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Editorial

The Budget vision

I

n retrospect, the Union Budget 201112 can be described as a futuristic and reform-oriented one with less short-term impact. Some of the positive highlights in this Budget include higher allocation on infrastructure, commitment to make Goods & Service Tax (GST) a reality, no change in Excise Duty, promoting research, increasing local manufacturing and promoting inclusive growth. In addition, the government targets 25 per cent GDP contribution from manufacturing by 2020 along with the commitment on raising governance standards and reducing surcharge marginally on corporates. On the flip side, the introduction of Minimum Alternate Tax (MAT) on Special Economic Zones (SEZs) and the phasing out of Export-oriented Units (EoUs) will impact their growth. Also, the rise in MAT will affect the corporate sector. Although these action plans have ample scope for inclusive growth and to help the country leap to the next league of global economic super-powers, in the long run a lot will depend on how effective the implementation has been. With the Indian economy experiencing an upward trend, the manufacturing sector is witnessing an unprecedented demand spike with many global players setting up production units here. In particular, industries such as automotive, infrastructure, aerospace are on the forefront. All these have resulted in a Editor Manas R Bastia Senior Features Writer Hema D Yadav

Features Writer Swapnil Pillai

Correspondent Rachita Jha Anwesh Koley (Delhi)

Editorial Trainee Nishant Kashyap

Copy Desk Meghanadan Sudhakaran

Assistant Art Director Varuna Naik

Products Desk Paskaline Sebastian

Photographer Neha Mithbawkar, Joshua Navalkar

Chief Photographer Mexy Xavier Sr. Designer Hemant Lambe Production Pravin Koyande, Dnyaneshwar Goythale, Vikas Bobhate, Ravikumar Potdar, Ravi Salian, Sanjay Shelar, Lovey Fernandes, Pukha Dhawan, Varsha Nawathe, Akshata Rane, Abhay Borkar Branding & Marketing Jagruti Shah, Ganesh Mahale CEO - Publishing Sandeep Khosla Associate Vice President Sudhanva Jategaonkar

bonanza of sorts for sheetmetal working, which provides for these industries. With high-volume production, consistent product quality, less material handling and minimum labour utilisation becoming order of the day for global competitiveness, cold roll forming process has generated considerable interest in the Indian sheetmetal industry. For further insights into some of the latest trends in sheetmetal working, turn to the ‘Sector Watch’. Want to know how innovative designs and features of industrial robots along with integrated vision and touch have significantly improved the quality, performance and on-time delivery aspects of new production and delivery systems? Take a look at the ‘Industry Update’. Last, but not the least, the special section focusing on DIEMOULD INDIA SOUTH - 2011 exhibition, presents an array of opportunities for the dies and moulds industry to leverage on the overall buoyancy in the manufacturing domain. Read on…

Manas R Bastia Editor manas@infomedia18.in

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Editorial Advisory Board M Lokeswara Rao President, IMTMA & MD, Lokesh Machines Ltd Vikram Sirur Vice President, IMTMA & Executive Vice Chairman, Miven Machine Tools Ltd N K Dhand Past President, IMTMA & CMD, Micromatic Grinding Technologies Ltd R Srinivasan Past President, IMTMA & MD, RAS Transformation Technologies Gautam Doshi Advisor, IMTMA & Consultant, Productivity & Quality Improvement Services S N Mishra Past President, IMTMA & Vice Chairman, Bharat Fritz Werner Ltd

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April 2011 - MODERN MACHINE TOOLS

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Contents

Regular Sections

Sector Watch

Editorial...................................... 25

Sheetmetal working: Revving up for future demand ............................. 94

National News ........................... 28 World News ............................... 38 Tech Updates............................. 43 Events ...................................... 130 Product Update ...................... 136 International Products ............ 160 Product Index.......................... 162 Advertisers’ List .......................172

Industry Update Industrial robots: Shaping future trends............................................. 100

Event Focus Curtain Raiser ................................................................ 48 Market Dynamics .......................................................... 52 Industry Insights ........................................................... 54 Product Showcase ....................................................... 79

Facility Visit Renishaw Metrology Systems Pvt Ltd: Where quality is priority................................................ 110

Manufacturing Excellence

Leaders Speak Ayumu Ikezumi, President & Vice Chairman, Dijet Industrial Co Ltd ............ 106

Tube deburring brushes: Lowering manufacturing costs ....................................... 114

Factory Fundamentals  Precision metrology supplier relies on HMC accuracy ......................................................

116

 Machining for air quality ............................................ 122 Curtain Raiser BLECH India 2011:

Highlights of Next Issue: Sector Watch: Control Systems Industry Update: Small & Medium Enterprises

Invigorating the Indian sheetmetal industry .................. 126 Details on page 127

Corrigendum: In the ‘Aerospace Supplement’ of March 2011 issue (Leaders Speak and Contents on page no. 42 and 10, respectively), the name of Jayaram Pillai, MD, National Instruments India, Russia and Arabia (IndRA) was inadvertently printed as Jayanth Pillai. This is regretted. 26

MODERN MACHINE TOOLS - April 2011

Report Engineering Expo Chennai 2011: Channelising knowledge, building brands ...................... 132


National News Sikorsky to manufacture helicopters in India The US-based company plans to design and manufacture civilian & military helicopters in India for local and Asia-Pacific markets in the next four years. This will be the first time that a foreign aircraft company will utilise the country’s aerospace know-how to make choppers for the overseas market. Arvind Jeet Singh Walia, Managing Director - India and South Asia, Sikorsky Aircraft, said, “We are looking at manufacturing an indigenous helicopter by 2015-16. We already have the helicopters that are suitable for the Indian climate.

We intend developing further technologies to cater to defence requirements for high-altitude and high-performance machines.” A boom in India’s civil aviation market, which is among the fastest growing markets in the world, and a military upgradation plan that may be worth $ 100 in the next 10 years, is persuading global aircraft manufacturers to form joint ventures with local companies to take advantage of the business opportunities. India has an offset clause for high-value defence purchases that requires overseas companies to base part of the manufacturing in the country.

Magna acquires grinding centre Tamil Nadu-based Magna Electro Castings Ltd has purchased new grinding/fettling centre from Maus SpA (Padua, Italy). The machine is a Maus SAM 600G, a compact yet powerful automatic grinding centre, with four-tool capacity and product load/unload time of less than four seconds.

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N Krishna Samaraj, Managing Director, Magna Electro Castings Ltd, stated that it was the company’s expectation that the machining system, which is scheduled for

start-up after July 2011, will result in significant improvements in the surface quality and production rates of the company. Magna is a vertically integrated foundry, as it performs various machining, surface treatment and heat treating operations, in addition to its full foundry capabilities for various products sold to the valve, refrigeration, rail, hydraulics, automotive, wind turbine and other industries worldwide.

The pioneering machine was unveiled at the IFEX, 2011 (7 th international exhibition on foundry technology, equipment and supplies). At the event, Viraj Naidu, Managing Director, DISA India Ltd, said, “This new machine will showcase DISA’s commitment to the foundry industry in India, and we are pleased to be the pioneers in bringing forth such a key development to the market. With its state-of-the-art technology, we are sure this will help us generate new business opportunities.” This machine has been jointly developed by Indian and Danish engineering and R&D teams in India.

Rolls-Royce aims to sell more than 100 cars The British manufacturer of luxury automobiles aims to sell more than 100 cars this year in India as compared to 80 sold last year.

DISA launches India’s first ever vertical moulding machine The company, one of the leading foundry machinery manufacturers in India, recently launched DISA 030 – India’s first vertical moulding machine.

Torsten Muller-Otvos, CEO, RollsRoyce stated, “After logging 600 per cent growth over 2009, our sales should cross the three-digit mark in 2011.” China will form the carmaker’s biggest market as early as 2014 followed by India. Apart from its existing dealership in Delhi and Mumbai, it is planning to open new dealership in two more locations, ie, Punjab and Hyderabad. The company sells the Phantom and Ghost brands in India, priced upward of ` 2.5 crore and ` 3.5 crore, respectively.


National News ArcelorMittal now planning small units Disappointed with the little or no headway made in big budget projects, ArcelorMittal, is now evaluating options of building small plants in the country with an investment of $ 1.5-3 billion each. In a press statement released by the world’s largest steel producer, it mentioned that the decision is based on implementation challenges associated with large greenfield projects and also to diversify investments in India. The company had announced plans to set up 12 million tonne per annum integrated steel plants in Jharkhand

“It is our understanding of the Indian customer and marketplace, which convinced us about the potential of Nagpur and its adjoining areas like Bhandara, Chandrapur, Yavatmal, Akola & Amravati,” said Honegg. The luxury car manufacturer has its bus building facility at Chakan in Pune, spread over 100 acre of land, and has rolled out 30,000 luxury cars (till last December).

The technique of effective coolant management

and Orissa at an estimated cost of over $ 10 billion each. It had also inked a pact with the Karnataka Government in June 2010 for a 6 MTPA plant, with a captive 750 MW power plant, at an estimated investment of ` 30,000 crore ($ 6.5 billion). However, none of the projects could take off due to regulatory and other hurdles like land acquisition, raw material security, etc. Faced with land acquisition issues, the company even had to shift the site of the proposed project to Bokaro from Khunti-Gumla in Jharkhand.

Mercedes-Benz opens dealership in Nagpur The company now enjoys a network spread across 28 cities, with over 57 touch points in India, with the establishment of its new facility at Nagpur. It was inaugurated by Peter Honegg, Managing Director & CEO, Mercedes-Benz India, along with Mohan Mariwala, Managing Director, Autohangar India Pvt Ltd. Located at the MIDC premises in Nagpur, the dealership is spread across 43,500 sq ft. The facility will be offering integrated after-sales and service facility. The company also unveiled its New E-Cabriolet in the city.

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Carl Bechem India in association with ‘Institute of Indian Foundry Men Chennai Chapter’ recently organised a technical seminar on ‘Improving Profitability, Safety and Quality with Metal Cutting Fluids’. The seminar with the objective of educating audience on the importance of coolant management was aimed at the production and maintenance personnel from metalworking and allied industries.

Ajay Arora, National Sales Manager - Metal Working Fluids, Carl Bechem India said, “Training and awareness about coolant management techniques to the operator backed with timely technical service can not only enhance productivity levels substantially but also provide pleasant working environment in a typical machine shop.” The seminar received good response with over 110 participants representing both industry and academia.

