Volume 05 No. 05 | October 2019 | ` 150
Pages 122 | RNI No. MAHENG/2015/64267
Anti-Vibration Turning Whisper Master
A N T I - V I B R AT I O N
Anti-Vibration Shank for Boring with Exchangeable Boring Heads
Boring Shaft with Internal Coolant
MACHINING
For All Materials
Variety of Exchangeable Turning Heads for Different Geometries of Turning, Threading and Grooving Inserts
Up to 10xBD Anti-Vibration Shank
INTELLIGENTLY
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
Green Manufacturing : Ready for the future
Shilpa Dongre
Assistant Editor Shweta Nanda
Marketing Team
Due to stringent regulations on carbon emissions, green manufacturing has become a critical issue in manufacturers’ strategic planning. Manufacturers are greening production through carbon abatement activities. The purpose of this paper is to investigate the factors that influence the effects of carbon abatement on environmental productivity growth.
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
Energy consumption makes up a big part of the manufacturing sectors’ impact on the environment, but another significant factor is the materials. A focus on sustainable materials management has emerged over the past few years as a result.
Bangalore E Vikram : +91 9591488434 Vaman : +91 9686721340 Hyderabad E Vikram : +91 9591488434
EAST (Kolkata & Other regions) Amol Powale - 09820488541
WEST (Maharashtra & Gujarat) Pune Kuldeep Kshirsagar - 09689403523 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 Printed & Published by Shirish Dongre on behalf of DIVYA MEDIA PUBLICATIONS PVT LTD., Printed at Anitha Art Printers 29/30, Oasis, Next to Vakola Market, Santacruz(E), Mumbai-400055, published from 303/304, Harmony Tower, N.S.Road, Court Naka, Thane West, Thane-400601. Editor : Shilpa Dongre
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MACHINE TOOLS WORLD
Manufacturing companies across the globe have resorted to more environmentally safe enterprise and marketing activities due to the upsurge in the environmental difficulties and increasing public demand to reflect on the effects of their activities in the environment. Strategic approaches have been adopted by several firms to meet the concerns of stakeholders in the manufacturing industry, while producing goods that meet customer expectation regarding environmental safety concerns .
OCTOBER 2019
More companies are now taking a look at their supply chains to ensure their materials come from sustainable sources — companies that get their materials in a way that preserves natural resources and protects the environment. This can also lead to increased profits as consumers seek out ways to live more ecofriendly lifestyles. Many consumers will even pay more for products from brands that make efforts to be sustainable. The manufacturing sector is getting greener, but there’s still a long way to go to create an environmentally friendly economy and curb climate change-causing emissions. If manufacturers continue to make their processes more sustainable and consumers continue to support their environmental efforts, perhaps we’ll one day live in a truly sustainable society.
CEO
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Contents
OCTOBER 2019
COVER STORY
Leadership in performance driven technology solutions
44
Mr. Moritz Lange-Piëch Coordinator Sales & Strategy DVS India DVS Technology Group
BUSINESS NEWS
IN FOCUS
20 Renishaw bags an award for alignment laser system
22 Mehta Cad Cam introduces combines Plasma and Oxyflume Cutting Machine
30 ANCA becomes a finalist in the 65th Victorian Training awards
Performance lubricants enhance productivity, profits
48
INDUSTRY SPEAK
32 YASKAWA INDIA awarded with WELDFAB TECH AWARD at Mumbai
34 BFW inaugurates new tech center at Aurangabad
42 Chennai Machine Tool Expo 2019 brings technologies to the doorsteps of Tamil Nadu
8
MACHINE TOOLS WORLD
OCTOBER 2019
52
54
AMT SECTION
57 www.mtwmag.com
Precision Grinding. Repeatable Results. We are Drake Manufacturing. We are a full service, turnkey manufacturer of precision CNC machines and provider of engineered solutions. Founded in 1972, Drake is headquartered in Warren, Ohio. The premium Drake brand is known around the world for innovation and process expertise throughout the thread grinding industry. WWW.DRAKEMFG.COM Contact our Local Representative MR. ALOK NAIK, alok@empiremt.com TEL. NO. 2493 7340 / 2494 7066 / 2497 3184 | FAX NO. 2496 2380 sales@empiremt.com EMPIRE HOUSE, GROUND FLOOR 414, Senapati Bapat Marg, Lower Parel, Mumbai – 400 013 BRANCH OFFICES: Delhi, Chennai, Bangalore, Hyderabad, Kolkata, Pune, Nagpur
Contents
OCTOBER 2019
TECH TRENDS
72
76
IGUANA – Diamond tool for copper electrode machining
Faccin Metal Forming taking the middle east by Storm
80 Achieving absolute precision for automotive production
86
100
CASE STUDY
98
112
Bevel gear: New perspectives for small series production and special products
Laser interferometer error-proofs linear scale calibration
PRODUCTS SHOWCASE
116
Electrical Safety for Power Supplies!
10
MACHINE TOOLS WORLD
117
Nylon Knitted Seamless Gloves with PVC Dots
OCTOBER 2019
118
118
Effortless cleaning Welding Fume of oily machinery, factory Extractor, King Extractorfloors and plastic bins by II-MU 3 the use of O-CLEAN3 www.mtwmag.com
Shaping the future. Together.
Two world leaders in industrial process fluids, Quaker Chemical and Houghton International, have come together as one company to keep our metalworking customers ahead in a changing world. As Quaker Houghton, we are proud to partner with metalworking industries around the world that are driving a sustainable, more prosperous future. We work with your teams to deliver expertise, service, and advanced technology related to industrial process fluids.
quakerhoughton.com ©2019 Quaker Houghton. All rights reserved.
Editorial Board
Editorial Index A Ador Welding
54, 108, 118
ANCA
30
AMT- The Association For Manufacturing Technology
Mr. GK Pillai Managing Director & CEO Walchandnagar Industries Ltd
Components
24
BFW
34
Bosch Power Tools
36
42
Danfoss
34
DMG MORI
20
DOLD Electric
Renishaw Metrology Systems Ltd.
116
20, 112
Rollon India
90
S
Specialities
118
STUDER
100
E
Bettinelli Automation Components Pvt. Ltd.
Elgi Equipments
22, 52 59
Superslides & Ballscrews
96
U 76
H
Unity Controls
117
Y
Haas
Sanjay Tools & Adhesives
Renishaw
44
FACCIN S.p.A.
Association of Ludhiana Machine Tool Industries
Millenia Technologies 68
DVS Technology
F
Machine Tools Manufacturers Association - Rajkot
80
Steel Plant
Mr. Rupesh Paparaju Director,
Mr. Suhas Belapurkar Director - Sales & Marketing ( Industrial Products)
22, 30
70
ExxonMobil Lubricants 48
Mr. Sushil Kumar General Secretary
Micro-Epsilon
65
Drake
ESPRIT
Mr. Yogin Chhaniara President
Mehta Cad Cam
117
Rocklin Manufacturing 67
D
Effica Automation Ltd.
M
R
Chennai Machine Tool
Ms. Samina Khalid Marketing Manager
86
C
Expo 2019
Mr. Arjun Prakash Managing Director
ISCAR
Mastercam
Bettinelli Automation
Mr. A.P. Jayanthram Ex-Managing Director, Heidenhain India
42
Marvel Gloves
B
Mr. Arun Mahajan General Manager
IMTMA
YASKAWA
Schleifmaschinen
98
Hardinge
61
32
Z ZECHA Precision
I igus
106
Tools
72
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
12
MACHINE TOOLS WORLD
Mr. B.P. Poddar Vice President - Sales & Marketing FEMCO Fatty Tuna India Pvt. Ltd.
OCTOBER 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
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Modular automation cells – compact, productive The loading options of the ML235 are modular, too. Standardised automation cells with rotary magazine, cage stacking magazine or linear automation for manual loading or process supply of up to two production cells with components. Raw parts and machined parts are always completely separated without a risk of mix-up. Traceability through consistent batch management is a matter, of course.
BUDERUS solves complex tasks such as gear wheels from passenger car gearboxes, the functional surfaces of which have to be machined to precise dimensions as quickly as possible, using the modular principle. Thus external and internal grinding can take place simultaneously. The front and rear faces are turned and, if necessary, the bore hole can also be honed in the same clamping.
Configuration examples
Find out more: www.buderus-schleiftechnik.de
BUSINESS NEWS
Renishaw bags an award for alignment laser system Renishaw’s new XK10 alignment laser system has won the MM Award for ‘Quality Assurance’ at the EMO 2019 exhibition held in Hannover, Germany. The awards were presented by the principal German trade magazine MM Maschinenmarkt. The MM award for XK10 was presented on 23rd September 2019 to representatives from Renishaw’s GmbH subsidiary; Rainer Krug, Sales and Business Development Director and Joerg Reichle, Sales Engineer. This award reinforces the success of XK10, having recently been
presented the Gold Medal at the MTP Fair, Poland. The XK10 alignment laser system has been developed for use during the build and alignment of machine tools, replacing the need for artefacts.
It can be used on linear rails to ensure that they are straight, square, flat, parallel and level, as well as to assess spindle direction and coaxiality of rotary machines. These factors can be measured
and aligned with the XK10 during build, using the system’s live display. The XK10 is also a powerful tool for diagnosing the source of errors following a collision or as part of regular maintenance.
DMG MORI, Jungheinrich partner to develop driverless systems DMG MORI and Jungheinrich announced their partnership to jointly develop solutions for driverless transport systems at the world’s largest trade fair for machine tools – EMO Hanover. The collaboration’s first product, DMG MORI PH-AGV 50 heralds a new era of flexible automation solutions in intralogistics. The driverless transport system enables fully automated loading and unloading of workpiece pallets on machine tools. Automated transport systems can be used in
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MACHINE TOOLS WORLD
an area-efficient manner and thus sustainably reduce transport times as well as assembly and logistics costs. The flexible automation solution DMG MORI PH-AGV accelerates the material flow and thus ensures more flexible and productive processes in production. With the DMG MORI Cell Controller LPS, all processes in the production and administration of pallets can be further optimized.
OCTOBER 2019
“The “Automated Guided Vehicles” are another important innovation element for the “Digital Factory” of the future. With automated transport systems we offer our customers a further product for automation and digitization,” said Christian Thönes, Chairman of the Executive Board of DMG MORI AKTIENGESELLSCHAFT. “Two innovation leaders speed up the digital transformation: together we unite Jungheinrich’s expertise in the field
of automated guided vehicles with DMG MORI’s integrated technology and automation solutions, thus creating significant added value for our customers,” says Dr. Lars Brzoska, Chairman of the Executive Board of Jungheinrich AG. The PH-AGV 50 is modularly expandable, moves freely in the production halls with precise laser navigation technology & automatically aligns itself optimally to the machines. Free access and safety for the user are guaranteed at all times.
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BUSINESS NEWS
Mehta Cad Cam introduces combines Plasma and Oxyflume Cutting Machine Mehta cad cam is the oldest and largest company in the field of CNC and Laser technology. They manufacture Fiber laser cutting machine in different types and capacity and wattage up to 12 KW which can cut S.S, Aluminum and M.S up to 50 mm of thickness. They have recently introduce combined plasma and oxyflume cutting
machine with gentry type in different size like 2 mt x 6 mt , 4 mt. x 8 mt. and they can also manufacture customize machine in any
sizes and capacity. All Mehta’s plasma cutting machine is equipped with Hypertherm plasma source. Their manufacturing
facility and H .O is at Ahmedabad and 22 branch offices across all India to provide quick sales and service support.
ELGi celebrates the opening of its new headquarters in Europe Elgi Equipments (BSE: 522074 NSE: ELGIEQUIP), one of the world’s leading air-compressor manufacturers, with 2 million installations across 100 countries, announced the opening of its new European headquarters in Belgium. Situated at DrèveRichelle 167, 1410 Waterloo, (Brussels- the nerve center of Europe), and spread over 400+ sq meters, the workplace will house over 20 people and feature training rooms and offices designed to build collaboration and foster innovation, in line with the ELGi values that form the backbone of our culture worldwide. Speaking at the inauguration Dr. Jairam Varadaraj, CEO, Elgi Equipments said “We’re proud of what we’ve
22
MACHINE TOOLS WORLD
built at ELGi. Over the years, our definition of Always Better has ensured we are focused on always being the customer’s choice. With this goal in view, we’ve concentrated on developing world class products with the best Life Cycle Cost (LCC). We’ve guaranteed the best in industry uptime. We’ve reaffirmed our commitment to reliability by providing customers with robust warranty and we’ve driven cost leadership through technology and innovation. All of this, has resulted in us witnessing significant success in the USA, the world’s second largest air compressor market, in a short span of 5 years. Europe is the third largest market worldwide and presents us with a huge
OCTOBER 2019
opportunity. We’re excited. And while we celebrate our successes, we will toast to the future.” Chris Ringlstetter, President, ELGi Europe said “We are proud to be part of a company that truly understands and believes in the importance of investing in its future. Over the years ELGi has been establishing itself across Europe, with a strong focus on diesel powered screw compressors (portables) and an expanding product portfolio of electric powered screw compressors (stationary). We will continue to evolve and grow our Pan-European presence substantially, while expanding our existing channel footprint. While we are confident we have
a strong leadership team in the region, we are now focusing on building our sales and service teams. Europe is a mature market, but we have quickly come to realize that the industry we serve and the distributors we choose to partner with are excited about our investment & growth plans.” The growing focus on energy efficiency, in line with the Paris agreement and the European Commission’s climate strategy has mandated energy efficiency improvements of at least 32.5% by 2030, causing companies to employ energy efficient compressor ranges to achieve high performance while remaining competitive in their respective sectors. Additionally, customer in-
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BUSINESS NEWS creased air quality standards have enforced the use of ‘Class Zero’ compressed air in the food and beverage, pharmaceutical and other sensitive industries. David De Pril, Head of Product Management and Marketing, ELGi Europe commented “ELGi has developed technology specifically to
address an existing need with air compressors that offer customers maximum energy efficiency, sustainable advantages, significantly lower maintenance and ease of use, as well as reliable, high air purity for sensitive industry applications.” ELGi, is a pioneer in cutting edge compressed
air technology, 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 manufactur-
ing units and a product portfolio of 400+ compressed air systems, ELGi redefines reliability, efficiency and cost-effectiveness across installations all over the world. For further information on the organisation and its products, please visit http://www.elgi.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 speed, with a high degree of versatility to offer customers the most suitable solution. They are used on
24
MACHINE TOOLS WORLD
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 is a great advantage to the machine builder. machines that require stability, precision, high speeds and low maintenance. They are different in terms of body width, allowing great flexibility and a more accurate choice during the designing phase. 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
OCTOBER 2019
Plastic Protections: In the TL range, the plastic protections have been studied to be applied on pallets in order to guarantee an anti-intrusion 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
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ATOM
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The building block of motion systems
New! Miniature optical incremental encoder system Accurate and reliable position feedback is essential when designing complex motion systems. In applications with tight physical envelopes there is the added challenge of finding an encoder that maintains a high level of performance within a small installed package. ATOM’s unique design avoids the compromises traditionally associated with miniaturised encoders. Make ATOM the building block of your motion system! The new ATOM optical encoder is the first to combine miniaturisation with uncompromised accuracy, leading-edge dirt immunity and long-term reliability. • World first: miniature encoder with filtering optics for excellent signal stability • Comprehensive range of linear and rotary scales: 20 µm and 40 µm pitch • Ultra-compact readhead: only 6.7 x 12.7 x 20.5 mm for space-critical applications • Quick, easy readhead installation: built-in set-up LED and auto CAL routine enable faster optimization • Reduce your system cost: ATOM assures high quality, fast delivery and competitive pricing
For more information please visit www.renishaw.com/ATOM
Renishaw plc New Mills, Wotton-under-Edge, Gloucestershire, GL12 8JR T +44 (0)1453 524524 F +44 (0)1453 524901 E uk@renishaw.com
www.renishaw.com
BUSINESS NEWS
ANCA becomes a finalist in the 65th Victorian Training awards ANCA was nominated as a finalist for the Employer Award for Apprenticeship Development at the 65th Victorian training awards. The winners from the finalists selected across 16 categories were announced recently at the Victorian Training Awards gala event, where the state’s ‘best of the best’ in the TAFE and training sectors were showcased. Stuart Gurney, ANCA Apprentice Master said, “To maintain our position as one of the global leaders in our field we invest in building teams that can design and create the latest technology – including automation, robotics, precision grinding and software among others. It is rare to have opportunity to access this type of advanced manufacturing in Australia and I find it extremely rewarding to see how much my team develops over the four-year program to graduate with a fantastic career ahead of them.”
