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Volume 05 No. 02 | July 2019 | ` 150

Pages 124 | RNI No. MAHENG/2015/64267


MILL Tangential High Feed Speed Master

ISCAR CHESS LINES

4

Unique Tangential Insert for High Feed Face Milling

3

2

1

Tangential Insert

For Steel, Cast Iron and Exotic Materials

MACHINING

Strong Cutting Edge

INTELLIGENTLY

Up to 3.1° Ramp Down Angle

DUSTRY 4.0

Phone: +91 77009 6370

Email: Sales@iscar.in

Website: www.iscar.in


Whatever industry sector you’re in? Aerospace, Automotive, Electronics, Medical or woodworking

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 6991 E: indiainfo@anca.com

anca.com

linkedin.com/company/anca


CEO CORNER

Publisher & Printer Shirish Dongre

CEO Shekhar D.

Editor

Technology innovation in manufacturing industry: The need of hour

Shilpa Dongre

Assistant Editor Shweta Nanda

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

Online Marketing Kailash P.

Print & Online Division Arun P. Shinde, Nandan S. Moghe, Ganesh B. Mahale, Dinesh S. Gawade

Online Division Ganesh Mahale

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 E Vikram : +91 9591488434 Vaman : +91 9686721340

The advancing technology has eased the lives of people in a big way. From morning till bedtime, one engages with technology to complete daily errands such as cooking, washing clothes and shopping. With the increasing reliance on technology, companies are adopting high-tech tools to render faster and better services to customers. In efforts to gain an upper hand in the market, companies are now exploring untapped niches to entice more customers. Since industries are changing globally, a series of setbacks have been faced by the secondary sector, essentially manufacturing businesses. The intrusion of digitalization has led to these changes in the industry. The manufacturing sector, also known as secondary sector, processes raw materials into new products which are ultimately employed by consumers. Similar to other industries, the manufacturing industry is also affected by the industrial changes that are taking place rapidly. To improve the production line, the manufactures can employ varied kinds of technology tools. Popular technologies such as cloud computing, artificial intelligence and augmented reality can upgrade any average manufacturing business and further, automate it. Besides the aforementioned software and tools, another array of tools is available in the market, which can improve the quality of manufactured goods and meanwhile, decrease the cost of production for the manufacturing firm.

Hyderabad E Vikram : +91 9591488434

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

WEST (Maharashtra & Gujarat) Pune Kuldeep Kshirsagar - 09689403523

Additive manufacturing ( AM ) is the new technology that will be turning helpful for manufactures in the offing. Essentially, it is called the standard form for applications in technology. For generating AM, objects from 3D models need to be assembled and meanwhile, subtractive technology is avoided. By adopting AM, manufacturing businesses will view positive impacts in the operations and have a better insight into the industry.

Nashik Abhijit B. Joshi : 09890002333 Rajkot (Saurashtra) Swapnil Bhatia: 09227909005

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

The digital transformation of manufacturing, ongoing convergence of IT and OT and the usage of IoT, in combination with other technologies, are changing the face of the manufacturing technology landscape and the face of manufacturing itself.

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

CEO 8

MACHINE TOOLS WORLD

JULY 2019

www.mtwmag.com


VLC 200 GT

HIGH PERFORMANCE HARD MACHINING FOR GEARBOX PARTS PRECISE

DYNAMIC

PRODUCTIVE

COMPACT

Gearbox production with 12 tool position tool turret and internal/ external aluminum oxide/CBN grinding spindle.

HIGHLIGHTS + Reduced machining time: The combination of hard

pre-turning and finish grinding reduces machining time.

+ Maximum workpiece quality: A combination of the best technology and a single clamping operation is used to ensure the best workpiece quality.

+ Shorter process chain: By combining the different processes, the process chain can be shortened.

+ Maximum technological diversity: Internal and external grinding spindles, tool block holders or the time-tested EMAG turret equipped with 12 tool positions are available.

Technical data for the VLC 200 GT: Chuck diameter, max. 210 mm I Swing diameter, max. 270 mm I Workpiece diameter, max. 160 mm I Workpiece length, max. 100 mm I Travel distances X (total stroke from pick-up to turret) / Z 1,700 / 250 mm I Loading time (depending on clamping device) 6 – 10 sec. I Main spindle capacity: 40% duty cycle / 100% duty cycle, 22 / 18 kW I Main spindle torque: 250 / 202 Nm I Main spindle max. speed: 3,000 rpm I Spindle bearing dia., front: 110 mm

EMAG India Private Limited “Technology Centre” I No. 17/G/46-3 · Industrial Suburb I 2nd Stage · Yeshwanthpur I Bangalore · 560022 I Karnataka · India Phone Sales: + 91 80500 50163 (Sales) I Phone Service: + 91 80500 50165 I E-mail: sales.India@emag.com I www.emag.com

www.emag.com


Contents

JULY 2019

COVER STORY

FACCIN: Global Technology Leadership in Metal Forming Machines Mr. Andrea Ceretti, CEO, FACCIN S.p.A.

BUSINESS NEWS

48 TECHNO FOCUS

PORTFOLIO

52

54

EVENT PROFILE

INDUSTRY SPEAK

58

62

22

Faccin Open Doors to bring High Productivity & Technology to the Metal Forming market

24

YASKAWA Technology driving the best-inclass automation solutions with partner Mehta CAD CAM at IMTOS 2019

32

ExxonMobil announces new hydraulic oil technology “Mobil DTE™ 20 Ultra Series”

34 36

GRIND MASTER ROBOFINISH Global Launch

Renishaw celebrated for successful UK-India relations

37

BFW announces a wholly owned subsidiary m2nxt Solutions

38

ELGi unveils upgraded Encapsulated Screw Air Compressors with variable frequency drives (VFD) & heat recovery systems at INTEC 2019 10

MACHINE TOOLS WORLD

JULY 2019

AMT SECTION

71 www.mtwmag.com


Contents

JULY 2019 Miniature infrared camera performs thermo imaging in VGA resolution

TECH TRENDS

88 84 80

Making Tracks: New Cutting Tools for the Railway Sector

92

98

Belt, rack and pinion or screw drives: Three options for different applications

104 96 Threading with maximum productivity & process reliability

102

PMI : Rotary Ball Spline

CASE STUDY

12

106

114

Improving speed & reducing cost with Renishaw additive manufacturing

Pankl Racing Systems chooses EMAG for Turning of Transmission Shafts and Gears

MACHINE TOOLS WORLD

JULY 2019

www.mtwmag.com


Editorial Board

Editorial Index I

A Ador Welding

62, 121

Allied Machine

44

ANCA

46

Bettinelli Automation

AMT- The Association For Manufacturing Technology

Mr. A.P. Jayanthram Ex-Managing Director, Heidenhain India

Mr. GK Pillai Managing Director & CEO Walchandnagar Industries Ltd

84

M Marvel Gloves

B

Mr. Arun Mahajan General Manager

ISCAR India

Components

44

Bharat Fritz Werner

37

Birla Precision Technologies

118

119

Mastercam

77

Micro-Epsilon

88

Millenia Technologies

52

P Patson Machines

121

D R

Delhi Machine Tool Expo 2019

32

DOLD Electric

119

E

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.

Elesa and Ganter

117

ELGi Equipments

38

EMAG

114

EMO Hannover 2019

58

ESPRIT

73

ExxonMobil Lubricants

32

FACCIN S.p.A. FLIR Systems

22, 48 110

Gala Precision Association of Ludhiana Machine Tool Industries

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

92

Shavo Technologies

54

Siemens

36

Spraymet Surface Technologies

101

Superslides & Ballscrews

104

W Walter Tools

96

Y

G Manjit Singh Matharoo General Secretary

ROLLON INDIA

36, 106

S

F

Mr. Dinesh Khambhayta President MTMA-RAJKOT

Renishaw

GEM Equipments

98

Yaskawa India

24, 26

120

GP Petroleums

80

Z

GRIND MASTER

34

ZECHA Precision Tools 102

Contact : For editorial contribution E-mail: shweta@divyamediaonline.com For advertising material E-mail: advt@divyamediaonline.com

Mr. P.K. Balasubbramaniian President VBS Corporate Support

14

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

MACHINE TOOLS WORLD

JULY 2019

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

For accounts E-mail: accounts@divyamediaonline.com For online advertising E-mail: ganesh@divyamediaonline.com

www.mtwmag.com


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DVS UGrind U won’t believe how flexible your shop floor production can be • Hard Turning, I.D. & O.D. Grinding and measuring in a single machine • Ideal for shafts and chuck parts in small to medium batches • Easy to operate thanks to UCee interface • Hassle-free loading with add-on automation cell Halle 17 / Stand C46

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Cylindrical grinding Radial grinding

Face grinding Cone grinding Internal grinding

Internal turning External cylindrical turning

Face turning

Groove turning

Universal hard fine machining for shafts and chuck parts The DVS UGrind combines the hard fine complete machining in one machine. Turning, measuring and grinding applications on external and internal surfaces can be carried out in a single operation. For example, various fit seats can be turned and ground with high precision in just one clamping without changing tools. This reduces set-up times and avoids re-chucking errors.

The multifunctional head. Flexible, fast and precise.

ULoad – the universal automation of the UGrind Equipped with the new ULoad automation cell, the DVS UGrind will work even more efficiently. With the universal loading unit, a wide variety of workpieces up to 130 mm in diameter can be automated.

Find out more: www.UGrind.de

The ULoad load cell can be easily integrated into UGrind machines.


BUSINESS NEWS

Faccin Open Doors to bring High Productivity & Technology to the Metal Forming market To showcase the importance of the rapport between high-productivity and technology Faccin SpA, a powerful group that combines leading brands – Faccin, Boldrini and Roundo - in plate rolling, profile bending and dished-heads manufacturing with more than 200 years of joint experience, has successfully held a 2 WEEKS Open Doors event from July 1st to July 12th 2019, at its Headquarters in Visano – Italy where it featured several high-capacity technologically-advanced machines to customers from all over the world avid of the latest technology news in metal forming equipment. Faccin is transforming the way it operates to continuously improve its ability to help fabricators worldwide by maximizing their benefits and satisfying their present and future fabricating needs. The group strongly believes in the positive interaction between the company and the customer’s feedback in terms of expertise, knowledge and vision which is a valuable source of improvement. Faccin is very proud of where it is today and excited about where it is heading. It has been an exciting time for the company as it continues to grow, always remaining customer-focused, relevant and innovative. The world of metal forming is a stimulating market for the development of advanced technologies, and Faccin will continue to organize international events like this, to ensure its customers can have the opportunity to appreciate the company’s technology first-hand. Presentations were focused on heavy-duty technology and automation. 3 and 4 rolls heavy22

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duty plate rolling machines, model HAV – variable geometry - and model 4HEL – linear technology – with the capacity of bending steel plates of up to 200mm and featuring oversized structures, powerful supports, clamping system, feeding table and the latest CNC technology for the wind tower industry. A full dished-head production line was also presented, comprising a dishing press with manipulator and a flanging machine, all controlled by the latest CNC and GAP Control System for the fabrication of dishedheads without central hole (as recommended by ASME) of up to 35mm thick and 5500mm diameter. Roundo has proudly showed its section bending machine model R-11-S, with shafts diameter of 360mm, rolls diameter of 800mm, capable of bending heavy duty profiles, such as angles 200x200x28mm, flat hard way 300x70mm, pipes up to O.D. 400mm, IPE 600 easy way, IPE 360 hard

way. With the largest selection on the market, ROUNDO is the leading manufacturer of section bending machines and produces over 20 different standard sizes, covering section modulus that range from 14 to 11.000 cm3. Full rolling automation was introduced by combining a Faccin’s HCU 550/5 model, a 2-roll plate rolling machine with the exclusive Faccin Precision Package that guarantees that thousands of parts are rolled daily with the same quality and within the limited tolerances required and a loading and unloading system entrusted to a robot that allows a considerable reduction of the production time, greater flexibility and adaptability to new products and a decidedly incomparable difference on the need for maintenance compared to a Cartesian system. And finally, a large levelling machine for straightening steel plates of 2500mm width by 30mm thick was of great interest due to the current www.mtwmag.com


DON’T LOOK FURTHER

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WIDER SELECTION OF TOP-QUALITY METAL FORMING MACHINES

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Hall

16 Stand D17

The Trusted Partner in Metal Forming Machines

+39 0376 670646 sales@boldrini.com www.boldrini.com

+39 030 99 58 735 info@faccin.com www.faccin.com

Follow us on

+39 030 67 29 300 info@roundo.com www.roundo.com


BUSINESS NEWS

Faccin high-capacity plate roll

variations of the price of steel. Faccin develops leveling machines for medium and large thicknesses that smooth out existing deformations of different origins with the use of flattening rollers, each one motorized and floating on independent axes that are always active and sensitive to load variations. Completing it all, the machines also include a backup roll system for the optimization of flatness, a Siemens integrated control

with a video camera system and rollers for automatic loading and unloading. Should you be interested in this technology, do not hesitate to contact us and book a demonstration

www.faccin.com

YASKAWA Technology driving the best-in-class automation solutions with partner Mehta CAD CAM at IMTOS 2019 With a constant futuristic approach, YASKAWA technology is driving the best in class automation solutions. This time Yaskawa India with its business partner Mehta CAD CAM showcased its array of powerful present day products at 8th IMTOS - India Machine Tools Show 2019, from 14th to 17th June, held at Pragati Maidan, New Delhi. Key decision makers and influencers from industry visited IMTOS to cater the machine tool needs of production and automation. The exhibition also assured the participation from influential international networks in machine tools segment to serve the needs of visitors. YASKAWA India and Mehta CAD CAM came up together at IMTOS to serve the customers at their best in a collaborated way promoting the system selling approach. The live demonstration of Yaskawa AR1440 robot with X350 power source showcasing the welding application attracted the huge gathering leading to good business potential. Both company’s accurate product segmentation and 24

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Display of Yaskawa Robot at its partner booth in IMTOS’19

Team showcasing the brand in high spirits

highly efficient solutions facilitated the establishment of powerful, direct connections with matching business partners visiting the show. Dynamic team present at the stall explained the visitors about the product features and futuristic technology of Yaskawa Robotics that would help industry in a big way in automation. Indeed this expo acted as a common platform for all to network with industry colleagues from around the globe involved in grasping the key market insights which would surely help businesses to expand themselves in the era of new industrial revolution Industry 4.0. “Yaskawa products & services will always be there to support businesses

of cutting & welding, pick & palletizing, automation, machine tools, etc. in keeping their machines running and hence reducing their downtime. This would help industrial market to realise the best choice of robotic solutions for the applications they require and ultimately achieving their short and long-term goals” said excerpts.

For more information about Yaskawa India Pvt. Ltd., Write us at arshleen.ahluwalia@yaskawa.in

www.mtwmag.com


BUSINESS NEWS

YASKAWA showcased its Futuristic Automation Solutions at Intec’19 in collaboration with its business partner YASKAWA is continuously focussed towards powering the best in class automation with its inventive and cutting edge technology. To demonstrate this, YASKAWA India in partnership with AXIS Global Automation showcased its equipment & technology at Intec 2019, CODISSIA Coimbatore from 6th to 10th June 2019 for the fourth consecutive time. With 2019 being the Golden Jubilee Year for CODISSIA, the event was redesigned and revamped to attract bigger footfall and more international audience in the segment of machine tools and automation. To provide visitors with a glimpse of the capabilities of Yaskawa Robotic Solutions, Live demonstration of Yaskawa product range was arranged at Axis Global Automation booth. Yaskawa MOTOMINI showcased pick and place application by serving Juices to the visitors and acted as a centre of attraction to the gathering. Another Live demo

Glimpses from the stall with YASKAWA Robots in action

included AR1440 with X350 power source for welding application and GP 12 for pick & place application with vision handling automation. Simulation software MOTOSIM & MOTO COCKPIT were also presented during the show displaying the practicality of working robot, programming, software diagonization, robot maintenance, life condition, etc. In addition to this Yaskawa introduced the concept of I3-Mechatronics,

Introduced the Concept of I3 Mechatronics

26

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JULY 2019

a three-dimensional digital data solution. The detailed theory of Integrated, Intelligent & Innovative solution was explained to the guests on how Yaskawa is empowering the next generation by synthesizing its knowledge of mechatronics technology where industry is looking to work in future. Being a major hub for manufacturing and education, Coimbatore is among the fastest growing tier-II cities in India housing small, medium and large industries primarily in engineering segment. Yaskawa India with its business partner showcased its futuristic automation solutions targeting auto & non-auto OEMs, Tier1/ Tier2 and education segment.

This year’s exhibition was specifically focused on Automation and Industry 4.0 solutions and witnessed the footfall of approximately 3, 00,000 visitors from industry and trade. Presence of brands in such exhibitions showcasing their latest technologies & powerful present day products enlighten and enrich the experience of businesses, industrialists and other entrepreneurs who attend these expo. This further wields the tremendous potential for growth.

