: +886-4-25120834 Email: sales@pmi-amt.com.tw / sales@superslides.in Websit: www.pmi-amt.com

“Cooling Nut System for Ball Screws”.By controlling the temperature rising from ball screws in order to reduce metallic deformations caused by heat, the system boosts the machine’s axial motion velocity and accuracy. Since the ball screws’ temperature variation can be stabilized in a short time, it expedites the functioning of the system and the machine’s warm-up time can be greatly reduced.Another benefit is that the lifetime of lubrication oil is extended since lower ball screw heat will not deteriorate the lubricant. It is a very helpful design to high precision machines tools. PMI is a highly professional manufacturer of ballscrews, precision ball screw spline, linear guideways, ball spline, actuator and various precision components required for machine tools such as machining centers, turning centers, electric discharging machines (EDM), wire cut EDM, plastics injection molding machines, semi-conductor equipment, precision orientation equipment and other machines. Over the past 27 years, PMI has been proud of being a supplier of high quality products and superior after-sale service to valuable customers needing solutions for all of the machines above. PMI sells numerous quality precision components not only in Taiwan, but also worldwide.

APRIL 2018

MACHINE TOOLS WORLD

117


PRODUCTS SHOWCASE

Dished Heads production made easy with Faccin’s line

For Product Enquiry Contact Faccin S.p.A. Via dell’ Industria, 19, 25010 Visano, Brescia - Italy Tel: +39 030 99 58 735, Fax: +39 030 99 58 771 E-mail: info@faccin.com Website: www.faccin.com

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There are hundreds of manufacturers of tanks, silos, pressure vessels, truck tanks and metal rolls components all over the world. Most of these companies need to produce or source Dished Ends of various types, sizes and specifications to complete their products. However, there are only few Dished Ends manufacturers that can supply this kind of product, a golden reason Dished End Production has become a very profitable business and a craft that companies are carrying on and conserving generation after generation. Faccin, one of the largest production companies in the world for bending systems and rolling machines, with ISO 9001: 2008 and ISO 18001: 2017 certifications, supplies dished heads production lines that include technologically advanced presses, flanging machines and manipulators, designed to offer maximum reliability and to meet the needs of manufacturers of dished heads in terms of achieving tolerances and lamination reduction. The PPM is a series of sturdy, reliable and efficient hydraulic presses. With an inhouse design, fabricating, machining and assembly, Faccin presses are suited for dished head crowning, featuring an exclusive design with threaded rods and available in various sizes: to choose the exact size you need to calculate the dimension of the largest development of the metal plate to be processed; then you may decide the distance between the uprights. All the PPM series include an exclusive HPT system utilising two solid forged tie rods (permanently preloaded) to keep the frame connected to the top rail. Thanks to the HPT system, which is able to minimise frame deformation, dished heads presses of the PPM range assure forming precision and high reliability. Faccin also provides affordable solutions to manufacture dished heads and tanks within this model. In these lines for dished heads, the frame is connected to the upper beam with keys machined on the structure or just welded to the structure in single monolithic pieces. There are also effective handling systems available upon request designed to allow accurate positioning of the plate under the dies of the hydraulic presses. These automatic manipulators in the MA range assure high quality and offer several advantages in production optimisation, saving time and processing several plates at once. In addition, Faccin offers the widest range of dished head flanging machines on the international market, machines able to improve production quality while reducing costs. The widely known BF series are built with C-shaped electro-welded structures and machined with stretching treatments, which are numerical control hydraulic and automatic flanging machines. Machinery movements are fully hydraulic and the whole system is protected against overload by safety valves. The forming and flanging rolls of the flanging machines are made in forged alloy steel. This assures a longer life cycle of tools. In the standard configuration, Faccin’s BF flanging machines are equipped with automatic working cycle to assure the utmost ease of use during the flanging process even by inexperienced operators. The BF range of flanging machines are available for dished heads with or without central hole and for thickness up to 50 mm. For specific customer projects, Faccin’s professional engineering and R&D department designs and produces customized solutions that effectively suit the requirements of the most exigent producers. Faccin is one of the world leaders, with more than 50 years’ experience, in the design, manufacturing and commercialization of plate bending rolls, profile bending machines, dished head machinery and special machines including ship frame bending rolls and presses and plate straightening machines.