Apprentices have always played a vital role at ANCA with one of its co-founders coming from a trade background who continues to value quality training and development. The establishment of a structured Apprenticeship Program in 2011 formalized this training and increased the number of participants who
could experience hands on learning in this exciting industry. ANCA has partnerships and links with a range of training providers in the community. In the last 12 months ANCA further developed our long-standing partnership with Chisholm Institute by extending its operation as a host-training site to include apprentices from similar industries. Additionally, ANCA hosts Industry Tours for Career Practitioners from local secondary schools to increase awareness of STEM related career pathways and skill requirements. ANCA also
collaborates with OELLEN, Yarra Ranges Tech School, the Yarra Ranges council and other local employers to host a “Tech Tours & Tech Talks” program that aims to broaden industry understanding for students regarding future career pathways within manufacturing. ANCA Group HR Manager, Eileen Kershaw said, “A key element of our apprentice program is that we have identified the specialist skills required for our advanced technology manufacturing and working alongside traditional TAFE programs, have tailored our own training program to build those specialist and niche skills. We have focused on not locking our apprentices into one stream, but instead give them experience across a number of our functions through a series of rotations, assisting them to develop a deeper understanding of the overall business and a broader set of skills.”
Mehta Cad Cam installed 6 KW fiber laser cutting machine at Ahmedabad Mehta Cad Cam is the largest and oldest company manufacturing CNC and laser technology machines. They have recently installed Fiber laser cutting machine with 6 KW fiber
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MACHINE TOOLS WORLD
laser cutting machine in their application center at Ahmedabad. For more information you can contact to Mr. Narendra Purohit on 9227985724
OCTOBER 2019
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EMAG GROUP TECHNOLOGIES Turning
Milling
Grinding
Gear Hobbing
Skiving
Heat Shrink Assembly
ECM / PECM
Laser Welding
Induction Hardening
The EMAG Group is one of the few manufacturing system suppliers that cover the entire process chain – from soft to hard machining. Access to a wide range of technologies (turning, drilling, milling, gear cutting, grinding, laser welding, ECM/PECM machining, induction hardening and automation) allows EMAG to implement complete process chains, not only for the manufacture of gear box, engine and chassis components, but also for components in the non-automotive sector including oil field, power generation, aerospace and large equipment.
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 Sale: +91 80500 50163 I Phone Service: +91 80500 50165 I E-mail: sales.India@emag.com I www.emag.com
BUSINESS NEWS
YASKAWA INDIA awarded with WELDFAB TECH AWARD at Mumbai With an objective to encourage and reward the welding industry for their excellence and innovations, WeldFab Tech Awards 2019 was organized on 14th September, 2019 at Hotel Sahara Star, Mumbai. For the very first time in India, an Awards Night was held exclusively for the welding fraternity. WeldFab Tech Times, India’s only welding magazine organized this event, and was successful in gathering various sectors like welding, fabrication, steel. The event gathered a good strength of delegates from welding industry and started with the lamp lighting followed by awards ceremony. To name a few diplomats present throughout the show were honorable Chief Guest Dr. P.V. Venkitakrishnan, Outstanding Scientist, Director, CBPO, ISRO; Guest of Honor Shri Santosh Kumar Sinha, General Manager, Indian Ordinance Factory Board, Ambernath; and the expert jury members. During the award show, Yaskawa India was announced as a winner of “WELDFAB TECH AWARD” bagging another feather in its cap for its outstanding performance and dedication towards the welding community. Over a period of time, Yaskawa India has evolved as one of
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MACHINE TOOLS WORLD
Team Yaskawa India awarded with the “WELDFAB TECH AWARD” during the award ceremony
the major robotic solution provider with its offerings that include comprehensive line of Robotic solutions with core strengths majorly in applications like Arc welding, Spot welding, Handling ( General Purpose series), Pick, pack & palletizing, foundry & forging, Painting and many more. Mr. Ajay Gurjar, Deputy COO, Yaskawa India (Robotic Division) expressed gratitude towards the organizer for holding such one of its kind event specifically focusing welding industry and acted as a common platform for delegates from government and welding Industry to network and understand the related market opportunities. He then also submissively
OCTOBER 2019
shared Yaskawa’s innovation of Polarity Switching Unit (XACU) developed for thin sheet welding and aluminum welding. With the use of XACU, the deposition efficiency increases by changing the polarity of the electric current output and which enables to limit the heat input to the base metal. This XACU is compatible to use with Yaskawa Robot Controller YRC 1000 and welding power source MOTOWELD-X350. With this we are offering an upgrade system, to enable our customers to use the AC unit depending on the change in welding environment. It can therefore be added when necessary with Yaskawa existing welding power source X350.
Besides this, the panel discussion on a topic “What can be the initiatives taken up to uplift the technical knowledge and overall development of SME & MSME’s in Welding,” by highly profiled panelists was witnessed. The 2nd Anniversary Issue of WeldFab Tech Times magazine was also unveiled during the show. With this win, Yaskawa team is in all spirits high and assured to continue delivering its high end quality products & services to the welding & other industries and support towards making progressive India with best in class motion control technology. For more details of Yaskawa India offerings, reach us at marketing@yaskawa.in
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Your system partner for intelligent manufacturing If your loading robots are still fenced in with grating in their way, you should give some serious thought to your bottom line. And consider the smart multi-spindle SW machining centers with integrated automation or portal loading. Be profitable. be SW.
Local contact in India: EMAG India Pvt.Ltd sales.india@emag.com | Phone: 08050050163 www.sw-machines.de | Made in Germany
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TECHNOLOGY MACHINE S SYSTE MS
17.07.2019 10:16:23
BUSINESS NEWS
Danfoss presents latest energy efficient drives technology Danfoss Industries Pvt. Ltd., recently presented its latest energy-efficient Drives technology at the Energy Efficiency Summit in Hyderabad. The drives solutions are in line with the government’s vision to incorporate sustainable development for nation building. Over the last 5 decades, the company has set a global benchmark of engineering solutions critical in reducing environmental and economic cost of progress with its energy efficient technologies. Danfoss Drives have proven to be front-runners in its commitment to minimize carbon emissions with utility across industries from food processing to
infrastructure building, chemical industry to water & waste water management. They have also enabled companies to challenge the manufacturing environment to derive maximum potential from the engineering systems. Speaking at the summit, Ravichandran Purushothaman, President, Danfoss India addressed the importance of Decarbonization across industries and said, “In this era of Industry 4.0, technology and the manufacturing processes are constantly evolving. With industry being responsible for over 38% of global total energy use, it is time for companies to emulate a way to address efficient
energy consumption and reduce carbon emissions. Understanding this, the first pillar towards decarbonisation is to employ energy-efficient technology and promote replenishable energy sources; secondly, it is important to integrate digitalization and electrification as means to promote efficiency across business divisions, increase flexibility and enable integration across function systems. Finally, it is important for the government and the industry to come together to promote a culture of innovation in the energy space, thereby allowing scope for new frontiers of sustainable development.” At the summit, Danfoss
addressed the need for companies to understand the complexities of safety issues involved in the industrial manufacturing space by drawing parallels to Danfoss’ real-life expertise across its varied customer base. It included examples that has helped large Indian companies in improving its productivity and reducing energy consumption. The Danfoss Drives Solutions on display were Drive Sync, Antisway kit, IP 66 Water proof and IP 55 dust proof kit. At the summit, it was also announced that Ravichandran Purushothaman was elected as the Chairman of the CII National Council for Energy Efficiency, India.
BFW inaugurates new tech center at Aurangabad BFW recently launched a new Technology Center at Aurangabad. The Tech Center was inaugurated by Rishi Bagla, a renowned industrialist and Chairman, OMR Bagla Group and director of Aurangabad Electricals, amongst a gathering of scores of entrepreneurs from Aurangabad. The managing director of BFW, Ravi Raghavan and senior leadership team of BFW was also present on the momentous
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occasion. There was live demonstration of star
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performance machines, cutting edge application
engineering and smart Automation solutions to enhance productivity, quality and to serve global competitiveness. Setting up of the Technology Center is a step forward by BFW in being close to the customers and industries in the Aurangabad and to provide turnkey process engineering solutions, prove out & application support, ready availability of spares, training & developments.
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BUSINESS NEWS
Bosch Power Tools launches cordless experiential mobile vans Bosch Power Tools India is set to amplify its consumer experience by enabling users to get hands on experience of the cordless range through mobile van demonstration vehicles. An extension of the recently launched user campaign ‘Cordless Matlab Bosch’. Bosch Power Tools will campaign across multicities starting 9th of September across for six months. Adding to the 40 cities covered by the previous ‘Cordless Matlab Bosch’ demo zones through channel partner outlets, Bosch Power Tools plans to expand its outreach to 50 more cities in India by the end of the month with the product experiential mobile vans campaign. The Bosch Power Tools experiential mobile van will commence its campaign in Kolkata, Delhi, Cochin, Ahmedabad, Pune, Hyderabad, Chennai, Bangalore, Ludhiana and Lucknow. These experiential mobile vans will not only engage and educate consumers on the availabil-
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ity and benefits of quality cordless power tools in the market but also improve accessibility and availability of the range by reaching across cities through the experiential vehicles. Part of the mobile van experiential, customers can avail a hands-on demonstration of Bosch Power Tool’s lithium-ion battery-powered screwdriver, the Bosch Go, with push and go functionality is 4x more convenient than its competitors available in the market. The cordless range on showcase will also include power drill drivers, high power impact wrenches, robust hammer drills, high-speed impact drills, ABR enabled impact
OCTOBER 2019
drivers, flexible drill drivers and the GSR 120-LI, a 12V cordless drill driver, re-introduced with an exclusive jacket packaging designed for India. Commenting on the launch of the mobile van campaign, Panish PK, Regional Business Director - India and SAARC – Bosch Power Tools said, “Some of these cordless tools for
professionals are optimized with ProCore18V batteries for maximum performance and efficiency, making cordless tools better than corded tools for the first time in the history of machine and toolmaking. Design and quality being key, the cordless range will offer all the conveniences of going cordless without added bulkiness or weight, encouraging every workman in the country to go cordless, thereby spearheading the vision of our campaign – ‘Cordless matlab Bosch’.” The products are also available immediately on Amazon & Flipkart. ‘Bosch Power Tools cordless range will be available at dealer stores across India.
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BUSINESS NEWS
Chennai Machine Tool Expo 2019 brings technologies to the doorsteps of Tamil Nadu The first edition of Chennai Machine Tool Expo was held recently from 26th to 29th September 2019. The event served as a platform for the growth of regional machine tool industries based in Tamil Nadu and South India. The four-day show, featuring around 55 exhibitors from India, Japan, Korea, Singapore, and the USA, showcased the latest technologies in metal cutting and metal forming. The machines and accessories on display were aimed at serving the needs of key user industries such as aerospace, defense, railways, automotive, medical engineering, construction, information technology, and electronics. Speaking about the auto sector disruptions, the Chief Guest for the expo, Srivats Ram, Managing Director, Wheels India Limited, Past President of ACMA and Governing Board Member of Advanced Manufacturing Technology Development Centre said, “The worst is over for the automotive industry and machine tool builders
need to focus on building technology capabilities. Overall manufacturing scenario is volatile and industrial units need to be cautious while investing in new areas and embarking on expansions. Although capacity addition may be less, the situation will improve. He further added, “I am delighted that IMTMA has launched a show in Chennai. There is a large pool of SMEs in Chennai which provides the potential for growth and exhibitions like this are key enablers.” Stating his views on CMTX 2019, Indradev Babu, President, IMTMA said, “IMTMA has always played an enabler role in the development of
machine tool industry and Chennai Machine Tool Expo is one such initiative to bring technology to the doorsteps of the industrial units located in Tamil Nadu and South India.” He added, “We have received an encouraging response to the show given the tough market situations. I can see immense potential for the show to grow in the future.” In his welcome address, Mr. V. Anbu, Director General & CEO, IMTMA said, “Chennai Machine Tool Expo will bring immense value to SMEs based in Chennai. We have 55 companies participating from 5 countries.”
Indradev Babu appointed as IMTMA’s President The Indian Machine Tool Manufacturers’ Association (IMTMA) held its 73rd Annual General Meeting (AGM) at the Bangalore International Exhibition Centre (BIEC). Indradev Babu, Managing Director, UCAM Private Limited was elected as the new President of IMTMA. Indradev Babu will succeed P. Ramadas, Managing Director, Ace
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Manufacturing Systems Limited as IMTMA’s President. Ravi Raghavan, Managing Director, Bharat Fritz Werner Limited was elected as the new Vice President of IMTMA. The new Executive Committee of IMTMA for the year 2019-2020 was also formed. Earlier, in a special session at the AGM, Kamal Bali, President and
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Managing Director, Volvo Group India Private Limited, spoke about the current economic downturn as well as the opportunities in store for the auto sector. He said that the slowdown that we see in the auto sector is cyclical and the industry should continue its efforts digitalization, innovation and providing solutions that are economically and environmentally viable.
Elaborating further he said that industry should move from the earlier definition of VUCA (Volatility, Uncertainty, Complexity, and Ambiguity) towards a new definition of VUCA, i.e. (Vision, Understanding, Clarity, and Agility).