Beckhoff India establishes its branch in Gujarat The company is all set to expand its

operation in the country by establishing a branch office in Pralhadnagar, Ahmedabad. The branch that commenced its operation in January 2011, is headed by Mitesh Gajjar, Area Sales Manager. With this expansion, the company will be providing innovative automation products to its customers in Gujrat. Apart from sales and marketing, the branch office will also have training centre to cater to the automation needs of machine builders from various fields like textile, plastics, packaging, pharmaceuticals and machine tool industries.

Vestas inaugurates R&D test centre in Chennai The wind power major has opened a state-of-the-art test centre for wind turbine components in Chennai. The company is also adding 35,000 sq ft to its existing office space. The centre continues the company’s development in India, one of the world’s fastest growing wind energy markets. On the occasion Servet Sert, Vice President - Test, Verification and Quality, Vestas Technology, said, “The new test centre will play an important role for Vestas. This new facility adds to our global testing and verification of wind turbine components to further improve their reliability and performance.”

Vestas Wind Technology India Pvt Ltd is a 100 per cent subsidiary of Vestas Wind Systems A/S Denmark. In India, the company has been present for over a decade and has an installed capacity of over 2400 MW. It has installed turbines in wind rich states like Tamil Nadu, Maharashtra, Karnataka, Gujarat, Kerala and Rajasthan and has world-class manufacturing facilities in Chennai and Puducherry.


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National News Escorts launches new range of tractors

the car, and produces 2,800 cars per week in double shift. The company has already invested $ 500 million at the Chennai plant and is planning to scale up the production capacity to 2 lakh units per annum. It is also planning to launch eight new models in India and will likely give more importance to small cars so as to become a dominant player in the booming small car market.

The tractor-maker recently launched Jai Kisan series of tractors for Punjab and Haryana - the states contribute 20 per cent of the company’s total sales. The new range of tractors will be arriving in five categories, which are specialised in various farm applications as well as land development activities.

EDS Technologies to set up finishing school

On the occasion, Rohtash Mal, Executive Director & CEO - Agri Machinery Group, Escorts, said, “The launch brings us closer to the philosophy of empowering Indian farmers by providing solutions that enhance productivity and improve quality of life in rural areas. Farm mechanisation is the need of the hour and a prominent vector that will enhance farm productivity & profitability. With the advent of new applications across cropping cycle as well as usage in commercial applications, there is a need for tractors to be customised and specialised to maximise profitability.”

come from tier II and III cities, where infrastructure at present is a big impediment compared to China. JD Power states that the current market leader Maruti Suzuki India will retain its number one position in the country, but its marketshare will fall below 50 per cent in the next decade, and the car market sale is estimated to be 21 lakh units for the current calendar year.

Ford to make India small car hub After the success of its new small car Figo in India, Ford Motors has announced that it is looking forward to make the company’s Chennai plant its global hub for small cars. Michael Boneham, MD & President, Ford India, revealed, “India will

India poised to be world’s 3rd biggest car market According to Mohit Arora, Executive Director, JD Power Asia Pacific, the Indian passenger car segment is expected to grow by over fourfold to 93 lakh units in 2020, to become the world’s third largest car market. The country will possibly cross the Japanese car market by 2014. Only China and the US will be ahead of India in 2020. China would be on top, with sales of almost 3.5 crore cars every year. He added that the growth in the country will primarily

One of the leading PLM solution companies in India, the company recently announced its strategic alliance with Mar Baselios College of Engineering and Technology (MBCET), Trivandrum, to set up a finishing school

be the small car hub for Ford and will be the sole producer of Figo in the world. And, there is no plan to assemble the car anywhere else. Besides, we will be exporting to markets in North Africa, Middle East and the Caribbean.” Currently, the Chennai plant is the only manufacturing facility for

for students in the pre-final and final years of mechanical engineering. The company will also conduct specialised training programmes for students from other institutes and working professionals seeking knowledge and enhancement of their skills. On completion of their course, the students will be awarded co-branded course certificate from EDS Technologies Pvt Ltd and Mar Baselios College of Engineering and Technology. S Senthil, President, EDS Technologies Pvt Ltd, said, “This initiative focusses on developing longterm relationship with educational institutions through in-depth engagements around student & faculty programmes and equip them with the latest in technology. The association will bridge the gap between industry requirements and academic excellence.”

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World News German machine tool raises toast to an iconic figure of the industry The industry recently celebrated the 90th birthday of the grand seigneur of Germany’s mechanical engineering sector. Senator E h Dr -Ing E h Bernhard Kapp is an enterprising entrepreneur, a visionary, an innovator, and also a staunch supporter machine tool business. Besides being the founder of KAPP Group, Kapp headed VDW (German Machine Tool Builders’ Association) for 29 years. He was also the President of the VDMA (German Engineering Federation) for three years and was Vice President of BDI (Confederation of German Industry), but the German federal government also made use of his talents. In his illustrious career he was awarded the Grand Cross of Lower Saxony’s Order of Merit, 1979; Bernhard Kapp the Bavarian Order of Merit, 1981; the Grand Cross of the Order of Merit of the Federal Republic of Germany, 1984; and the ‘Croix de chevalier de l´Ordre National du Mérite’, 1988.

Tata presents pocket-sized dynamo for its European markets At the 81st Geneva Motor Show, Tata Motors presented the Tata Pixel, a new city car concept for Europe. Based on the Tata Nano, the Pixel is just over three metre in length and can accommodate four adults. The car’s ability to manoeuvre and park in the tightest of spaces is made possible by its Zero Turn toroidal traction-drive Infinitely Variable Transmission (IVT), which assists rotation of the outer rear wheel forwards and the inner rear wheel backwards, while the front wheels turn

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at acute angles. The result is a turning circle radius of 2.6 metre. The ‘scissor’ doors rotate upwards from the front to allow passengers to enter or exit. Key functions are controlled by the driver’s smart phone, running ‘My Tata Connect’ - the first integrated HumanMachine Interface (HMI) concept from Tata Motors. With optimised aerodynamic drag, low rollingresistance tyres, stop-start technology and intelligent battery charging, the Tata Pixel returns European combined cycle (NEDC) fuel economy of 3.4 l/100 km and CO2 emissions of just 89 g/km.

whether an electric drivetrain might be feasible for the Rolls-Royce brand, both in terms of functionality and in terms of consumer perception. A press release issued by the company stated, “It is the company’s intention to carefully test the opinions and reactions to alternative drivetrain options of a range of stakeholders including owners, enthusiasts, members of the public and the media.”

Volvo to start factory in China The Swedish automaker is planning a manufacturing base in the western Chinese city of Chengdu (although Shanghai and the northern city of

Rolls-Royce unveils an allelectric Phantom The luxury brand has a history of producing EX cars, experimental models, and the 102EX is the latest and the most daring. It is the world’s first fully-electric ultra-luxury car, featuring a 71 kWh battery (almost three times the capacity of the Nissan Leaf) that can be charged in as quickly as eight hours. Inductive charging is also available. The range of the 6,000 lb vehicle is up to 200 km, about 125 miles, and the 0 - 60 roll takes somewhere under eight seconds. No estimated cost has yet been applied.

The car is a one-off project that was unveiled at the Geneva Motor Show. It will also tour the world as a tester to see

Daqing were also in the race) as it aims for expansion in the world’s biggest auto market, following its buyout by independent car manufacturer Geely. The factory will focus on making compact and economic cars on a large scale. While the forcast for sales of cars is likely to slowdown from their torrid growth in recent years, sales in the provinces are surging. The factory in Chengdu is already under construction and is due to begin production by 2013, with an initial capacity of 1,25,000. Privately-owned Geely Holding Group agreed in March 2010 to buy Volvo from Ford Motor Company for $ 1.8 billion, the biggest acquisition by a major Chinese automaker. The Group based in the eastern city of Hangzhou, China has built a business selling cars, motorcycles and scooters with little government support.


World News Nippon, Posco in $ 1.8 billion deal The two companies along with JFE will buy a 15 per cent stake in a Brazilian rare metal miner. The deal adds to growing cross-border tie-ups between Japan and South Korea to secure natural resources to power their manufacturing-based economies.

The Brazilian company is Companhia Brasileira de Metalurgia e Mineracao (CBMM), which mines and processes niobium, a rare metal utilised to produce high-grade steel used in automobile, aerospace and pipeline to make steel products lighter and stronger. The country is the world’s leading niobium producer with 80,000 tonne (83,000 tonne was produced globally in 2010). “Behind the move is a growing demand for niobium in China, and its aggressive move to secure supplies from abroad because its domestic output is limited. Japanese steelmakers, worried of China’s

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aggressive moves, moved quickly in a tie-up with Korean firms,” said Kaz Machida, President, KAY International - a rare metal consultant. China’s domestic niobium production is limited, although demand is expected to soar in the future. In contrast, China has rich rare earth supplies, producing 97 per cent of the minerals. The Japanese investors including Nippon Steel, JFE Holdings and trading firm Sojitz Corp will buy a 10 per cent stake in CBMM. South Korea’s Posco and National Pension Service will jointly buy 5 per cent of the unlisted company, investing around $ 312 million each.

China agrees to buy US plane manufacturer The state-run company behind China’s stealth fighter has recently agreed to buy Minnesota-based private aircraft maker Cirrus Industries Inc. The deal highlights the expanding ambition of China’s aerospace industry. A unit of Aviation Industry Corporation of China (AVIC), it will acquire Cirrus’s line of four-seat propeller aircraft

with an eye towards expanding in China’s general-aviation market, which are owned by individuals and small businesses.

The Asian superpower is considered one of the world’s most promising markets for aviation growth although the usage of such aircraft is limited in the country and most of its airports lack facilities to handle small, privatelyowned planes. The country’s Civil Aviation Administration has recently proposed relaxing restrictions for low-altitude airspace in 5 - 10 years to open flight lanes for small planes. The acquisition by AVIC will provide Cirrus resources to expand. The company is in the process of developing a jet - Vision, which will have up to five full size seats. The deal between the two companies is expected to close around midyear.


World News Daimler, Rolls-Royce in joint bid for Tognum Aircraft engine manufacturer RollsRoyce Group Plc and car & truck manufacturer Daimler AG have formed a Joint Venture (JV) to buy German engine parts supplier Tognum AG for $ 4.4 billion. The 50-50 JV will also acquire the 28 per cent stake that Daimler already holds in Tognum,

strong, and in richer countries, where older existing engines will need new, more environmental-friendly replacements. The companies are not aiming at cutting jobs. “The complementary capabilities we are bringing together will provide us with a world leading proposition, and will enable us to expand the business by developing a broader portfolio of integrated power systems and services for existing and new customers,” said, Sir John Rose, CEO, Rolls-Royce Group.