PRODUCT INDEX A

Gas Management

77

Power Conditioners

93

AC / DC Geared Motor

91

Gear Boxes

97

Precision Air Moving Products

77

AC Linear Servo Motor

91

Gears, Racks & Pinions

91

Precision Ball Screws

91

Actuator

73

Grinding Machines

Press Brake Machines

41

Actuator Line

87

Ground Threads

63 35

77

25

Gun Drilling Machine

Pressure Control Solutions

Air Compressors Alloy Wheel Machining Solutions

61

Project Engineering Solutions

79

41, 47

H

Aluminium Profiles

91

Angle Encoders

69

Harmonic Filters

93

Automation Products

79

High Pressure Filtration

77

Horizontal Boring Machines

41

Ballscrews Bevel Gear Boxes

Reamers

93 FALSE COVER

Horizontal Machining Centres

41

Reffnlng Furnace

13

91

Hydraulic Press

95

Rotary Encoders

69

73

Hypid Gear Boxes

Rotary Tables

49

B Ball Transfer Units

R Real Time Power Factor System

80, 81

80, 81

Brake Motors

97

I

S

Infrared Temperature Sensors

C

Inserts

CAD CAM Software Cam Driven Systems

Instrumentation Fittings & Valves

77

75

IOT

41

FALSE COVER

Chamfers

FALSE COVER 85

Laser Cutting Machine

Clamps for Linear Guides

91

Laser Cutting Machines

27, 31

CNC Lathes

61 41, 45, 61

Screwiacks

91

Shear Machines

41

Slewing Ring

91

Spindles

101

Spotting Drills

L

Clamp Meters

CNC Horizontal Boring Machine

FRONT GATEFOLD

29

Centre Drills

CNC Grinding Machines

51

22, 23 41

FALSE COVER

Spray Cleaning

55

Stabilizers

93

Static Elimination Solutions

77

Lathe Machines

19

Length Gauges

69

Stepper & BLDC Motor

91

Light Energy Management Systems

93

Surface Cleaning

77

BACK PAGE

Linear Actuators

91

CNC Smart Mills

61

Linear Encoders

69

CNC Solutions

17

Linear Guideway

73

Taps

Linear Line

87

Telescopic Line

87

Linear Motion Guides

91

Test & Measurement Tools

85

CNC Machines

CNC Tool Grinding Machine

7

CNC Vertical Jig Borer

37

Consumables

79

Contouring Controls

69

M

41

Machining Centers

11

Coolants

21

Mass Flow Controllers

77

91

Metal Cutting Tools

57

Metal Forming Machines

33

Milling Machines

41

Cycloidal Gear Boxes

80, 81

D

Moisture Meters

Deep Hole Drilling Machine

35

Mold & Die Machines

Dimensional Measurement Systems

83

Motion Toolpaths

Double Column Machining Centers

61

Multi-axis Servo System

Drill Tap Center

61

Multimeters

Drills

End Mills End Mills Cutters

Energy Absorption & Vibration Isolation Products Engraver Cutter

77

FALSE COVER

Flexible Couplings

85 91

55 71

9 85

Gas Flow Products

59

91

Oxy-Fuel CNC Cutting Machines

79

Plasma CNC Cutting Machines

G 77

U

Universal Machining Centers

Oil/ Coolant Mist Cleaner

Planetary Gear Boxes

FRONT GATEFOLD

41 IBC

O

Parts for Die & Mould

53

Tool Holders

93

P

F Flex Clamps

Tool Cabinets

Ultrasonic Cleaning

FRONT GATEFOLD, IFC FALSE COVER

51, 85

85

N Non-Contact Tool Setting System

85

Thermal Imaging Cameras

Ultra Isolation Transformers

FRONT GATEFOLD, FALSE COVER

E

FRONT GATEFOLD, 63

Test Instruments

Conventional Lathes Curvic Coupling

T

49 80 - 81 79

Polishing Machines

41

Position Displays

69

V Vacuum Drying

55

Value-Selling Training Solutions

89

Vertical CNC Lathes

45

Vertical Machining Centers

61

Vertical Machining Centres

41

Vertical Turning Machines

41

Voltage Detector

85

W Waterjet Cutting Machines

41

Welding Equipments

79

3D Printing

41

APRIL 2018

MACHINE TOOLS WORLD

119


ADVERTISERS INDEX COMPANY NAME

PG. NO.

A

COMPANY NAME

PG. NO.