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COVER STORY Q. What’s the standing of DVS Technology globally? The letters D, V and S stand for the technologies turning, gear tooth cutting and grinding. The technologies in the group name have a meaning, because all companies of the DVS Group do not only see their tasks in the mere sale of products. The mastery of the relevant technologies combined with the objective of performing the customer processes in an optimal manner is the focus of our endeavours. Hence, it is not surprising that not only machine manufacturers, but also tool manufacturers and service providers are united under the roof of the DVS Group. Optimal solutions can only be found if the process is looked at from a holistic perspective, together with all partners involved in the technology. Thus, we jointly develop innovative solutions for the manufacture of your work pieces. If required, we provide you with the entire process chain for work pieces, from the first machining step to the finishing operation. This also comprises the machines, the entire automation, the measurement instrumentation and of course the technology, as well. That’s what we do for turning, gear tooth cutting and grinding. The DVS Technology Group is strategically located worldwide to provide a fast & flexible service to all our customers. With our long-term partner, Nemade, we also have a highly qualified service & sales team in India for our Indian customers. Q. What’s your product portfolio? The DVS TECHNOLOGY GROUP is made up of experienced machining companies focussing on the turning, gear cutting and grinding technologies. The DVS TECHNOLOGY GROUP has more than 1,400 employees worldwide and is one of the leading system suppliers for machines, tools and production solutions for the machining of vehicle powertrain components before and after hardening. The following divisions make up the DVS TECHNOLOGY GROUP: DVS Machine Tools & Automation: Manufactures and sells high-precision machine tools, automation equip-ment and the associated services. DVS Tools & Comp-onents: Develops, manufactures and sells customised machine components, tools and abrasives. DVS Production: Series production of components for passenger cars and commercial vehicles using DVS machine tools.
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DVS International Sales & Service: Local DVS Contact for Sales and Service on international markets. DVS Machine Tools & Automation
DVS Tools & Components
DVS Production
DVS International
Q. What are the design features of your DVS products? With highly efficient machining technologies for maximum precision in conventional, hybrid and electric vehicle drives, the companies of the DVS TECHNOLOGY GROUP have made a name for themselves in the international automotive industry. The technology spectrum ranges from soft to hard fine machining of drive components. Specially developed tools tailored to the respective technology as well as a wide range of automation systems make the group the leading system provider in the industry. For companies in search of more flexibility, several million drive components are manufactured each year with high precision at two locations in Germany and one in China. Q. What are the unique advantages of your products? Thanks to access to the DVS technology pool, we offers machines with integrated production solutions from the blank to the precision component. PRÄWEMA gear honing achieves the highest degree of precision on the gearing. Through our experience which we have gained over the last ten years in our three production plants, equipped with our own machines, we have been able to continuously develop our machines through our knowledge, from which our customers today benefit. Q. What’s the common thread in infusing quality in all your products? The most important components of a machine tool are the spindles, the clamping devices and the tools and are manufactured by our own DVS companies such as WMZ, DVS Tooling, Naxos Diskus, SWS and Klopfer to ensure the
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COVER STORY
Leadership in performance driven technology solutions Mr. Moritz Lange-Piëch Coordinator Sales & Strategy DVS India DVS Technology Group
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COVER STORY
quality and delivery times of the machines. The experience and the latest development status are thus automatically incorporated into the next generation of machines, resulting in a consistent and continuous further development of the DVS machines and their quality. Q. Is maintenance crucial in your kind of products? One of the best known products, which is also very common in India, is the Diskus (Naxos Diskus) machine DV600, some of which have been in operation for over 40 years and require very little maintenance. As is the case with modern cars, today’s machine tools have become more complex and powerful. To ensure continuous quality and performance, all machines should be serviced after a certain number of operating hours to check the wear parts. In India, our partners Nemade have more than 12 service engineers who are working around the clock for our customers. Q. What’s your single most contribution towards enhancing automation & productivity in the industry? The DVS Technology Group is currently pursuing two strategies to counter automation and productivity in times of strongly fluctuating call-off numbers and fast pace in the automotive industry. The first strategy is based on the development of flexible automation solutions using camerabased workpiece recognition, for which we incorporated the company RBC-Robotics into DVS-Technology Group in February 2018. The second strategy is our UGrind 800 machine from Universal Grinding. Thanks to the innovative possibility of efficiently changing between chuck workpieces and shafts and the integrated grinding, milling, turning and measuring technologies, customers are offered an extremely flexible and high-precision machine at a very fair price.
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Q. Who are your major customers.? In principle, every customer is important to us. Our main sales market with almost 80% is the automotive industry or powertrain. We have also successfully completed orders for the Indian automotive industry with very good results. In addition, we work closely in technology development with a company based in Pune, which has recently opened its new factory ceremon-iously, where you will also find some of the DVS machine. Q. What are your growth plans? The DVS Technology Group would like to concentrate not only on the old growth markets but also use this time to strengthen its presence in possible new growth markets such as India, especially in times of fluctuating global economy characterized by trade conflicts and reorientation of modern mobility concepts. Q. And are your future thrusts to make the most of the opportunities brought by a burgeoning economy? As a basic principle, a company should not assume a permanently flourishing economy, but should always expect a fluctuating economy. In order to maintain and further expand our success in good and bad economic times, we offer our customers an extremely extensive product portfolio, ranging from large series machines to shop floor machines to special machines, from tools, clamping devices and spare parts to fully automated systems. Several years ago we started concentrated on e-mobility and have acquired a comprehensive and one of the most technologically advanced know-how in our industry. In the coming years there will be almost no BEV from a German OEM in which at least one part of a DVS machine has not been manufactured.
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IN FOCUS
Performance lubricants enhance productivity, profits
Mr. Deepanker Banerjee, CEO, ExxonMobil Lubricants
Q. What are the current technology trends in lubricants for infrastructure equipment? The infrastructure equipment in India is witnessing a new wave of global benchmarking, and so is the country’s lubricant sector. Companies are waking to the benefits of technologically superior world-class application-specific lubricants that yield huge dividends in terms of improved productivity and significant cost savings. The lubricant industry is gearing up to meet the need for customised specialty products, giving Indian customers best-in-class products developed through global expertise of decades. The trend is of synthetic lubricants, or like we call them,
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designer lubricants. Synthetic lubricants differ significantly in composition and performance from conventional lubricants. The new generation of MobilTM lubricants aptly demonstrate the immense value created by synthetic lubricants. Q. Could you elaborate on your range of lubricants for construction, mining and material handling equipment? The machinery and equipment in the construction and mining sectors face harsh conditions - from heavy loads and high temperatures, to excessive wear, dirt and water contamination. These industries require lubrication solutions that are as durable as their equipment.Our offerings for the construction and mining equipment
have been designed specifically to meet the needs of customers with heavily loaded equipment that require high EP/anti-wear performance. The greases remain in place even in tough conditions of water wash, high sliding and high temperature. We have a portfolio of advanced product offerings for the construction, mining and material handling equipment sectors. The customized lubricants for the mining sector include Mobilgrease XHP 321 Mine and 322 Mine. The Mobilgrease XHP Mine series has excellent extreme pressure and anti-wear properties in addition to exceptional staying power, good water wash-out, water spray-off and extended service
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IN FOCUS capabilities under harsh operating conditions. Q. What are the features of your lubricants in terms of performing in extreme weather and temperature conditions? Our Mobil SHC™ line of synthetic lubricants is designed to protect equipment operating under severe conditions, including loads and pressures, frequent starts and stops, wide operating temperature ranges and contamination. These lubricants offer long oil life and extend equipment life, creating less waste and potential energy savings, while helping increase worker safety by minimizing potentially hazardous maintenance. The advantages of Mobil SHC synthetic lubricants include high-temperature capability, excellent resistance to oxidation, low-temperature flow properties and protection against wear. The Mobil DTE 10 Excel™ Series, a mineral product that can perform in extreme conditions, consists of high performance anti-wear hydraulic oils specifically designed to meet the needs of equipment hydraulic systems. Its outstanding oxidation and thermal stability allows long oil life and minimized deposit formation to protect critical hydraulic system components from malfunction. While the shear stable, high viscosity index allows for a wide operating temperature range maintaining maximum hydraulic efficiency at all temperatures, the zinc free anti-wear system provides a high degree of protection in gear, vane and piston pumps while minimizing deposit formation. When it comes to choosing the right lubricant, viscosity is another key factor. As temperature rises, viscosity decreases, and as temperature decreases, viscosity
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increases. Synthetic lubricants with high VI, such as those in our Mobil SHC™ family of synthetic lubricants, can help protect equipment from a wide range of operating environments and conditions. They are formulated to resist thinning at elevated temperatures to deliver superior equipment protection as compared to conventional, mineral-based lubricants that have a lower VI.
Q. How are lubricants gearing up to save wear and tear of engine parts? Lubricants are the lifeblood of machines and the right lubricant not only saves wear and tear of engine parts but also helps increase productivity, reduce unscheduled downtime, improve equipment durability and lessen lubricant consumption. For instance, we have the Mobil Delvac™ 1 line of heavyduty diesel engine oils, designed to help commercial fleets drive business growth by boosting uptime and reducing fuel costs. Formulated to exceed the prescribed norms, Mobil Delvac 1 oils deliver fuel economy without sacrificing wear protection and can help extend engine life by reducing the wear and tear. Q. What do customers look for while selecting a lubricant for construction/ mining/material handling application? Customers are looking for industrial expertise like Mobil’s that has helped companies and equipment owners around the world lower costs, improve productivity and enhance equipment efficiency. Our highly experienced Equipment Builder engineers work closely with leading
OEMs to help guide our research chemists and lubricant formulators in developing lubricants for the most demanding applications. Our wide and responsive distributive network is another big advantage, considering that mining operations are located in scattered locations. The strong distribution network allows us to give urgent attention and support to our customers. if the need arises. Q. Where do you see the market for lubricants in the next five years? What will be the demand from infrastructure equipment segment? The lubricants market in India is robust and expected to grow consistently at a CAGR of 4.64% over the next five years. The construction and mining equipment sectors are the areas where we expect strong demand in the coming years. This growth can be attributed to green field projects, capacity expansions and embracing of new technology in key sectors like construction and mining. Q. What are your product and market expansion plans? We are bringing our finest specialty lubricants to meet the growing demand for high-quality and improved-efficiency materials that enhance productivity and profits. In terms of product expansion, the Mobil SHC™ Elite is the newest member of our Mobil family of synthetic lubricants that provide performance advantages far exceeding the capabilities of conventional oils. These lubricants can help extend equipment longevity and generate potential energy savings, for our customers, while their significantly longer life – thanks to a 12x oil drain interval - lowers maintenance costs & reduces worker exposure during oil changes.
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INDUSTRY SPEAK
Women in Manufacturing Is manufacturing offering lucrative career opportunities to women? What kind of jobs are they getting in this sector? What are the opportunities available to them for career progression? Industry leaders reflect on this important topic. - P.K. Balasubbramaniian
Mr. R. Jayakanthan, Director - People, Systems and Strategy, ELGi Equipments Ltd. Q. Do you think Manufacturing is offering a lucrative career opportunity for women? Today, modern manufacturing is undergoing a transformation – the fourth industrial revolution. With technological advances and the convergence of conventional and digital manufacturing, the skillset demands are changing. Talent, apart from being key, is also in shortage. Women are largely underrepresented and underutilized in the manufacturing workforce and represent one of the largest pools of untapped talent for manufacturers all over the world, however. A study on Indian women in manufacturing sector reveals that women represent only about 3% in core engineering industry while it is up to 12% in sectors such as electronics. This is against the women representation of ~21% in the organised sector. Global Studies reveal that women make up at least 40% of the workforce in more than 80 countries
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and in contrast, studies have also revealed that manufacturers’ top concerns have been the inability to attract and retain a quality workforce . In fact, there are about half a million jobs open in manufacturing right now, across the world. So, yes, there is tremendous opportunity for women to not just build meaningful careers in manufacturing but also drive the future. Q. What kind of jobs women are getting in this sector? Well, it does depend on the skill set really – but the opportunities are quite limitless. At ELGi for example we have women in every function, from shopfloor to leadership.. They’re blazing trails and inspiring other women, every step of the way. Q. What are the opportunities available to them for career progression? At ELGi, career progression is purely
based on performance and passion and one’s gender doesn’t play a role. Employees move to the next level based on their potential and the opportunities available in the organization. In my view, the industry need to focus on building female role models to inspire and encourage young women. We need to adopt and develop more inclusive workplaces and we need to find creative ways to build flexible and good work-life balance for all our employees. Q. How is the women workforce distributed in ELGi? What kind of job roles they serve in the company? At ELGi, as I mentioned before, we have women workforce in blue collar and white collar. From shopfloor to R&D to supply chain, Sales & Marketing, IT, finance and If we look at our current distribution, we’re at about 30% in sales & marketing support; 18% in finance & HR and 14% in technology.
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INDUSTRY SPEAK At ELGi, We conduct a two day women exclusive sports event once in a year in line with the Annual Sports Day with varied outdoor activities. Q. Because of technological advancements women are now opting for jobs in the manufacturing industry as compared to IT industry – What is your view on this? Well, studies reveal that over 70% of women would stay in manufacturing if they were to start their career today. Now this is very encouraging, however despite progress, studies also reveal that less than 15 percent of women surveyed believe their industry is very accepting of family / personal commitments and allows them to meet these commitments without impairing their career . More than 4 out of 10 women surveyed are either responsible for the majority of household duties or share home
manufacturing, especially with young students and aspirants. Besides some public sector enterprises, organisations such as HAL, L&T, Mahindra, Tata motors, Mondelez to quote a few, are attracting and retaining women, not just in factory floors but in operations leadership. Other companies should learn to create ecosystem and environment that help women succeed The industry also needs to look at engaging and retaining women at career points when their lives become more complex. Providing support, extending flexible options and alternate career pathways can also help manufacturing organizations attract the right talent. Finally, all efforts to address the gap, starts with leadership including board and need to begin with the dominant group; that’s men.