ArcelorMittal eyes stronger presence in Asia which is based in Friedrichshafen, Germany. The merger will also take over Rolls-Royce’s Bergen engine division. “The planned combination will provide a strong platform to realise the huge market potential,” said Dieter Zetsche, Chairman, Daimler Board of Management. The tie-up will offer strong growth potential both in emerging markets, where demand is

In a bid to strengthen its Asian holdings, world’s largest steelmaker has agreed to buy a 40 per cent stake in Thailand’s G Steel Public Co Ltd. The investment is part of a broader plan to strengthen the finances of G Steel and its subsidiary, G J Steel Public Company Ltd. ArcelorMittal will provide a $ 500 million credit facility, which G Steel and G J Steel will utilise for working capital and other corporate

purposes, provided that both the companies can reduce their outstanding liabilities. The deal indicates ArcelorMittal is ready for more growth after largely halting major investments in 2008 as the global economic downturn caused

steel prices to fall. The company appears poised for rapid expansion this year. It plans to increase by 51 per cent its long-term spending such as for equipment and acquisitions to $ 5 billion in 2011 from $ 3.3 billion in 2010. The deal is worth $ 246 million. “G Steel is an important component of our overall emerging markets strategy and will provide ArcelorMittal with a major manufacturing presence in Thailand and the Association of South-East Asian Nations region, where we expect steel demand to continue growing,” said Aditya Mittal, CFO, Arcelor Mittal.

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World News Hexagon Metrology opens factory in USA The company has recently opened its new facility in Oceanside, California. The state-of-the-art factory and Research and Development (R&D) Centre, will serve as the North American manufacturing headquarters for the ROMER brand of portable co-ordinate measuring machines. The new 14,000 sq ft facility was designed especially for the production of portable co-ordinate measuring machines such as the newly released Absolute portable articulating arm series. The layout and design of the new building integrates the latest in just-intime and lean manufacturing concepts, which enables efficient, cost-effective, and high-volume production of highprecision devices. The new Hexagon Metrology plant also includes an expanded R&D facility to drive innovation in the portable metrology market. All manufacturing and R&D functions in Hexagon’s Carlsbad, California facility will transition to the new Oceanside location.

JLR will deploy Dassault Systèmes’ V6 software for Product Lifecycle

Management (PLM) - the process that drives and controls all vehicle creation processes - to increase operational efficiency and reduce complexity through accelerated development capabilities. The company was chosen by JLR as its preferred partner in the PLM field following an 18-month evaluation period that included a full analysis of the Process, Method, Tools, Information (PMTI) environment at JLR.

Tata Steel sells UK plant to Sahaviriya The company has decided to sell certain assets of Teesside Cast Products to a unit of Thailand’s Sahaviriya Steel Industries (SSI) PCL for $ 469 million as part of the Thai company’s effort to ramp up production.

Jaguar Land Rover collaborates with Dassault Systèmes The two companies recently entered into a strategic partnership for future co-operation and collaboration. The agreement, signed by Bernard Charlès, President & Chief Executive, Dassault Systèmes, and Dr Ralf Speth, Chief Executive, Jaguar Land Rover (JLR), will see advanced digital 3D simulation and development tools transform JLR’s product development processes.

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The said plant was partially shut last February after four steel slab buyers pulled out of a joint 10-year contract. SSI is planning to restart production by the end of this year and will spend $ 1 billion on the plant in the next two years, including the $ 469 million to buy the plant and $ 150 million

to improve efficiency at the plant. The company, which has previously purchased slab from Teesside, intends to ship steel back to its own four million tons-a-year operation in Thailand and ramp output back up to 3.5 million metric tonne of slab, which Teesside was producing before 2008. “We buy from Brazil and Russia and the shipping distance is similar,” said Win Viriyaprapaikit, President, SSI.

German machine tool industry’s bookings up at year’s end In the fourth quarter of 2010, order bookings in the German machine tool industry doubled once again. Compared to the previous year’s equivalent period, order bookings from October to December rose by 99 per cent. The principal driver was demand from abroad, which was up by 105 per cent, while domestic orders increased by 87 per cent. Overall, demand in 2010 was up by 85 per cent from the previous year. Domestic Dr Wilfried Schäfer, customers Executive Director, ordered 75 per German Machine Tool cent more, while Builders’ Association export orders (VDW) came to 90 per cent more than in the preceding year’s equivalent period. “Recently, it has been forming-technology projects, in particular, that have been fuelling the upturn,” said Dr Wilfried Schäfer, Executive Director of the VDW (German Machine Tool Builders’ Association). The high level of order bookings in the forming technology sector has also boosted production output: during 2010 as a whole, it was a mere 3 per cent down on the preceding year’s figure. The German machine tool industry ranks among the five largest sectors in the country’s mechanical engineering segment.


Tech Updates Your gateway to the latest trends and technologies worldwide

Cutting head ideal for thick material

Measurement system for complex and large parts

Jet Edge Inc has introduced high-flow Abrasivejet cutting head, which is ideal for portable waterjet cutting. The new waterjet cutting head delivers up to 3.5 lbs/minute of abrasive, and 8.6 GPM of ultra-high pressure water. This high-

FARO Technologies Inc, a leading provider of portable measurement and imaging solutions, has released the new 3D imaging product line, featuring the FARO 3D imager AMP. The imager is a high-performance non-contact 3D imaging system, capable of collecting millions of points in few seconds. The AMP achieves groundbreaking accuracy on parts, assemblies and tools.

flow jet is capable of delivering up to 3.5 pounds per minute (5.95 L/minute) of abrasive and up to 8.6 gallons per minute (31.15 L/min) of ultra-high pressure water for abrasive waterjet cutting applications. The new Abrasivejet cutting head is ideal for cutting thick materials such as reinforced concrete or for making separation cuts in steel plates or pipes. It can be utilised with any waterjet system. It is available in three sizes: standard 9 in (230 mm), low-profile 90º inlet - 7.62 in (194 mm) and 90º Inlet 10.22 in (260 mm). Nozzle length of the new Abrasivejet cutting head is 4 inch (102 mm) and inside diameter 0.095-0.125 inch (2.4-3.175 mm). It is capable of operating up to 55,000 psi (3800 bar). This jet is especially suitable for low-pressure and high-flow waterjet pumps.

It is ideal for complex shapes or large parts. In just one click, it captures the complete and detailed image of the object within its half-meter field of view. It is an advanced 3D imaging solution that can help customers embrace the types of technology that can make their products and processes more efficient. The AMP is the perfect tool for applications in quality control, reverse engineering, and rapid manufacturing. It offers improved measurement of dark and shiny parts that are often missed by optical systems, and with its portable, rugged and thermallystable design, it is right at home on the shop-floor or the assembly line. The key to achieve high accuracy is the AMP’s advanced technology ‘Accordion Fringe Interferometry’ (AFI), which uses lasers to generate infinitely focussed fringe patterns that are projected onto the part.

Microscope offers high accuracy Thread tooling manufacturer Vargus has expanded its renowned MiniPro threading solution range with the introduction new microscope line of single-ended micro tools. The line is unmatched for its highly accurate small bore (down to 1.7 mm diameter) threading, grooving and boring applications in all materials. The new line features high wear-resistant VBX TiCN-coated inserts (of 4 mm, 5 mm, 6 mm or 7 mm diameter) for both high and low cutting speed tasks. Also, the microscope range offers high performance in all popular applications on a consistent basis: for threading – ISO, UN, Whitworth, NPT, partial 60o and partial 55o; boring – the new design of a combined boring and copy tool promotes excellent

chip evacuation; grooving – square grooving at profile widths of 1 mm to 2 mm, and depths from 0.8 mm to 2.5 mm; round grooving to radius size groups from 0.5 mm to 1 mm; and internal & external face grooving solutions from 2 mm to 6 mm depths. The microscope is suited to prepart off applications, and is designed to eliminate any burrs created during cut-off. The new addition to Vargus’ MiniPro line of threading solutions – Mini, PowerBore and double-ended Micro – also features a new fast and easy clamping system utilising a single screw, together with a slanted location system for precise radial and axial positioning, guaranteeing highly-repeatable edge height and overhang.

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Tech Updates Insert holder provides high cutting rates

Gauging system offers high speed and repeatability

Solid carbide milling cutters ideal for stainless steel

The new HT 800 interchangeable insert holder from Guhring provides high cutting rates. It is available in the diameter range of 11.5 mm to 25.99 mm, with cutting lengths of 1.5 x D, 3 x D, 5 x D, 7 x D and 10 x D. They posses heat and wear resistance. The nickel plated holder is equipped with rigid insert seat and optimised flute profile, preventing chip congestion, especially in deep holes, with coolant ducts opening on the flutes for better chip evacuation and the interchangeable inserts are produced in ultra fine carbide grades. The main advantages of HT 800 are its completely play-free fitthrough elastic clamping insert slot providing high rigidity and the shank designed to DIN 6535 HE (whistle notch grinding) for side locking.

Renishaw has launched its first gauging product line with the introduction of the Equator. The new gauging system reduces purchase, maintenance & fixture costs, and it can be programmed for multiple parts & re-programmed in minutes for design changes.

The new solid carbide milling cutters S356 and S357 (corner radii) from Dormer’s are designed for usage in the aerospace, energy, dies & moulds and medical sectors. The new cutters are said to be specifically designed to compensate for these deficiencies; they are intended to offer improvements in metal removal rates and component surface finish. The new Elect M range of solid carbide milling cutters will be apt fpr any production area involved in the high-precision machining of stainless steel. The company’s unequal helix geometry provides stability and high productivity. By reducing tool vibration, the unequal helix design not only promotes superior workpiece surface finish, but reduces the tool wear also. It improves dimensional control of the component and also enables better axial and radial depths of cut to be

The overall construction of the holder has been made rigid and simple, to change the wear out inserts without damaging the holder after its usage in few seconds time. The new HT 800 has a broad range of applications. It saves time & cost, and therefore increases the production. It is equipped with standard programme with favourable prices as well as short delivery times.

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The design is capable of high-speed comparative gauging for inspection of high-volume manufactured parts. It has been developed and proven on the shop-floor in collaboration with leading companies in the sector like automotive, aerospace and medical. It is light-weight, fast and highly repeatable gauge and can switch between parts in seconds, which is perfect for flexible manufacturing processes or accepting parts from multiple machines. The new gauge is based on an easily scaleable and adaptable ‘parallel kinematic’ structure; Equator’s unique patented principle allows high-speed scanning and rapid moves between features, while retaining stiffness that delivers impressive point-topoint repeatability. The systems are available with two levels of software, a programmable version for production engineers to create Dimensional Measuring Interface Standard (DMIS) programs; and a shop-floor system, which allows those programs to be executed but prevents operators from making modifications.

achieved at high-cutting parameters - even on old generation CNC machines. According to company, it has a number of additional features, which ensures maximum benefit in a range of stainless steel applications, including roughing, semi-finishing and finishing. Similar to the combination of flat relief and cylindrical land width has a positive influence on the milling process, further contributing to a steadier pass and reduced chatter. It has high rake angle that reduces heatgenerated during milling.