For more information about Yaskawa India Pvt. Ltd., Write us at arshleen.ahluwalia@yaskawa.in

www.mtwmag.com


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BUSINESS NEWS

ExxonMobil announces new hydraulic oil technology “Mobil DTE™ 20 Ultra Series” ExxonMobilTM today announced the launch of Mobil DTE 20 Ultra Series– a technologically advanced series of hydraulic oils. The new series is designed for all types of hydraulic systems and components such as close clearance servo-valves and high accuracy numerically controlled (NC) machine tools. Designed to deliver upto 2x longer oil life and exceptional performance in harshest conditions, the new series help industries achieve unprecedented performance goals easily. The Mobil DTE 20 Ultra Series would lower maintenance frequency thus minimizing man-machine interaction, which makes the site safer for industrial workers. In addition to this, with 2 time oil life it would also support environmental

care by reduction in hydraulic oil consumption. Providing improved deposit control of 89.2% for longer oil life and precision operations, Mobil DTE 20 Ultra Series also delivers superior wear protection to extend component life. Extensive testing shows that it comes with better water handling and filter rating. According to Eaton 35VQ25 Test – an industrial test recognized for hydraulicfluid qualification,the oil

provides >72% better wear protection. “Hydraulic systems operate under highpressure and high-output environment. One of the major challenges faced by industries, is that of performance, productivity and efficiency,” said Shankar Karnik, General Manager, Industrial Lubricants, ExxonMobil Lubricants Private Limited. “With Mobil DTE 20 Ultra Series, consumers now

have a new technology developed to deliver trusted performance and extended component life, with reduced maintenance costs and system wear.” Hydraulic systems need maintenance due to both oil and machine factors. As the oil oxidizes with time, deposits are formed causing replacement of both oil and filter. Moreover, often times even valves, pumps and other parts of the machinery wear with age wherein the damaged components require replacement. This maintenance can be reduced and made effortless by using Mobil DTE 20 Ultra as it plays a major role in slowing down equipment ageing and decrease maintenance efforts. For more information, Web: www.mobil.com/industrial

Delhi Machine Tool Expo 2019 Sets the benchmark for Manufacturing Excellence Indian Machine Tool Manufacturers’ Association (IMTMA), organizing the third edition of Delhi Machine Tool Expo (DMTX 2019) at India Expo Centre & Mart, Greater Noida, Delhi - NCR from 8th to 11th August 2019, is laying out a red carpet for regional industries’ growth. The expo will also feature special 32

MACHINE TOOLS WORLD

pavilions on Metrology Expo (metrology, testing instrument and equipments), Weld Expo (welding, cutting and joining), Additive Manufacturing Expo (3D printing), and Factory of the Future (Industry 4.0). DMTX 2019 is likely to feature over 200 exhibitors occupying an exhibition space of 12,240 sq.mts. of

JULY 2019

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BUSINESS NEWS gross area showcasing latest technologies in metal cutting and metal forming. Foreign exhibitors are also expected to participate. The machines and accessories on display is expected to serve the needs of key user industries such as aerospace, defence, railways, automotive, medical engineering, construction, information technology, and electronics, etc. The expo will provide a platform for the manufacturing industry

to upgrade and improve productivity and quality requirements and demonstrate solutions to manufacturing industries, especially the various small and medium enterprise industries. Focus will be on the industrial units located in Himachal Pradesh, Punjab, Haryana, Delhi, Rajasthan, Uttar Pradesh & Uttarakhand, etc. Stating his views on DMTX 2019, P. Ramadas, President, IMTMA said, “We are glad to organize the

third edition of the expo as the past two editions of the show evoked anencouraging response from the machine tool industry. Manufacturers who participated in the previous shows were able to expand their range and I firmly believe that this edition of the show will help them to build on to their earlier success and reach out to the regional industries.” Speaking on the objective behind organizing the expo, V. Anbu, Director General &

CEO, IMTMA said, “IMTMA is organizing the show to enable India’s regional industrial units to keep pace with the changing technologies. Shows like DMTX will play an enabling role in addressing the numerous requirements of OEMs and component manufacturers in Tier 2 and Tier 3 cities. We expect a good turnout and I am confident that the expo will continue to evolve and grow bigger in future editions.”

GRIND MASTER ROBOFINISH Global Launch ROBOFINISH by Grind Master is being launched globally as an Advanced Technology Solution for Grinding and Deflashing of Castings and Forgings. ROBOFINISH Technologies have been refined by Grind Master and perfected for highly flexible and adaptive operation in foundry and forge shops. “Starting first R&D efforts in this domain in 2012, we have successfully developed over 125 applications. The Technologies and products have been refined multiple times in this period and we are now launching our 3rd Generation Robotic Machines at the GIFA 2019”, says Sameer Kelkar, CEO and R&D Head of ROBOFINISH. ROBOFINISH by Grind Master team members are global leaders in process expertise, systems development, and customized programming for Robotic Grinding/Machining of Castings and Forgings. Grind Master Group is an International Organization with Operations in India, China, France and USA – with 6 Factories and over 400 employees including over 150 Engineers. Headquartered out of India since 1984, Grind Master operates through subsidiaries in China since 2009 and France 34

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JULY 2019

since 2017. The Milwaukee ROBOFINISH facility is the latest addition to the Grind Master Group, starting in 2019. This global presence allows Grind Master specialized teams to be close to the foundry and provide turnkey solutions.

ing Studies (FEES), 3-D Animated Part Finishing Simulations, Tooling, Training, Offline Part Programming.

Robotic Grinding/Fettling Machine

ROBOFINISH R&D Centre

Each Grind Master ROBOFINISH facility is equipped with Robotic Casting Grinding Test Machines, which integrate Robotic Machining technologies with specialized LASER MultiTasking Scanning systems through proprietary ROBOFINISH Software. This machinery and systems provide state-of-the-art Robotic finishing solutions for all types of metals. The Tech Center will be providing services including Front End Engineer-

With a great response to the ROBOFINISH launch at the Recently held CASTEXPO 2019 (Atlanta, USA), Grind Master will be showcasing the 3rd Generation Technology at the GIFA 2019 (Dusseldorf, Germany). Mohini Kelkar, Grind Master Director Business Development says, “ROBOFINISH revolutionizes foundry and forge shops with enhanced productivity, quality and safety. We are proud to partner with global Foundry industry to bring about this transformation”. Grind Master boasts over 35 years of global industry-leading experience and has a growing list of major global Automotive & Foundry customers. www.mtwmag.com


Precision

as standard

Ensure machine tool build accuracy with the XK10 alignment laser system Measure – straightness, squareness, flatness, level, spindle direction and coaxiality Single digital solution – replace the need for traditional artefacts Intuitive software – reduce reliance on highly skilled operators

For more information visit www.renishaw.com/xk10

Renishaw plc New Mills, Wotton-under-Edge, Gloucestershire, GL12 8JR, United Kingdom T +44 (0)1453 524524 F +44 (0)1453 524901 E uk@renishaw.com

www.renishaw.com


BUSINESS NEWS

Renishaw celebrated for successful UK-India relations At the third annual Indian Awards, global engineering company, Renishaw, won the Larger Business Award. Presented at the UK’s Houses of Parliament on May 29, 2019, the accolade celebrates Renishaw’s successful operations in India, as well as the company’s work with the High Commission of India. Renishaw has offices infive Indian cities, as well as sales engineers in other regions. In Pune, Renishaw operates from an 80,000 square foot building, which includes a manufacturing facility, customer demonstration and training facilities, a procurement operation and an Additive Manufacturing Solutions Centre. Alongside this, Renishaw is involved in several programmes and initiatives to improve UK and India relations. Rhydian Pountney, Director of Group Commercial Services and

an experienced export professional, has been the UK chair of the UK-India Joint Economic and Trade Committee (JETCO) Working Group since 2013. Pountney has also been involved in the Make in India initiative and works as a mentor as part of the Access India Programme (AIP), organised by the High Commission of India in London,to help smaller businesses to establish Indian manufacturing operations. “Renishaw’s operations in India started as just a small office,”

explained Pountney. “30 years later, we now employ over 430 people, across five offices, including our biggest manufacturing site outside the UK. As the industrial economy in India continues to grow, Renishaw is at the forefront, working with customers and partners to provide cutting-edge manufacturing solutions. We also work with smaller UK companies, to help them realise success overseas. “This is the first time Renishaw has won a UK award specifically for its work in India,” added Pountney. “This award recognises the work of Renishaw’s employees, both in the UK and in India, and commemorates the company’s investment in facilities, people and expertise. Renishaw will continue to invest in India and to strengthen the relationship at a time when Indian relations are increasingly important to Renishaw and the UK as a whole.”

Siemens sharpens focus on Innovation and Start-Ups Siemens India announced that it will accelerate efforts to develop and bring to market innovative solutions that create sustainable value for businesses and societies. Siemens is also opening the India office for Next47, an independent global venture firm committed to helping connect Siemens customers to startup innovation from around the world. 4,000 IoT and software experts will collaborate with 36

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teams around the world to conceptualize, develop, test and bring-to-market applications in the areas of Smart Urban Infrastructure, Digital Enterprise, Connected Mobility, Future of Energy and Artificial Intelligence.The IoT solutions developed in India will complement the work done at the MindSphere Application Centers, based in Pune, Noida and Gurgaon where software developers, data specialists

JULY 2019

and engineers work together with Siemens customers to develop digital innovations for data analysis and machine learning. Dr Roland Busch, Chief Operating Officer, Chief Technology Officer and Member of the Managing Board, Siemens AG, said, “India is a key focus market and plays an important role in our global digitaliza-

tion strategy. Research and Software Development in India coupled with the sharpened focus on Start-Up innovations through Next47 will actively drive the implementation of cuttingedge technologies.With our unique IoT platform, comprising an advanced technology stack, domain know-how and an inclusive innovation ecosystem, Siemens is well prepared to support India into the www.mtwmag.com


BUSINESS NEWS digital age.” Sunil Mathur, Managing Director and Chief Executive Officer, Siemens Limited, said, “India needs to harness digitalization to optimize manufacturing growth. We are seeing an acceleration in interest and

demand from customers for our digitalization portfolio. IoT enabled applications are the need of the hour andwill focus on contributing tocustomers’ efforts to maximize the potential with digitalization through data insights.” Siemens Innovation Day

2019 showcased innovative solutions that create sustainable value for businesses and societies. It was a platform for dialogue around output-driven, market-oriented technological and business innovations. Siemens experts from

Digital Industries, Smart Infrastructure, Gas and Power, Mobility, Corporate Technology and Next47 also shared the latest innovations, industry trends, and demonstrated how Siemens solutionscreate value for customers and society.

BFW announces a wholly owned subsidiary m2nxt Solutions Bharat Fritz Werner Ltd. (BFW), India’s leading solution provider in the area of machine tools, announced the incorporation of a wholly owned subsidiary m2nxt Solutions. The new entity will provide complete offerings for Smart Manufacturing using both the Cyber and physical automation and solutions. Digitization and Automation are the next big disruption in the manufacturing sector. As an industry leader BFW, will be in the forefront of today’s Industrial Revolution. The Company will be a knowledge- based solution provider for advanced manufacturing processes including Jig& Fixtures,

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Industrial IoT, Robotics and Data Analytics. The vision of the company would be to help enhance profitability through enhanced productivity of manufacturing companies. BFW has inaugurated its first digital factory in Hosur, Tamil Nadu in August 2018. BFW used all its Digital Knowledge and Competency to showcase productivity

improvement in this Factory. Speaking at the announcement Ravi Raghavan, Managing Director, Bharat Fritz Werner Ltd. (BFW) said, “The digital transformation is bringing sweeping paradigm shifts in the manufacturing segment. Our new subsidiary m2nxtSolutionswill enable our clients to significantly enhance the efficiencies by

creating Smart Manufacturing through Smart Process, Smart Machine and Smart People.” Praful Shende, Chief Sales & Marketing Officer, BFW said, “We are appropriately placed to enable Industry 4.0 ECO System for our Customers with all the three business verticals – Automation, Process Engineering &IIOT solutions.” V Jagannath, Business Head, m2nxtSolutions said, “Under our new company, we are excited about bringing in a compelling value proposition for our clients to accomplish lean manufacturing.” Website: www.bfwindia.com

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BUSINESS NEWS

ELGi unveils upgraded Encapsulated Screw Air Compressors with variable frequency drives (VFD) & heat recovery systems at INTEC 2019 ELGi Equipments Limited, one of the world’s leading air-compressor manufacturers, with over 2 million installations across 100 countries, reaffirmed its commitment to building customer centric, energy efficient compressed air solutions at INTEC 2019. A platinum sponsor at INTEC, ELGi showcased an upgraded range of Encapsulated (ENCAP/EN) screw air compressors with variable frequency drives (VFD) and heat recovery systems at the ELGi stand no. 2, Hall B. As part of the exhibit, ELGi also displayed its range of EG Series screw air compressors and direct drive piston compressors. INTEC, the much awaited exhibition highlighting technological advancements in the manufacturing industry expects to witness wide global participation with over a 100 thousand business visitors, 626 exhibitors and 200 product categories on display. “Energy accounts for almost 75 – 80% of the lifecycle cost of an air compressor. Across the world, business owners are increasingly faced with not just the rising costs of fuel, but global concerns about the environment and air quality. At ELGi, we’ve made a commitment to every customer across the 38

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globe - our compressors offer maximum energy efficiency and sustainable advantages from a total cost of ownership perspective” said Dr. Jairam Varadaraj, Managing Director, ELGi Equipments. The new range of Encapsulated (ENCAP/EN) screw air compressors address a customer’s varying air flow demands with high energy efficiency. The EN VFD optimizes air flow by varying the motor speed of the compressor according to air demand, thus saving energy costs unlike that of fixed speed compressors. The EN series models also come equipped with smart controllers that monitor, control and protect the compressor from failures by shutting down the compressor whenever necessary. The ELGi heat recovery system (HRS) helps companies

JULY 2019

recover approximately 96% of heat generated during the compression process which can then be utilized for heating air (space) or water. This in turn eliminates additional equipment requirements to heat water or air, thereby becoming an energy saving device and contributing to a reduction in CO2 emissions. Speaking at the product launch, Dr. Jairam Varadaraj, Managing Director, ELGi Equipments said ‘’Improved energy efficiency begins with understanding the customer. At ELGi we’re committed to ensuring we right-size every customer for their compressed air requirements. Our sales teams the world over study customer applications and recommend the right size of compressor for maximum energy efficiency.”

Mr. S. Ravi, Chairman & Managing Director, Craftsman Automation, an ELGi customer for over 15 years said “ELGi powers our plants across India and ELGi’s screw air compressors have not just enabled significant energy savings but also delivered best-in-class life cycle cost. The uptime warranty offered by ELGi has helped us improve productivity and profitability at all of our units. We look forward to our continued association and we wish ELGi the very best always”. ELGi, is a pioneer in cutting edge compressed air technology with a presence across over a 100 countries, offering a complete range of compressed air solutions from oil-lubricated and oil-free rotary screw compressors, oil-lubricated and oil-free reciprocating compressors and centrifugal compressors to dryers, filters and downstream accessories. With state of the art manufacturing units and a product portfolio of 400+ compressed air systems, ELGi redefines reliability, efficiency and cost-effectiveness across 2+ million installations all over the world. For more information, Website: www.elgi.com

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BUSINESS NEWS

Allied Machine Launches Newest App – Machinist Tool Allied Machine & Engineering, a leading manufacturer of holemaking and finishing cutting tool systems headquartered in Dover, Ohio, releases their most recent mobile app, Machinist Tool, available for download now at both the Apple Store and Google Play. This app is designed for machinists, tooling distributors, and manufacturing engineers working with Allied’s tools.

Machinist Tool offers easy to navigate utilities and streamlines operations on the shop floor by mobilizing resources for drilling, boring, threading, reaming, and roller burnishing. Allied’s Machinist Tool includes speed and feed, as well as trig functional, calculators, G & M machine code definitions, and seven different tap drill charts including the ACME general purpose (full profile), the Unified National, and the ISO Metric – J Series. The app offers hot links to call Allied’s engineers or to find a local Allied tooling distributor if users need technical support. Machinist Tool also includes quick

access to GD & T definitions as well as the Boring Insert Selector, a utility that helps machine operators choose the correct insert for each boring application they might encounter. The mobile app compiles a quick reference library of Allied Machine’s valuable holemaking and finishing resources such as technical guides and operation manuals. Accessible tech guides include an illustrated pocket reference for threading as well as recommended cutting data for ISO material types like hardened steel, stainless steel, and titanium. Machinist Tool is available for download on both

iPhone and Android devices and is available in Chinese, English, French, German, Korean, Mexican Spanish, and Russian. Ben Morrett, a senior product manager at Allied Machine, says, “No need to fumble through multiple apps. We created the Machinist Tool app as a one-stop shop to be used in conjunction with Allied Machine’s product lines.” For more information info@alliedmachine.com www.alliedmachine.com.