responsibilities equally with their spouse or partner. Nearly three quarters of women surveyed believe they are underrepresented in their organization’s management team. Manufacturers worldwide, have room for improvement when it comes to attracting, retaining and developing women talent. Q. How do you think more women can be brought in the manufacturing sector? The perception of manufacturing continues to be slightly outdated among women. In my view changing or improving that perception is key to attracting women talent. Creating an environment that is supportive for women, extending parental leave and providing work life balance is something to be worked on. What is also critical is sharing success stories and positive views about
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INDUSTRY SPEAK
Women are underrepresented in India’s manufacturing sector : Satish Bhat Mr. Satish Bhat, Managing Director, Ador Welding Limited Q. Do you think Manufacturing is offering a lucrative career opportunity for women? Women are underrepresented in India’s manufacturing sector with participation ranging from only three in the core engineering sector while it goes up to 12% in the computer engineering sector as per latest studies. Compounding this problem and creating an urgency around getting more women into manufacturing is the fact that plenty of jobs are out there ready to be filled, as manufacturers currently face a workforce crisis. Attracting more women is critical to helping manufacturing companies grow, fill job vacancies, and replace their existing aging workforce. However, this does not mean that opportunities are scarce. With each passing year, we see an increased representation of women in the core manufacturing sector with companies consciously providing the necessary safety, convenience and skill development for women . There are a wide variety of positions — including high-level, high-earning positions — in manufacturing in areas such as life sciences, technology, media and telecommunications,
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energy, automotive, and many others. Today we already have several examples of companies having significant women representation including our own. Q. What kind of jobs do women get in this sector? There is a dearth of women in senior positions overall. A study reveals that this is due to lack of role models. To dwell on this topic further and reasons for it, I would say that this is due to a number of factors - some like a general underlying thought that women are not built to handle tough conditions on the shop floor. Women in India face biases in gender discrimination right from their upbringing where the roles of their parents become very crucial. When they grow up, they are expected to strike the right balance between work and family which makes them leave career half way to focus on their family among other issues. In the manufacturing industry, as a direct result of the abundance of men, internal company cultures tend to be male-oriented. Abolishing this culture will help increase women’s interest in manufacturing. Q. What are the opportunities available to them for career progression? Women represent one of the
largest pools of untapped talent for manufacturers and closing manufacturing’s gender gap is the key to closing the skills gap that has limited businesses’ ability to evolve and expand. In addition to filling open positions, gender diversity benefits manufacturing firms by creating a culture that improves their ability to innovate and grow. Today opportunities are available at every level for women in the manufacturing sector. The need of the hour is to facilitate the growth of women in their careers. The manufacturing Sector is facilitating this with actions taken to ensure that women are provided a conducive working environment and relevant training. Ador Welding has been taking giant strides in enabling the entry of women at various levels and providing opportunities to women on the shop floor. Women in manufacturing are increasing; they are building meaningful careers—and quite literally building the future. Q. How is the women workforce distributed in your organization? What kind of job roles do they serve? We have taken a lot of effort to provide a conducive working environment to all employees within the organisation. We have a POSH (Prevention of Sexual
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INDUSTRY SPEAK Harassment) policy in place with the sole intention of educating the male counter part on enabling a conducive working environment for his lady colleague at work. At Ador Welding we have women at all positions working-hand-inhand with their male counterparts at our Manufacturing plants, be it as Manufacturing In-Charge, Welder on the shop floor or Women working on assembly lines. Besides we have women working across departments at senior managerial positions at F&A, HR, Legal & Secretarial, R&D & Marketing. Q. Because of technological advancements, more women are now opting for jobs in the manufacturing sector as compared to IT industry. Your comments? I agree. Rapid technological advances and the convergence of physical and digital manufacturing are helping change the way manufacturers operate and raising the bar for required employee skill sets. The manufacturing sector is seeing
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large scale digitalisation, the use of IOT & AI as it progresses towards smart factories and Industry 4.O. The skill sets required for running these factories will even out the playing field to a great extent for women and hasten their presence in the Manufacturing sector. Also, the Manufacturing sector provides vast avenues for continuous core learning which gives an added appeal to this sector. Q. How do you think the ratio of women workforce be increased in the manufacturing sector? Some thoughts… Attrition: It has been observed in India that a woman may take maternity leave and not come back. To ensure that women are retained, the concept of parental leave should be brought into place, to ease the burden off women’s shoulder, and the responsibility could be equally divided between both the parents. Eliminate difference in Pay scales: There is still difference in pay scale when it comes to men and women,
but now there are more women who are willing to work, a lot of them don’t really mind working odd shifts as well because they want to grow on par with men Creating the right culture: Organizations can unleash the full potential of their female workforces by creating a culture where unique strengths thrive. Culture can’t change without women in the room, so companies should incorporate strategies to attract high-performing women and develop solid retention strategies. Grooming them for Leadership positions: Further, focusing on leadership development can drive retention and foster diverse leadership perspectives. Understanding and addressing needs such as flexible workplace options also aid in recruitment and retention. If unique strengths aren’t thriving, it is time to adapt and make changes to build a beacon that attracts the best and brightest.
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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
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AMT SECTION
TECH TRENDS
The new HAUSER™ 2000 Universal jig grinder
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he new HAUSER™ 2000, the successor to the H35400 model, is a universal jig grinder with proven technical features such as automatic taper grinding, automatic grinding tool changer (ATC) and automatic pallet changer (APC). It can be expanded easily to an autonomous grinding unit. The HAUSER 2000 not only meets the demand of the market for combined grinding and hard milling on a single jig grinder, but also enables further improvements in machining precision to meet future requirements. The main technical feature is the dual-frame design, which significantly increases the rigidity of the grinder and therefore ensures even higher precision. In this boxtype design, the machining head is positioned centrally within the machine frame, thus enabling machining forces to be optimally controlled. Almost no transverse forces are created – the prerequisite for ultra-high geometric precision machining. Since the tool machining point is located at the center of the machine, practically all thermal
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expansion effects are eliminated. With higher dynamic axis movements and significantly greater rigidity, the HAUSER 2000 gives the best possible conditions for finishing with hard precision milling. The overall result is a significant increase in productivity not only for the ultraprecise grinding processes on the machine but also for hard milling. For more information, harsha.subbaraju@hardinge.com
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TECH TRENDS
OCTOBER 2019
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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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www.Mastercam.com
OCTOBER 2019
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Dimensional Measurement Systems For Manufacturing Quality Control
Advanced optical and multisensor systems from QVI are engineered for use in everyday manufacturing settings www.qviindia.com
More Information
info@qviindia.com
AMT SECTION
TECH TRENDS
DIE CASTING WEAR PROTECTION The sCarbide Application Equipment is the proven solution to the greatest wear problems facing die casters. Just “Rocklinize,” or apply a precisely controlled amount of tungsten carbide, to eliminate: Heat Checking Small cracks form a closed network, and become so large that the casting metal will flow into the steel surface below, often requiring resinking or remaking the die entirely. Rocklinize the areas most prone to heat checking Soldering Soldering of the zinc or aluminum casting material to the die surface is a cause for rejection of many castings. Rocklinize prior to a production run to eliminate soldering at gates, vents, parting lines, and the die cavity where molten metal will often solder to the cavity. Galling or Seizing of Cores The thermal expansion of zinc and aluminum die cast metals is much greater than that of the steel core. The metal shrinks onto the cores, resulting in extreme pressure at the core section. Rocklinized cores make the lubricant or die releasing agent adhere better to the steel, providing a nice finish on cast parts. Wear on Gates, Vents & Runners These wear areas stay much cleaner when they’ve been Rocklinized. Ejector Pin Flashing: Rocklinize the ejector pin about one inch back from the face of the cavity. What are the ultimate results of the portable Rocklinizer in die casting operations? • LESS Machine Downtime • LESS Operator Idle Time • LESS Die Removal & Reinsertion Time • LESS Die Maintenance • MORE Die life, Productivity, and Cost Savings.
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National Distributors Sanjay Tools & Adhesives X20, MIDC Ambad, Nashik 422010 Suhas Belapurkar - Mobile : +91 9892516810 Email: sbelapurkar@sanjaytoolsnsk.com Mr. Mandar Gokarn - Mobile: +91 9822028518 Email: mandar@sanjaytoolsnsk.com
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TECHNO FOCUS
Advanced Chemical Vapor Deposition Coating Systems Bernex™ CVD systems are the most reliable CVD machines on the market. Since their introduction in the 1970s they have proven their reliability in hundreds of installations world¬wide. They are used by all major manufacturers of cemented carbide inserts & are increasingly used for coatings on forming tools.
C
ontinuous innovation in process technology ensures state of the art coatings and a long life time of the investment. The systems are delivered with the most advanced process know-how and recipes for coatings on cemented carbides, steel and other substrate materials. The turn-key Bernex™ BPXpro CVD systems have a dual com¬puter system, self-diagnostic capabilities and fully automatic process control. Fully modular system architecture Optional CVD modules allow for the extension of the stand¬ard installation and enhance the production portfolio, im¬prove operational procedures and provide safety for opera¬tors as well as the environment. TiAlN module α and κAl2O3 module Automated TiCl4 Filling System The latest development is a low pressure module for the pro¬duction of high aluminum content TiAlN coatings at moder¬ate temperatures. TiAlN has been a mainstream PVD coating for cutting tools. With a higher aluminium content, CVD TiAlN features higher oxidation and wear resistance. Process temperatures: High temperature (HT) CVD: 900-1050 °C Moderate temperature (MT) CVD: 700-900 °C Process pressures: 2-900 mbar
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Multilayer CVD Coating In addition, a variety of interesting, application oriented variations can be deposited by means of multilayers, interface-layers, different coating morphologies, textures and grain sizes.
reaching internal cooling channels Controlled high and low activity processes Dual reactor design for high capacity. In contrast to the conventional pack, out of pack, above the pack and slurry processes, CVA does not clog internal chan¬nels and
Aluminum Diffusion Equipment As a further development of the CVD platform, the Bernex™ CVA systems are dedicated to the diffusion of aluminum into superalloy components like hot-section turbine blades of aircraft engines and land-based gas turbines, which are sub¬ject to hot corrosion. The CVA vacuum process uses gaseous precursors. It allows a very accurate control of diffusion depth and thickness over all inner and outer surfaces of the parts, irrespective of their geometrical complexity. The design of the Bernex™ CVA system allows for the control of low and high diffusion activity as well as co-diffusion of elements such as Silicon, Chrome, Zirconium, Hafnium or Cobalt and post diffusion process heat treatment within the same process cycle. Active gas flow
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TECHNO FOCUS
leaves no byproducts on the surfaces and therefore does not need postprocess cleaning of the components. It is environmentally friendly and leaves no residues. Chemical Vapor Infiltration Equipment Bernex™ CVI systems are designed to coat the internal surfaces of porous materials such as carbon fiber bundles or 3D bodies that are used to make fiber-reinforced composites (FRC). The equipment is designed to deposit high temperature protective coatings such as SiC,
BN, and pyrolytic C. Typical applications include aerospace, automotive, medical, and industrial compo¬nents. The resulting coating improves the mechanical properties of fibre reinforced composite materials in a way to protect the fibres from the matrix (ceramic, metal, carbon) while improv-ing the adhesion. The coating is infiltrated in a bundle of fib¬ers or a complex body in order to homogeneously coat each single fiber. Ionbond has used its extended know how of de¬signing High Temperature, Very-Low Pressure
CVD coating machines and went a step further to develop a state of the art CVI process. The design of the equipment allows for the infiltration to take place between 1 to 200 mbar and for deposition on the sur¬face even up to 900 mbar in the temperature range of 900 °C to 1600 °C. The flexible design allows for coatings to be de¬posited on large single objects or many small objects. Sev¬eral types of holding jigs are available to permit the coating of components on all surfaces. Additional customer tailored solutions can be considered.
Pmec India 2019
26 - 28 November 2019 India Expo Center, Greater Noida, Delhi NCR, India
Millenia Technologies (I) LLP HALL No. 14 & Stall No. A44
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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TECH TRENDS
Drake Internal Thread Grinders
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rind a full range of internal threads, grooves, ball tracks and other forms on Drake’s GS:TI Internal Thread Grinders. All GS:TI models are fully programmed and delivered with a grinding process optimized to run customers’ parts. Equipped with a power helix and Drake PartSmart™ menu-driven screens, these machines are easy to operate and deliver repeatable, accurate results. Drake grinders are built using premium materials, ensuring dependability and longevity regardless of your production schedule. Drake machines are designed for accuracy, consistency, and reliability. These internal thread grinders are built on high mass, cast polymer bases for vibration damping and thermal stability. The use of linear motors and linear roller ways allows for maximum acceleration and contouring. Dressing software is available for contour dressing of ISO, 60°, Whitworth, Acme, Buttress, full radius, Gothic arch, and other thread forms. Other standard features of Drake internal grinders include a high precision workhead and motorized wheel spindle. Additional upgrades, including automation, are also available. After assembly and verification is completed, Drake offers hands-on training. Working with the Drake team ensures that all your thread grinding requirements are met. Drake’s line of precision machines also includes: • External Thread Grinders: grind
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external threads up to 4m • Dual Spindle Grinders: grind multiple operations in one fixture setup • Crown Grinders: grind drums for tapered roller bearings • Vertical Thread Mills: rough mill parts for finish grinding • Rack Mills: high speed rack milling
process expertise throughout the thread grinding industry. For more information, WWW.DRAKEMFG.COM For additional information, contact our local representative. EMPIRE MACHINE TOOLS Mr. Alok Naik, alok@empiremt.com 2493 7340 / 2494 7066 / 2497 3184
DISCOVER DRAKE We are Drake Manufacturing. We are a full service, turnkey manufacturer of precision CNC machines and provider of engineered solutions. Founded in 1972, Drake is headquartered in Warren, Ohio. The premium Drake brand is known around the world for innovation and
sales@empiremt.com
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TECH TRENDS
IGUANA – Diamond tool for copper electrode machining With the IGUANA line of diamond-coated high-end milling cutters, ZECHA HartmetallWerkzeugfabrikation GmbH is setting a new standard for micro-precision tools for copper machining. IGUANA ball nose end mill, end mill with corner radius, and micro end mill are multi-cutters in the small-bore sector from 0.4 mm to 3 mm and ideally suited for the machining of non-ferrous metals such as copper or high-strength copper alloys (e.g. CuBe).