Ad Name: Ceratizit Pg No. 45 MMT Apr-2011 MMT Apr-2011

Ad Name: Ceratizit Pg No. 45


MMT Apr-2011 Ad Name: JP Machine Pg No. 62 MMT Apr-2011

Ad Name: JP Machine Pg No. 46


Event Focus

Curtain Raiser .............................. 48 Market Dynamics ......................... 52 Industry Insights .......................... 54 Product Showcase

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Curtain Raiser

Moulding success in a buoyant economy Carrying a legacy of more than a decade, the event DIEMOULD INDIA, in each of its previous editions, has provided a platform for leaders and innovators from the entire spectrum of tool making, to showcase their basket of solutions. As a buoyant economy spells growth for the domestic dies & moulds industry, the mega trade show will host its south edition – DIEMOULD INDIA SOUTH – 2011, demonstrating the latest in technology and tools. Rachita Jha

T

he manufacturing sector is on a growth path, with positive boom in the automotive, infrastructure and aerospace sectors. This growth has boosted the demand for tools and tool parts, bringing in gains for the dies & moulds industry – the foundation of tool making industry in India. Keeping in line with the demands of the industry, the DIEMOULD INDIA SOUTH 2011 exhibition is all set to provide all business-related entities in the tooling industry an ideal opportunity to display and market their products & services in the presence of industry

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leaders from India and around the world. To be held during April 7-10, 2011, at the Chennai Trade Centre, Tamil Nadu, the flagship event, organised by Tools & Gauge Manufacturers Association of India (TAGMA), will provide an ideal opportunity for the tool making industry to witness the latest advancements in machines and technologies. As automation gains importance on shop-floors, the event promises a display of a variety of machine tools for dies & moulds and the latest in CNC machines.


Curtain Raiser The regional event will continue to be held biennially and the venue will be decided later, based on exhibitor feedback for this event.

Flashback

Business advantage

TAGMA organised the first DIEMOULD INDIA (DMI) international exhibition in 1998, at Mumbai (dedicated to the country’s tooling industry, which was highly successful), thus laying the foundation of subsequent biennial DIEMOULD exhibitions. With consistent support from the industry, DMI has steadily grown to become one of the largest exhibitions for the dies & moulds industry. The previous edition of DMI was held in March 2010 at Mumbai. The range of exhibits at the event included the latest technology of ‘hot runner systems’, which generated significant interest. Today, technology has gained much acceptance in the Indian moulding industry. The edition also witnessed Electronic Discharge Machining (EDM) equipment with super-surface finishing wire cut machines. Besides, cutting technology for a variety of materials such as steel, carbide and graphite were on display. The event was quite successful, despite the downturn in the economy. Experiencing this enthusiasm TAGMA Executive Council (EC) unanimously decided to brand the present series of the Biennial DIEMOULD Exhibition held in even years at a permanent location - Mumbai. Hence, the 8th DMI has been decided to be held in the financial capital of the country.

This focussed exhibition on dies & moulds has regular participation from leading global brands from India and abroad, showcasing their latest proven technologies, with features to improve productivity & quality and reduce costs. The exhibition will feature the latest offerings from the entire spectrum of the tooling industry, an essential and a vital partner of the successfully growing manufacturing sector. It will showcase high-grade innovative state-of-theart CAD/CAM/CAE solutions, various types of dies & moulds, press tools, cutting tools, tool steels, hot runner systems, machine tools for making dies & moulds, CNC milling/machining centre, EDM, etc. Measuring machines & instruments, accessories for machine tools, gauges, machines, texturising, rapid prototyping & modelling, tool design, product design & analysis, consumables & spares for EDM cutting & wire cut, mould base & standard parts of dies & moulds, CAD/CAM system related to dies & moulds, digitising, heat treatment, reverse engineering, die/mould polishing machines/tools & diamond consumables, die casting machines/ moulding machines, etc will also be exhibited. The event will provide visitors a global opportunity to update themselves on technology trends, find innovative ideas & new approaches to their current practices, network & discuss manufacturing & other complex issues with professional experts, who will help analyse and execute solutions for their operations.

South edition In view of the above decision, to meet the growing demand and need of the other regions, the EC has decided to conduct an additional regional DMI show during odd years, beginning with DMI 2011 at Chennai, a growing manufacturing hub for automobiles and auto components sectors.

Country pavilion DMI is well-known for its international participation. A niche sector in the

Exhibitor profile

       

Dies & moulds, press tools Mould base and standard parts of dies & moulds Die casting machine/moulding machine Machine tools for making dies & moulds, CNC milling/ machining centre, EDM, etc Hot runner systems - tool steel Die spotting Cutting tools CAD/CAM system related to dies & moulds

machine tool industry, the entire end-to-end value chain of the dies & moulds industry will be wellrepresented at the event. As a key business partner for the Indian dies & moulds industry, a dedicated country pavilion of China will bring a host of opportunities for the visitors to forge partnerships, crack business deals and network with some of the leading companies.

Looking ahead TAGMA has always aimed at providing opportunities to the tooling industry by improving competitiveness, building exposure through domestic & international visits, seminars and exhibitions. S C Kalyanpur, President, TAGMA avers, “DMI 2011 will mark the beginning of a successful period for the dies & moulds tooling industry. The show will feature global suppliers, materials for dies & moulds making, special tool steel, carbide electrode materials, all consumable for production and repair of dies and moulds under one roof.” Technology upgradation has been a major draw at the previous events, as the visitors get to witness the latest machinery that can be incorporated in various applications. As companies chase shorter time cycles and improved efficiency to leapfrog from the conventional methodologies, the event will strive to offer a one-stop solution for all business and technology demands.

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Market Dynamics INDIAN TOOL ROOM

Courtesy: Indo German Tool Room

Time for an overhaul Industries in India always demand moulds with less delivery time because the moulds from countries such as China, Taiwan, South Korea, etc are available at minimum delivery time, sometime less than one month period. Hence, the main challenge for Indian tool rooms is to deliver good quality moulds in minimum delivery time. Ketan Panchal

Q

uality of moulds implies functionally efficient products with good finish, high level of precision, better mould life, along with fast delivery time. The quality of moulds from Indian tool rooms has always been compared as per European standards. Mostly, tool rooms in India target 300-400 moulds per annum. They maintain the delivery time and produce accepted quality of moulds. The common thread running between various tool rooms is that they achieve their target with better planning, utilising standard designs and mould parts.

Designing moulds The tool rooms carry out mould design in-house within two-three days and also purchase standard mould bases and parts such as latches, locators, cooling baffles from local markets. They only concentrate on manufacturing core & cavity, and carry out assembly of the mould. Further, they deliver moulds in about two months. Once

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the tool room has developed the clusters among family members, more options are not necessary. While one parent tool room designs moulds, manufactures core & cavity and carry out the assembly of moulds, mould base manufacturing is carried out by another family member, chosen according to segmented sizes. Round mould bases will be manufactured by one family member and the facility is developed solely for this purpose. While one of the family members makes rectangular mould bases up to 300x300 mm size and has the facility for the same, other members will engage in manufacturing mould bases above 300x300 mm sizes. Also, guide pillars, guide bushes, latches and locators are manufactured by another tool room. Together, they can manufacture moulds within two months and be ready for delivery as well. With this cluster management among family members, they make more than 300 moulds per annum. Such cluster management needs to be developed in small tool rooms.

Skilled manpower Another segment of tool rooms is moulds for engineering plastics and engineering products. Moulds for engineering products are complex in nature and require high precision. In this segment, experienced and expert manpower is necessary. In the case of new product development, the tool rooms must utilise latest technologies to have foolproof manufacturing. New product development is always on trial & error basis, which takes time and more number of trials. After every trial, rectifications & modifications consume time and cost as well. In the process, introduction of the final product may be delayed and time-tomarket also increases. Today, plastic rapid prototyping has enabled manufacturing of products without making mould. With this, one can check fitments, aesthetic appearance and carry out functional tests. Also, feedback can be taken, with rapid prototype products. With this technology, product design can be freezed, eliminating product modifications and avoiding


failure of product. Once the product design is finalised, one can ensure mould design by mould flow analysis. Filling of components, air traps and weld lines can be checked with mould flow analysis. With the analysis, data such as clamping tonnage requirement, injection pressure & time, velocity and processing parameters can be generated, which in turn helps in fixing the trial data in advance. The cost of these can be covered in terms of time taken for trial and error of the moulds. Rectifications and modifications may lose the mould quality and life.

Technological advancements In case of rapid prototyping, the metal powder sintered on machine blocks makes the core and cavity. This can be made with 20 micron accuracy and good surface finish. Polishing and hardening are processes that come later on. Deviations and rejections

will not occur. The life of core & cavity in this case will be about three lakh shots, which is never the requirement of engineering products. One can also design and provide conformal cooling and reduce cycle time of the injection moulding process and avail better quality products due to conformal cooling. One tool-room in Mumbai is making core & cavity with this technology, and moulds for irrigation drippers. This technology is still not easily available in the Indian market. The manufacturing time of core & cavity is less than a week, with no deviations, and can save three weeks of the current manufacturing time. Cost can be reduced by saving time, especially if the product is

Courtesy: Indo German Tool Room

Market Dynamics

introducted in the market earlier than its competitor. The tool rooms in India are striving for faster delivery and quality. The usage of standard mould design & parts, cluster management and the utilisation of latest technologies are the way to lead in the market.

Ketan Panchal is Production Manager at Indo German Tool Room Ahmedabad. He has more than two decade of experience in the field of tool and die making. He is presently responsible for production division and looking after manufacturing, assembly, planning, injection moulding, and store & purchase. Email: ketan17in@gmail.com

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Industry Insights

The crucial requirement is investing in modern technologies Alexander Blum, President Blum-Novotest GmbH

Q Demand patterns and

emerging trends Companies have to optimise their production processes for manufacturing more efficiently and with less wastage. A growing number of measuring and quality testing tasks, which were earlier carried out in the measuring room, have now been integrated into the machine tool. For example, with our new measuring software FormControl V4, comprehensive measuring tasks can be executed in the machining centre. This enables detection and rework of machining errors in the original setting as well as reduction of cycle times.