Bettinelli’s High Precison Link Conveyors: A range in constant evolution Cam Driven Systems (CDS), a division of the Bettinelli S.p.A. group, has come up with the widest range of positioners, rotary tables and cam mechanisms for the automation processes. CDS Precision Link Conveyors TSL, TL and TXL provide the industry’s highest accuracy and repeatability for automated assembly and manufacturing machinery platforms combined with the highest dynamic performance available on the market. The precision link conveyor TL series has been designed to meet the requirements of high productivity and reliability of modern automation, combined with excellent precision and 44

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allowing great flexibility and a more accurate choice during the designing phase.

speed, with a high degree of versatility to offer customers the most suitable solution. They are used on machines that require stability, precision, high speeds and low maintenance. They are different in terms of body width,

The need of the market and customer orientation, added to the desire of CDS to expand & improve its product range has brought new innovations to the TL series: TSL 200 : In TL 200, the depth of the body has been reduced, with the same stroke, with a consequent reduction of the gearwheel diameter and a better ratio with the driver unit and a better positional accuracy. This makes the machine far more compact and it www.mtwmag.com


ENDLESS POSSIBILITIES

MARPOSS FLEXIBLE SOLUTIONS OPTOQUICK is the latest generation Marposs flexible solution, for high precision gauging controls on shafts, as for instance cam, crank or gear shafts, gear shafts or electric motor shafts. Optoquick helps operators with fast and precise quality controls while located directly at the side of the manufacturing machines. The combination of optical and tactile sensing technologies - complete MARPOSS design - allows the Optoquick to deliver extended gauging capabilities and flexibility, at the highest level of its category. OPTOQUICK, NO MATTER WHAT THE GAUGING CHALLANGE IS.

M A R P O S S I N D I A P v t . L t d . 1 4 7 , S e c t o r 7 , I M T M a n e s a r 1 2 2 0 5 0 - Te l . + 9 1 1 2 4 4 7 3 5 7 0 0 | s a l e s @ i n . m a r p o s s . c o m


BUSINESS NEWS is a great advantage to the machine builder. Plastic Protections: In the TL range, the plastic protections have been studied to be applied on pallets in order to guarantee an antiintrusion covering for the components being processed. These covers are printed in 3D. Special Links Chain: Together with the plastic protections a new links chain has been developed.

The latter is equipped with special seals to reduce the accumulation of powders or abrasive material during the process and increase the protection of leads and bushes. In a nutshell, following are the salient features of these conveyors: • Versatile and compact modular-component design • Precision machined cast iron chemical-nickel plated links • Precision chordal compensation cams

• Cam Driven for fixed indexing motion or servo driven for flexible positioning The competitive price and fast lead time together with CDS quality and reliability make this series very attractive for the market, says Rupesh Paparaju, Director, Bettinelli Automation Components Pvt. Ltd., based in Pune.

For more information, Website: www.bettinelli.in

ANCA’s industry first ANCA Tool of the Year winners announced ANCA’s industry first competition is back with the 2019 winner to be announced live at EMO, Germany. Last year the industry welcomed the opportunity to show off their skills with almost 30 entries received from across the world being seen by over 122 thousand fans generating 3,000 comments and reactions on social media. Pat Boland, ANCA CoFounder comments: “I have great respect for our customers’ knowledge in designing and grinding quality cutting tools. Their skills drive our industry forward and most of ANCA’s new technology is born from a customer’s need to achieve something new.” “We should celebrate the collective acumen of our industry and showcase the fantastic work that is conducted every day to 46

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build our world. I encourage all cutting tool makers to enter our competition and show off your talents,” he concluded. The cutting tool industry has cultivated and refined their craft over the years to design beautiful tools, applying science to achieve a sub-micron surface finish and superior cutting performance. With 2,200 exhibitors and 130,000 visitors - EMO remains a key event in the cutting tool makers calendar and is

JULY 2019

the perfect opportunity to showcase the legends who are creating superior cutting tools. Ralph van Hoorn, Managing Director at Van Hoorn Carbide and first time Judge said: “Technology is moving forward faster than ever, demanding more and more of the tool grinders of today. Designing and grinding these great products demands for a combination of great ideas combined with technical knowhow and top class

machinery. Thanks to ANCA and their customers, revolutionary new ideas have come to practice making our technology move forwards.” Charles R. Day, Vice President and General Manager at CONTOUR360and winner of 2018’s competition said, “In the two years I’ve been with the CONTOUR360° organization – I have told everybody that would listen (and even some who wouldn’t) how over-the-top this company’s toolmaking ability is! Steve Hutchins and Mario Ercolani are responsible for the submission and two of the most talented and capable toolmakers I have ever met! And they represent an entire organization of others just like them!” For more information Website: www.anca.com

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COVER STORY

FACCIN: Global Technology Leadership in

Metal Forming Machines Q. Machine Tool industry is posing the significant growth in recent years, Faccin Spa being the pioneer player in Machine Tool industry managed to acquire significant growth, what are underline facts for this bounteous growth? Our success is determined by the machines installed around the world during all our years of existence; our biggest achievement is the thousands of references from satisfied customers and our most important award is the appreciation and recognition we receive every day from the metal forming market as one of the few trusted manufacturers that still delivers what it has been promised, which lately translates into repeated orders. Q. Please brief us more about overall outlook of Faccin Spa? Our Group is now a very powerful combination of the best brands in plate rolling, profile bending and dished-heads manufacturing all united under one roof each brand specializing on a certain type of product that delivers the best quality and technology available in the market.

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Our strategic and technical vision is to keep growing as a group, using the synergies provided by each brand not only technically but also commercially in order to offer the customers an even wider range of high-quality options easily available. Q. Is there are any global alliances that has been made by Faccin Spa in order to out-front the competition? This year, we have been able to concretize very important projects, due to our long standing relationship with our network of distributors, beating our nearest competition in many emerging markets, by delivering heavy-duty machines that show how our group is the chosen partner when high performances and tights tolerances are required. We have also consolidated our leading position in Europe with our branch in Germany, Faccin Deutschland GmbH, with new offices and a brave new showroom and stock readily available in this market, strategically very important for our future group expansion. We are also opening our new offices, showroom and warehouse in the United States, setting a very

strong basis for the growth in the north American market (US and Canada) as a group of strong brands and capitalize on the thousands of machines that our group has already installed. Q. What are the market prospects for the Faccin Spa products in India and How do you plan to position these products? We believe Asia-Pacific is expected to drive the demand of the metal forming machines market with countries like India acting as a significant player, unceasingly displaying an infrastructural evolution, which in turn will drive the metal forming industry. Our strategy is to keep working through our distribution network, companies we have been collaborating with for many years now and consolidate our position in new regions through new powerful distributors with very professional technicians that will be able to support our machines. High quality and great service is the key to our success in the Indian market as confirmed by the many customers currently working with our equipment.

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COVER STORY

Our biggest achievement is the thousands of references from satisfied customers and our most important award is the appreciation and recognition we receive from the metal forming market

Mr. Andrea Ceretti, CEO, FACCIN S.p.A.

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COVER STORY Q. In your opinion how can the Indian Machine Tool industry become globally competitive ? The volatile steel market and the difficulty to find experienced operators are driving manufacturers to improve the quality of their metal forming equipment, particularly looking for precision and automation. India must specialize in providing metal fabricators with equipment of the highest quality that is powerful, technologically advanced but above all precise. When the steel prices go up and the margins get smaller, precision is the solution. Machines will have to be designed to provide a return of investment based on the precision of the forming and elimination of metal waste combined with powerful technology that augments the productivity cycle. Q. What are the key technological trends that are driving machine tool industry? The markets will continue to increase the demand of metal formed products but due to the current geopolitical

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situation, the volatility will be high and will push the metal fabricators to be as flexible and as reactive as possible. The metal industry will attempt to standardize as much as possible with measures like Industry 4.0 in order to maximize the production capacity of each equipment, to apply energy saving measures and lobby/demand the governments for more tax reforms and incentives to stay competitive and improve the workforce development. Q. What is your future plans for Faccin Spa? Industry 4.0 has become more and more prevalent in the industry and a must for any manufacturer that wants to bring the best quality machines, advanced connectivity and analytics and people to work together in order to change the way of the day-to-day operations and to obtain a powerful business outcome. As a group, we have always been

developing leading technology to help manufacturers obtain the maximum from our machines and we see Industry 4.0 as a way to capitalize on the technology we already provide. Our machines are ready for Industry 4.0 thanks to SMART packages that offer features like Systems Diagnosis, Teleservice, Management Control, Drawing Imports, Rolling & Production Lot Statistics and Flexible Network Solutions between others, helping the manufacturers of today, face the challenges of tomorrow. Indeed, we already started thinking about Industry 5.0 as company attitude. Q. lastly is there any new products which will be launched by Faccin Spa in near future? Our Group has always been at the vanguard in terms of precision and automation of the forming process, Faccin being the first to offer a CNC for plate rolling machines, back in 1984. We will keep focusing in providing metal forming companies with equipment of the maximum quality, powerful, cutting-edge but above all accurate and highly automatic.

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An ISO 9001:2015

An ISO 9001:2015


TECHNO FOCUS

Geometry and wear measurement of cutting tools

T

he geometry of a tool is the crucial factor for tool lifetime and machining results. Production and quality assurance need to make sure to continuously manufacture a defined geometry. In order to judge the quality of cutting tools it is necessary to measure their geometry and wear during their use. This allows taking measures to improve the quality and durability of the tools as well as to increase the machining speed. In the following we demonstrate how the 3D metrology device InfiniteFocus can be used for such complex geometry and wear measurements. Due to its special technology it is able to measure even very steep surface slopes and delivers highly accurate 3D data together with perfectly registered true color information. By using special algorithms the system is able to compare the threedimensional structure of the tools before and after their usage and to determine important parameters such as the total volume of worn and accumulated material.

InfiniteFocus G5

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The three-dimensional measurement of cutting tools, drill bits and milling cutters is an important aspect of quality control in the industrial process, since the form and wear of cutting edges have a significant influence on the quality of machined parts. Among others the edge geometry influences the possible cutting speed as well as the lifetime of the tools. Since these tools often have a very complex geometry including steep flanks and undercuts, their 3D measurement is a big challenge for optical 3D metrology devices. The evaluation of 2D images is possible for simple measurements where no occlusions occur, however it is not possible for measurements where real 3D information is necessary. In the last years optical 3D measurement methods have become more and more popular in various fields. The 3D measurement of drill bits and cutting tools however is often hardly possible with optical devices due to their complex geometry and their steep surface flanks. White light interferometers e.g. only allow the measurement of flank angles up to about 30°, which typically is not enough for the evaluation of cutting tool radii. An optical measurement technology which is suitable for the measurement of steep edges is Focus-Variation [ISO 25178-6. This device fulfils on the one hand the requirement to measure steep flanks up to 87° and on the other hand it allows the measurement of quite large areas with high vertical resolution.

Edge Master X

The optical 3D measurement device based on Focus-Variation, is InfiniteFocus by Alicona. In order to perform 3D measurements the device vertically scans the specimen by the sensor while continuously acquiring data. By analyzing the variation of focus during the scanning process for each measurement a complete 3D model is obtained. In addition to the 3D data, the measurement device also delivers true colour information for each measurement position, which is perfectly registered to the height data. This colour information often enables the user to classify regions that have not been used, and those where wear has occurred. Additionally a repeatability measure is analytically estimated for each measurement point. This repeatability measure is an estimation of the standard deviation of the z-coordinate of the measurement point as it would occur in a measurement series. This

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TECHNO FOCUS

measure can be used for different investigations such as the estimation of the quality of the measurement points, the filtering of measurement points with bad repeatability, the detection of vibrations or other exterior influences during the measurement. In order to analyze the geometry of a cutting edge, a special software module is available that analyzes cutting edges on a surface profile based basis. Surface roughness can be can be either calculated according to the draft of the ISO standard 25178 [ISO 25178-2 in an area-based matter or on a profile based basis according to [ISO 4287, ISO 4288]. The knowledge of the surface roughness has a significant influence on the production since it influences among others how well the material can be chipped. Volume measurement is also important parameter to know the worn of the manufactured tools and used tools. To perform cost efficient quality assurance, crucial parameters such as radii and angles have to be measured

Name

Value

Ra

2.895

Rq

3.729

Rt

17.147

Rz

12.365

Rmax

16.872

Rp

7.553

Rv

9.594

Rc

10.343 Profile Based Roughness

production integrated. Measurements need to be quick, easy and in a high resolution. Usually, tools are measured with a number of different measurement devices during different stages of production. With InfiniteFocus, a non destructive, high resolution 3D measurement is offered that covers the measurement of all necessary parameters. Clamping and overall usability of the systems is extremely user friendly whereas measurements are achieved very quickly. Process reliability and consequently the overall quality are raised significantly.

In a further step, measurements can be performed directly in the grinding machine which shows its inline capability. The use of InfiniteFocus enables fast and easy handling of production steps which leads to a more cost efficient production with continuous quality at fewer rejections. With our 3D measurement device InfiniteFocus you measure form and roughness of drills, mills, etc. with only one system. In R&D, InfiniteFocus is the only system that can measure the full geometry of a tool automatically and therefore most efficient. Meaningful surface analysis for maximizing surface state and consequently tool life-time can be performed with a highly accurate, simple to use and very cost efficient measurement device.

For more information visit at Website: www.alicona.com

A real based Roughness Millenia Technologies 311, Options Primo, Plot No. X-21, CTS-31, Near Passport Office, Kondivita, MIDC, Andheri (E), Mumbai - 400093, Maharashtra, India. | Tel: +91-22-28316101 / 28320401 Email: sales@millenia-technologies.com | URL: www.millenia-technologies.com

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53


PORTFOLIO

Shavo’s tailor-made technology solutions

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

F

rom static elimination solutions to precision air moving products to instrumentation fittings and high purity gas delivery systems, Shavo is dealing in a wide spectrum of products and technologies. “Our endeavour has always been to work in niche high technology areas across industries where we can offer significant value for a variety of problems. Our products and their applications find solutions in a diverse range of industries such as Semiconductor, Aerospace and Defense, Converting, Automotive, Chemical and many more,” says Rushil Shah, Managing Director. The company’s core selling concept is its deep application knowledge and command over the technologies it sells.

Applied gas delivery systems

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Shavo Technologies Pvt. Ltd., a part of the Shavo Group with a standing and reputation spanning over five decades, is in the frontiers of niche high technologies cutting across diverse disciplines. The company 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 product portfolio, the company serves over a thousand customers from diverse key sectors including semiconductor, aerospace, defence, chemical, oil & gas, automobile and so on. The company has gone from selling component to systems and solutions and turnkey capability in an effort to keep offering better value by leveraging the technologies it provides. Cutting edge technologies All Shavo’s Principals have specific technologies that would be classified ‘cutting edge’ considering that almost all its principals are world leaders in their fields. For Static Elimination, it has integrated power supply ionising bars with full feedback control for Gas Delivery. Shavo has some of the most sophisticated fully automated systems capable of dealing with the most dangerous gases. It offers from HORIBA a multi gas, multi range Mass Flow controller - a first in the industry.

Static measurement for effective static neutralization

The company’s journey of working with High Technology Industries has started with Gast which today remains one of the world leaders in Air Motors and Fractional horsepower. Over the years, it has released many new pumps that have extended typical service life to new frontiers especially with the new rocking piston technology pioneered by Gast. Its latest 87 R series offers industry leading pressure performance at lowest noise levels. Corrosive gases are used in a wide range of industries from Chemical, Tooling and the new areas of Nanotechnology, Photovoltaics, etc. Handling corrosive gases requires deep application knowledge, understanding of the materials to be used especially soft goods. Many corrosive gases are

High quality instrumentation valves

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Circuit Identifiers Clamp Meters

Multimeters Power Analyzers

Continuity Testers

Voltage & Current Testers

Motor Rotation & 3-Phase Testers

Ground Resistance Testers

Megohmmeters

Just like the human body, electrical equipment require a complete examination to identify any glitches. Whether the process is of installation, maintenance or repair, Extech’s testers and meters are always up for the task. To ensure smooth operation of your electrical equipment, Extech offers a wide range of test instruments that help you identify a problem before it occurs. For more details call us on: +91-11-4560 3555 or write to us at flirindia@flir.com.hk FLIR Systems India Pvt. Ltd. 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034 Fax: +91-11-4721 2006 | Webiste: www.extech.com

FLIR Puzzle Find Problem & Extech AD 24x18_2019.indd 1

PROBLEMS ARE ALWAYS HIDDEN, AND WE HELP YOU FIND THEM

Problems like unplanned shutdown, overheating of electrical appliances and connections, insulation problems and harmful gas leakages can lead to a major issues and bring an entire production to a standstill. To tackle these problems and to resolve them on time, FLIR brings a wide range of preventive maintenance solutions which help you identify problems before they arise or start to worsen. Include FLIR's state-of-the-art gadgets in your regular preventive maintenance check-up and make your business operations hassle-free.

INDUSTRIAL APPLICATIONS: Electrical & Mechanical | Building Diagnostic Automation | R&D | Gas Detection | Firefighting Test & Measurement

Images for illustrative purposes only.