IGUANA ball nose end mill, end mill with corner radius, and micro end mill with laser-processed, sharp cutting edge. The trend towards copper electrode The trend towards copper electrode – developments, improvements, and innovations ensure continuous process changes in the production of electrodes. In recent years the trend in the field of die-sinking EDM is in the direction of copper. Miniaturization of components and lightweight construction are leading to increasingly filigreed geometries, for which the advantages of copper outweigh graphite. In comparison to graphite, in the manufacture of electrodes not only is tool wear greatly reduced with copper, but also the surface quality and dimensional
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accuracy are significantly improved. With the IGUANA line of diamondcoated high-end milling cutters ZECHA HartmetallWerkzeugfabrikation GmbH is setting a new standard for microprecision tools for copper machining. IGUANA ball nose end mill, end mill with corner radius, and micro end mill are multi-cutters in the small bore sector from 0.4 mm to 3 mm and ideally suited for the machining of non-ferrous metals such as copper or high-strength copper alloys (e.g. CuBe). With the help of laser processing, sharp cutting edges like
those that are already achievable with soldered CVD tools can be transferred to multi-fluted CVDcoated solid carbide tools – without affecting the hardness and strength of the diamond coating. A special benefit of this are the cutting edge radii of 1 µm that can be produced with a sealed diamond coating, which could be achieved previously only with radii above 5 µm. Especially when machining small copper electrodes with complex free-form surfaces, it is challenging to ensure geometrical and dimensional accuracy. Any deviation is transmitted 1 to 1 to the
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TECH TRENDS
form during die sinking and thus directly to the end product. In the automotive industry and in medical technology, tolerances of 0.02 mm are the standard in series production. In order to guarantee the required tolerances in the end product, these must be considered and, at the same time, maintained during the preceding processes. In the case of a plastic injection-molded part with a tolerance of 20 µm, the tolerance for the electrode production decreases over the course of the process chain to only 5 µm. In tests of copper electrode machining with the IGUANA end mills The surface quality was improved by more than 50% - with an average roughness of Ra= 0.035 µm and peakto-valley roughness of Rz= 0.2 µm. The filigree webs demonstrated no feathering or chatter marks due to tool wear. Even the finest structures at the end of the webs could be produced again with process reliability. Also, the cutting efficiency of the tool is unequalled in the industry – where previously a lateral infeed of 5 µm – due to tool deflection caused by wear on the tool – was necessary, with IGUANA the target contour was achieved directly. With an optimum process design, process reliability can be accomplished thanks to a tool service life, depending on component material, of up to several hundred hours. The high-end tool alone, however,
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The sharp and defined cutting edge with sealed diamond coating of the new IGUANA high-end milling cutters. is not a guarantee of optimum results. The determining factor is rather the interaction of tool, machine, and application. In addition to the continued basic abilities such as carbide selection, grinding of prestages, and subsequent CVD coating, laser technology opens further options along the path towards the perfect tool. The IGUANA line of end mills, which can demonstrate a sealed diamond coating despite sharpened cutting edge, offers enormous potential for optimizing processes and eliminating inefficient postprocessing operations, as well as increasing overall profitability thanks to longer service lives and therefore fewer tool changes. IGUANA – diamond-coated, laserprocessed tools. The potential offered by this new tool technology can also be applied to other materials. New findings combined with optimum
Precision Copper Electrode milled with IGUANA. adaptation to the requirements of component materials promise great improvements in different areas of use. It will be exciting to see where the technology will take us in the future. For more details please contact ZECHA Precision Tools Limited Mr. Mangesh Awate DGM- Business Development Email: mangesh.awate@zecha.in WEB: www.zecha.in
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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
TECH TRENDS
Faccin Metal Forming taking the middle east by Storm
Written by: Eng. Federico Bonfogo, Senior Technical Sales Manager
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apital investments are long-term decisions that allow companies to generate revenue for many years by adding or improving production facilities and boosting operational efficiency. Finding the right manufacturer is key to turning an investment into a significant asset for the business. The Kingdom of Saudi Arabia, spearheaded by its national oil company Saudi Aramco, has taken the ambitious strategic decision to involve more domestic companies
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in the development of the country’s infrastructure and as consequence, an important flow of investment in machinery and equipment is taking place. Aramco’s goal is to purchase 75% of all their material needs locally by 2021. Currently at 35% means they are going to slightly double their purchases from Saudi businesses in the next two years. Following suit, a large Saudi organization, approved to be listed in the Saudi Stock Exchange and
one of the first companies Saudi Aramco has worked with “in terms of achieving their objectives”, has decided to appoint Faccin to supply them with three 4-rolls plate rolling machines with capacities ranging from 75mm to 125mm plate thickness for their Storage Tank and Process Equipment business sectors. These three new rolling machines have been added to a medium sized plate rolling machine they acquired some time ago, a doubtless decision due to their positive experience with
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NEXT GEN
DEEP HOLE DRILLING MACHINES BTA DEEP HOLE DRILLING MACHINES
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Most complete range of deep hole drilling and hole finishing solutions in the industry Solutions cover nearly 200 applications in 15+ industries Hole sizes from Ø1 mm to Ø250 mm and hole depths up to Ø10,000 mm can be drilled and finished Precision crafted machines with 30+ years of proven industry experience One stop shop for all deep hole drilling and hole finishing needs Solutions are guaranteed to perform and produce world class results Local service and support in your area Precihole Machine Tools Pvt. Ltd.
Behind Harmony Arcade, Pimpalghar, Bhiwandi - Kalyan Road, Taluka Bhiwandi, District Thane - 421311, Maharashtra India. Mobile: +91 9167620639 / 643 / 648 / 231 | www.precihole.com | Email: sales@precihole.com
TECH TRENDS the company’s solutions and the after sales support received during these past recent years. Another demonstration of client loyalty is the installation, by an important shipyard based inside the port of Dammam, the home of the National Oil company Saudi Aramco and part of one of the largest Marine Infrastructure companies in the Kingdom of Saudi Arabia, who controls and manages a number of maritime and construction projects in the MENA region, of a 3-rolls plate rolling machine with variable geometry configuration model HAV, an unbeatable combination of rolling power and pre-bending precision. Furthermore, a Dubai state-owned company, primarily focused on the upstream oil and gas industry with top level customers such as Schlumberger, Halliburton, Baker Hughes, Weatherford, after having experienced the company’s quality and reliability at theirs plants in Middle East and Far East, has awarded FACCIN with another order for a new plate rolling machine for its new manufacturing facility in Saudi Arabia. The investment was driven by the need to enhance the company’s IKTVA (in-Kingdom Total Value Added) and thus ordering a 4-rolls plate rolling machine, a solution that combines power, reliability and precision in an exclusive package that makes it the state of the art in modern plate rolls. When it was time to expand their factory, due to the continuous growth in customer’s demand, a
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UAE based company specialized in oil and gas, petrochemical, power and water, marine and mining industries has selected the 4-rolls plate rolling machine as the right answer to its needs. More importantly, the success obtained in many challenging projects in the Middle East, have led the company to increase the level of trust amongst its clients, showing the company’s long-term commitment and converting Faccin in the number one choice for metal forming machinery. Hundreds of plate rolling machines successfully installed in the region from medium thick plates to over 300mm plate thickness, demonstrate a prompt service support available not only for installation & commissioning but also for training and preventive maintenance makes the company’s plate rolling machines the solution suitable to effectively cover the needs of each manufacturer.
The Company More than 200 years combined experience, forming today’s future. Faccin S.p.A. is a very powerful group which combines the best brands – Faccin, Boldrini and Roundo – in plate rolling, profile bending and dished-heads manufacturing, all united under one roof and offering the widest range of high-quality options available in the metal forming market.
Should you be interested in this technology, do not hesitate to contact us and book a demonstration. www.faccin.com
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TECH TRENDS
Achieving absolute precision for automotive production Sensors are rampantly being used to meet the ever increasing precison requirement of automotive production. From the pressing plant to assembly and quality assurance, sensors are used in process control, monitoring of supplier parts and in final inspection, while optimizing the production process
I
n fully automated processing, a large number of sensors is required for monitoring and control tasks. Due to the increasing requirements for process stability, production reliability and quality, ever increasing precision and data rates are necessary. In terms of Industry 4.0, sensors from Micro-Epsilon ensure that data is acquired in real-time and can be used for the respective application. From the pressing plant to assembly and quality assurance, sensors are used in process control, monitoring of supplier parts and in final inspection, while optimizing the production process. Monitoring metal sheet infeed during the pressing process A core process of automotive
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production is the manufacturing of frame, chassis and car body parts in the pressing plant. A tool punch presses the plate to be formed into the mold (die). The flange of the sheet is partially pulled inwards because the thickness of the component decreases as a result of the deep-drawing process while the displaced material flows from the edge of the sheet. This distortion can be detected as a change in distance. This value is crucial for the quality assessment of the pressed part and for controlling the tool punch. The measurement of the distortion is carried out using several optoNCDT 1420 laser triangulation sensors, which are placed around the metal sheet, either in the tool or on the side of the
tool. Due to their extremely compact design, these laser sensors can be effortlessly integrated into restricted environments. The arrangement is chosen in such a way that the laser beam measures on the edges of the sheet, which is between the top and bottom of the tool. Due to the extremely small measurement spot size, the sensor is able to measure extremely tight gaps between the two tool parts. The measured values are transmitted via analog or digital outputs to the controller. They allow a conclusion to be drawn on how much material has flowed which enables to control the pressing force during the process. Marriage of engine and car body optoNCDT laser displacement sensors,
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TECH TRENDS for example, monitor the “marriage” of the car body and the engine. Car body and engine, i.e. the entire drive train, are joined together in so-called marriage lines. Therefore, the drive train is moved into the production line on a frame. At this point, the car body is suspended from a device and is swiveled from above by a robot in such a way that the car body is above the drive train, which is then lowered onto it. Laser displacement sensors mounted on the device measure the distance between the car body and the engine. Via the distances values, the robot receives the exact position of the engine. This is how the car body must be placed exactly onto the drive train and fastened accordingly. Due to their large measuring ranges and their insensitivity to different reflections, optoNCDT laser sensors are particularly suited to this
Strengths of laser point sensors optoNCDT laser point sensors are used in the automotive production for displacement, distance and thickness measurements. Due to the RTSC real-time surface compensation feature, the laser-optical measuring system operates almost regardless of material and color. Their extremely small measurement spot size also enables the measurement of very small objects, while simultaneously providing high accuracy measurements with an accuracy down to the micrometer range. Measurement data is generally available via different interfaces and so can be used to control the production process. Laser sensors from MicroEpsilon are available in different models which cover measuring ranges from 2 to 1000mm and measuring rates from 2 to 49.14kHz with resolutions up to 0.03µm. As well as in the automotive industry, laser sensors from Micro-Epsilon are used in high-tech automation such as the automotive industry, semiconductor manufacturing and 3D printing.
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measurement task. Another advantage is that the sensors are equipped with an integrated controller. This makes the installation of an external controller superfluous and simplifies mechanical integration and wiring considerably. Highly accurate cockpit positioning Another robot-based assembly step is the cockpit installation in the car. The car cockpit includes hundreds of individual parts and weighs up to 100kg. Its installation requires extremely precise positioning work. Therefore, a rectangular frame of metal struts with two grippers is mounted on the outsides on a robot arm. The gripper grabs the cockpit on both sides and moves it horizontally in the direction of the vehicle, which is fed into the assembly line on a conveyor belt. Shortly before reaching the vehicle, the robot inclines the cockpit side to be mounted slightly downwards. In this position, the cockpit is swiveled into the passenger compartment over the robot through the opening, which is intended for the driver door and then turned horizontally again.To monitor the position, four optoNCDT laser sensors are used which are installed in the four corners of the metal frame respectively. The sensors measure reference points
in the vehicle interior. These can be prominences and depressions. These four sensors ensure that the cockpit is properly aligned in the x-, y- and z-axes. When all sensors have detected their respective reference marks, the robot is stopped in order to move the cockpit forward into exactly this position relative to the car body, to dock it on and to fix it in place. For the entire process including the fitting of the cockpit, an extremely short cycle time of less than one minute is required. The sensors must operate independently of the surfaces, as different reflections occur due to the multitude of different surface paints used – from dark to bright colors and from mat to shiny surfaces. Therefore, the laser sensors must be able to control the intensity and the reflections in real-time to ensure reliable positioning processes. Car windows In the automotive industry, there are
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More Precision
NEW
Smart laser triangulation displacement sensor optoNCDT 1420 Laser triangulation sensors for displacement, distance and position Compact and user-friendly: easy integration into confined spaces Robust and long-life design Repeatability from 0.5µm Small light spot Analog and digital outputs Unique ease of use via web browser Presets for various surfaces
+91 20 4913 1030 | info@micro-epsilon.in | www.micro-epsilon.in
TECH TRENDS measurement tasks which require simultaneous detection of several measurement values or threedimensional detection of measurement objects within short cycle times. For example, when installing the windshield, a scanCONTROL laser line sensor detects detailed distance values in all axes. In the installation process, the sensor is mounted onto the robot, which fits the window into the vehicle. When the windshield is placed on the car, the scanner detects the complete profile and vicinity of the windshield while all necessary values are determined with a single run in quick time. It can be determined whether the windshield is placed Strengths of laser line triangulation The strength of scanCONTROL laser scanners, also called laser profile sensors, is their compact design, which allows for the sensors to be integrated also in restricted installation spaces. The entire electronics is housed in the sensor, i.e. no external controller is required. Robot-suitable cables enable extreme twists and torsion movements on the robot. In addition, laser scanners from Micro-Epsilon have a sensitive receiving matrix with high resolution that enables measurements on almost all industrial materials, largely independent of the surface reflection. Laser scanners detect up to 2048 points on a laser liner. Via a relative movement from the sensors to the measured object, also three-dimensional captures with high resolution can be generated. Micro-Epsilon offers laser scanners with either red or blue laser diode, which is usually only used when the red laser light is operating at its limits, e.g. with organic materials, wood, semi-transparent materials or red-hot glowing metals. The blue laser light can be more sharply focused on certain surfaces where it provides high precision measurement results.
straight and centered or whether it fits perfectly in every plane. The results, which are in this case the gap and flushness, are directly generated in the sensor and output to the PLC. Another measurement task concerns the adhesive, which is already applied before the windshield is fitted into the chassis and also detected by a laser scanner. Therefore, the scanner is directly mounted onto the robot that applies the adhesive beading. Here, the sensor moves along the adhesive bead to create a 3D image. It reveals whether the adhesive quantity is constant, whether it is applied evenly and whether the bead is applied in the correct places. All detected measurement values are stored separately. If an error occurs in the process at a later point in time, these measurement values can be used for analysis purposes. Gap inspection When assembling a vehicle, numerous gap and flushness measurements are necessary. This includes, among other things, the position inspection of airbag stitching. The scanner detects the contour of the stitching while being guided by a robot arm and evaluates several features synchronously. The laser scanner continuously inspects the distance between the stitching and the separating point between the single
stitches and outputs the evaluation directly as 0 (NOK) or 1 (OK) via the Ethernet interface. Beyond that, the height difference between two single components is directly inspected in order to immediately recognize any faulty assemblies that might impair the safety. Another measurement task involves gap monitoring in car interiors. Important parameters of quality are homogeneous gap sizes of cockpit elements and the center console. Depending on the inspection situation, a single scanner applied on a robot arm can measure different gaps in a static or dynamic mode; alternatively, a special frame on the robot arm is used that enables the scanner to detect a number of different gaps in the interior in static mode within fractions of a second. The sensor evaluates these measurement values and sends a signal to the control system if the values measured lie within the tolerances defined by the customer. Other gap inspections also concern the car body, e.g. when measuring gaps in doors or when assembling body trims.
Authors: Erich Winkler Product Management Laser Triangulation Sensors Christian Kämmerer, Sales Manager 2D/3D Optical measurement technology
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TECH TRENDS
Advanced system for parting & grooving Always at the cutting edge of developments in the field of cutting tools, ISCAR introduces a new system for parting and grooving operations
P
arting and grooving are essential aspects of the turning process and the metalworking industry faces a constant challenge to integrate methods that will increase efficiency and decrease downtime for these popular operations. ISCAR fully understands the importance of parting and grooving operations in the turning process and that multiple factors need to be considered for every application, including machine tool selection, the type of material being parted/ grooved, required depth of cut, and feed and speed rates. ISCAR has responded to these complex needs by developing a comprehensive range of highly effective parting and grooving solutions that include an extensive choice of insert geometries, chip breakers, and carbide grades –and the range continues to expand.