Q Challenges One of the biggest challenges is to manufacture excellent quality products at best possible rates. This is one of the reasons why we experience an increase in demand for production metrology, helping customers in manufacturing goods at high speed, with full or partial automation and qualitycontrolled production, throughout the day. Human errors are the biggest risk in these environments. Therefore, many customers utilise laser measuring systems & touch probes to realise a closed loop production in multinational companies and small job shops.

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Q Technological developments Many companies, even in India, employ highly dynamic High Speed Cutting (HSC) machining centres with linear drives. In such machines, in-process measuring equipment is an essential instrument. Due to the measurement at nominal spindle speed, it compensates tool growth caused by high-spindle speed or temperature change, and can have a dramatic effect on cutting precision.

Q Need of the hour The crucial requirement is investment, especially in modern production technologies, and to find well-skilled & motivated staff. These are the key factors for the dies & moulds companies, which will help them cope with future tasks. We are also seeking staff for our new sales and service offices in New Delhi, Pune and Chennai. Further, the need is to address the growing requirements from demanding industries like automotive, electrical, electronics, etc. The challenge is to produce dies & moulds of high quality in short lead time and at a competitive price. The implementation of the latest manufacturing processes and technologies is another necessity.

Q Benefits of participating in

DIEMOULD INDIA SOUTH - 2011 India is a fast growing and important market having high quality standard. The exhibition provides specialists of the dies & moulds industry a chance to see the best production technologies in a concentrated form, facilitating technically challenging discussions with experts, which often leads to innovative ideas. Also, the fact that Chennai is one of the largest industrial centres in India, and more than 40 per cent of India’s automobile production is located here, will make the exhibition interesting for local as well as international visitors.

Q Growth prospects for mould

industry The growing standard of living will push the demand for dies & moulds products in India. In addition the demand will rise in the automotive as well as the aerospace industries. The companies will further invest in more sophisticated solutions as well as features, allowing high productivity. We expect a shift in manufacturing of consumable products, featuring dies & moulds solutions from China and South Eastern Asia.


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Industry Insights

Computer-aided simulations need to be employed in small shops Arunagiri Nathan, Proprietor K A R Moulds

Q Challenges ahead The real competition is from the mould maufacturers of China, Thailand and Korea. We need to advance and develop the techniques for precision and fast delivery. We also need to utilise computer-aided simulations even in small shops to cut down the optimising time.

Q Current trends We are witnessing a lot of advancements in the field of highspeed machining. The idea is to finish all processes in the machine itself, including inspection and reducing benchwork. This will not only increase efficiency but also reduce the total time required to finish a task.

Q Technological innovations in

recent years The industry has seen the availability of high-quality steel, better machine tools, accessories and several developments in simulation & CAM packages. The availability of better technologies has enabled several companies to venture into the aerospace sector. This, coupled with the accessibility to best rapid prototyping technologies at reasonable cost, has helped

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many in bringing the part to market in a short project time. The availability of standard die & mould elements is also beneficial for the industry.

Q Support from government

and associations Ample supply of quality manpower is needed from institutions. Short courses in CNC programming, operation and manufacturing of dies are necessary. The training programmes of technical institutions must be reviewed continuously and updated according to the industry needs. Immediate government action in this regard is the need of the hour. Without continuous availability of manpower, the industry is forced to train people, which results in losing precious manpower hours. It is true that rather than training the young labour force to meet demands., the institutions have become production centres. These institutions must focus only on training. Also, the students from some of the existing educational institutions are no match for the current industry requirements. We need world-class trainers to provide practical knowledge.

The big pool of IT professionals who graduate every year must be utilised to develop indigenous CAD/ CAM simulation, project management applications to the demands of the dies & moulds industry, at affordable price. This is the time to think cautiously about such issues. All required technologies are available in the market, but at a premium price. Skilled manpower is scarce, so they charge a premium. These should be made available at an affordable cost.

Q Impact of economic

downturn The recent economic downturn had an adverse effect on the industry. With declining demand, sales also diminished simultaneously. Compared to the manufacturing sector as a whole, which suffered on a large scale, the dies & tools industry managed to retain most of the labour force and post reasonable sales as well. As we form a part of the supply chain for the automobile and other manufacturing industries, we are expecting more orders along with the steady growth in the automotive sales across the country.


Industry Insights

The industry now faces an uphill task of matching delivery expectation A S Agarwal, CEO Abhijeet Dies and Tools

Q Current scenario Dies & moulds is a continuously evolving industry in India, growing at a rate of about 15 per cent per annum. It is poised to grow more than ever before. Last year, the automotive sector grew above expectations, which provided the industry with a much required thrust. In the plastic tool segment, mindsets are changing, and toolmakers are now considering capacity enhancements, accompanied by technology upgradation such as high-speed machining and above 3-axis machining. This is going to be more visible in the large mould segment, which was a low-priority area for many years due to Original Equipment Manufacturers (OEMs) reluctance to source such tools from local manufacturers. Today, the rising cost pressure and intense competition have made them develop and support the move to local sourcing.

Q Need of the hour The mould industry now faces an uphill task of matching delivery expectation, which is normally based on an OEM’s past experience with overseas tool suppliers. This

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is not going to be easy for the industry, as it is not yet organised like the toolmakers abroad. Their strengths lie in cluster tool-rooms, shared facilities, excellent contract machining as well as the availability of ‘ready to employ’ skilled and trained manpower. In terms of installed capacity, our tool-shops are still far behind. Yet, the scenario may change over a few years. There are a couple of overseas tool-shops present in India, which will make competition tougher, and manpower further scarce. Retaining skilled manpower in tool-shops has already become the need of the hour, and has its own cost impact.

Q Emerging sectors The emerging sectors driving the tooling industry are automotive, auto ancillaries, consumer durables and packaging. In fact, other sectors like personal hygiene and medical are growing rapidly as well. More than 50 per cent of the tooling demand comes from automotive OEMs and ancillaries, which still remain the main driving force. As urbanisation and common man’s income are rising, the demand for consumer durables are on the rise too, which is fuelling

the tooling demand as well. As the manfacturers are under pressure to reduce cost due to competition, a big portion of tooling demand is fulfilled by overseas tooling manufacturers.

Q Role of exhibitions Many of the above issues can be addressed collectively by the association of tool-shops. Events like DIEMOULD INDIA have offered a platform to bring this fragmented industry closer to each other. In addition, they have provided an opportunity to showcase one’s capabilities to prospective customers, and more importantly, build their confidence for local sourcing. Foreign participation provides a chance for interaction and self-evaluation. The event, which used to be once in two years, has now become an annual event, proving its relevance and strength of the association.

Q Future of the industry Healthy growth is assured, as the business scenario in India is vibrant, and unaffected by global meltdown. There are ample opportunities for the right tool-shops to prove themselves and excel. The future of the industry is bright.


Industry Insights

Acquiring skilled workforce is the biggest challenge

D Jayaseelan, Managing Director Vishal Precision Products Pvt Ltd Q Current scenario The current scenario is positive in the case of dies & mould industry, even though there exists tough competition. As a mould base manufacturer, the flow of enquiries is good, which helps us plan future growth strategies and machine tool investments.

Q Demand pattern and

emerging trends Tool and Gauge Manufacturers Association of India (TAGMA) has indicated the demand pattern for the Indian market for tooling, which includes sheetmetal dies, plastic moulds, forging dies/others, casting dies, jigs & fixtures, etc for the financial year 2010 to be about ` 13,080 crore. Significant efforts should be made to meet the demands in terms of machine tool investment and requirement of skilled workforce. Industry-oriented training in educational institutions is required, which can produce jobready professionals for the industry.

Q Challenges faced Tackling the lack of skilled workforce is the biggest challenge. Labour attrition in short intervals lead to delivery delay, which spoils the trust among customers. The trained CNC

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operators in India seek only shortterm assignments to work in Indian tool rooms, and they are more interested in overseas assignments.

Q Technological development The evolution of IT and its integration into manufacturing is rapidly changing equations. For example, CNC and robotics have led the way in rapid prototyping and instant manufacturing, which has provided tool rooms the flexibility to quickly and easily change/adapt/ modify any product design, irrespective of batch sizes. Also, in large corporations, there might be a distinct division of labour between tool room work and production machining, with different employees assigned for each job; whereas job-shop work is often a blend of tool room work and production work, because each project requires some of both, and the same employees may wear each hat in sequence. On the other hand, if CAD/CAM and instant manufacturing are developed to their full potential, this paradigm shift would become moot, as after the initial building of machine tool, there is only the running of an endless variety of programs by it, with no tool room work left to be done.

Q Need of the hour Power is a major constraint, and decisive steps need to be taken by the government to supply uninterrupted power to the industry. Recent power cuts have hit the industry hard. Moreover it is essential to establish a ‘CNC Techno Park’ consisting of all types of tool rooms, supportive machines with skilled workforce, under a single roof, where all tool rooms can utilise this facility. This initiative should be taken either by the government or by the machine tool manufacturers. Another aspect is that market survey-related reports are less, as far as tool rooms are concerned. This has to improve to help tool rooms understand the market pattern and plan their investments. The government should help tool rooms improve their infrastructure and facilities by offering credit facilities through banks.

Q Future growth prospects In the global market, India is identified as one of the potential areas for quality products. This encourages international companies to forge business ties with local companies. Hence, the growth of the mould industry will be good in the near future.


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MMT Apr-2011 Ad Name: Emuge Pg No. 66 MMT Apr-2011 Ad Name: Emuge Pg No. 66


Industry Insights

Lack of standardisation results in the sector being unorganised

Harshit Shah, Managing Director Vijaydeep Mould Accessories Pvt Ltd

Q Current scenario The Indian market is expanding, with more investments being made in the tooling industry. Competition is also on the rise. Currently, the market is shifting from an unorganised sector into an organised one.

Q Demand patterns and

emerging trends Demand and supply grow directly in proportion. There is an increasing demand in the market, but no standard trend can be observed, as the demand changes according to the tooling requirement.

Q Challenges in the sector Lack of standardisation results in the sector being unorganised. Also, the market is scattered, and there is lack of skilled labour as well.

Q Technological developments Several technological developments have taken place in the tooling industry since the past decade. The awareness about the usage of hot runner systems has been significant. This has changed the way moulds are being made. More importance is being given to the manufacturing of high-performance injection moulds and multi-cavity tooling.