FOR A COMPLETE HEALTH CHECK-UP OF YOUR ELECTRICAL EQUIPMENT

For more information, please call us at +91-11-4560 3555 or write to us at flirindia@flir.com.hk FLIR Systems India Pvt. Ltd. 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034 Fax: +91-11-4721 2006 www.flir.in /FLIR |

/FLIR |

/FLIR

18/04/19 12:50 PM


PORTFOLIO

Rocking piston compressor

also liquefied which need special considerations, from heating to weight measurement, etc. The awareness on the causes and cures for static electricity are low in industry but steadily growing. A lot of problems of contamination, material misbehavior, etc., are often attributed to other causes when they really are static related issues. Shavo continues to publish articles and bring awareness to the industry by working with a number of industrial associations. The valves and regulators it supplies to the Chemical Industry in general have a wide range of certifications. For valves, it has course type approvals from various third parties like Llyod’s, TUV, DNV, etc. and the products meet all industrial standards wherever required such as ASTM F-1387, for Oil &Gas , ECR 110 for Automotive NACE, for Sour Service and many more. Tescom vaporizing regulators, in addition to having ATEX Approval, is the first such unit to have PESO / CCOE Approval from Nagpur. Generally of course ‘Energy Absorption’ has applications wherever we need to decelerate motion, in the Industrial space. Factory Automation especially with Pneumatics is the key application, but Shavo also finds safety applications such as end stops for large cranes like those found in steel and ports as an important area. Lately the company’s focus has been vibration isolation with special attention to strategic electronics in the

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Shock absorption products

Defense Sector which has some of the most stringent requirements for G force transmissibility. The company’s Fluid Control products once again find applications in a very diverse range of industries, but the main end-users are Oil & Gas, Chemical, Analytical and general manufacturing. The growth areas in the Fluid Control Industry lie in Semiconductor manufacturing and Photovoltaics which demand ultra high purity gas delivery systems. Equipment to service these industries is typically made to the exacting specifications of the SEMI code which controls all processes from raw material to manufacturing, testing and even packaging. The surface finish and cleanliness requirements for these industries are extremely demanding often requiring products to be assembled in Class 100 environments. The company’s supplies to the Automotive Industry almost cover the entire range of its product lines e.g. all engine testing for the new EURO IV and Euro VI norms use Shavo’s Tescom Central Gas Supply Systems for calibration of gases. It supplies Gast Air Motors almost extensively to all automotive paint kitchens. You will also find Enidine shock absorbers at the end of travel on many assembly lines. The Meech Jet Stream Ionizing Systems, on the other hand, clean & neutralize car bodies and plastic parts prior to painting. Other Fluid Control

High pressure regulators

products find extensive applications in the CNG space and the automotive testing area such as car air bag testing for instance. Shavo is currently working with some of India’s Top Companies such as Reliance, Tata’s, Biocon, GE, Department of Space, Ministry of Defense and many more. The company has over 1000 live accounts as of today. Eminent service set-up Shavo’s service set-up / service team has been growing from strength to strength. It has full service capability at the Pune office and is in the process of building a world class center in its Bangalore Factory. “Our service support is a key pillar of the value we provide,” underlines Mr. Shah. When asked about addition of new agency lines, Mr. Shah says: “We have generally been extremely selective and have refrained from having a long line card, preferring a deeper involvement with our current partners to fully exploit their potential, but we have recently signed with Horiba to introduce flow control solutions and we would probably close with 2 more agencies in the Fluid Control area over the course of the next year.”

- P.K. Balasubbramaniian

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EVENT PROFILE

EMO Hannover 2019: Digital approaches to sustainable machining Industrial processes can either be digital or sustainable – at least that is the belief of many who have not yet given the issues involved the consideration they de-serve. But the VDMA Technology Forum at EMO Hannover will be proving the opposite: applied sensibly and judiciously, digitalisation can even increase sus-tainability. Four companies whose digital solutions are helping to make the pro-duction and use of tools more sustainable offer their insights.

Konrad Keck

F

or Konrad Keck, Sales Manager DACH of Benz GmbH Werkzeugsysteme in Haslach (near Offenburg), Smart Service is the key to preparing services and products for Industry 4.0 (IoT-ready). For Benz, Smart Service represents an in-tegrated service concept in which ever larger amounts of digital information (e.g. from sensors) are used for preventive service processing.

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Energy harvesting supplies sensors with power Sometimes the devil is in the technical detail: sensors often consume additional energy. Keck points out an alternative: “With rotating tools, the energy for the sen-sor system is obtained from energy harvesting, basically allowing battery solutions to be dispensed with.” Energy harvesting users “harvest” electrical energy from sources such as ambient temperature, vibrations or air currents to power mobile devicesor low-power electronics. However, the most sustainable aspect of “Smart Service” is that the tools last longer due to preventive maintenance intervals. In the future, when digitalisation renders products aware of their own condition, such parameters can be used as the basis

for control loops that increase the service life of the tools. In Hanover, the Haslach-based company will be demonstrating how digitalisation can affect applications in daily practice in the form of its newly developed rotating tool mag-azine Benz Hybrix and the LinA broaching system which is

Daniel Meuris

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EVENT PROFILE now IoT-ready. Daniel Meuris, Head of Digitalisation and Virtualisation at the machine tool manu-facturer Klingelnberg GmbH, Hückeswagen, will be presenting the company’s GearEngine platform for gear production at EMO Hannover 2019. This serves as a central collection point for production data and an interface between the produc-tion department and the management. The platform facilitates the deployment of software-based data services for Klingelnberg machine tool operators. Software tool raising tool efficiency Meuris believes that tool efficiency is the key to sustainable machining. One ex-ample is bevel gear production in which it was not previously possible to assess efficiency levels due to the special tools involved and the lack of data. Klingeln-berg’s new SmartTooling system can identify tools and fixtures for bevel gear mill-ing machines using Data Matrix codes and manage them centrally in a database. Meuris: “The means of production are described to any required level of precision as digital twins in a central database. Production data is added to this database during and after the gear cutting.”Klingelnberg will be demonstrating how this works in practice in Hanover by showing actual operation on a machine. Dr. Raphael Rohde from the Tech-

Dr. Raphael Rohde

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nology Development department of the Tools and Parts business unit of Blomberg-based Phoenix Contact GmbH & Co. KG will be explaining how production can be optimised using tool data at the Technology Forum of EMO Hannover. The connection and automation technology manufacturer networks its injection moulding tools with the aid of RFID-based data acquisi-tion and optical markers. “All manufacturing and production information is availa-ble at all times,” Rohde explains. “The required data is made available to employ-ees and individual users in the form of visualisation boards or through the use of augmented reality. This helps reduce any mistakes due to incorrect interpretation and keep consequential errors to a minimum, thus contributing to sustainability in production.” Measurement technology supports digital transformation The digitalisation of industry is bringing measurement technology ever closer to and into production, as Prof. Heiko Wenzel-Schinzer, Managing Director and Chief Digital Officer of Wenzel Group GmbH & Co. KG in Wiesthal has observed: “We can take more and faster measurements with optical solutions, 5-axis meas-uring heads and special measuring machines, and give direct feedback to the processing machines via closed control loops.” However, when measurement technology moves into production, it is crucial that it more or less eliminates downtimes. The measurement technology manufacturer offers additional solu-tions which are designed to detect and correct any problems on the machines at a very early stage. This extends the service life of the production equipment and makes it more sustainable. Wenzel’s measuring machines are also designed for extremely long

Heiko Wenzel-Schinzer

service lives. “We are deploying modern measuring technology that can repeatedly be modern-ised without the entire machine having to be replaced,” explains the managing di-rector. “With process monitoring, the closed control loop between the measuring technology and the processing machines reduces the number of rejects, as we can provide feedback on any production problems at a very early stage. “On the Wenzel Group stand at the EMO Hannover the company will demon-strate the interaction between production and new measuring technology – from portable measuring arms through to high-speed scanning machines. Those who are interested can find out more about sustainability and digitalisation in production at the Technology Forum of the VDMA-HighPrecision Tools and Metrological and Testing Technology trade associations on stand D39 in hall 4.

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INDUSTRY SPEAK

Welding plays a pivotal role in the manufacturing process in the automotive industry: Satish Bhat

Mr. Satish Bhat, Managing Director, Ador Welding Ltd.

Q. Please enumerate your activities and niche. Ador Welding Limited (AWL) (formerly Advani-Oerlikon Limited) since inception in the year 1951 are regarded as the pioneers in the Indian welding industry. With business segments like Welding Consumables, Welding Equipment, Gas Cutting Products (GCP) and Personnel Protective Equipment (PPE), Welding Automation Products and Systems (WAPS), Project Engineering Business(PEB) and the Ador Welding Academy (AWA), we are complete welding solution providers to the manufacturing sector. Our footprints are present in every manufacturing sector – Automotive, Fertilizer, Wind, Hydro & Thermal electric power, Infra – structure,

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Mining, Nuclear, Railways, Oil & Gas, Ship building, Wind energy and many more. With four strategically located manufacturing plants, AWL has the highest capacities compared to any other welding company in India. All the plants are ISO 9001/ 14001 / 18001 certified with the state-ofthe-art manufacturing facilities and testing facilities. AWL has 11 sales offices spread across India and has the biggest distributor network. AWL has evolved with the growing demands of the industry and is India’s largest manufacturer of welding consumables catering to the Domestic market and an International clientele spanning more than forty countries. Our equipment and consumables

and manufacturing and their quality systems are constantly and periodically evaluated by both the national (e.g. BIS / IBR / NPCIL / EIL / RDSO / BHEL / DRDO) and inter-national (ABS/LRS / BV / DNV / CWB / CE) third party agencies. We have more than 200 product approvals and are probably the only Indian manufacturer in welding industry to have many products CE and CWB certified. We are the only Indian welding company to an NABL accredited testing laboratory. Q. What are your offerings to the automotive industry? The most commonly used welding methods for automotive applications include resistance spot welding, resistance seam welding, metal

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More Precision Non-contact temperature measurement

Infrared Temperature sensors  Tiny measurement spots from 0.45mm  Temperature ranges from -50 °C to +2200°C  Up to 250°C ambient temperature without cooling  Analogue & digital outputs incl. Profibus DP  Specific wavelength versions for glass, metals, ceramics

Compact thermal imaging cameras  Up to 1kHz for fast processes  Temperature ranges from -20°C to 2000°C  Compact cameras ideal for OEM applications  Resolution up to 764 x 480 pixels  License-free analysis software and complete SDK included

+91 20 2674 1009 | info@micro-epsilon.in | www.micro-epsilon.in


INDUSTRY SPEAK

ADOR - GTAW Inverter Champ TIG 300AD And Champ Pulse 500

inert gas (GMAW) welding, tungsten inert gas (GTAW) welding as also laser beam welding (LBW), friction welding (FW) and plasma arc welding (PAW). Ador Welding Offers a plethora of solutions through its wide range of Welding consumables, Welding equipment, Welding Automation, Plasma and Gas CNC based cutting systems encompassing most of these processes. The Champ Pulse 500 is arguably India’s first indigenously manufactured Pulse MIG machine. Designed and developed at Ador Welding Pune plant, the Champ pulse 500 is excellent for welding of thin and thick sheet Aluminium, Copper and their alloys, Nickel and its alloys, Stainless Steels, Carbon Steels, Alloy Steels, etc. Q. How do you contribute to automation, productivity and operational efficiency in the industry? Automation in welding and the

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use of robotic welding is the need of the hour as we strive towards becoming a world-class exporter of engineering products. Robotic solutions offer the much-needed skill and repeatability to critical jobs on mass manufacturing lines which makes them absolutely vital in this age of consumerism. IOT, AI, and ANN are being put to good use to help create impeccable ‘first time right’ welding process planning and the same is slowly but surely finding takers in India. Developing import

substitutes for welding consumables is our biggest challenge as this will define India’s path towards being a top-quality manufacturer to the rest of theworld. Q. Have you come up with any pathbreaking technology or customized solution for this industry? Auto- Exhaust applications The use of stainless steels in automobiles started when automobiles came to be equipped with 3- way catalytic converters to meet intensifying regulations over exhaust gas emissions. The requirement to have longer service life accelerated the switchover from hot dip aluminized carbon steel to stainless steel in this application. Today, stainless steel is used in almost all exhaust system parts from the cylinder head gasket to the tail pipe. The consumption of stainless steel in the exhaust system per passenger car varies from model to model but averages about 15kg per car. The stainless-steel consumption is expected to increase in the exhaust system of diesel-powered automobiles, mainly trucks, to meet the growing social demand for stricter exhaust gas emission regulations. Exhaust system materials are exposed to a variety of harsh conditions and must be resistant

Axle Welding Automation setup from ADOR

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23 - 28 January 2020, Bangalore, India


INDUSTRY SPEAK

Resistance Spot Welders from ADOR

to such degradation mechanisms as high temperature oxidation, condensate and salt corrosion, elevated temperature mechanical failure, stress corrosion cracking, and inter-granular corrosion. The exhaust gas emitted from automobiles is one cause of air pollution, and various efforts have been made to prevent this problem. One of the preventive measures is the system shown in the figure. The components downstream from the muffler of an exhaust system must have sufficient corrosion resistance to withstand the internal attack of condensed water containing these corrosive ions and external attack of these salts. The materials mainly used for these components are low-carbon ferritic stainless steel incorporating not less than 11% chromium. The components nearer to the engine in front of the muffler need high oxidation resistance, because they are heated to about 773K (500) during operation. The

exhaust manifold, which is heated to the highest temperature, must possess both high-temperature strength and resistance to thermal fatigue. High-chromium stainless steel is now used mainly for these upstream components. As a result, the life of the exhaust system has been substantially extended. Stabilized ferritic stainless steels represent the best cost / benefit solution for exhaust system components: it gives designers optimal combinations that work both in elevated temperatures and complex corrosive environments. The exhaust system components are manifold: close coupled and under-body catalytic converters, flexible bellow, muffler, resonator, connecting pipes, flanges, and tailpipe. The part of the exhaust system containing the manifold, converter and the flex joint is named as hot end since this part of the system is relativelyhot due to the hot exhaust gas passing through these components. The part consists of intermediate pipe, resonator and the muffler is named as cold end since the gas tends to cool down from the exit of the flex tube. The temperature of the hot end of the gasoline operated vehicle can be as high as 1050°C while the highest temperature of the cold end is about 650°C. There are benefits of Nb regarding oxidation resistance at high temperatures.

Stainless Steel and Carbon Steel plasma cutting systems:

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It has been demonstrated that Nb containing ferritic grades have better high temperature performance when compared to Ti single-stabilized or austenitic grades. This is because Nb forms a thin, homogeneous and adherent oxide layer in the surface of the steel, avoiding spalling and re-oxidation of the material during the exhaust system thermal cycling (the typical on/off operation of the car’s engine). It also results in lower loss of material which can be translated into higher life cycles of the component, meaning a longer life, reduced frequency of replacement and long term cost savings. Study on metal loss of different stainless steels at 950°C shows that with increase in Nb content, higher temperature oxidation resistance improves as Nb forms less porous and more adherent oxides which results in less spalling and less reoxidation. ADOR offers comprehensive solutions for Auto Exhaust Applications: Solid wire for GMAW welding: Miginox 430LNb • Superior wire of unique chemistry stabilized with Nb. • Minimizes the consumption of nozzles and avoids the excess of projections during welding. • Best welding performance with shielding gases 98Ar+2O2 and 1-5CO2 mixed with Ar. GMAW & Metal-cored wires from ADOR for auto exhaust applications: Autoweld 400 • Ferritic Stainless Steel solid wire • High corrosion and heat resistance • Suitable for joining and cladding of typical 17% Cr steels

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INDUSTRY SPEAK

danger of burn-through. The above comes with an additional advantage of better root-gap bridging ability. The above point is best illustrated in the graph here.

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• Best suited for ferritic martensitic chrome steels

Miginox MC 409 : • Ti stabilized metal cored wire that gives minimal / no slag • Operates at higher current densities • High deposition rate gives very high productivity

Metal cored wire: Metal cored wires offer higher productivity in terms of higher welding current densities and hence higher welding speeds. It gives much higher range of welding parameters to weld without the

Both the solid and metal cored wires are supplied in layer-wound condition in plastic spools with 12.5 / 15 kg wire per spool. ADOR evolves continually to meet the emerging needs of the industry in its relentless pursuit of excellence.

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For more information, Website: www.adorwelding.com

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AMT SECTION

TECH TRENDS

AMT SECTION LEARN MORE ABOUT AMT’S CHENNAI TECHNOLOGY CENTRE AMT’s Chennai Tech Centre (CTC) is located in the MEPZ duty free zone just 7 km from the Chennai airport. It encompasses an area of 1,500 sq.m., including a 650 sq.m. technology demonstration area. Operational since May 2011, CTC has successfully served as a bridge between the Indian manufacturing sector and American advanced manufacturing technology. To learn more, please contact or visit CTC: AMT - Chennai Technology & Service Centre A 44 - Phase 1, MEPZ, SEZ Unit Tambaran, NH 45, Chennai - 600 045 Tamilnadu, India Phone: (+91) 44-22622690-92 Fax: (+91) 44-22622693 Arun Mahajan General Manager AMahajan@amtonline.org Cell Phone: (+91) 9790887032

WWW.AMTINDIA.ORG

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LOW HORSE POWER? No problem. The APX™ Drill delivers the strength and versatility needed for any deep hole drilling application. Achieve higher spindle speeds by taking advantage of the power curves on modern CNC machines.