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With Industry 4.0 demands and standards fueling industry development at extraordinary rates, ISCAR has introduced new parting and grooving technologies capable of integrating seamlessly with the new wave of machining centers that work with incredibly high feeds. MULTIF-GRIP has been designed to answer these needs and to achieve high productivity and lower costs. A revolutionary parting system
designed for increased productivity, MULTI-F-GRIP comprises a robust tool block carrying square blades that feature four pockets, with a unique parting concept capable of parting off up to 120mm bar diameter to optimize performance. MULTI-F-GRIP is simple to mount and operate on all machine types, including multi-task and machining centers on X-AXIS, without any need for special adjustment. The system enables the mounting of both TANG-FGRIP and DO-GRIP blades on the same blocks. The square blades possess a support system that provides totally vibrationfree grooving and parting. MULTI-FGRIP also saves on setup time as, in cases of pocket damage, the block’s configuration allows a blade to be rotated to a new pocket without setup. MULTI-F-GRIP is intended for
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TECH TRENDS high feed parting. It extends insert life, improves surface finish and part straightness, and features high stability - especially when parting large diameters. The new patented blades reduce cutting time and also enable significant material savings for instance, a 120mm bar can be cut with a 3mm blade with HF (high feed) inserts at a feed rate of up to 0.4 mm/ rev (.0157ipr). The HF tangential single-ended insert was developed to enable highly efficient parting at very high feed rates, by use of a unique chipformer technology. The insert features a new insert chipformer to allow unobstructed chip flow, which increases insert and blade tool life and leads to very high productivity gains. All TANG-GRIP inserts can be integrated into the MULTI-F-GRIP system, which is also compatible with DO-GRIP DGN double-sided twisted geometry parting inserts, to provide an extensive choice of parting widths for all application ranges. ISCAR offers a wide variety of chipformers and advanced grades to ensure unbeatable performance and extended tool life. A secure clamping method using a tangentially orientated pocket facilitates pocket life that is three times longer than that of any other conventional self-grip system. The
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robust clamping method enables machining at high feed rates and provides excellent straightness and surface finish characteristics, while the flat top configuration prevents chip obstructions under all possible machining conditions. The JETCUT system incorporates ingeniously designed through coolant channels to deliver coolant close to the cutting edge, which improves chip formation and slashes flank and cratering rates. When machining materials such as stainless steel or high temperature alloys, the temperature near the cutting-edge area becomes extremely high. In addition, these material types tend to adhere to the tools cutting edge, causing built-up edge. These problematic phenomena can be
moderated by targeting high pressure coolant directly to the cutting zone. ISCAR maintains its unrelenting progress as a result of the company’s continuous development of innovative, high-quality products, based on the talented work of the company’s R&D Department and prompted by the evolving needs of global industry. This desire to provide customers with the very latest, most efficient metal cutting technology is reflected in the introduction of MULTI-F-GRIP solutions to ISCAR’s comprehensive GRIP range of parting and grooving tools.
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An ISO 9001:2015
An ISO 9001:2015
TECH TRENDS
Linear Bearings for CNC machines doors and auxiliary axes
On CNC machines, not all motion axes are created equal. While spindle motions are all about accuracy and precision, doors and other auxiliary axes require a linear motion solution that’s easy to install and reliable.
Doors and auxiliary axes on machine tools need different linear motion components than spindles.
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he makers of CNC machine tools are not known for skimping on their motion control components, especially those related to spindle movements. Yet not every motion on a CNC machine is mission critical. In fact, most machines have one or more axes that, unlike the spindle, do not require high degrees of
Rollon’s Compact Rail bearings are both self-aligning and resistant to contamination.
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accuracy and precision. These axes can include doors and other auxiliary systems not associated with cutting. By picking an appropriate motion solution for these auxiliary axes, machine builders can not only take some cost out of a CNC machine but also improve that machine’s reliability in the field. Doors, in particular, are an axis that are often designed with less-thanideal motion components. From an
accuracy standpoint, door motion may seem like an open and shut case, but they do present some challenging design issues of their own. They tend to be large sheet-metal structures that are subject to deflection and alignment problems. They also have to work reliably in a contaminationprone environment filled with metal chips and cutting fluids. These size and contamination issues can be especially hard on linear bearings. Engineers who work in machine tools will sometimes reflexively specify recirculating ball linear bearings, in part because of familiarity. Yet this style of bearing is not the best choice when it comes to creating a dependable, cost-effective door. Rollon has developed an alternative bearing solution for doors and related
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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 auxiliary applications. It’s based on Compact Rail bearings, which are both self-aligning and resistant to contamination. Self-aligning. Aligning linear bearings is usually a difficult process that takes place during the machine building phase. Machine builders must first machine mounting surfaces to near perfect flatness. Then they’ll install bearings using fixtures to ensure that rails are aligned horizontally and vertically. Both of those steps can add significant time and cost to the machine. And in the case of machine tool doors, both of those steps may be both ineffective and unnecessary. They’re ineffective because the doors tend to be large sheet metal structures that will deflect in use, undoing even the most careful installation techniques. And they’re unnecessary because selfaligning bearings can accommodate deflection without the need for the expensive machining or fussy installation procedures. Rollon’s Compact Rail system gets its self-alignment capability from the way that its large roller bearings interact with a set of rail profiles. The profiles are designed to allow the rollers an extra degree of freedom or two to offset misalignment between rails. In the case of machine tool doors, an emerging solution combines Compact Rail’s U and K rail profile to support the slider (See Figure 1). The U-style rail has a flat raceway that allows a roller freedom translate in an out relative to the axial direction of the rail. The K-style rail has a geometry
a Compact Rail ranges from 0.003 and 0.006, depending on size.
that allows for limited angular rotation of the roller, while still offering precise linear guidance. Together, these rails can absorb significant alignment errors in two axes: Parallelism on the horizontal plane and height differences between rails in the vertical plane. How significant? It depends on the distance between rails. For example, at a two-meter span between rails, the system can absorb parallelism errors up to 4 mm in the horizontal plane and differences in rail height of +/- 50 mm. (See Table 1 for self-alignment capabilities at other rail distances). With the Compact Rail system, the source of the alignment errors is not important. Whether the errors are caused by the machine structure, installation or deflection in the field, the Compact Rail will adjust and do so without affecting the wear characteristics or lifespan of the bearing. Low Closing Force. Compact Rails additionally make the doors easy to open and close–and not just because design tolerates misalignment without impeding motion. Compact Rails also contribute to the smooth door motion because they have a low coefficient of friction (COF). The typical COF for
Contamination Resistant. Another important linear bearing attribute important in doors and other machine tool auxiliary axes is contamination resistance. Recirculating ball linear bearings, which have little clearance between balls and raceways, have historically been susceptible to contaminationrelated failures and require elaborate protective measures. Making matters worse, metal chips are among the most damaging contaminants in the industrial world. Rollon’s Compact Rail keeps contamination at bay in a few ways. It has small features, like seals and wipers, that minimize contaminants on the rails. Installation tricks, such as installing rails upside down, can further reduce contamination levels. Mostly, though, Compact Rail’s contamination resistance rests on its overall design. Its small ball bearings are permanently sealed within larger rollers. And the rollers have a large size relative to typical contaminants. They can roll over many chips that would stop a recirculating ball bearing in its tracks.
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
PMI’s advanced Ball Spline Series assembly simple. Due to keyway is machined, thus it may be deformed, and where the housing width is small. It is most suitable for model SLF. rigidity and large moment. • Ball Retaining Type With ball holder, prevent balls falling from the spline nut while assembling.
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 at the same time, and then increase the service life and rigidity. The balls recirculation in ball holder, prevent balls falling from the spline nut while assembling. Features • Large Load Capacity Every groove of the shaft is precision ground to form a 30° angular contact points. Thus, this model has large load capacities in the radial and torque directions • No Angular Backlash At a contact angle of 30° to provide a preload in an angular-contact structure. This eliminates an angular backlash in the rotational direction and increases the rigidity.
Types of Spline Shafts Precision Solid Spline Shaft (Standard Type)
Application Robots, Transporting equipment, Wire winder, ACT (auto tools change, etc. Types and Features Types of Spline Nuts • Cylindrical Type Ball Spline Model SLT
Special Spline Shaft
Hollow Spline Shaft The most compact type with a straight cylindrical spline nut. When transmitting a torque, a key is driven into the body. • Flange Type Ball Spline Model SLF The spline nut can be assembly to the housing via the flange, making
• High Rigidity Due to large contact angle, it can give proper preload subject to availability. Thus, it can get high
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TECH TRENDS
Bevel gear: New perspectives for small series production and special products
For bevel gears, this new solution significantly increases surface quality and component accuracy in precision grinding of small batches, while at the same time reducing manufacturing costs
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he creativity of the designers knows no bounds with new drive element and gear geometries. Faced with constantly increasing demands from a wide variety of industrial sectors, today solutions are being sought that often cause major problems in production. In addition to the challenges of mass production, the trend towards special products, small and special series, prototypes and test setups is omnipresent. But can these specific components still be manufactured economically and efficiently? Without compromising the required precision and repeatability in the manufacturing process? Previously, the production of small series had to be carried out at very high cost, which ultimately caused unit costs to explode. So far!
Haas Schleifmaschinen: Bevel gear produced on a Multigrind® CA. For bevel gears, there is now a completely new solution on the market that will make both designers
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and production departments sit up and take notice. Precision grinding of small batches on the Haas Multigrind® significantly increases surface quality and component accuracy, while at the same time reducing manufacturing costs many times over. Circular arc or cycloid - The Multigrind® realizes all conceivable gearings in quality 2 and 1. On the Haas Multigrind® grinding machine, almost all variants of special bevel gears can be ground extremely economically, both circular arc and cycloid geometries. And not only that: the ground bevel gears set new standards with regard to precision and reproducible quality. Wolfram Hermle, Chief Developer at Haas Schleifmaschinen, describes this in an example: “In every industry, be it automotive, aviation, robotics, wind power, etc., there are standard requirements for series products and a growing number of specific special applications. A modern high-performance transmission or differential in a production car can always be produced in series on a conventional milling machine. But not a special gearbox for a racing car. The demands on material and precision are so extraordinary that it makes sense to choose a much more suitable production route. Or let’s think of a satellite, whose awning has to be unfolded reliably after reaching the final position. The conditions in space make a second, third or fourth chance difficult. Also in the prototype development of the robot industry, no designer wishes that expensive
blanks be milled and ground until the desired result is almost perfect.” Bevel gear - milling or grinding? Grinding of course! For special productions in small series the use of expensive milling tools is not worthwhile. And in order to produce a perfect surface, you would have to regrind anyway. The Haas Multigrind® grinds even highly complex workpieces directly from the solid, faster, more precisely and also considerably more economically. And this article describes in detail how this succeeds. Bevel gear all-rounder + problem solver = Multigrind® In terms of flexibility, precision and productivity, the Haas Multigrind® grinding machine series is the perfect choice for small series production of highly demanding bevel gears. With at least 5 axes and an enormous drive power in spindle and rotary axes, this production unit offers a maximum of power and dynamics. The machine’s thermostable, vibration-damped cast mineral bed provides the required stability. Multigrind®: Gear cutting and (or) cylindrical grinding in a closed loop Complex workpieces such as special toothing on bevel gears can be completely machined in a single clamping, which significantly increases precision and saves a lot of unnecessary set-up time. Should, in exceptional cases, further clamping be necessary, this is done with
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TECH TRENDS repeat accuracy and without loss of precision. In automated machining, the patented tool changer guides the required grinding wheels of various sizes and designs into the spindle up to 58KW drive power. The grinding wheels with a size of up to 300 mm are dressed again and again during the entire grinding process, i.e. brought back to their correct geometric shape. The desired quality 2 and 1 for all gearings can only be achieved by exact form dressing in a closed loop. How new customer requirements push the boundaries of what is feasible Wolfram Hermle knows what relevance this new standard will have in bevel gear production in the various industries. “With our
Haas Schleifmaschinen: Wolfram Hermle.
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customer-centric approach, Haas Schleifmaschinen is part of the solution for many design engineers and workpiece manufacturers. We are often asked when the limits of what is feasible should once again shift in favour of more precision, economy and complex special shapes. The fact that a Multigrind® grinding machine, i.e. a universal grinding machine, masters these special tasks best seems to be a contradiction for many people who are not familiar with our technology. Our customers and users know that the high degree of flexibility of our grinding technology is also based on the intelligent control by the Multigrind® Horizon software. The perfect interaction of software and hardware makes the difference Thanks to the cooperation with Ph.D. Claude Gosselin of Involute Simulation Software Inc. and the software solution HyGEARS, the projected bevel gear is calculated according to exact path specifications. The interaction of Multigrind® Horizon and HyGEARS enables a very fast and exact 1:1-simulation, which is visualized three-dimensionally. In this way, the real image of the bevel gear to be produced is obtained and minimal programming errors can be
resolved in advance. The automatic collision monitoring before the start of production provides additional safety. The path-optimized calculation of traverse movements saves a lot of time later in production. The Multigrind® Horizon software together with the HyGears module allows you to configure, control and operate control instructions as well as machine data such as measured values, sensor data, control variables and parameters from the tablet. The complex mathematical design data can be described by a few parameters. The result: A user-friendly user interface with an intuitive operating concept. There is no need to spend a lot of time setting up the system individually with “fingertip sensitivity”. Orders are allocated automatically, either via the RFID codes of the raw parts and comparison with the ERP system or from the online shop. Haas has implemented the integration of production and measuring technology in the closed loop both with its own software and in the Multigrind® grinding machine. This means that the Multigrind® Horizon software is optimally designed for the production environment of Industry 4.0, a consistent step towards digitization in bevel gear production.
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TECH TRENDS
A new lease of life for your machine
STUDER machine overhauls - a second life for your machine.
A machine overhaul at STUDER can refurbish your machines’ guideways to the original specifications. After the assemblies have been reinstalled, the machine geometry is equivalent to that of a new machine
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5,000 operating hours. This is how long - or even longer - a 15-year old cylindrical grinding machine is in use. Anything that does this much will wear, and this particularly shows itself in the geometry and precision. High time to give the machine a good overhaul. A machine overhaul at STUDER makes an old machine into one that is as good as new; in other words, a machine that has the same tolerances as when it was first delivered. If the requirements on the machine have also changed, the machine can be configured and retrofitted to the customer’s requirements during the overhaul. The S40 was in use at LMT Kieninger for 14 years. The company specializes in highly demanding machining tasks and manufactures special tools for die and mold making. “The S40 was the Rolls Royce of grinding
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machines. But the machine still wears over time and after intensive use”, admits Heiko Braun, Group Manager of Cylindrical/Surface Grinding and Assembly. It was clear to LMT Kieninger that they should send the cylindrical grinding machine to the STUDER factory in Switzerland for an overhaul. STUDER provided them with a loan machine for around three months and took care of everything from A to Z - from collection through to customs formalities. “We were very satisfied with the loan machine. Apart from a few little things, we were able to continue grinding as usual”, sums up Braun. The special feature about a machine overhaul at STUDER? It is the only company to refurbish the machines’ guideways to the original specifications. After the assemblies have been reinstalled, the machine geometry is
equivalent to that of a new machine. Braun’s view: “This point in particular really convinced us. We notice the difference. Since the overhaul we have been grinding with the precision of a new machine. I can only recommend a machine overhaul. Everything went without a hitch, the investment has paid off and a 1600 mm machine is worth its weight in gold for us.” Rebuild – new from old A rebuild, or a machine overhaul, makes sense, and not just economically. The operator gets his familiar machine back and continues where he stopped before the overhaul. But he is full of enthusiasm! Because his old machine is like new. In the STUDER factory the specialists disassemble the machine into all its individual parts. The guideways are completely refurbished, the assemblies overhauled,
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TECH TRENDS the wear parts in the electric cabinet replaced, hydraulic and lubricating system as well as all valves replaced. If old spare parts can no longer be obtained, STUDER provides an alternative solution. The casing and components are sand-blasted and then given a fresh coat of paint. After assembly the geometry is like that of a new machine. Commissioning is carried out by STUDER Customer Care, including a functional and geometry inspection, all CE-compliant. “Over 20 people work on machine overhauls at STUDER. This shows the value of rebuild and retrofit at STUDER. The customers are always enthusiastic about the transformation and are delighted to put an as-new machine into operation at an excellent price-performance ratio”, says Marcos Cotarelo, Divisional Head and Customer Care Consultant. Expanding the component range If the customer wishes to expand his component range at the same time as the overhaul, he does this with a retrofit. During the machine overhaul the machine can be modified or retrofitted to the customer’s requirements. This opens up new production possibilities
STUDER grinding headstock before and after. on the same machine. Ingold Tools AG has taken advantage of this STUDER service. Ingold Tools AG has been producing high-precision and complex parts for spindle, compressor, hydraulic and general machine manufacturing with 25 employees since 1946. The machinery includes a variety of CNCcontrolled and conventional machines, including robot-automation solutions
Christoph Jenzer, Managing Director (Head of AVOR) and Edgar Stich, Managing Director (Head of Production) in front of one of the many STUDER machines at Ingold Tools AG.