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Q Need of the hour Designing knowledge and awareness about the quality of tools being made are essential for this industry to grow. A body, which represents the tooling industry, must make an attempt to bring this highly scattered market under one roof and should collect more data from the market, which in turn will support the growth of the industry. Tool designers have to work continuously to reduce cycle times as it is directly related to the cost of the product. For this die parts, which run faster and for longer duration between breakdowns are required. Now-a-days many standard die and mould elements are available which can satisfy the needs of the designers. The rapid development and reduction in delivery times has to be attributed to the development of various software which are currently used by tooling industry in almost all facets of tool development cycle - including product designing. Specifically designed software is extensively used in the area of product design for conceptualisation and visualisation. This has opened up limitless options for styling which has even surpassed functionality,

as more and more customers are choosing products based on styling features of product rather than its functionality or utility.

Q Benefit of participating in

DIEMOULD INDIA SOUTH - 2011 Geographically, the Indian tooling industry is spread over an extensive area covering different demographics. The exhibition will act as a suitable platform to interact with prospective buyers from the southern part of India. It will also provide us a chance to showcase our products and technological abilities and forge business relations with local as well as international companies.

Q Future growth prospects of

mould industry The requirement for plastics is increasing, as it is increasingly being substituted in place of metals. More and more products are being made from this wonder material. This offers a good scope and opportunity for the tooling industry to develop and flourish. With the country’s automotive industry projected on a growth track, the future of tooling industry also looks bright.


Industry Insights

Quality has become priority in current scenario

Hemakant Garde, Managing Director GL1 InnoMold India Pvt Ltd Q Current scenario After the economic slowdown, the situation is gradually improving, as the demand is also increasing. Good quality tool makers are booked for months in advance, which is a good sign for the market. The expectation of customers is growing, and currently, every customer seeks technology that boosts their production. Quality has become priority in the current scenario.

Q Demand pattern and

emerging trends The demand for the industry is to bring down input costs like steel and other raw materials. But, this demand is not constant, as tier I companies may delay the projects. Hence, to handle the delay and additional workload, the job needs to be outsourced. Looking at this pattern it is difficult to allocate resources and plan efficiently. Today, customers are expecting to invest in moulding business, so that they have a single window for communication. More tool makers are investing in moulding machines to support the demand of their customers. Its also gives liquidity at the tool makers end, as moulds business is more capitalintensive business, and hence it is always difficult to manage working capital needs.

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Q Challenges The main challenge is to meet quality expectations of the customers. Technological upgradation is the second challenge, as demand for quality is growing each day. To meet these expectations, tool makers have to invest in technically advanced machinery, which increases capital investment. The Indian government needs to formulate industry-friendly and specific policies Another challenge in the sector is to retain the skilled talent. In case of the tooling industry, there is a need to create brands to attract skilled human talent from other industries. Making tools is one of the most difficult and highly technical jobs, and finding the right workforce is a herculean task facing the industry. There is a huge difference in talent availability and talent requirement, especially in manpower to handle complex machines. Therefore, most of the companies do not tend to buy high technological machines, as the talent to operate the same is not available. But to compete in a cut-throat environment, companies need to invest in technology. Also, to invest in high-end technology, customers need to be convinced of such advanced

products. Once, this is accomplished, companies can start exploring more and more avenues in developing such type of products.

Q Benefit of exhibitions Exhibitions like DIEMOULD INDIA SOUTH – 2011 provide a comprehensive platform to meet potential customers under one roof, and understand what is the latest in the market. As this event has a focussed audience, it gives us an opportunity to showcase our technologies and developments. At this event, we will be displaying moulds, along with auto parts. Besides, we will be showcasing new technologies intended for the Indian market such as stack moulds, gas injection moulds, tandem moulds, two component moulds, etc.

Q Future growth prospects The future potential of the mould industry is good, as our Finance Minister has notified in this year’s budget session that Gross Domestic Product (GDP) will grow around 9 per cent. Considering this growth pattern, the mould industry will also grow respectively. New industries are setting up in India, and hence there will be demand for new moulds, which can be sourced locally.


Industry Insights

The industry is facing capacity constraints mainly due to low return on investments K Govindarajan, Sales Director LMT (India) Pvt Ltd Q Current scenario The dies & mould industry has been registering good growth rate, in view of increasing demand across the manufacturing industry. However, this growth is not at the same pace as that of the end-products/ components growth, since the manufacturing volume and organic growth of mass-produced goods is much more than the need of new models/ requirements. Also, the industry is facing capacity constraints mainly due to low Return on Investments (ROI), impeding the capacity expansions. In the past two years, rapid development of the Indian manufacturing sector is driving the demand for dies & moulds. However, imports are also on the rise, catering to this demand, resulting in a moderate growth of the domestic output.

needs low cycle time and more intricate profiles to improve the aesthetics of the end-products. Also, rapid prototyping will be the main differentiator, and speed & flexibility will play major roles. With the current large-scale growth witnessed in the manufacturing sector, especially in automotive and consumer electronics, coupled with OEMs desiring to develop domestic tooling manufacturing for price competitiveness, we can foresee rapid growth in tooling.

Q Challenges Availability of skilled workforce, low ROI, competition from imports and shrinking lead times are the major challenges. Also, from machining perspective, the adoption of high productive and innovative tooling in tier I and II industries is not as common as in OEMs.

shrink fit-holders for high rigidity and long reach can improve the overall machining efficiency.

Q Need of the hour There is a need to increase productivity to meet local demand. Co-operation with OEMs for more acceptance & building a win-win business model is of paramount importance. Also, machine tool industry should look at improving the yield. This will prove crucial in the near future.

Q Benefit of participation The event is an excellent platform for introducing new products and latest technologies to potential customers. Also, it will help in networking and being abreast with evolving technology and changing industry needs.

Q Growth prospects of the Q Emerging trends The demand is witnessed across all manufacturing segments – automobile/electronics/ plastics/electricals, etc. It will grow mainly in automotive and consumer durable sectors, since OEMs are introducing new models, and the life cycle of the models are cut down year over year. The industry

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Q Technological developments In the case of cutting tools for this segment, high-feed machining to reduce cycle time is a new trend. The finishing ball nose cutters with indexable inserts also gives superior finish in high-speed milling. It eliminates the polishing operation in most cases. Also, these highperformance tools utilised with

mould industry With the aspiring middle class population, and Gross Domestic Product (GDP) growth rate of around 9 per cent, the prospects look promising in the coming years. However, the possibility to take away a share of overseas competitors will always provide a chance to grow better.


Industry Insights

Unprecedented growth is witnessed in terms of volume and variants N Gopinath, Vice President MMC Hardmetal India Pvt Ltd Q Current scenario The dies & mould industry depends on the manufacturers of end products. It is the feeder industry to the endproduct manufacturer. With an overall boom in the Indian engineering industry, the dies & moulds industry is also growing rapidly. Every dies & moulds manufacturing company has its order book full and is working overtime to meet the demand of their end-consumers. For example, in the automobile industry in India, from the 80s till the 90s, there were only a few car manufacturers. The market demand for automobiles was less, and production volumes were low. But today, unprecedented growth is witnessed in terms of volume and variants. Many auto manufacturers have set, or are in the process of setting up manufacturing facilities in the country. This has also put pressure on manufacturers like Maruti Suzuki and Hyundai to introduce more models to beat competition. In this rapidly changing scenario, the dies & moulds industry has also seen a perceptible change in demand - both in terms of volume and variety.

Q Demand patterns and

emerging trends With product life cycles becoming

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shorter and with increase in the variance of products, the need of the hour is to have multiple moulds for a given product. This automatically converts to a larger variety of moulds for each variant. This is an emerging trend. With the increase in the variety of mould requirement, the demand is also growing, and at the same time the demand pattern is changing too. Customers now seek dies that can be produced in short time, which comes with high accuracy. For mould manufacturers used to small demands and less variety, a change has been incorporated into their way of functioning, with large investments in terms of high-speed machinery, process and planning.

Q Challenges in the sector The biggest challenge is in meeting delivery schedules. In comparison, South East Asian and East Asian countries including China and Taiwan are better equipped to offer cheaper products at a much faster rate. In addition, the dynamics of the business is changing fast. As the demand increases, manufacturers have to add more capacity, offering technologicallysuperior products, reduce cost and deliver fast.

From a machining perspective, the development of high-speed machines, capable of spindle RPMs of as much as 2,00,000, have been conceived. Currently, many machine tool buildiers provide RPM up to 60,000. From a cutting tool perspective, the high-feed cutters are available from most of the leading cutting tool makers across the world. However, insert retention in the tip seat pocket while cutting at high RPMs are always an issue, and most manufacturers have claimed to develop milling cutters for high-speed applications. The newgeneration coated grade inserts also play an important role in terms of achieving high tool life as well as for machining new-generation tool steel material.

Q Need of the hour Technological advancements in dies & their machinability, and high efficient machines & cutting tools are in demand. Also, in-process management and efficient manufacturing processes will play key roles in the future.

Q Future growth prospects of

the mould industry The future of the dies & mouldsindustry is bright, as long as the engineering industry continues to thrive and grow. The dies & mould industry will piggy-back and grow along with it comfortably.


Modern Machine Tools (Apr 11) IGF Inner Pg75 76


Modern Machine Tools (Apr 11) IGF Outer Pg77 78


Product Showcase This section gives information about the products to be showcased at DIEMOULD INDIA SOUTH - 2011

CNC micro-mill engraving machine

Measuring software

N-Gravetek offers CNC micromill engraving machine, which is specially designed for the mould industry. This machine has Taiwanmade HINWIN high-precision ballscrews and linear slides. It has steel foundry body and completely enclosed protection covers. Automatic lubrication systems and enclosed protection covers are also provided. The machine is fitted with the latest CNC programmable multi-axis controllers with handle pulse generators. Standard G-code files are received using a direct Ethernet connection via TCP/ICP. The CNC micro-mill engraving machine also has Japan-make Yaskawa AC servo motors and drives. It comes with automatic tool sensors. Optional accessories include: optional spindles, rotating axis, vacuum hold-down table, etc.

Blum-Novotest offers advanced measuring software FormControl. Besides a host of innovative improvements, and simplifying applications, Version 4 enables fast workpiece control by measurement and analysis of geometrical standard elements. This software, which was first developed for contour measurement in dies & moulds production, becomes an instrument for comprehensive production control directly on the machine tool. FormControl V4 offers the optimum solution for both applications. On one hand, contour control by measurement of single points as per Version 3 is possible where eventual deviations from the CAD-model can be detected by set-actual method. On the other hand, the latest software version now offers the possibility to measure different correlated geometrical elements by mouse click and to check their characteristics via the integrated analysis functions. So by the application of FormControl V4 machining errors are detected in original setting, which reduces cycle times and enables easy remachining. Till now, the typical application of FormControl was in dies & moulds production. In the future, it can also be in medical technologies, automotive or aerospace industries, in principle for all industries of cutting operations for minor and medium serial production.