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SPECIALS


AMT SECTION

TECH TRENDS

High-Performance 3 Axis CNC Programming with ESPRIT

E

SPRIT offers a powerful suite of 3-axis machining cycles for roughing, prefinishing, finishing, and remachining of complex freeform parts. ESPRIT SolidMill FreeForm™ is extensively used by customers in mold and die, tool making, discrete parts, and model-making markets. With ESPRIT’s Modeless Programming™, the FreeForm cycles may be used on any configuration of mill, lathe, mill-turn, and Swiss-style machine. These 3-axis cycles may also be combined within any other ESPRIT cycle to create one complete part program for the entire part. Dynamic Stock-Aware Toolpath ESPRIT’s FreeForm milling cycles are dynamically optimized based on the real-time state of the stock, cutting tool, tool holder, workpiece setup, and machine tool, resulting in minimizing repositioning, eliminating air cutting, and providing collision-free machining. This allows for programs with shorter cycle times that are safe to run on the machine. Simulation and Verification See exactly what will happen at the machine before a single chip is ever cut. View the entire machining environment, including stock materials, fixtures, and clamps in dynamic, solid-shaded graphics. All the kinematic action of the machine

is displayed in real time, providing an incredibly accurate verification of the entire machining process. Using ESPRIT’s built-in part inspection, the original “as-designed” part can be compared to the “as-machined” workpiece to ensure part accuracy. Adaptive High-Speed Machining High-speed machining (HSM) functionality is built into all of ESPRIT’s FreeForm machining cycles for shorter cycle times and longer tool life. The FreeForm cycles provide for the capacity to cut hardened materials in minimal time by utilizing the smooth, continuous movements so critical in 3D HSM.

High-Performance Roughing ESPRIT’s roughing cycles will machine workpieces down to a near net shape using the highest possible material removal rates, resulting in the shortest cycle times. ESPRIT’s patented ProfitMilling® allows for the removal of more material in less time by maintaining a consistent cutter load, consistent tool engagement angle, chip load, lateral cutter force, and machine acceleration throughout the machining process to achieve optimal results. Prefinishing Following roughing, ESPRIT has a variety of prefinishing cycles available to ensure the varying surfaces of

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the workpiece all have the exact required stock allowance. As a result, the finishing tool(s) have a constant volume of material to remove, which results in maximizing tool life and optimal surface finishes. Finishing With the idea of superior surface finish in mind, the ability to select from a wide range of ESPRIT finishing strategies guarantees that a suitable strategy will be found for any surface. Select from nine different finishing cycles to machine the workpiece — use one cycle for finishing the entire part or define containment boundaries to machine zones differently using the most appropriate cutting styles for each. Remachining Maximize part quality and minimize bench work by remachining areas where the nose radius of the finish cutter could not follow the surface. ESPRIT’s remachining cycles automatically calculate where material remains from larger cutters and creates toolpaths for a smaller cutter to finish just these areas. Remove material in tight places without the risk of tool breakage with strategies for vertical corners, horizontal corners, and pencil tracing. For more information, Website: www.espritcam.com

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AMT SECTION

TECH TRENDS

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AMT SECTION

TECH TRENDS

Make Better Parts Faster with Mastercam® 2020

M

astercam 2020 is now available for purchase. This software was developed to help you make better parts faster with more efficient CNC programming and process improvements for the digital age. This CAD/CAM software is developed to streamline your entire manufacturing process from job setup to job completion with enhancements based on feedback and requests from the world’s largest CAM community. Some of the new features and areas of improvement you will find in Mastercam 2020 include: • Enhanced Accelerated Finishing™

• Skip Drill Cycle Pecking

• Improved Dynamic Motion™

• And much more!

• Streamlined hole making

You can make better parts faster.

• Advanced Toolpath Display • Model-Based Definition • New Mill-Turn Component Library • Thread milling enhancements • Analyze associativity • Updated rotary axis positioning • Machine Configuration Workflow advances • More realistic simulation

Contact info@mastercamapac.com to

• Faster, easier chaining

learn how Mastercam 2020 can help improve your productivity.

• Associativity tracking

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TECH TRENDS

Enhancing Tube Mill Performance with IPOL Jogesh Sharma – Head Industrial Lubricants, GP Petroleums Ltd, IPOL

Challenges in Tube Mill How to stop rusting of the tube immediately after forming? How do we get the thin & glossy film as per end user requirements? How do I reduce the per tonnage consumption of rust preventive? How can we increase the life of coolant sump life? How do I get the best rust prevention for the finish tubes?

B

eing the largest supplier & having dealt with many Tube mill manufacturers we have developed enough Technical expertise to offer the perfect solution in Lubrication & protective products required in Tube mill application. Before going in the details let us first understand as what ERW pipe is & what the manufacturing process is. What is ERW Pipe & how it is manufactured? The steel pipe is produced from two basic forms of steel, the round billet & the slab. A billet gives seamless pipes. Slabs are re-heated & processed into Coils which are further used to

produce steel pipes by Fusion weld, electric resistance weld, double submerged arc weld. Here we will discuss about the significance of lubricants & rust preventives requirement in ERW

pipe manufacturing. The process of electric resistance welded (ERW) pipe begins as a coiled plate of steel with appropriate thickness & specific width to form pipe of required specification. The steel coil is passed through a series of rollers gradually giving cylindrical shape & the edges are welded together to form tube. For successful manufacturing of ERW pipe appropriate soluble cutting oil & rust preventives plays a major role, which is being elaborated below. Role of soluble cutting oil All tube mills have large emulsion oil tanks ranging from 10000 to 60000 Ltrs from which emulsion is supplied to various tube mills to facilitate the tube forming operation. Forming, welding & cutting operations are conducted while manufacturing of

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TECH TRENDS inability of the coolant to provide the temporary rusting are sometime maintaining the emulsion tank at very low concentration, salt built-up in the emulsion tank, accumulation of the tramp oil in emulsion tank. In order to avoid this soluble oil concentrated emulsion should be added in main tank at regular frequency & not in a long gap, also the constant check of the salt deposition of the emulsion is must.

preparation of tube surface for the rust preventive application. Some of the practices for removal of soluble oil before application of rust preventive is given below, 1. Immediately after production, tubes should kept on ramp to allow the draining of the emulsion. 2. While moving the tubes from the ramp compressed air can be applied from one end for removal of emulsion from the tube. 3. While transferring the tube bundles

the tube where very high temperature is generated and cooling becomes inevitable which calls for a stable cooling oil. Major requirement for the coolants are listed below, 1. To offer temporary rust prevention. 2. It should have good bio stability. 3. Coolant should have good tramp oil rejection capability. How can we increase the sump life of cutting coolant tank? • Maintenance of correct concentration of emulsion • Do not allow the pH to go down below the optimum level. • Regular monitoring of hardness & chloride of the emulsion indicates the inside of the emulsion condition for taking the appropriate action in time. Higher chloride presence in emulsion creates conducive environment for the formation of rust, therefore chloride level should be as low as possible. • It is also advised to keep a constant watch on microbiological growth & tramp oil mixing in the tank.

Why IPOL Aqua Cut 125 is the best coolant for the tube mill. This is formulated & developed at IPOL’s most advanced R&D centre near Mumbai where constant testing is carried out to improve the rust prevention characteristics & biostability. Specific ingredients are used in the product to fortify the quality of product & sustain the constant pH which eventually helps in maintaining the long sump life in Tube mill. IPOL Aqua Cut 125 is most widely used soluble cutting oil, covering most of the major tube Industries across the country. How do we get rid of the emulsion from the tubes before RP application? Once tubes are produced it is very essential that every effort should be made for removal of the emulsion from the tubes as it affects in

to RP tank, tilting of bundle in air can help in draining of the emulsion.

Rust preventives – The most critical product In case of precision tubes after the tube forming is completed immediately tubes are bundled & dipped in rust preventive tanks of capacity 10-15 KL. All tubes when produced have the coating of the emulsion oil on outside as well as inside the tube. When these tube bundles are dipped in rust preventive tanks, cutting oil emulsion gets mixed up with the rust preventives & if the emulsion remains with the rust preventives it can be a potential danger of rusting of the tubes. Therefore it is extremely important that the rust preventive used in tank should have good water dewatering quality and it should form thinnest possible film as end users prefer less

Some of the trigger points for the microbiological growth in the tube mill tanks which ultimately results

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TECH TRENDS oil content on the tube which support them for safe welding & removal of rust preventive films if any.

has also developed the superior quality high flash special rust preventive for the Tube Industry, this product offers lesser consumption & thin film

The performance requirements for rust preventives for tubes are listed as under, • Appropriate rust protection. • Fast de-watering quality • Thin & glossy film as required by end users of tubes • Ease of removal

which eventually offers good cost benefits.

Some of the good practices while using rust preventives in Tube mill. 1. For better protection, surface preparation of the tube is extremely important therefore religious separation of

Strong Technical Service back-up For successful operation of all the tube mills constant monitoring of the emulsion, water in used, rust preventives & other used lubricants is essential. IPOL have a strong back-up team with all the technical expertise to take care of all such aspects which offers solid support to Tube Mill manufacturers & assurance for taking care of issues associated with lubricants & rust preventives.

emulsion from the rust preventive

Why IPOL Rust preventive for Tube mill? IPOL special rust preventives for tube mill namely IPOL RP SB 103 BS, 103BS HF, DW50 are the results of many years R&D & exclusive working in order to meet the most arduous requirement of the tube mills. 1. During development, special thrust is given to see that the product must have the best dewatering properties which is the prime requirement for

tank is important. Good quantity of the rust preventive can be recovered from the emulsion drained from the tank as over a period good rp separates out from the emulsion which again can be added in the tank & effective consumption per tonnage of tube production can be reduced. 2. Dipping time is critical, sufficient dipping time has to be given for better film forming. 3. It is very important to allow adequate

the Tube mill rust preventives. Water

drying time in case of solvent based

displacement properties removes cor-

rust preventive, enough time should

rosive contaminants from the surface

be given for the draining of the rust

The writer is Head Industrial

ensuring the consistent film applica-

prevention.

Lubricants for IPOL Lubricants which

tion & rust preventive protection. We

4. The top up of the rust preventive in

is the most trusted brand in the Indian

are proud to state that in view of our

the tank should be done in regular

Industries & very well known for the

long research we could develop the

frequency as evaporation of solvent

high performance Metal working

rust preventive which is having the

leaving behind the additives concen-

fluids operating since last more than

best water separation quality among

trate. This will results in increase in

40 years in India & export to several

all the rust preventive manufacturers

film thickness, decrease in coverage &

countries. GP Petroleums is an ISO

in the country.

which in turn reduces the dewatering

9001:2008 & EMS 14001:2004 company

capability of the rust preventives.

having well equipped manufacturing

2. Product is formulated with advanced chemistry which is globally proven for over 50 years giving the best humidity cabinet & salt spray results which ultimately offers the best rust prevention to tubes. 3. Product is designed seeing the major requirement of thin film as this gives convenience to end users & also reduces the consumption per tonnage which eventually in addition to improvement offers the cost benefit. 4. Further since these tank are open & prone for excessive evaporation IPOL

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Lastly in tube mill if appropriate soluble oil & rust preventive is used then quality product with the cost benefits is assured.

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facilities, quality control lab with the

Apart from Soluble cutting oils & rust preventives tube mill requires various other lubricants & greases like hydraulic oils, Industrial gear box oils, greases for the bearing of the tube mill. These are all standard products & should be used as per the technical specifications specified by equipment manufacturers. IPOL have all these products & same are performing very well in various tube mills across country.

advanced R&D centre with the state of art equipment, automated filling & packaging station. IPOL is a part of GP Global, a global organisation, having various strategic business units namely oil refining, bunkering, lube & grease manufacturing, Oil terminals, Bitumen manufacturing, shipping & logistics with the total group turnover of over 5 billion dollars.

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TECH TRENDS

Making Tracks: New Cutting Tools for the Railway Sector including crossover, switch diamond, and three-way switch.

T

he railway industry is one of the main consumers of cutting tools and ISCAR is increasing its role as a supplier of complex projects for this key sector that incorporate essential elements to fulfil the need for layout solutions, efficient productivity, and a reduction in machining time and costs – all demanding a large variety of both standard and tailor-made solutions. Machining railway parts represents a challenge for manufacturers and cutting tool producers alike, who must contend with a host of constraints - such as the relatively large size workpieces, complex structures, and complicated final machined profile - along with the need to remove a large volume of material, ensure predictable tool life, and avoid high maintenance costs. When selecting the correct tools and inserts for each job, certain parameters need to be taken into

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consideration, for example the type of material to be machined, the condition of the part, the available machine tool, its condition and power characteristics, clamping fixtures etc. A central factor in optimal tool development is the creation of a virtual manufacturing environment that simulates machining processes and cutting conditions, to ensure that the tools produced will overcome material and manufacturing limitations and that they will provide the best solutions to the specific needs of railway parts producers. As an example of this dynamic, it is useful to consider how new tools and processes are adapted to machine bogie components and switchers. The bogie frame is utilized in each of the three main categories in the railway sector: urban transit rail, passenger rail, and freight rail. The switcher is one of the most common parts produced, with typical switchers

Rotating tools Many operations for railway part machining involve rotating tools, especially for milling and drilling functions. In milling, due to the high volume of removed material, conical and profile indexable extended flute cutters are used. The cutters with tangentially clamped inserts feature better possibilities for improving tool strength and ensuring higher tooth density that result in increased productivity. In many cases milling the railway parts requires long-reach tools with different overhang. Modular shell mill design configuration offers a flexible and economical alternative to large-size extended flute cutters with integral body (integral-type design). T490 – A modular solution Extended flute shell mills The combinations of the base units and extensions ensure a variety of extended flute shell mills with different cutting lengths. The modular extended flute assembly possesses another advantage in improving operations. As the first-row inserts in extended flute cutters, which are located near a cutter face, are

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TECH TRENDS involved not only in side milling but also in face milling, they experience harder loading and their wear is more intense compared with the other inserts of the cutter. In integral-type cutters, a sudden breakage of a firstrow insert can cause serious damage of the cutter and even render it inoperable. In the modular assembly, each damaged insert can be replaced individually, which enables efficient operation and extended tool life. All the new cutters are designed with coolant through to extend tool life and improve chip evacuation in problematic areas such as slotting and deep shouldering. This is especially valuable for tangential clamping as the special profile extended flute cutters ensure a reduction in machining time. In some cases, the profile in the switcher can be machined in one single pass and in other cases it is necessary to divide the machining into several passes to produce the right profile and diameter with the correct dimensions. Face milling The newly introduced T890 line represents a range of face mill cutters for rough and semi finish machining that carry tangentially clamped inserts with 8 cutting edges, intended for facing and shouldering operations in the switchers and bogie frames. The inserts feature different cutting geometry, designed

for machining various engineering materials. FFQ4 for high feed machining A new family of high feed mills that carry square single-sided inserts with 4 cutting edges, the FFQ4, is designed to reduce cutting forces when used on low power machines or long overhang applications. The cutters are available in different design configurations: shell mill in 40 up to 100 mm diameters, and end mills and replaceable milling heads in smaller diameters. The cutters are intended for roughing operations, such as machining plane surfaces, cavities and pockets, including ramping by line and helix. Drilling

Old traditional bridge-type machines sometimes require high overhang and the drills often need to operate in conditions of reduced rigidity. The new SUMOCHAM drills with exchangeable drill heads, cylindrical shank and internal coolant holes enable high feed drilling, high accuracy and good surface finish. Exchangeable ICP-

type drill heads are recommended for carbon and alloy steel (ISO P material group), commonly used in producing railway components, and have already received good marks in drilling operations in producing bogie frames. Combined drills enable users to perform drilling and chamfering operations with the use of the same tool. Manufactured in different diameters, cutting depths and overhangs, the design of the drills facilitates an increase in cutting range conditions and a reduction both in cycle time, as well as in the number of drills involved in the process. The railway industry is a large consumer of special (tailor-made) drills. In many cases applying special drills ensures minimizing tool overhang, increasing durability of a drill body and utilizing a single tool for several operations. ISCAR proposes a variety of special drill solutions for this sector, in particular for connections between the rails and the switchers, which result in significant reductions in machining costs. The railway sector’s distinctive characteristics and demands impact on cutting tool development in many ways. ISCAR has responded accordingly by designing innovative, productive and reliable solutions intended for heavy-duty applications, that have already been adopted with enthusiasm by manufacturers to improve their processes. For more information, Website: www.iscar.in

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Shavo Technologies Pvt. Ltd. 29/2 Kharadi, Off Pune Nagar Road, Old Kharadi Mundhwa Road, Pune: 411 014 Tel. No.: +(91) (0) 7030938211, 7410004817, Fax No.: +(91) (080) 28395963 Email: shavogroup@vsnl.com | Website : www.shavogroup.com


TECH TRENDS

Miniature infrared camera performs thermo imaging in VGA resolution

The world’s smallest VGA infrared camera, the thermoIMAGER TIM 640 from Micro-Epsilon, performs radiometric video recording at a resolu-tion of 640x480 pixels, detecting even the smallest of thermal defects reliably.