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for turning, milling/drilling, honing, lapping, barrel finishing, sand-blasting, laser marking as well as surface and cylindrical grinding. The cylindrical grinding shop already has several conventional and CNC STUDER machines. A further machine is currently being overhauled in the STUDER production halls. This is an 18-year old S21 with two external spindles and continuous fine adjustment of the turret wheelhead (B-axis fine), which the two managing directors Christoph Jenzer and Edgar Stich recently took on as a secondhand machine. The S21 will not only be updated in line with the latest developments, but will also be retrofitted to suit the needs of Ingold Tools AG. The cylindrical grinding machine will have an additional internal grinding spindle for internal cylindrical grinding and the relevant fixture for swiveling the tailstock into the park position. The S21 will also have a new spindle cooling system with its own circuit, as well as a hydraulically swiveling dressing unit. So that all grinding machines have the same mounting, the universal tool headstock will also be upgraded
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TECH TRENDS from MK4 to MK5. “This deal is perfect for us. Thanks to the retrofit, we get the second-hand machine with 50% new hardware”, enthuses Jenzer. Trusted quality The S21 is the second factory-rebuilt STUDER machine at Ingold Tools AG. In 2016 the company took on a second-hand S31 machine, which STUDER overhauled. “We grind to a bearing tolerance and diameter of 1my. STUDER guarantees this accuracy after the overhaul. Either way: An overhauled STUDER will run just as long as a new machine,” attests Stich. Jenzer and Stich see a further advantage of the machine overhaul in the operation: “The employees don’t have to get used to a new machine with a new control system.” Ingold Tools has relied on STUDER since it was established in 1946. The first external cylindrical grind-
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ing machine was a type 01 from the year 1955. This was still in use when Christoph Jenzer joined the company 13 years ago. “We like working with STUDER. The service personnel are quick to respond, and our Customer Care Consultant supports us wherever he can. It’s not without reason that we have so many STUDER machines.” A new machine? Jenzer and Stich say: “We wouldn’t rule it out – a new machine always offers advantages which an old one doesn’t have, such as faster travel in all axes, simpler set-up of the machine, and easy programming with less technical knowledge.” But the employees are looking forward to the overhauled S21, which will soon be on its way to Inkwil in Bern. Machine overhaul at a glance • Machine base: Completely overhauled, ribbed guideways milled, recast and repainted. • Control cabinet: Replacement of
wear parts in the electric cabinet. • Pneumatics: New valves, hoses and filters. • Hydraulics: New hydraulic and lubricating system, all new valves and hoses. • Tool headstock: Completely overhauled. • Wheelhead: Completely overhauled. • Tailstock: Completely overhauled. • Axes: Tables as new, installation of new recirculating ball screw and bearings. • Component casings: Sand-blasting, repainting, color according to STUDER design or customer requirement. • Control system: Existing control system is retained. • Delivery: Always with precise measurement of new machine tolerance including test certificates. • Loan machine: We can provide a loan machine on request. • Renewed original CE certificate
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TECH TRENDS
A lubrication-free world for heavy machines
igus has developed a lubrication-free, two-component bearing iglidur Q2E to survive extreme conditions; tested to withstand loads up to 130 MPa
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n construction machines, agricultural machines, utility vehicles and offshore installations, plain bearings often have to cope with extreme conditions such as heavy loads. igus has therefore further developed its lubrication-free two-component bearing iglidur Q2E. The material iglidur Q2 ensures a tested high degree of wear-resistance, and a hard polymer shell protects the heavy-duty bearing. Dirt, impacts and high edge loads bearings in construction equipment, agricultural machines and offshore installations often have a hard time and have to cope with extreme conditions. Durable materials and dirt-resistant components are therefore called for. igus has now upgraded its iglidur Q2E heavy-duty bearing for exactly such scenarios of use. igus is expanding its range of bearings for heavy-duty applications and closes the gap between
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existing bearings and solutions made of metal and composites. The bearing consists of highperformance plastics and is therefore completely lubrication and corrosion-free. The absence of lubrication allows maintenance-free operation of the bearing points and prevents machine failures due to lack of lubrication. Expensive central lubrication systems are no longer necessary. Dirt and impurities can no longer adhere to the bearing points, and this minimises wear. In addition, less grease and oil escapes into the environment, a result of which the annual consumption of over 35 million metric tons of lubricant, as measured by RWTH Aachen University, is reduced. Another advantage: the injection-moulding method used to manufacture the plain bearings is especially cost-efficient.
The combination is the secret Two materials in an encapsulated design ensure that the bearing can cope even with the most extreme edge loads. This is because the iglidur Q2E has a hard polymer shell and a tribologically optimised core composed of iglidur Q2 as the material. When used for a plain bearing with a diameter of 20 millimetres, this material is also very dimensionally stable and wearresistant even under high loads of up to 7 metric tons. Functioning as a protective sheath, the shell makes the bearing very sturdy and ensures that it has a longer service life. igus has proven this in its own in-house test laboratory. In the swivel test, the material withstood a radial load of 130 MPa. iglidur Q2E is initially available for shaft diameters of 20, 25, 30 and 40mm.
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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.
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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
TECH TRENDS
Use of TIP-TIG Technology in Process Equipment Plants by Rakesh Choudhary, Head WAPS, Ador Welding Ltd. (with inputs from Plasch, TiP-TiG, Austria)
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IP-TIG welding is a new advanced innovation of the common GTAW Process. This process uses new, patent-pending technology (TiPTiG), that delivers the highest possible weld energy with the lowest possible weld heat, all while still being user-friendly. What is TIP-TIG welding? TiPTiG new welding with a hot wire process can be used in every industry. It is very simple to learn, use and simple to teach. This process is so unique that higher travel speed, lower heat input, reduced cycle time, and an overall better-quality welding advantage can easily be achieved. The Process The TIG weld receptivity for higher weld deposition rates is done by decreasing the speeds for the weld solidification process and increasing the fluid weld area. This allows for a 100%-400% increase in TIG wire feed rates, increasing the overall weld deposits. All these attributes like faster speeds and higher than normal weld energy, increase the resulting TIG weld quality and overall process productivity. The process is also slag-free and
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uses the lowest possible heat input of any welding process, producing a Heat Affected Zone (HAZ), all of which help to reduce distortion and weld stress. It produces some of the highest quality products with the best metallurgical and mechanical properties on all alloys, but also increases production up to four times the normal speed. There is also no inter- pass cleaning, creating availability for an increased Arc on time and weld quality. The TIP TIG process is available in manual and automated capability to attain weld and clad quality levels way beyond the conventional TIG – Hot – Cold Wire TIG – Pulsed MIG and the Flux-Cored process.
Fig.3 How it Works A TIP TIG welding system uses a wire fed GTAW system just like a typical TIG system, but it’s distinctive for the vibratory effect on wire at weld pool which is achieved by a linear forward and backward mechanical motion created by the customised wire feeder system. The forward and backward motion of the filler wire creates an oscillation that is then transferred to the weld, agitating the molten weld pool and ultimately disrupting the surface tension. In addition to this vibratory
Fig.1
Fig.2
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TECH TRENDS effect on the wire, a hotwire current (powered by a secondary power source) is also applied to the filler metal, prior to entering the weld puddle. The two pictures (fig. 1 & 2) describe the weld finish with Manual GTAW & Manual TIP-TIG process. ChampTig 400P Power source from Ador Welding with the TipTig wire feeder. Benefits of the TIG-TIP process • Increased fluidity of the weld pool • Greater tolerance to joint fit-up • Significantly reduced joint sensitivity • Greater ability to accept more wire into the weld pool, results in a higher deposition • 4-6 times increased travel times • Reduced cycle time and heat input • Cleaner welds with agitated weld pool • Reduced weld stress with the reduced heat input Approved Alloys TiPTiG welding can work on a wide range of alloys such as carbon steel, stainless steel, duplex and super duplex stainless steels, inconel, titanium, aluminium, copper, nickel, and many other critical materials like P-91, which are used in process plant production. Heat Exchangers Heat Exchangers are commonly constructed from low Carbon Steel, Copper, Copper-Nickel, Stainless Steel, Hastelloy, Inconel, or
Fig.4
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Titanium. There are certainly some unique applications and challenges associated with the welding of heat exchangers, such as the position and access for the popular circumferential welding of Tube to sheet welds or the half tube shell welding. A trained TIP-TIG welder can typically weld a 50mm tube in 30 seconds… or less with the highest quality and lowest heat input. Our typical travel speed for fillet welds will be between 300 to 500 mm/min on most applications. Compared with 80 to 150 mm/ min with conventional GTAW. TiPTiG manual system is a low cost semi-automatic solution to tackle any job by selecting a wide variety of torches for different applications, with modified 180 deg torch it allows a complete tube sheet welds without repositioning the wire or stopping, allowing for defect free welds. The typical customers in the manufacturing and repair of various sized heat exchangers are in power plants, chemical plants, petrochemical plants, petroleum refineries, natural gas processing, and sewage treatment.
Fig.5 pipe and make the welds look simple, that’s a process that should be given consideration. With TIP-TIG, no brushing, no grinding, no spatter, no weld rework, no feeding of wire, no foot control, less skills. Note weld smoke prep machining lubricants. (*Incoloy refers to a range of superalloys produced by the Special Metals Corporation group of companies. They are mostly nickelbased, and designed for excellent corrosion resistance as well as strength at high temperatures; there are specific alloys for resistance to chemical attacks)
INCONEL CLADDING Normally, when you manually clad the end of a pipe ID with Inconelusing Pulsed MIG as shown in the picture and result is often not so good. However when we use TIPTIG, the results are visible as shown on the mentioned pictures. In the pictureTIP-TIG cladded Job, TIP -TIG Inconel 800 pipe was welded with Inconel 82 wire on 10 inch pipe 3/4 Wall. The TIP TIG weld cycle time for the Inconel pipe was 40 – 50 minutes, whereas the customer used to take around 4 hrs with regular TIG. When your weld process can weld a complex incoloy*
Fig.6
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TECH TRENDS Duplex Steel Welding Applications Application The picture (fig.5) is of a very thin Gage Duplex Boiler. Traditional automated TIG process with cold wire may result in sluggish duplex welds. The customer typically attained a maximum Hot Wire TIG weld travel speeds from 12 – 15 inch/min. Then the customer switched over from Hot Wire TIG to the TIP-TIG process. The TIP TIG weld parameters and speeds were achieved using an 0.035 (1mm) 2205 Duplex wire, with TIP-TIG travel speed of 35 inch/min was achieved providing 200% increase in weld travel. The welds had a superior, less sluggish weld bead appearance and the parts had a dramatic reduction in weld distortion, (note the much smaller HAZ). Also the TIP-TIG process was much more stable and consistent. TIP-TIG produces the cleanest welds from lowest possible oxidation. The welds will have the lowest possible weld pores and inclusions and the smallest possible weld HAZ. Welding of P-91 Material Welding of Grade 91 (9Cr-1Mo-V) chromium-molybdenum steel has presented numerous challenges since its introduction inthe 1970s. The gas tungsten-arc (GTAW) process can produce welds of high quality;
however, manual welding can be expensive and labour intensive, requiring skilled welders with extreme hand-eye coordination and dexterity. Grade 91 productivity can beincreased in either shop or field fabrication by introducing a semiautomatic high deposition metal transfer (HDMT) GTAWwelding process that combines controlled excitation of wire with a hot wire addition. This technique is costeffective and can beused for the entire weld from root to cap while producing high quality welds that industry expects from the GTAW process. With TiP-TiG weld study, it indicates that semiautomatic HDMT GTAW welding process is capable of producing toughness valuescomparable to or exceeding manual GTAW and that the process provides an attractive alternative for welding P91 root and hotpasses or the entire weld from root to cap.Results of this study indicates that semiautomatic HDMT GTAW welding process is capable of producing impact valuescomparable to or exceeding manual GTAWT. The process also provides an attractive alternative for welding P91 root and hotpasses or the entire weld from root to cap. The semiautomatic HDMT GTAW welding process permits an increase in energy(heat input), larger weld puddle and increased deposition rate while still
Fig.7
Fig.8
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providing tempering of the previously deposited weldbeads or layers. TIP-TIG HDMT (HIGH DYNAMIC METAL TRANSFER) FOCUS TIP-TIG HDMT FOCUS is a unique TIP-TIG welding process. Its precision and reliability make the TIPTIG HDMT FOCUS welding process particularly suitable for automatedapplications in combination with linear axles, robots and other guiding systems. Nearly all steels, non-ferrousmetals or galvanized sheets can be welded in one layer with filler material; e.g. CrNi-steels with a material thickness of up to 10 to 12 mm can be welded in single pass without any Joint preparation. Some of the welded examples are listed below. it has resulted in elimination of backing gas in austenitic stainless steel welds using high deposition metal transfer gas tungsten-arc welding(HDMTGTAW) TIP-TIG HDMT FOCUS PROCESS Example • Material: CrNi 8+8mm • Weld current: 500A • Weld speed: 46 cm/min • Wire feed speed: 2,0m/min Details of Welded Samples • Material: CrNi 10+10mm • Weld current: 500A • Weld speed: 32 cm/min • Wire feed speed: 1,8m/min TIP-TIG REDUCED COSTS BY OVER 60%, WHEN COMPARED WITH CONVENTIONAL TIG PROCESS TIP-TIG Cost Comparison The following comparison shows the actual savings calculated on a real stainless-steel welding application comparing conventional TIG and TIP-TIG on a pipe application (2” Sch 80 Stainless) in the 5G position.