COMPANY NAME

PG. NO.

FATTY TUNA INDIA PVT. LTD.

61

MMC HARDMETAL INDIA PVT. LTD.

INSIDE FRONT COVER

ACCUSHARP CUTTING TOOLS PVT. LTD.

57

FIBRO INDIA PRECISION PRODUCTS PVT. LTD.

49

ACE MICROMATIC GROUP

BACK PAGE

FLIR SYSTEMS INDIA PVT. LTD.

85

ACMEE - 2018

15

G

ADOR WELDING LIMITED

79

ALEX MACHINE TOOLS PVT. LTD.

GALA PRECISION ENGINEERING PVT LTD

31

AMTEX - 2018

113

PARADIGM TRAINERS PRIVATE LIMITED

89

55

PARAGON MACHINERY CO. LTD.

27

GEDEE WEILER PRIVATE LIMITED

19

PRECISION MOTION INDUSTRIES, INC. ( PMI )

73

39

71

ANCA MACHINE TOOLS PRIVATE LTD

7

GLOBE-TECH ENGINEERING EXPO - 2018

APEX PRECISION MECHATRONIX PVT. LTD.

91

GROB MACHINE TOOLS INDIA PVT. LTD.

ARHAN TECHNOLOGIES PVT. LTD.

37

B BECKHOFF AUTOMATION PVT. LTD.

9

BETTINELLI AUTOMATION COMPONENTS PVT. LTD.

75

BIRLA PRECISION TECHNOLOGIES LIMITED

63

BLASER SWISSLUBE INDIA PVT. LTD.

21

C CNC SOFTWARE, INC.

INSIDE BACK COVER

D DAHANUKAR MACHINE TOOLS

47

DOWEL ENGINEERING WORKS

95

Q QVI INDIA PVT. LTD.

H HEIDENHAIN OPTICS & ELECTRONICS INDIA PRAIVATE LIMITED

69

HOSABETTU HEAVY MACHINERY LLP

45

HYUNDAI WIA INDIA PVT. LTD.

11

IMTOS - 2019

110

INDO AFRICA B2B TRADE EXPO - 2018

109

INTERTOOL DELHI - 2018

112

13

ELGI EQUIPMENTS LTD.

25

EPPINGER TOOLING ASIA PVT. LTD.

80 - 81

RADIUS ENGINEERING SOLUTIONS PVT. LTD.

35

RAJKOT MACHINE TOOLS SHOW - 2018

111

RENISHAW INDIA (PUNE)

59

ROLLON INDIA PVT. LTD. - INDIA

87

SETCO SPINDLES INDIA PVT. LTD.

101

SHAVO TECHNOLOGIES PVT. LTD.

77

41

TRUCUT PRECISION TOOLS PVT. LTD.

FALSE COVER

U MACHINING SOFTWARE PVT. LTD.

29

MARPOSS INDIA PVT. LTD.

65

MGM-VARVEL POWER TRANSMISSION PVT LTD

97

MICRO-EPSILON INDIA PRIVATE LIMITED

51

UNITY CONTROLS PVT. LTD.

93

Y YAMAZAKI MAZAK INDIA

22-23

YG-1 INDUSTRIES INDIA PVT. LTD.

FRONT GATEFOLD

Z

F FACCIN S. P. A.

120

R

T

M MAC MACHINE TOOLS AND AUTOMATION

83

S

I

E ELECTROTHERM (INDIA) LTD.

P

33

MACHINE TOOLS WORLD APRIL 2018

MITSUBISHI ELECTRIC INDIA PVT. LTD.

17

ZOLLER INDIA PVT. LTD.

53


DIFFICULT MATERIALS MADE EASY

LESS CHATTER. SHORTER CYCLES. YOU CAN HEAR THE DIFFERENCE. Mastercamâ&#x20AC;&#x2122;s Dynamic Toolpaths deliver a consistent chip load, making difficult material easier to cut. That means longer tool life, reduced machine wear, and shortened run times. See and hear the difference at Mastercam.com/dynamic.

For more information, visit mastercam.com/dynamic


RNI No. MAHENG/2015/64267 Postal Reg. No. THC/173/2018-2020. 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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MACHINE TOOLS WORLD - APRIL 2018

MACHINE TOOLS WORLD - APRIL 2018  

MACHINE TOOLS WORLD - APRIL 2018

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