N-Gravetek Nashik - Maharashtra Tel: 0253-2317432 Email: sales@ngravetek.com

Hall 2 6 Stall G0

Double-column vertical machining centre DCV series from YCM Supermax is an advanced doublecolumn vertical machine series that delivers one of the best craftsmanship, which is designed for high-accuracy machining. DCV offers the next level of machining dies & moulds, strengthened with two-piece structures. Axes are supported with roller-type guideways driven directly by a powerful motor with dual nut ball screw. This ensures the machining capability from precision reflector mould to car bumper moulds. Y-axis is supported by three roller guideways for Z-axis headstock to move steadily & smoothly supported by hardened & ground box ways for high machining stability. The machine is powered by 22 kW spindle motor power ranging spindle speed option from 4,500 rpm to 20,000 rpm. High-speed machining mode with manual guide i Functions and i Operation Plus delivers the best cutting rigidity & smooth movement during 3D contouring operations. S&T Engineers Coimbatore - Tamil Nadu Tel: 422-259 0810, Fax: 422-257 3629 Email: stengine@md3.vsnl.net.in

Hall 1 4, Stall C0 01 K & 4 F0

Blum-Novotest GmbH Grunkraut - Germany Tel: 49-751-60080, Fax: 49-751-6008156 Email: vk@blum-novotest.com

Hall 1 7 Stall C0

Die spring Global Special Springs offers die spring in international standards ISO 20243,JIS B 5012 Metric, US Oval Wire, as well as many other die components as wire die springs, nitrogen gas springs, hexagon socket head, shoulder screw ISO 12.9, ground spacer sleeve and shoulder screw. The quality, reliability, safety and highvalue-added special spring products are guaranteed by a perfect combination of best CNC machine tools and highly qualified operators, with process steps monitored and checked by central computerised system manager supported by inhouse metallographic and technical labs equipped with the most recent latest instruments and control software. Global Special Springs Pvt Ltd Ahmedabad - Gujarat Tel: 02764-273 065, Fax: 02764-273 065 Email: info@globalspecialsprings.com

Hall 1 2 Stall A1

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Product Showcase CNC desktop engraving machine N-Gravetek offers CNC desktop engraving machine in all-aluminium foundry body. This engraving machine is compact in structure and comes with excellent stiffness. The machine is economical, has all-inone compact design and is as small as a computer printer. Some of the features include: DSP 3D controller, USB connection, 32M flash memory, separable with PCs for independent work; various processing options & user-friendly controls; automatic self-cooling brushless spindle (frequency convertible) with high precision & long life; and handheld keypad interface controller & auto knife sensor. The CNC desktop engraving machine has a wide range of applications, such as steel seal, brass stamp, moulds, jewellery, rapid prototyping, etc. N-Gravetek Nashik - Maharashtra Tel: 0253-2317432, Mob: 09881469232 Email: sales@ngravetek.com

Hall 2 6 Stall G0

QuantuMike Mitutoyo offers QuantuMike, the first major upgrade since the micrometers innovation by James Watt in 1772. This offers faster measurement using coarser thread which feeds the spindle by 2 mm per revolution of the thimble instead of the standard 0.5 mm. This increase in thread lead is due to new high precision thread-cutting and test techniques. Reduction in positioning times of 60 per cent and measuring times of 35 per cent can be obtained, compared with the conventional micrometer. With an accuracy of Âą 1 micron, IP65 protection level, it is an excellent product for the tough and demanding Indian shop-floors. Mitutoyo South Asia Pvt Ltd New Delhi Tel: 011-2637 2090 Email: delhi@mitutoyoindia.com

Hall 1 1 Stall C0

hot runner. Laser CUSINGÂŽ is an innovative technology in tooling, capable of manufacturing inserts with conformal/ 3D cooling. This innovation helps in reduction of cooling time up-to 30 per cent also results in reduction of shrinkage, distortion on injection moulded parts. For die-casting and precision machining, the company is equipped with 8 machines ranging from 80 tonne to 350 tonne, including a Frech 125T hot chamber, having in-house machining capability with 5 & 3-axis VMCs and an array of CNC lathes & few robots. For injection moulding, it is equipped with 22 machines up to 450 tonne, including Arburg, Engel & Fanuc and few robots with a capability to handle all engineering resins. G-Plast Pvt Ltd Coimbatore - Tamil Nadu Tel: 0422-2243439, Fax: 0422-2242760 Email: marketing@gplast.com

Hall 1 0 Stall A4

Vertical machining centre DMG/Mori Seiki offers the NVX5000 series vertical machining centre, which is a modified version of NV5000 series. The machine has features such as high rigidity, measures against thermal displacement, variations, energy saving and MAPPS IV + ESPRIT. By using slideways for all axes, the NVX series offers improved vibration damping performance and dynamic rigidity. It also offers longer tool life and capabilities for heavy-duty cutting. In addition, it achieves a rapid traverse rate of 30 m/minute in all axes. The NVX series utilises a spindle in which air and cooling oil pipes are arranged symmetrically relative to the centre of the spindle. The heat-symmetrical structure minimises thermal displacement in the spindle by dispersing heat evenly. In addition, coolant circulation inside castings (a bed & column), which is available as an option, allows the machine to achieve active control over thermal displacement caused by cutting heat and changes in the ambient temperature. Three variations, for different workpiece sizes are available for the NVX5000 series: the NVX5060 (X-axis stroke: 600 mm), NVX5080 (800 mm) and NVX5100 (1,050 mm). These are designed to reduce the environmental burden and running costs. It saves power consumption by stopping the spindle motor, servomotors and fans inside the control panel during standby, as well as by using LED lighting.

Rapid prototyping service G-Plast offers rapid prototyping services selective laser sintering technology. The company manufactures moulds and dies in worldclass standards. They have the expertise in handling tools with multi-cavity, auto un-screw, and

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DMG / Mori Seiki India Bengaluru - Karnataka Tel: 080-4089 6500, Fax: 080-4113 1285 Email: info@dmgmoriseiki.com

Hall 1 B15 3,B14, B ll Sta 1


Product Showcase High-feed cutter

Integrated mill turn centre

Nickunj Eximp offers high-feed milling cutting inserts from ATI Stellram Engineering Products. These can be used for materials like alloyed steels, unalloyed steels, cast iron, aluminium and hard steel. High-feed milling cutter can dramatically reduce machining time and cut cost by allowing tools to be used for facing, pocketing, slotting and plunging. Its features include high-volume metal removal up to 3 mm, close to profile pocketing compared to round inserts, reduced vibration & cutter deflection in deep cavities, and utilises same CAD/CAM programs as round insert tools.

The NTX1000 integrated mill turn centre from DMG/Mori Seiki is an ideal choice for machining small precision parts for medical equipment and measuring instruments, which have complex shapes but need highprecision and high-efficiency machining. The machine is designed with features including original technologies, high operability, space saving, measures against thermal displacement, and MAPPS IV + ESPRIT. The NTX1000 uses Mori Seiki’s original Direct Drive Motor, Octagonal Ram Construction and Built-in Motor Turret technologies, offering high-precision machining of small parts. It offers improved operability by using a slanted keyboard. The installation area has been reduced by approximately 40 per cent compared to conventional models. The combination of automatic programming software (standard) and ESPRIT CAM software (standard) allows the machine to handle complex machining programming and to flexibly meet customer needs. In addition, the 3D interference checking function (standard) checks interference between spindles, workpieces, soft jaws, tools-holders, and turrets in 3D. If interference is detected, the machine stops, in both automatic and manual modes.

Nickunj Eximp Enterprises Pvt Ltd Mumbai - Maharashtra Tel: 022-2219 0300, Fax: 022-022-2206 0424 Email: info@nickunjgroup.com

Hall 1 8 Stall D0

Alloy steel flat bar Mould Steel Hotline Co offers alloy steel flat bars (type P20) that have good polishability, photoetch performance and machinability. The bars are suitable for plastic mould requiring polishing and photoetching. One can apply the bar to mould machining directly, thus shortening the working time. These alloy steel flat bars are suitable for large, medium scale & precision mould, as well as for Sn, Zn, Pb alloy die-casting mould with melting point. Mould Steel Hotline Co Ltd Shau Kei Wan - Hong Kong Tel: +86-757-26326691, Fax: +86-757-26326667 Email: gary.mouldsteel@gmail.com

Hall 2 0 Stall K1

DMG / Mori Seiki India Bengaluru- Karnataka Tel: 080-4089 6500 Fax: 080-4113 1285 Email: info@dmgmoriseiki.com

Hall 1 15 3,B14,B B ll Sta 1

Plastic injection mould

Threading insert

Titan Industries offers plastic injection mould made out of higher quality alloy steel material procured from well known supplier. The critical elements of the mould are machined in state-of-the-art tool room, to the best accuracy, with highly professional tool makers. Moulds are manufactured tested and guaranteed for quality performance by the company in order to meet the global standard.

Zhuzhou Cemented Carbide Cutting Tools offers external and internal threading insert in grade YBG201. The PVD TiN coated carbide grade comes with good toughness and wear resistance. It is good for threading and drilling (both peripheral & central inserts) low carbon steel, stainless steel heat resistance steel and cast irons.

Titan Industries Ltd

Zhuzhou Cemented Carbide Cutting Tools Co Ltd

Hosur-Tamil Nadu Tel: 043-4466 4818, Fax: 043-4427 6523 Email: shrikanth@titan.co.in

Hall 1 Stall F3

Pune - Maharashtra Tel: 09881498237 Email: sandip@zccct.com

Hall 1 1 0 & C1 Stall C1

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Product Showcase Hand deburring tool

Bore gauge

Nickunj Eximp offers wide range of hand deburring tool. The hand deburring tool is manufactured by Vargus in Israel.This tool is built with the help of breakthrough technology such as the first triangular laydown threading insert, the first indexable thread milling system and the original hand-deburring system. It is equipped with ergonomic handles and fits one’s hand more naturally and comfortably. It is a simple tool which renders unmatched performance and is safer than the traditional methods. It is easy to use with its adjustable telescopic holders and changeable blades which can be used extensively on difficult to deburr areas.