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TECH TRENDS
Variable / Results
Units
Conventional TIG
TIP TIG Process
Welding process
GTAW
GTAW
Wire type
ER308L
ER308L
Wire size
mm
2.4
0.9
Wire deposition speed
mm/min
100
1900
Melt off rate
g/h
200
580(3 times)
Deposition efficiency
%
100.00%
100.00%
Deposition rate
g/h
200
580(3 times)
Duty cycle
%
100.00%
100.00%
Final deposition rate
g/h
200
580(3 times)
Argon
Argon
Gas type Flow rate
cfh
30
30
Gas/Wire ratio
cf/g
63.05
23.62(60% Reduction in gas per gm of wire)
The above data shows, the deposition rates approx. 3 times to standard TIG process which reduces the production costs by 60%. Conclusion TIP-TIG is an innovative TIG process and good alternative to standard gas tungsten-arc (GTAW) process. Its versatility and simplicity makes the manual welder to give higher output. The Automated High Deposition Metal Transfer (HDMT) GTAW welding process that combines controlled excitation of wire with a hot wire addition and gives very
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promising results to challenging applications. Plant equipment manufacturing, wherever GTAW is applicable, is possible to be replaced by TIG-TIG process which gives very high output without compromising on quality. The success in P91 welding with TIP-TIG, also increases the application possibility in that area.
References: 1. Paper on ‘ACHIEVING TOUGHNESS IN P91 WELDS FROM ROOT TO CAP USING SEMIAUTOMATIC HIGH DEPOSITION METAL TRANSFER (HDMT) GTAW WELDING PROCESS ‘ by Charles W. “Pat” Patrick 2. Information from TiPTiG USA 3. Information from TiPTiG International AG .
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CASE STUDY
Laser interferometer error-proofs linear scale calibration To achieve consistent sub-micron measurement accuracy, an automated line scale calibration system developed by the Standards and Calibration Laboratory (SCL) in Hong Kong made automatic error compensation a key design criteria. A Renishaw XL-80 laser interferometer and XC-80 compensator were used to successfully manage any sources of Abbe error, as well as changes in environmental conditions
P
recision linear scales are often deployed in highaccuracy length measurement equipment, including comparators, microscopes and surveying instruments, where they provide an accurate benchmark for precisely measuring distances or travel. Generally made of glass, linear scales are precisely engraved on their surface with equidistant parallel lines running perpendicular to the line scale axis. To measure and verify the distances between line
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scale graduations, high precision instruments are needed. The Standards and Calibration Laboratory, a part of the Innovation and Technology Commission of Hong Kong’s Special Administrative Region, is responsible for formulating and maintaining physical measurement reference standards for the Hong Kong region. It provides local users of measurement standards and measurement instruments with calibration services, to ensure that they are able to accurately perform
their measurement tasks and correctly trace their work back to the relevant standards. SCL set itself the task of designing and manufacturing a new automated linear scale calibration system capable of achieving submicron measurement precision. Importantly, it would need to be able to compensate automatically for Abbe errors caused by the minutest of angular displacements in any of the equipment, and any variation in environmental conditions.
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CASE STUDY Challenge Described by Ernst Abbe of Zeiss in 1890, the Abbe Principle has been called ‘the principle of alignment’ and it states: “If errors of parallax are to be avoided, the measuring system must be placed co-axially (i.e. in line with) the line in which displacement (giving length) is to be measured on the workpiece.” An Abbe error is therefore introduced when a point to be measured is separated laterally from the axis of measurement, and when the positioning system is subject to angular motion. It causes the measured displacement to appear shorter or longer than the true displacement. The spatial separation of measured point and axis of measurement is called the Abbe offset. As a very simple illustration, consider a measuring caliper. Between the axis of the scale and the axis of measurement (formed between the jaws) there is an Abbe offset. Any issues of calliper straightness, squareness or ‘play’ will all lead to an angular movement in the jaw and therefore an Abbe error. J.B. Bryan who described the Abbe Principle as, “the first principle of machine design and dimensional metrology”, went on to restate it more in machine terms as: “The displacement measuring system should be in line with the functional point whose displacement is to be measured. If this is not possible, either the slideways that transfer the displacement must be free of angular motion or angular motion data must be used to calculate the consequences of the offset.” In simple terms, the measurement of the accuracy of the graduations on a line scale are performed by measuring the distance between a reference line (generally the zero
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position) and the target graduation. Imaging analysis and compensation technology then have to be applied, so that the system can calculate and adjust the line scale reading positions, and thereby reduce the Abbe error. However, when actually using such systems, it’s also necessary to factor in real-world influences and other uncertainties in the design. For this reason, it is essential that effective compensation for errors caused by a variety of environmental and human factors is incorporated. In this case, SCL was actually located on the 35th floor of a 48-floor building, so even vibrations caused by wind and traffic needed to be taken into account. “In-depth analysis has shown that with the integration of the XL-80 interferometer, this Abbe error figure is reduced by 99%.” The Standards and Calibration Laboratory (Hong Kong) Solution SCL’s measuring system arrangement is shown in Figure 1. It uses a displacement method whereby the measuring device travels on a gantry above a fixed linear scale to measure the distance between a zero position and a linear scale graduation. The whole assembly is mounted on a vibration-damping table floated with air, and for better temperature profile control an enclosure is used.
The measurement is performed by a high-resolution microscope, mono CCD camera and a pixel-counting software algorithm, mounted on a sliding air bearing stage driven by an AC/DC mode piezoelectric motor. The system’s sliding stage achieves a linearity of 0.9 µm for a measurement travel of 800 mm and repeatability of 20 nm. The maximum roll, pitch and yaw are each ± 0.5 arc seconds. To compensate for any Abbe error, the SCL system then adopts an approach built on J.B. Bryan’s thinking. Instead of using angular motion data to calculate a compensation value, it uses a symmetrical laser path on both sides of the axis of measurement. In this way any angular movement detected, that leads to either an increase or decrease in reading due to Abbe error, can be automatically compensated for. Automation In response to operator input the sliding stage moves to a default position for a target line measurement. Once stationary, the laser interferometer reads the positional data and the camera takes images of the graduated scale. The images are then analysed to obtain the current position (using the distance from the zero position to the equivalent pixel value displayed).
Figure 1: Schematic of the measurement set-up
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CASE STUDY
In-depth analysis has shown that with the integration of the XL-80 interferometer, this Abbe error figure is reduced by 99%. The Standards and Calibration Laboratory (Hong Kong)
The position is compared with the actual calculated position, and the system then compensates for the difference by instructing the sliding stage to fine-tune the position. Next, the interferometer takes another reading of the position data. The entire process is repeated a number of times until the error is within the specified pixel range and the final line position is obtained. Precision stabilised laser source The system design uses the Renishaw XL-80 laser interferometer to compensate for Abbe errors in the measurement system relating to any kind of angular displacement incurred in the setup. This could relate to sliding stage linearity, line scale placement or reflector positioning, for example. With a nominal wavelength of 633 nm, the interferometer ensures a linear measurement accuracy of ±0.5 ppm thanks to a precision stabilised laser source and accurate environmental compensation. Readings can be taken at up to 50 kHz, with a maximum linear measurement speed of 4 m/s and a linear resolution of 1 nm, even
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at maximum speed. All measurement options are based on interferometric measurements, assuring greater confidence in the accuracy of the data recorded. The interferometer setup employs a classic linear measurement configuration. The laser beam is split into two paths as it passes through beam splitter S, with one path forming a reference beam that passes through transfer lens T and reflector R back into the laser source probe, and the other beam passing through transfer lenses T1, T2 and T3 and reflector R to form a length change measurement beam. In the SCL system, the XL-80 was used with the XC-80 compensator. Environmental conditions are measured using internal sensors for air pressure and humidity, with respective accuracies of 1 mbar and 6%, as well as three material temperature sensors and an air temperature sensor, having 0.1°C and 0.2°C accuracy respectively. Results SCL has successfully developed a highly accurate automated line
scale calibration system. Supporting line scales up to 750 mm in length, the system has a measurement uncertainty of just 0.15 nm - 0.41 nm. In system testing a 500 mm glass scale calibrated by the Korean Institute of Standards and Science (KRISS) was used as an artefact to validate the calibration system. A total of 23 distances between scale graduations and the zero were selected as measurands. Measurement results were compared with the values obtained from KRISS. The differences in measurement values were all within their individual measurement uncertainties and well within normalised error ratio of 0.7. In the system, the root-sum-square of the Abbe error, caused by the 5 sec of arc in pitch and yaw of the microscope sliding stage for a distance of 100mm can be calculated to be 3.4 µm. In-depth analysis has shown that with the integration of the XL-80 interferometer, this Abbe error figure is reduced by 99%. For more information, Website: www.renishaw.com
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PRODUCTS SHOWCASE
PRODUCT SHOWCASE 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
Nylon Knitted Seamless Gloves with PVC Dots Features & Benefits Nylon gloves more flexible, sensitive, comfortable & more Mechanical Protection. Nylon Knit Construction makes more snug fit allowing workers to do more delicate of operations. The dots on Nylon offers positive & enhanced grip. The Nylon is Lint free.
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 Phone : +91 22 2262 6546 / 2262 6876 Email : marvelgloves@gmail.com www.marvelgloves.com
Application • General maintenance • Shipping & receiving • Food processing • Light fabrication • Shipping & Port Handling • Drilling Rigs & Offshore companies • Packaging • Automotive Assembly • Material Handling
Steady Volt Servo Voltage Stabilizers Frequent voltage variations are a menace that can damage electronic components like power supplies, drives, PLCs, controllers, etc. Their effects are widely felt in CNC, printing and textile machines as well as laboratory, data processing, medical & telecommunication equipment. Frequent breakdowns of such machines are costly to repair. This apart, the downtime and frequent interruptions in operation brings substantial loss of revenue. Steady Volt from Unity Controls is a state-of-the-art Voltage Stabilizer designed to protect such equipment from voltage variations and its ill-effects. Following are some of its unique features: • Intelligent microprocessor-based system(available in new digital models) • Digital interface with large LCD display and keypad • Auto re-start, adjustable output voltage, trip bypass, fault list • No hunting, oscillation and noise generation • Innovative transformer design to minimize power loss • Constant output voltage across a wide input voltage range • Single phasing prevention, surge suppressor and EMI / RFI filter 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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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.
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PRODUCTS SHOWCASE
Effortless cleaning of oily machinery, factory floors and plastic bins by the use of O-CLEAN3
For Product Enquiry Contact STEEL PLANT SPECIALITIES LLP 211, Raikar Chambers, Govandi East, Mumbai - 400 088, India Tel.: 022-67978060 / 022-25552459 Cell: +91-9820493373 Email: info@steelplantspecialities.com www.steelplantspecialities.com
Cleaning of factories is carried out meticulously during the festival season of Dussera and Diwali in India. Oil and dirt accumulated on machinery and factory floors since many months is very difficult to clean. To reduce cleaning efforts, hazardous chemicals, acids, kerosene, thinner, sawdust and such items are used. Besides being harmful or flammable, these products often damage or stain machinery and remove the lustre of paint finish. O-CLEAN3 is an eco-friendly, economical water-based alternative to harmful acids, kerosene or sawdust. It works by breaking the bonds of hydrogen and carbon molecules that form hydrocarbons or oils. As a result, oils and dirt that have accumulated since many months can be cleaned effortlessly and in less time. Using O-CLEAN3 is easy: it must be applied on the oily machinery, allowed to react for approximately 30 minutes, and then washed off with water or with wet cloth to achieve oil-free, clean surface. The residue, that is water and small portion of carbon, can be easily separated and disposed off,as required. If disposed off in effluent treatment plant, the treatment time will be substantially reduced as compared with effluents of harmful chemicals. O-CLEAN3 is a safe, multipurpose cleaning liquid that can be used for effectively cleaning oily machinery, CNC/VMC, chequered plates, plastic bins, epoxy floors and concrete floors. It is also used for degreasing machine parts and as a handwash for cleaning workmens’ oily hands.
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
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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.
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ADVERTISERS INDEX COMPANY NAME
PG. NO.
A ACCURATE ENGINEERING CO. PVT. LTD.
51
ACCUSHARP CUTTING TOOLS PVT. LTD.
89
ACE MICROMATIC GROUP
BACK PAGE
ADOR WELDING LIMITED
87
ANCA MACHINE TOOLS PRIVATE LTD
5
APEX PRECISION MECHATRONIX PVT. LTD.
105
COMPANY NAME
PG. NO.
COMPANY NAME
GLOBE-TECH ENGINEERING EXPO - 2020
115
P
GP PETROLEUMS LTD.
35
PARAGON MACHINERY CO. LTD.
23
PRECIHOLE MACHINE TOOLS PVT. LTD.
77
PRECISION MOTION INDUSTRIES, INC. ( PMI )
81
H HANGSTERFER'S
60
HITTCO TOOLS LIMITED
53
HURCO INDIA PVT. LTD.
62
I
B ISCAR INDIA LIMITED
BEARING EXPO & CONFERENCE - 2019
39
BETTINELLI AUTOMATION COMPONENTS PVT. LTD.
97
BIRLA PRECISION TECHNOLOGIES LIMITED
73
C CLEANOIL
36
R RENISHAW PLC
29
41
ROLLON INDIA PVT. LTD. - INDIA
91
RR KABEL LIMITED
43
K 64
L
DVS TECHNOLOGY GROUP
18-19
M
47
S SEW-EURODRIVE INDIA PRIVATE LIMITED
77
STEEL PLANT SPECIALITIES LLP
79
SUGINO MACHINE INDIA PVT. LTD.
37
MACHINE TOOLS, MANUFACTURING & TECHNOLOGY EXPO
15
T
MARVEL GLOVES INDUSTRIES
101
THE ASSOCIATION FOR MANUFACTURING TECHNOLOGY
57
MASTERCAM INDIA
INSIDE BACK COVER
TRUCUT PRECISION TOOLS PVT. LTD.
FALSE COVER
13
31, 33
66
JYOTI CNC AUTOMATION LTD.
LAKSHMI ELECTRO CONTROLS & AUTOMATION
EMAG INDIA PVT. LTD.
QVI INDIA PVT. LTD.
49
9
25
11
RENMAKCH INDIA PVT. LTD.
DRAKE
ELGI EQUIPMENTS LTD.
QUAKER HOUGHTON
63
103
ELECTROTHERM (INDIA) LTD.
Q
JERGENS INDIA PVT. LTD.
DOWEL ENGINEERING WORKS
E
ENGIMACH - 2019
27
MEHTA CAD CAM SYSTEMS PVT. LTD.
EPPINGER TOOLING ASIA PVT. LTD.
94 - 95
MGM-VARVEL POWER TRANSMISSION PVT LTD
107
V M TRADERS
MICRO-EPSILON INDIA PRIVATE LIMITED
83
W
MMC HARDMETAL INDIA PVT. LTD.
INSIDE FRONT COVER
WOHLHAUPTER / ALLIED MACHINE & ENGINEERING COMPANY
F FACCIN S. P. A. FLIR SYSTEMS INDIA PVT. LTD.
17 75
71
GEDEE WEILER PRIVATE LIMITED
7
MACHINE TOOLS WORLD OCTOBER 2019
N. GANDHI & CO.
V 93
58
Z
N
G
120
J
KINEFAC CORPORATION
D
INNER INSIDE FRONT COVER
PG. NO.
85
ZECHA PRECISION TOOLS LIMITED
21
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