T

emperature measurement is used frequently in industrial environments. Wherever temperature is a critical process variable, it is good practice to ap-ply IR sensors, whether they are used for defect detection of injection mould-ed plastic components, for monitoring components in the electronics industry, for temperature measurements in the food industry or even for the hot rolling of metal sheets. Non-contact temperature sensors are ideal due to their fast mode of operation and because they exert no influence on the measurement object. IR sensors and cameras for process automation enable continuous monitoring of temperature. Intelligent, digital systems allow the customer to remotely programme the sensors, as well as online transmission and record-ing of measured data. Thermal imaging cameras detect and measure the temperature on a surface.

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Micro-Epsilon offers its new miniature high-resolution infrared camera, the thermoIMAGER TIM 640. Due to its high geometrical resolution and its high thermal sensitivity, the infrared camera is ideal for precision measurement tasks. The camera is connected via a USB interface, which also supplies the power. The thermoIMAGER TIM 640 infrared camera is the smallest VGAresolution thermal imaging camera in the world, providing pin-sharp thermal images in real time due to its

optical resolution of 640 x 480 pixels. With di-mensions of 46x56x90mm and weighing just 320g (incl. optics), the ther-moIMAGER TIM 640 is one of the most compact thermal imaging cameras available on the market. The new camera covers the spectral range from 7.5 to 13 µm. A process interface with analogue and digital I/O simplifies process integration. The scope of supply includes the TIM Connect evaluation soft-ware. The temperature range is from -20°C to +900°C, and a thermal sensi-tivity of 75 mK.

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TECH TRENDS Measuring principle Infrared radiation is emitted from all bodies whose temperatures are above absolute zero. The infrared sensor captures the emitted radiation and deflects this onto one or more detectors. The energy of the infrared radiation is con-verted into electrical signals in the detector, which are then converted into temperature values based on the calibration of the sensor and the specified emissivity. Based on this evaluation, the measured temperature can be shown on a display, output as an analogue signal or displayed on a PC via a digital output. Therefore, fast and reliable temperature measurements of moving, very hot or difficult-to-access objects are possible. While a conventional temperature sensor or probe can influence the temperature of the measurement object and the product itself can under certain circumstances become damaged or soiled, the noncontact method always ensures precise measurements. Features The thermoIMAGER TIM 640 thermal imaging camera offers a variety of features. Using automatic hot spot detection, objects can be examined ther-mally and hot or cold locations (hot or cold spots) can be found automatically. An industrial process interface with 3 input/outputs and an integrated watch-dog feature simplify process integration. This watchdog protects the meas-urement process from interference by using intelligent self-monitoring. The thermoIMAGER TIM 640 is protected to IP67, which makes it particularly suitable for process monitoring in automation systems and in harsh ambient operating conditions. The TIM Connect evaluation software offers numerous possibilities for automatic process and quality control, e.g. individual setting of process-dependent

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alarm thresholds, line scan features for monitoring of processes with moving objects, definition of visual or acoustic alarms, and analogue data output. Temperature distributions of surfaces can be captured accurately at millisecond intervals. Applications Outstanding features such as high resolution, compactness, and userfriendly, simplified integration make the thermoIMAGER TIM 640 VGA infra-red camera suitable for applications in quality control, process monitoring and for analysing electronic microcomponents in almost every industrial sector. Industry-specific software enables the monitoring of very small components during production (inline thermography), especially in plastics injection mould-ing processes. In this kind of quality control, thermography complements the human eye – it detects and visualises the infrared radiation emanating from the measurement object. In injection moulding, temperature distribution pro-vides a global quality statement about incorrect temperature control of work-pieces: tool malfunction, visible geometry errors and hidden defects, such as material

defects, can all be detected. For every field of application, the re-spectively suitable model is always available as Micro-Epsilon offers different performance classes. In particular, using the new thermoIMAGER TIM 640 enables the identification of the smallest of defects in the mm² range. Micro-Epsilon offers a thermography-based system as a turnkey solution (software and hardware) for inline quality control of injection moulding machines. The camera uses the thermal radiation from the workpiece to detect visual faults, as well as hidden material defects. The operating software visualises the workpiece and compares it to an infrared reference image. The system ena-bles the control and automatic sorting of defective parts. The system also en-sures fast, secure machine changeovers, as any newly produced parts are assessed immediately after changing the mould tools. This continuous quality control is particularly valuable to automotive suppliers, for whom the value of injection-moulded parts increases by several hundred per cent during this process. For more information, Website: www.micro-epsilon.in

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TECH TRENDS

Belt, rack and pinion or screw drives: Three options for different applications INTRODUCTION Linear actuators are mainly moved with belt, rack and pinion, or screw drives. Each of these systems has features that make them suitable for specific applications. Rollon, the international Group with a direct branch in Bangalore, has a broad and extremely varied range of axis solutions, which include different models of actuators for each of the drives mentioned above. Let’s look more closely at three different cases, and together, we will define the different needs and assess the correct choices for each application. The correct actuator defined by the peculiarities of the application allows us to maximize results and reduce costs.

CASE 1 - High Performance Packaging Systems Productivity, performance and safety: in the packaging sector, speed is fundamental and reducing cycle times translates directly into an economic advantage, while component reliability translates into reduced maintenance costs and increased productivity. To obtain high performance and production rates on discreetly long strokes, choosing one of the belt solutions would be spot on. Belt solutions allow high speed accelerations on distances as long as 10-12 m strokes. At the same time, load capacities are high: an X-Y-Z portal built with a belt drive solution can manage loads in the range of 150/200 kg. The absence of lubrication on the belt, unlike

the other two solutions, involves less maintenance and avoids costly “machine downtime”. The choice of a different type of actuator would not guarantee the same results: for example, a screw system would be too slow and would not be able to handle such long strokes. For packaging applications, Rollon has created the Plus System, a high performance product family of extremely robust linear actuators in extruded aluminum with a high level of protection of sliding and drive systems; and the Smart System linear actuator product family, which features simplified construction that successfully combines performance and competitiveness. Both product families are driven with toothed belt systems, they use linear rails with recirculating balls, and they reach accelerations of up to 50 m/s2 and maximum sliding speeds of 5 m/s. Both of these product families also offer dedicated solutions for vertical applications on the Z axis. CASE 2 - Pick & Place systems with long strokes Our second case involves large portals for pick and place systems, such as

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Linear solutions global provider.

Linear Line

Actuator Line

Telescopic Line

Actuator System Line

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

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


TECH TRENDS those that move metal sheets for the appliance industry or various types of production lines. Load capacities are crucial aspects of these systems, along with the rigidity of the system and the possibility of moving several vertical axes independently along Y axes and strokes possibly longer than 30 m. A belt solution would be limited in this case. Since belts are made of polyurethane, when we assess applications, we must consider elastic deformation rates with the resulting loss of rigidity in the system, and the reduction in precision as the stroke becomes longer. A belt system also usually has a single motor that uses a motor head to drive the belt and move the different carriages and their respective vertical axes in perfect synchronization. A Y axis moved with a rack and pinion drive would, instead, maintain its rigidity along potentially infinite strokes and offer the option of moving each carriage independently. For these reasons, a rack and pinion drive would be the best choice for these large portals, especially on the Y axis. The series of actuators in the Tecline family by Rollon mounts induction hardened steel racks with inclined teeth, and rails with recirculating ball bearings or prismatic rails with bearings depending on the application. They also have extruded aluminum profiles with different sized sections, up to 360 mm. Able to handle loads up to 1000 kg, these systems can easily be

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configured with actuators from the Modline family (these are belt driven) to create portals. CASE 3 - Assembly systems for semi-conductors Precision is undoubtedly the main feature for a system used to assemble small parts, such as in the semiconductor industry. Precision is necessary in terms of positioning and repeatability, to allow the assembly system to be efficient and produce high quality over time. Moreover, when speaking of precision in the semi-conductor industry, the level must be extreme (two-place decimal tolerance). The ideal choice for this solution would be the an axis with a screw drive unit. The Precision System product family by Rollon includes several models of linear tables for translating with great precision. These systems are built with anodized extruded aluminum profiles and rails with recirculating ball bearings, and they are driven with screw units with recirculating ball bearings, which can achieve a level of precision of 10 µ with regard to positioning and ±5 µ with regard to repeatability.

All mounting and reference surfaces of higher performance models are finished. Needless to say, this level of precision is impossible to reach with any belt or rack and pinion drive system.

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

Threading with maximum productivity & process reliability Walter AG is releasing the new TC620 Supreme thread milling cutter in diameters up to M20

Walter TC620 Supreme thread milling cutter

H

igh cutting pressure and tool deflection are the greatest challenges when it comes to thread milling. This results in restricted cutting parameters, necessary cutting passes and short tool lives or even tool breakage. With the TC620 Supreme universal thread milling cutter, tool wear is drastically reduced thanks to minimal cutting forces and the resulting high feeds per tooth. The multi-row concept not only reduces the machining time and wear, but also improves process reliability and handling – even when used with more demanding materials such as stainless steels

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or Inconel 718. Reliable chip evacuation, thanks to internal coolant, and simple handling of the TC620 Supreme guarantee maximum process reliability. Radius corrections are seldom necessary, and when they are required, it is often only once competitor tools have already reached the end of their tool life. Walter is launching the TC620 Supreme for thread depths of 2 and 2.5 × DN in the dimension range from M4 to M20 as well as UNC 8 to UNC ¾.

For more information, Website: www.walter-tools.com

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TECH TRENDS

The Process of Phosphating Some FAQs by Gala Precision Technical Team Q. What Is the phosphating Process? Phosphating is the process of converting a steel surface to iron phosphate. This is mostly used as a pretreatment method in conjunction with another method of corrosion protection. A layer of phosphate coating typically includes iron, zinc or manganese crystals. Phosphating is a chemical process for treating the surface of steel, where barely soluble metalphosphate layers are formed on the base material. The layers created are porous, absorbent and suitable as a conversion layer for subsequent powder coating without further treatment. Q. Why is phosphating done? The process of Phosphate coating is employed for the purpose of pretreatment prior to coating or painting, increasing corrosion protection and improving friction properties of sliding components. Metal coating offers both zinc

Gala’s Phosphating Plant

phosphate and manganese phosphate coating. Manganese phosphate coating is applied when wear resistance and anti-galling properties are required. Manganese phosphate also possesses the ability to retain oil, which further improves anti-friction properties and imparts corrosion resistance to the coated parts. Zinc and manganese coatings are used to help break in components subject to wear and help prevent galling. Most phosphate coatings serve as a surface preparation for further coating and/or painting, a function it performs effectively with excellent adhesion and electric isolation. Q. Why is phosphating done before powder coating? The process of phosphating aluminum and steel parts is typically

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listed as a conversion coating because the process involves metal removal as part of the reaction. However, it is not like anodizing or black oxide in that the phosphate coating is actually a precipitation reaction. Q. How many types of phosphating are there? 3 Types of Phosphating. Phosphating is a conversion coating applied to Steel and Iron components. In its basic form, the process involves immersing a component in a dilute solution, which converts the surface of the metal into a layer of microscopic Phosphate Crystals. Q. How does phosphate prevent corrosion? Corrosion resistance and resistance to detergents are also higher when compared to Zinc Phosphate.

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TECH TRENDS

Appearance is gray. Manganese Phosphate: Used primarily on friction and bearing surfaces to prevent metal-to-metal contact and reduce wear. This coating is also used as a base for dry film lubricants. The following is a typical phosphating procedure: Cleaning the surface, Rinsing, Surface activation, Phosphating, Rinsing, Neutralizing rinse (optional), and Drying. Q. What are the main applications of phosphating? The main applications of phosphating are: • Corrosion protection in conjunction with organic coatings, such as paints and polymer films • Facilitation of cold-forming processes, such as wire drawing and tube drawing, or deep drawing • Corrosion protection in conjunction with oils and waxes • Corrosion protection with no subsequent treatment • Improving anti-friction properties, such as break-in, wear resistance, anti-galling and coefficient of friction • Providing strong adhesion bonding for subsequent painting or other organic coating Q. What are the highlights and salient features of Gala’s Phosphating Plants? The phosphating process comprises

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alkaline degreasing, water rinsing, activation, manganese phosphate application, water rinsing again, protective oiling and then drying in that sequence. Gala’s multi-stage phosphating plants are compatible for use with all modern phosphate formulations with multiple process stages to include degreasing / phosphating and multiple rinse cycles. Ideal for batch processing, these units are operatorfriendly with easy-to-use control systems to set independent fluid tank temperatures and cycle times. The component basket is rolled from the wash machine on to an external fixed or mobile platform for easy loading and unloading of the components. Corrosion resistant electric immersion heaters and stainless steel wash pump are fitted as standard accessories. Sturdy construction with thick thermal insulation, heavy duty stainless steel component basket, component holding jigs, fully independent fluid tanks, low fluid level protection, integral fluid filtration network,

electric heating, load / unload station, auto fresh water refill in rinse tanks and digital display fluid temperature control are some of the prominent features of this totally PLC controlled system. Gala also offers the following optional extras with the system: Hot wash, rinse, air knife & dry cycles to suit the application; Disc type oil skimmer; Fine inline fluid particle filtration; Oil / water separator units; Effluent transfer pump; Steam extraction fan & condenser units; Auto dosing units and DI water plant. Gala Precision Engineering is a leader in disc springs, assemblies and surface engineering solutions in India. The company designs and manufactures integrated systems for mass finishing, washing & cleaning for a wide range of applications in automotive, defense and general engineering segments.

For more information, Website: www.galagroup.com

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TECH TRENDS

Ceramic coatings for refurbishing

machine tool parts M achine Tool Industry has undergone major developments in providing enhanced service life to spindles, arbors, bearings, etc. Ceramic Coatings by Plasma Spray have been in use in many industries since 1960. Since last decade, this process and ceramic coatings are being used to provide surfaces to seal areas of spindles, contact faces of arbors and electrical and heat insulation to bearings. Apart from OEM level coatings, many user industries are using ceramic coating for refurbishing of spindles and other machine tool parts. Typical Spray Materials used with Plasma Spray Metals and its alloys: Steels, Ni alloys, Co alloys, Moy, bronze, copper, Babbit, etc. Ceramics: Chromium Oxide, Aluminium Oxide, Al Oxide + TiO2, ZrO2, etc. Carbides: Tungsten carbide, Cromium carbide, TiC Hardness range of coatings: From

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SOFT 60Rb (Bronze) to HARD 70 Rc (ungsten carbide)

Benefits of Plasma Sprayed Ceramic over Hard Chrome Environmental: Less hazardous as there is no Hexavalent chrome involved dust disposal; easier than bath liquid.

Performance: 3-4 Times more wear resistant than Hard-chrome; Micro porosity holds lubrication; Selective area coating is possible; Higher thickness up to 300 microns per side is possible. Limitations: Ceramics are brittle and are to be handled carefully. The process is not as widely available as hard-chrome. Spraymet Surface Technologies Bangalore-based Spraymet Surface Technologies Pvt. Ltd., headed by Mr. P.T. Bindagi, Technical Director and a veteran metallurgist, is engaged in thermal spray, ENP plating and weld surfacing. While their main plant is in Bangalore, the second plant is located in Pune, to stay

closer to its customers especially from the automobile sector which is demanding technical excellence, proximity and service all at the same time. Spraymet has the distinction of having pioneered the carbide coatings in the steel mills and galvanizing line roll coating. Spraymet owns a few proprietary coatings like Moly bend (Spraymet MoB) for metal-to-metal wear, and Ductile matrix carbide (Spraymet DMC) for plastic process feed screws. Mr. Bindagi is working towards expanding applications in turbine industry, medical implants, and other frontiers. In his quest to spread knowledge, Mr. Bindagi also picks students from universities for project work related to tribology and wear metallurgy. Spraymet has helped the industry save a lot of money and helped conserve its scarce resources.

– P.K. Balasubbramaniian

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TECH TRENDS

The evolution of milling tool, hard & PM steel up to 67 HRC-PEACOCKZecha, India The tried-and-tested PEACOCK mill cutters from ZECHA Precision Tools Limited are the go-to tools for achieving fine contours in the hsc processing of highly alloyed and hardened steel up to 67 HRS. They effortlessly ensure precision, stability and smooth surfaces in different areas of application, particularly in mould making. A new family member, the 599 series, offers additional support for the mill cutters 581P, 583P and 597P.

Series 599 as ball and torus mill cutter with 2 or 4 flutes

PEACOCK welcomes a new member to the family. The new mill cutter series offers ideal machining preconditions for a vast number of materials, material hardness values and alloying components such as, for example, powder metallurgical steels, tungsten copper, nickel-chromium alloys and cobalt chromium. Its special tool properties make the new family member eminently suitable both for finishing as well as roughing and its flexible and versatile properties can find efficient application in mould and tool making, the automotive and aerospace industries, light

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engineering as well as in medical technology. The PEACOCK expansion contains ball and torus mill cutters with two or four flutes that will be gradually taking over the hard machining role from the well-established 581H and 583H lines in Zecha’s comprehensive tool range. The two-flute ball cutters are available in diameters 0.2 mm - 6.0 mm, whereas the four-flute variants in the 599 series come in selected dimensions with a diameter ranging from 3.0 mm to 6.0 mm. The torus mill cutters are available with two flutes in diameters 0.2 mm - 0.8 mm.

If the machine operator wants to turn to a four-flute torus mill cutter, he can choose between diameters from 1.0 mm to 6.0 mm. Irrespective of whether two or four flutes, torus or ball cutter - all boast precise cutting performance down to the core. Robust tool despite high stress The adaptation of the microgeometry combined with a new geometric design created by the internal development department produces optimum results. The special groove geometry of the mill cutters reduces forces and friction. Thanks to the shaft,

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TECH TRENDS

geometry - no sharp edges and corners - greater stability and milling depths are possible. The stresses occasioned by high temperatures during robust machining can be avoided almost completely due to the easy cutting construction and the high-end coating technology. The chips are quickly removed with the aid of the smoothly polished chipping spaces and the process temperature can be very well controlled. The 599 series mill cutters can also be used for machining of high wear-resistant super alloys containing chromium by means of KSS emulsions, as they are both suitable for dry and wet processing. They also achieve

very good results regarding surface quality. High performance cutters brave high loading Mangesh Awate, Sales Manager at Zecha India: “In order to be capable of reliably mastering the hard processing of materials up to HRC 67 it is necessary to run the tools at high feed and cutting speeds. The HSC cutters save a great deal of machining time and produce superb surface qualities. Nevertheless, this very efficient strategy has a downside the extreme temperatures that make the whole operation more difficult! This is because the heat normally generated during demanding hard

machining translates into a lot of stress for the tools.� The robust PEACOCK cutters avoid this stress by heat, virtually in its entirety, because the easycutting design and the smooth WAD coating result in hardly any high temperatures being generated during machining. Smoothly polished chip spaces swiftly remove chips from the tool so that the process temperature can be easily verified. The strong shaft and cutting geometry greatly prolongs service life. Conclusion: PEACOCK is an all-round talent! As with the entire PEACOCK family, the micro-geometry of the mill cutters ensures high precision during hard machining. Apart from significant life cycle increases due to the stable shaft and cutting geometry, the WAD-coated mill cutters achieve excellent surface qualities. In addition, the micro mill cutters, configured for shape and concentricity accuracies of 0.005 resp. 0.003 mm, guarantee a high dimensional precision of the component. Not to be forgotten are the highly detailed recording of all work processes as well as the identification number at the end of the shaft of the mill cutters that enable exact reproducibility. For more details please contact ZECHA Precision Tools Limited Mr. Mangesh Awate

The four-fluted high performance milling cutters in the 597P series are especially suitable for the HSC machining of highly alloyed and hardened steel up to 67 HRC.

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DGM- Business Development Email: mangesh.awate@zecha.in WEB: www.zecha.in

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TECH TRENDS

PMI : Rotary Ball Spline therefore having higher positioning accuracy.

Design Principle The ball spline has load groove of three row on the outside diameter of shaft. Due to the gothic arch groove design, it could be make sure three grooves withstand clockwise or counterclockwise of torque, and then increase the service life and rigidity. The spline nut has a special designed support bearing directly set up on the outer ring of the nuts. The spline is capable of performing two modes of motions (rotational and linear) with a single shaft by rotating or stopping the spline nut. The rows of balls are held in a special resin retainer incorporated in the spline nut so that they smoothly roll and circulate. The balls recirculation in ball holder, prevent balls falling from the spline nut while assembling. Features • High Positioning Accuracy The ball spline groove profi¬le is designed gothic arch. By applied preload, the backlash in the rotational direction is eliminated

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• Compact Design Spline nut and the support bearing is integration structure. The spline nut is designed lightweight. Therefore, the highly accurate and compact design is achieved. • Easy Installation The spline nut and the support bearing are integrated, thus the rotary ball spline can easily be mounted simply by securing it to the housing with bolts.

• Support Bearing The support bearing of the Ball Spline has a contact angle of 45°, thus it has the average force of axial and radial direction. Application Robots, Transporting equipment, Wire winder, ACT(Auto Tools Change)…etc.

For more information Website: www.superslides.in

Specification of STRA Series

Accuracy grade of maximum manufacturing Length

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CASE STUDY

Improving speed & reducing cost with Renishaw additive manufacturing

After investing in a Renishaw AM 400 additive manufacturing (AM) systems, Frazer-Nash has produced a novel fastener for its customer, Kwikbolt, for use during aircraft assembly

A

fter investing in a Renishaw AM 400 additive manufacturing (AM) systems, Frazer-Nash has produced a novel fastener for its customer, Kwikbolt, for use during aircraft assembly. The new component can be made quicker and at a lower cost whencompared to traditional subtractive machining methods. In 2014, Frazer-Nash decided to bring AM capabilities in-house with Renishaw’sAM250 system. Having worked closely with Renishaw since then, they have now purchased the AM400, whichiscurrently used to produce metal parts for customers. One of Frazer-Nash’s most successful projects is for its customer

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Taming power quality is now child's play

When you use DigiVolt Stabilizers, Tranquil Ultra Isolation Transformers and Powercon Power Conditioners from Unity Controls, power quality is under total control and would no more hamper your production and product quality. These silent sentinels protect your sophisticated, high precision production equipment from the ill-effects of voltage, spikes, surges, transients, sags, noise and harmonics affecting AC power lines. Thus ensuring continuous uptime and enhanced productivity and consistent quality.

Intelligent Microprocessor-based, High Efficiency, Energy Savers specially designed for CNC machines

Our equipment are approved by major OEMs and exported (up to 2000 KVA) to countries in Europe, Middle East, Africa

Our Allied Products: n

Active Harmonic Filters K-Rated Transformers Light Energy Management Systems

n

KVAR MAX - Real Time Power Factor System

n n

and Asia Pacific. So leave power quality and energy management to the experts – Unity Controls. With our nationwide network we are only a phone call away!

Contact us for Power Quality & Harmonic Audits to Conserve Energy and Save Costs.

The power quality & energy experts

D-137, TTC MIDC Industrial Area, Nerul, 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E),400 Mumbai 400 077, India Navi Mumbai 706, INDIA +91-22-2501 3832 +91-22-2761 1872/ 33 / 4612 sales@unitycontrols.in www.unitycontrols.in

Ahmedabad l Bangalore l Chennai l Delhi l Gurgaon l Hardwar Indore l Jalandhar l Jamshedpur l Kolkata l Kanpur l Mumbai l Pune l Rajkot

l l

vijayshreyaarts@gmail.com

UNITY CONTROLS PVT. LTD


CASE STUDY Kwikbolt, who are working to revolutionise the assembly of aircraft. Kwikboltis one of only a few businesses in the world to produce a specific temporary fastening device, which is used to align aircraft panels and fuselage during assembly. The component simplifies the manufacturing process and ensures that aerospace companies no longer require a bespoke tool for every panel, helping to reduce costs, improve precision and speed up assembly. To simplify the fastener’s manufacturing process, Frazer-Nash now additively manufactures the fasteners on Renishaw’s AM400. By using AM instead of subtractive machining, the fasteners can be produced with custom geometries at comparatively lower cost. “By using AM, Frazer-Nash is able to produce components cost-effectively in small batch sizes,” explained Stuart Offer, AM Sales Manager at Renishaw. “In contrast to machining, no custom tooling is required, which results in improvements in speed and a reduction in manufacturing

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costs, particularly for such a difficulttomachine part.” “The Kwikbolt project is a true AM success story,” explained Paul Mortlock, Managing Director at Frazer-Nash. “Using AM means we can easily produce a bespoke component based on each aerospace customer’s requirements. Renishaw’s AM systems have been flawless since we started working together. FrazerNash now produces 25,000 AM parts a year and has expanded its range of components.” “Over the last five years, we have

developed a close partnership with Renishaw,” added Mortlock. “We originally chose to partner with Renishaw due to its support services and we have found these to be invaluable.”

For more information Website: www.renishaw.com

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HIGH QUALITY FOR YOUR HIGH QUALITY FOR YOUR MACHINERY MACHINERY

MGM brake motor main features • TEFC 3-ph asynchronous brake motor (0.09kW-130kW)

MGM motor main orfeatures • ACbrake 3-ph brake (no rectifier) DC brake on request

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

VARVEL production lines • RS-RT worm gearboxes: 28 to 150 mm centres.

VARVEL production lines and double worm. One stage worm, helical/worm

• RS-RT mmNm. centres. • RD worm helicalgearboxes: gearboxes:2850toto150 2300 Two and three stages. One stage worm, and double • RN parallel shafthelical/worm gearboxes: 180 to 3300 Nm.worm. Two and three stages. • RD helical gearboxes: to 2300 Nm. andNm. three stages. • RO-RV bevel/helical50 gearboxes: 180 Two to 3300 Three stages. • RN shaft gearboxes: to 3300 Nm. and three • parallel RG precision planetary180 gearboxes: 10Two to 230 Nm. stages. • RO-RV gearboxes: 180 to 3300 Nm. Three stages. Onebevel/helical and two stages. • RG precision planetary 10 to 230 Nm. • VR dry friction speedgearboxes: variators: IEC63 to IEC90 One1and stages. to 5two stepless speed range, 300 to 1500 rpm. • VR• dry friction speed variators: IEC63 to to IEC90 VS planetary speed variators: IEC71 IEC112 1 to15tostepless speed range, 300200 to 1500 rpm.rpm. 5 stepless speed range, to 1000 • VS planetary speed variators: IEC71 to IEC112 1 to 5 stepless speed range, 200 to 1000 rpm.

agency.com

agency.com

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

MGM-VARVEL Power Transmission Pvt Ltd Ware House No.No. G3 G3 and and G4 •G4 Ground Floor •Floor Indus •Valley’s • Unit 3Park • Mel Ayanambakkam • Vellala Street •Chennai - 600 095 Ware House •Transmission Ground Indus Valley'sPark Logistic • Unit 3 • Mel Ayanambakkam • Vellala Street MGM-VARVEL Power Pvt Logistic Ltd • Tamil Nadu, Phone: +91 INDIA 44 26533665 / 9629691777 • info@mgmvarvelindia.com • www.mgmvarvelindia.com Chennai - 600INDIA 095 ••Tamil Nadu, • Phone: +91 44 64627008 • info@mgmvarvelindia.com • www.mgmvarvelindia.com Ware House No. G3 and G4 • Ground Floor • Indus Valley's Logistic Park • Unit 3 • Mel Ayanambakkam • Vellala Street th REGIONAL KOHLI TOWERS • 4+91 Floor, Dapodi •• info@mgmvarvelindia.com Near Bharat Petrol Pump ••Pune - 411012 Chennai - 600 095OFFICE: • Tamil Nadu, INDIA • Phone: 44 64627008 www.mgmvarvelindia.com th


CASE STUDY

Bottledwater Company Implements Large-Format Irwindows

O

ne of North America’s leading bottled water companies - dedicated to both providing customers with healthy hydration options and to keeping their employees safe - needed a solution to help optimize their asset life cycles. Their primary goal was defining cost-effective, consistent maintenance processes for their facilities, and adopting the technologies needed to support and sustain these processes throughout the U.S. and Canada. The company brought in consultants for recommendations on placement, sizing, and types of infrared windows to be installed at the Ontario, Canada facility. After an initial site survey, the consultants recommended the IRW-xPC series in various sizes to complete this project. The IRW-xPC series is a NEMA 4 / IP65 rated IR window and ideal for indoor applications. Available sizes are 6, 12, and 24 inches. ANALYSIS OF INSPECTION PROGRAM The company developed a reliability and maintenance policy that includes a 3- to 5-year improvement plan. This policy was then communicated to all employees. The company outlined all essential reliability and maintenance elements, their key performance indicators, why these are important and the importance of a Reliability Centered Maintenance (RCM) and Reliability Based Maintenance (RBM) program for overall plant safety. The company had done the necessary research and determined that they would retrofit using the transparent polymer infrared windows - a safer method of conducting standards-compliant inspections. It was decided by the reliability team to implement the large format infrared polymer windows for main switchgear bus connections; main breaker connections and fused switches to help eliminate the hazard of live work by finding hot spots through the IR windows. As a result, more frequent inspections of energized equipment could be performed by retrofitting with IR windows for routine inspections. The closed panel

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Consultants chose large-format IR windows in several sizes for the project

inspections with the windows in place did not require the elevated levels of Personal Protective Equipment (PPE) mandated in NFPA 70E, thus reducing time and maintenance costs. Thermal imaging was not new to the maintenance and reliability team as they had previously retrofitted some equipment with traditional round calcium fluoride windows. However, it was determined that a transparent polymer IR window available in various large formatted sizes would provide both visual and thermal inspection with fewer units needing to be installed. The polymer-based IR windows are unaffected by environmental and mechanical stresses that often impact IR windows fitted to electrical distribution equipment. By installing polymer-based windows, the company could help ensure that temperature data collected through the IR window would be accurate and reliable for the whole life

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CASE STUDY of the installation. Industrial-grade IR windows meet mandatory impact and load testing requirements of UL, CSA, IEEE and IEC. With the infrared windows installed, there was no need to remove panels or wear increased levels of PPE. Inspections could now be performed more often and on electrical equipment that had previously been considered “uninspectable” due to high levels of arc flash incident energy. The installation process proceeded smoothly and included: • Pre-planning to identify the equipment and obtain approval to shut down. • De-energizing the equipment with two electricians to make sure it was safely isolated, locked out and tagged out. • Once de-energized, the two electricians removed all covers on the equipment in question. • The IR windows were installed using supplied drill/ cut templates in the appropriate location and the covers were replaced. • Appropriate PPE was put on by the electricians and the equipment was re-energized. • Together with operations, the electricians confirmed

the equipment was operating at normal load levels and allowed sufficient time for the equipment to become thermally stable. • Thermographer electrician then performed the infrared inspection on the equipment to secure baseline temperature data. • Personnel completed the inspection by taking notes of any problems discovered.

Incoming line connection and main breaker cabinets were also fitted with 24-inch windows

RESULTS The bottled water company has recognized a huge savings in time and money with the implementation of transparent polymer infrared windows into their condition-based monitoring program. The use of polymer IR windows allows more convenient and frequent inspections resulting the ability to catch and fix potential problems long before they turn into unexpected outages. In this way, the bottled water locations will see increased Mean Time Between Failure (MTBF) on their critical electrical infrastructure. Most large facilities with large distribution power systems find that their insurance provider requires annual IR inspections of their electrical systems. This mandate is a direct result of verbiage found in NFPA 70B but retrofitting IR windows enables the facility to perform these inspections in a fraction of the time and in a much safer way. Based on the results at the first sites, the bottled water company has now proceeded with implementation of the IR window solutions at 29 of their sites around North America.

1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034, INDIA

The bottling company installed 24-inch large-format IR windows in main breaker buss cabinets

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Tel: +91-11-4560 3555 | Fax: +91-11-4721 2006 Email: flirindia@flir.com.hk | Webiste: www.flir.in

www.mtwmag.com


CASE STUDY

Pankl’s High Performance Drivetrain Plant

Pankl Racing Systems chooses EMAG for Turning of Transmission Shafts and Gears Rapid response times, central points of contact for all questions, and comprehensive technology expertise were crucial. What is distinctive about the quality of the various assembly line and standalone systems at Pankl?

A

ny new production plant built on “greenfield” land is a challenge for planners—especially with the longterm future in mind. Unit volumes, for example, should always remain scalable, and the processes should satisfy the requirements of modern industrial production for a long time to come. The construction of Pankl Racing Systems’ “High Performance Drivetrain Plant” is a particularly impressive example: In just two years, an ultramodern plant was erected at the site in Kapfenberg, Austria, including a smart, digitalized transmission manufacturing facility. Installed in that facility were a total of 16 EMAG machines for soft and hard machining of shafts and gears. One of the key factors behind the choice of

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EMAG as a central machinery supplier was the support the company provided in the planning phase: Rapid response times, central points of contact for all questions, and comprehensive technology expertise were crucial. What is distinctive about the quality of the various assembly line and standalone systems at Pankl? When you talk to the managers at Pankl about the new “High Performance Drivetrain Plant,” terms like “full traceability,” “zero-error strategy,” “top performance,” and “digitalization” come up a lot. They give you an idea of the demanding task that was given to them at the beginning of 2016. Detailed planning for the new plant started at that time, encompassing not only transmission manufacturing but also a heat

treatment system, four assembly lines for ready-to-install transmission shafts, and an “additive manufacturing” facility. The overall goal was to develop an ultramodern plant for the production of drivetrain systems—with an eye on the growing technological challenges in motorcycle manufacturing, because the new plant would produce complete motorcycle transmissions for Pankl’s customer, KTM. Europe’s leading motorcycle maker, KTM constantly places great emphasis on component quality and lightweight design. Additionally, Pankl produces more than eleven different transmission models for KTM, which means a relatively high component diversity for drive input and output shafts and idler and sliding

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CASE STUDY gears. “Ultimately all the production chains have to follow the principles of quality, safety, and flexibility,” saidBernd Kögler, plant manager for transmission manufacturing at Pankl. “This means we use ultramodern and extremely precise machines that are interlinked by intelligent automation systems and are flexible in use. And, all the quality data relating to a component is 100 percent traceable— from the original melting of the alloy through to the finished part. That gives us high process reliability. If weak points arise, they can be quickly identified and remedied.” Partner with Complete Turning Expertise Pankl’s technology partner in the “turning” application area is EMAG, with a total of 15 turning machines and one grinding machine from EMAG being installed in the new plant. These include three complete production lines, each with three VL 100 machines for the soft machining of gears, two connected VL 200 machines for the hard machining of gears, two VTC 100-4 units for the soft machining of shafts, and an additional production line for the hard machining of shafts that includes the VTC 100-4 turning center and the HG 204 horizontal grinding machine. Last but not least, there are two more VL 100 pick-

EMAG machine control interface

up turning centers that are used as standalone machines, for tasks such as the manufacturing of prototypes. With such a high volume of orders, the question naturally arises, how did the company decide on EMAG as its primary partner for turning? “I should start by explaining that although we’d been developing and producing complex mechanical systems for hightechnology industries such as auto racing and aerospace for many years, we hadn’t previously had any mass production of transmissions,” said Stefan Zinner, technical director of transmission manufacturing at Pankl. “So we were looking for a partner who could assist us right from the start, advise us about the turning processes

Shaft production at Pankl

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required, and finally provide us with complete systems. In that sense, EMAG is an obvious machine supplier who has a very good reputation especially in the area of turning.” Soft Machining of 22 Different Shafts To understand the requirements that are important in choosing a machinery manufacturer, it helps to look at the lines installed for the soft machining of the drive input and output shafts, which handles eleven different models of each. Pankl opted here for a process that is both demanding and perfectly synchronized, with a stacking cell, two EMAG machines, a pick-and-place unit, and a gantry robot. The slugs and blanks are transported by gantry loader to the O-belt of the first VTC 100-4. This vertical turning center has two workpiece grippers that can each pick up a part and put down a finished one, in parallel to the machining operation. This reduces non-productive time when turning the first side. Additionally, a four-axis turning operation is used to minimize machining time. Once that operation is completed, a pick-and-place unit picks up the parts and turns them over for equally rapid turning of the second side in the second VTC 100-4. The

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CASE STUDY gantry robot then conveys the part to a laser marking system. The writing and data matrix applied to the part ensure that every shaft is traceable. The production process then continues with gear teeth cutting, case hardening, truing, and hard machining—with the latter again involving EMAG technology. The machines used here are another VTC 100-4 for hard turning of recesses and shoulders, and the HG 204 horizontal grinding machine for plunge grinding along the entire shaft. Michael Mogg, team leader for machine turning at Pankl, summed up the situation: “The lot sizes in our shaft production vary considerably between 800 and 5,000 units. So it’s important to us that all processes, including re-tooling, go smoothly and quickly. We make sure of that with these flexible production systems.” High Reliability of Supply A similarly perfect solution was achieved in the production system for the soft machining of a total of 110 different idler and sliding gears for various motorcycle transmissions. The three production lines, each with three EMAG pick-up machines of the VL 100, rapidly carry out

Different transmission models for KTM motorcycles

rough-machining of the first side (OP10), rough-machining and finishmachining of the second side (OP20), and finish-machining of the first side (OP30). Once again, a gantry loader provides the link between the machines. An interesting additional feature here is an image processing system, which guarantees that the part has the correct radial alignment before being clamped. The workpiece carriers used were developed specifically by Pankl. They ensure rapid and flexible loading of the machines with a wide range of parts—lot sizes between 800 and 2,500 units are typical for the

company’s gear production. In total, Pankl currently produces about 80,000 transmissions every year, and that number is rising fast: The company is already aiming for more than 100,000 transmissions in 2020. What is the leadership team’s overall take on the situation more than one year after the start of production? “We feel our plans have been vindicated,” said plant manager Bernd Kögler. “We’re now seeing an efficient process for the many different components we make. We’re reaching the target volumes we aimed for in our planning, and at the same time we can guarantee the required level of quality at all times. Our customer can rely on this reliability of supply—and exactly that was far and away our most important objective. EMAG has basically been our technology partner in the area of turning, and will continue to play that role.”

For more information,

Gearwheel machining processes

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Website: www.emag.com

www.mtwmag.com


PRODUCTS SHOWCASE

PRODUCT SHOWCASE Slam latches with compact design legantly designed and extremely functional: The new slam latches GN 936 from Elesa+Ganter, secure against manipulation and available with or without integrated lock.

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 Email: info@elesaganter-india.com Web: www.elesa-ganter.in

www.mtwmag.com

They are compact, universally compatible and secure against ma-nipulation: The slam latches GN 936 from Elesa+Ganter serve as surface-mounted latches, primarily in systems engineering. By auto-matically latching doors, flaps or other access points to work rooms, automation zones and machine enclosures when the latch snaps into place, slam latches are always the first choice when quick and easy solutions are required. The new slam latches are mounted on the surface and are compati-ble with a very wide range of profile systems as chosen by the cus-tomer. Naturally, they can also be mounted to smooth surfaces. In the latter case, it is also possible to affix the part from the rear. Socket head cap screws, hexagon head screws and hexagon nuts, all in thread size M6, may be used for mounting. Thanks to the slot design, it is easy to adjust for different gap dimensions between the frame and the door. The housing as well as the lock mechanisms are made of robust die-cast zinc and are available with black or silver coating. The latches and covers are produced of plastic in matching colors featuring a subtle texture. A wide bevel running around the edge gives the slam latch an elegant and lightweight appearance, as does the accentuat-ed shape of the release grip. The compact standard part is available in three versions: a non-lockable variant entirely without lock and two versions, one with universal key and one with a unique key. In addition to the robust design, protection against manipulation was a high priority during development: The catch and the latch engage with an offset and with relative positioning that prevents unauthorized opening right from the start. The front or rear mounting options are also designed in consideration of security aspects. In the closed state, the slam latch cannot be removed. The mounting points remain hid-den under plastic covers that can only be removed while the slam latch is open. Only then it is possible to access the screws.

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PRODUCTS SHOWCASE

“ENGINEERING FILES” Indian Tool Manufacturers “ITM”, A division of Birla Precision Technologies Ltd. is one of the leading “Engineering Files” suppliers in India, “Dagger Brand” Files are made out of finest steel material, with state -of – the Art manufacturing facility to produce best quality of Files in its category. A Engineering File is a tool used to remove fine amounts of material from a metal work piece. It is commonly used for removing burrs, sharp edges in engineering process. Most are hand tools, made out of High Carbon Steel bars of rectangular, square, triangular, or round cross-section, with one or more surfaces. A narrow, pointed tang is common at one end, to which a handle will be fitted. Files teeth are cut with unique, automised, hydro-pneumatically-controlled cutting machines forming equally spaced teeth and uniform dept of cut to ensure consistent cutting quality and desire surface finish. Uniform, well- spherodized steel structure and required carbon rich surface produces uniform hard tooth for longer life. The shape and size of work piece, the material it is made of and the desired surface finish will have to be considered for selecting the right File. Our product range consists of Machinist Files, Saw Files, Wood and Rasp Files, Needle and Diamond Files etc. 1.Machinist Files: All Machinist Files are available in 3 cuts i.e., Bastard, 2nd Cut and Smooth. Size Range: 100 mm – 350 mm (4” -14”) 2.Saw Files: All Saw files are available in single Cut i.e, 2nd Cut. Size Range: 100 mm – 200 mm (4” -8”) 3.Wood and Rasp Files: All Wood & Rasp Files are available in 3 cuts i.e, Bastard, 2nd Cut and Smooth. Size Range: 150 mm – 350 mm (6” -14”) 4.Needle Files: Needle Files are generally used in Jewelery Industries and small component manufacturers, These Files are available in shapes of Flat, Three Square, Square, Half Round, Round, Knife Edge etc. Size Range: 160 mm 5. Diamond Files: Diamond Files are generally used in Tough and difficult to cut materials etc. These Files are available in shapes of Flat, Three Square, Square, Half Round, Round, etc. Size Range: 160 mm Advantages of ITM File are: • Extra Life • Corrosion Resistance • Better Productivity • Superior Finish • Finest Quality Steel.

For Product Enquiry Contact Birla Precision Technologies Limited Email: itmth@indiantool.com

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Tips for Better Performance: • A new File should be used with light pressure in the beginning, preferably on a surface which has been filed earlier. • In case of clogging of File teeth, clean the teeth with a soft metal wire brush. • Use the Files for cutting in the forward stroke only. • Filing jobs should be hold rigidly.

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PRODUCTS SHOWCASE

Polyester (Spun or Filament) Knitted Features & Benefits The Synthetic Yarn is used to make the gloves lighter, lint free & economical than Nylon or Polyamide. These gloves are available in option of 10G in Man & Lady sizes & colours like White, Natural White, Blue, Black, Grey etc.. These gloves are made from 100% Polyester Continuous Filament Yarn, which absorbs the moisture to be absorbed during extended wear, which makes more comfort to the wearer. The less lint makes less or no contamination of the products while handling.

For Product Enquiry Contact Marvel Gloves Industries Manufacturers, Exporters & Importers of Gloves & PPEs 187/188, 2nd Floor, Ashoka Shopping Centre, G.T. Hospital Complex, L. T. Marg, Mumbai 400 001 INDIA Phone : +91 22 2262 6546 / 2262 6876 Email : marvelgloves@gmail.com www.marvelgloves.com

Application • Mechanical Protection • Cleaning • Paint Shop • Packing • Precision Handling- Assembly • Automotive Industries • General Maintences

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

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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.

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PRODUCTS SHOWCASE

GEM’s Bottle Type FRP Cooling Tower GEM’s Nexgen Bottle type FRP Cooling Tower is known for the benefits it offers like low maintenance, high efficiency, noiseless operation, minimum water loss and long service life.

For Product Enquiry Contact GEM Equipments (P) Ltd. SF No.103, Avinashi Road, Arasur, Coimbatore 641 407 Tel : 0422-2363800 / E-mail: sales@gemindia.com

Following are some of the constructional features of this trendsetting product: • Superior extended shaft flange mounted frame, waterproof with aluminium body, epoxy painting, SS shaft and EPDM sealing; saves power; highly reliable and built to last. • RTM Mould body, UV protected and with glossy finish • FRP Louver profile reduces water spillage loss, prevents entry of foreign particles and extends cycle for blow down. Also proper L/G reduces evaporation loss. • High Efficiency Aero Dynamic Fan: Axial flow, direct driven, low noise, long life, corrosion -free aluminium, computerized balanced and wind tunnel tested. • Revolutionary Spiral Fills: Rigid PVC – with long life, clogg-free and ease of assembly. UV stabilized • The product is offered to the customer with a 5-year warranty – for the first time in India.

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.

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

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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 • 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.

www.mtwmag.com


PRODUCTS SHOWCASE

Drilling and Tapping Machines

For Product Enquiry Contact Patson Machines Pvt. Ltd. `Sheh’, C-11, Erandwane society,14/5, Erandwane, Pune, Maharastra 411004 Tel. 020-25442913. Fax. 020-25410836 Email: patsontech@vsnl.net Web: www.patsontech.com

Patson Machines Pvt. Ltd. offers multispindle drilling and tapping machines for lighting industries. This machine is specially designed for drilling and tapping for components such as Flood light of different watt, Aluminium heat sink, aluminium pole Etc. No. Of spindle for machine will be according to no. of holes to be drilled as per component. Machine has two stations ,one for drilling operation and second for tapping operation. Tapping operation will be of pitch controlled type. Different tapping sizes in one component is possible. Floating type tap holders are used for tap. Drilling station is hydraulically operated. Rapid feed-feed-rapid return cycle is used for drilling operation. Labour involvement is drastically reduced due to this machine. Reduction in machining time, rejection rate and increased productivity is the advantages of this machine. The company is committed to deliver quality at economical price.

Welding Fume Extractor, King Extractor-II-MU 3 Welding Fume Extractor, King Extractor-II-MU 3 is a mobile mechanical high efficiency self-cleaning filter designed for workplaces. The filter cleans air from different kinds of dry dust, welding aerosols and other dry contaminants from most industrial processes. The filter cartridge is cleaned automatically without interrupting the filtration process. The cleaning extends the cartridge service periods and minimizes maintenance.

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

The Filter is designed for continuous indoor operation under the following climatic conditions: • Air temperature from +10 deg. C to +45 deg. C. • Relative humidity : 80% at 25 deg. C • The compact construction integrates the filter, extraction arm and fan • The filter can be used at workplaces unreachable to other ventilating equipment, and • The filter requires connection to a general compressed air supply. The standard delivery set includes Built-in fan, Control console, Filtering cartridge of respective type, Spark arrester, Oil separator with reduction box for compressed air system, & Electrical grounded cable L= 5 m with plug.

Looking for industrial Products for your plant/workshop ??? Connect to right manufacturers & suppliers http://www.mtwmag.com/category/products/ www.mtwmag.com

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ADVERTISERS INDEX COMPANY NAME

PG. NO.

A

PG. NO.

COMPANY NAME

PG. NO.

GEDEE WEILER PRIVATE LIMITED

11

PRECISION MOTION INDUSTRIES, INC. ( PMI )

25

ACCUSHARP CUTTING TOOLS PVT. LTD.

51

GEM ORION MACHINERY (P) LTD.

59

Q

ACE MICROMATIC GROUP

BACK PAGE

GLOBE-TECH ENGINEERING EXPO - 2020

113

QVI INDIA PVT. LTD.

ADOR WELDING LIMITED

95

GP PETROLEUMS LTD.

33

R

ANCA MACHINE TOOLS PRIVATE LTD

7

H

APEX PRECISION MECHATRONIX PVT. LTD.

99

HANGSTERFER'S HURCO INDIA PVT. LTD.

B

35

73

ROCKLIN MANUFACTURING CO.

79

75

ROLLON INDIA PVT. LTD. - INDIA

93

RR KABEL LIMITED

41

91

I

BIRLA PRECISION TECHNOLOGIES LIMITED

47

IMTEX FORMING - 2020

67

ISCAR INDIA LIMITED

INNER INSIDE FRONT COVER

CHENNAI MACHINE TOOL EXPO - 2019

61

J

CLEANOIL

37

JERGENS INDIA PVT. LTD.

76

JYOTI CNC AUTOMATION LTD.

31

D DOWEL ENGINEERING WORKS

111

M

DVS TECHNOLOGY GROUP

20 - 21

MACHINE TOOLS, MANUFACTURING & TECHNOLOGY EXPO

E

S SEW-EURODRIVE INDIA PRIVATE LIMITED

39

SHAVO TECHNOLOGIES PVT. LTD.

87

SPRAYMET SURFACE TECHNOLOGIES PVT. LTD.

97

T

17

THE ASSOCIATION FOR MANUFACTURING TECHNOLOGY

71

MARPOSS INDIA PVT. LTD.

45

TRUCUT PRECISION TOOLS PVT. LTD.

FALSE COVER

MARVEL GLOVES INDUSTRIES

89

U

MASTERCAM INDIA

INSIDE BACK COVER

UNITY CONTROLS PVT. LTD.

ELECTROTHERM (INDIA) LTD.

15

ELGI EQUIPMENTS LTD.

27

EMAG INDIA PVT. LTD.

9

MEHTA CAD CAM SYSTEMS PVT. LTD.

83

V

ENGIMACH - 2019

29

109

V M TRADERS

EPPINGER TOOLING ASIA PVT. LTD.

MGM-VARVEL POWER TRANSMISSION PVT LTD

64 - 65

MICRO-EPSILON INDIA PRIVATE LIMITED

63

W

MILLENIA TECHNOLOGIES

52 - 53

MMC HARDMETAL INDIA PVT. LTD.

INSIDE FRONT COVER

WOHLHAUPTER / ALLIED MACHINE & ENGINEERING COMPANY

F FACCIN S. P. A.

23

FATTY TUNA INDIA PVT. LTD.

19

FLIR SYSTEMS INDIA PVT. LTD.

55

G

N N. GANDHI & CO.

43

69

MACHINE TOOLS WORLD JULY 2019

PARAGON MACHINERY CO. LTD.

107

85

72

Y YG-1 INDUSTRIES INDIA PVT. LTD.

FRONT GATEFOLD

Z

P

GALA PRECISION ENGINEERING PVT LTD

78

RENISHAW PLC

BETTINELLI AUTOMATION COMPONENTS PVT. LTD.

C

122

COMPANY NAME

57

ZECHA PRECISION TOOLS LIMITED

13


Mastercam X8 is retiring.

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