Mitutoyo offers new bore gauge in which the flagship models of inside diameter measurement tools/bore gauges are fully remodelled. This has achieved smooth operation and long operating life by reviewing the materials and shapes of various components to meet the need for still higher accuracy inside measurement and more improvement in operability & durability. The bore gauge inherits the conventional simple structure, thereby improving the measuring accuracy of all models by 50 per cent or more than that of its predecessors. It also expands the contact point stroke of flagship models as much as 33 per cent, and improves abrasion resistance and surface roughness by utilising carbide balls for the contact point in touch with a workpiece and the tips of each anvil. In addition, this series reduces the influence of temperature from the operators hand as much as 50 per cent by increasing the size of the grip to be held by hand during measurement by 20 per cent and also making the grip hollowstructured (design registered in Japan). Major accessories such as anvils, replacement washers, and extension rods are compatible with those of existing models.

Nickunj Eximp Enterprises Pvt Ltd Mumbai - Maharashtra Tel: 022-2219 0300, Fax: 022-022-2206 0424 Email: info@nickunjgroup.com

Hall 1 8 Stall D0

CNC lathe DMG/ Mori Seiki offers the NLX2500 series CNC lathes. It is packed with extensive features including high rigidity, measures against thermal displacement, energy saving, space saving, MAPPS IV + ESPRIT, and compliance with safety standards. The NLX2500/700 (turning specifications), NLX2500MC/700 (milling specifications) and NLX2500Y/700 (Y-axis specifications) use different platforms for each model to ensure high rigidity. In addition, the machines offer longer tool life and capabilities for heavy-duty cutting by using slideways. As standard specifications, the NLX series uses a bed with coolant circulating inside. This allows the machine to achieve active control over thermal displacement caused by cutting heat and changes in the ambient temperature. It uses a compact CNC that consumes less power, an inverter–type hydraulic unit, and LED lighting to reduce environmental burden and running costs. The total power consumption has been reduced by approximately 13 per cent for the NLX2500/700 (turning specifications), by approximately 10 per cent for the NLX2500MC/700 (milling specifications), and by approximately 14 per cent for the NLX2500Y/700 (Y-axis specifications). Additionally, the lubricating oil consumption has been reduced by approximately 15 per cent by stopping the oil supply during standby. The combination of MAPPS IV and ESPRIT allows the machine to handle complex machining programming and to flexibly meet customer needs. DMG / Mori Seiki India Bengaluru - Karnataka Tel: 080-4089 6500, Fax: 080-4113 1285 Email: info@dmgmoriseiki.com

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Hall 1 15 3,B14,B B ll Sta 1

Mitutoyo South Asia Pvt Ltd New Delhi Tel: 011-2637 2090 Email: delhi@mitutoyoindia.com

Hall 1 1 Stall C0

Small hole sprue bushing Punch Industry India offers small hole sprue bushings. The hole diameter of the nozzle contacting part of sprue bushings is normally made larger than the nozzle diameter of the injection moulding machine to prevent resin leakage from the nozzle contacting part. Earlier, the diameter of the sprue bushings had to be matched to the nozzle diameter of the injection moulding machine, even for components such as mobile phone parts or electronic components that are easy to mould using a narrow sprue runner. The new small hole sprue bushings overcome this problem. The nozzle contacting part is countersunk, allowing the sprue diameter to be fixed independently of the nozzle diameter of the injection moulding machine. Punch Industry India Pvt Ltd Chennai - Tamil Nadu Tel: 044-4201 8487, Fax: 044-4201 9487 Email: nakano-t@punch.co.jp

Hall 1 Stall 16


Product Showcase Portable roughness tester

Cutting tool

Mitutoyo offers portable roughness tester, SJ-500. This high-precision and high-performance compact roughness tester is equipped with dedicated control unit, having a 190 mm TFT LCD, employing a colour icon display and touch panel which makes it u s e r- f r i e n d l y. Simple input functions allow inputs according to drawing instruction symbols of ISO/JIS roughness standards. In addition to the roughness parameters, numerous form analysis features (uneven steps, uneven area, circle, angle, coordinate difference, steps and slope amount) are available. It offers 46 types roughness analysis parameters compliant with 1997 ISO and 2001 JIS surface roughness standards. This is a useful instrument for the bearing industry, as micro contours and roughness parameter can both be checked with this tester, traditionally two separate instruments were required to check the same.

Nikunj Eximp Enterprise offers a wide range of products from ATI Stellram, world-renowned developers and producers of high-performance metal cutting tools for difficultto-machine materials, which are used, in a wide variety of industries such as aerospace and defence. The extensive product range comprises inserts and tool-holders suitable for applications such as milling, turning, drilling, threading and grooving. In addition, ATI Stellram develops new grades and specialist combinations of substrates and coatings that are more resistant to the heat and wear demands of high temperature alloy machining. As the official agents for ATI Stellram in India, Nickunj provide solutions that match the requirements to have the right tools, geometries and grades for machines and materials. The company supplies cutting tools and the combination of grades best suited to the material specification. Renowned for solving hard machining challenges, ATI Stellram’s technology enables Nickunj to provide innovative cutting tool solutions, designed to deliver better productivity, lower costs and higher quality. The tools are specifically designed for the latest generation of nickel, cobalt and titanium-based alloys, used in aerospace, defence & power generation industries.

Mitutoyo South Asia Pvt Ltd New Delhi Tel: 011-2637 2090 Email: delhi@mitutoyoindia.com

Hall 1 1 Stall C0

Drill tap centre S&T Engineers offers drill tap centre from YCM SUPERMAX. FV50T is designed for industries that demand high precision, high productivity & cost effective solution. It has 10000 rpm BT30 direct drive spindle supported with high precision ceramic ball bearings with low centrifugal force assures optimal cutting performance under high speed machining. All the three axis X/Y/Z are equipped with powerful direct drive motors for 48 mt rapid feed & inbuilt encoders provides backlash free axial movement, 1g acceleration is key to increase productivity & ultimate efficiency, very compactly designed for the smallest footprints in its class. FV offers ultra wide base & strongly supported by delta design column reduces overhang problem & delivers exceptional cutting finish with accuracy. S&T Engineers Coimbatore - Tamil Nadu Tel: 422-259 0810, Fax: 422-257 3629 Email: stengine@md3.vsnl.net.in

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Hall 1 & K01 4, F04 Stall C0

Nickunj Eximp Enterprises Pvt Ltd

Hall 1 8 Stall D0

Mumbai - Maharashtra Tel: 022-2219 0300, Fax: 022-022-2206 0424 Email: info@nickunjgroup.com

Turning insert Zhuzhou Cemented Carbide Cutting Tools offers ISO turning insert in grade YD201. This turning insert comes in carbide grade with wear resistance and toughness. It is suitable for roughing and semi-finishing machining of cast iron and heatresistant alloys, non-metallic materials, such as plastic, wood. The ISO turning insert is specially used in aviation industry with sharp edges inserts. Zhuzhou Cemented Carbide Cutting Tools Co Ltd Pune - Maharashtra Tel: 09881498237 Email: sandip@zccct.com

Hall 1 0, C11 Stall C1


Product Showcase Sustainability software

Vision measuring system

SIM Technologies offers SolidWorks sustainability software, a where one can reduce the environmental impact of the products they produce. SolidWorks sustainability software has been created so that sustainable design becomes easy to understand and effortless to employ. The sustainability software provides an assessment of the environmental impact

Customised Technologies offers Rapid-I™, which is a combination of a profile projector, toolmaker’s microscope, video measuring system and a CMM. It is applicable in a wide variety of areas including aerospace, automotive, cutting tools, diamond tools, electronics, horology, plastic & rubber injection moulded parts, medical devices, sheetmetal, precision machining, electronics parts & assemblies, etc. The intelligent geometric measurement engine enables measuring in an intuitive and graphical way. Seamless CAD integration allows easy import and overlay of design drawings onto the component. Moreover, on-screen measurements quickly allow one to quantify the deviations from the original design. One can export all geometries created in Rapid-I to a 1:1 DXF drawing, which can be opened in any CAD software (reverse engineering). Customised Technologies (P) Ltd

of your complete design, seamless integration with your design process and the power to create more sustainable products. The sustainability technology includes diverse range of tools in Sustainability Xpress package (initial analysis of each part, alternative materials search, environmental impact dashboard) with the additional ability to apply them to both parts and assemblies. In addition, sustainability software includes assembly-level environmental parameters such as primary mode of transportation and use-phase energy consumption. Sustainable design assessment results are saved with each configuration, helping one to easily compare parts and assemblies. Seamless solid work software integration and one-click report generation allow one to quickly communicate the sustainable design solution. SIM Technologies Pvt Ltd Chennai - Tamil Nadu Tel: 044- 2250 1458, Fax: 044- 2250 1459 Email: simtek@vsnl.net

Hall 1 8 Stall A0

Forging block Mould Steel Hotline Co manufactures and offers XPM forging block.These forging blocks are available with thickness ranging from 200 mm to 610 mm and width ranging from 610 mm to 1260 mm.

Bengaluru - Karnataka Tel: 080-2852 2858, Fax: 080-2852 0622 Email: custom@vsnl.com

Gas spring PI-Tech Services offers gas spring manufactured by Quiri located in France. Gas spring comes with special features that are covered under international patents. This has an oil-chamber inside the cylinder to provide lifelong lubrication, which lies in the area between the 2 lip-seals. Other main features include:single-piece body of the gas spring (unwelded); singlepiece piston-rod(unwelded);and a double lip-seal system inside the cylinder. These help to prevent the escape of nitrogen gas held under a high pressure of up to 150 bar (250 bars if fully compressed) with 2 protections instead of one. The guide-bush in bronze (oil-soaked) prevents stick-slip between the chrome-plated piston rod and the bush. The small dia piping for connection between the cylinders and the manifold eliminates the need for excessive machining of the die. These are used mainly in dies and press-tools for sheetmetal operation and in plastic moulds where uniformity of pressure is required within the die,without having the need for doing pre-loading. PI-Tech Services

Mould Steel Hotline Co Ltd Shau Kei Wan - Hong Kong Tel: +86-757-26326691, Fax: +86-757-26326667 Email: gary.mouldsteel@gmail.com

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Hall 2 0 Stall K1

Hall 2 5 Stall K0

New Delhi Tel: 011-2651 3704, 2656 1687 Fax: 011-2651 2940, 2685 1390 Email: ptservices@hathway.com

Hall 1 9 Stall A0


Product Showcase Wire die spring

Carbide tool

PI-Tech Services offers wire-die-spring from Bordignon. They produce these in the complete range of ISO-10243 standard. This international standard from Europe specifies the colourcode and the spring dimension for each load-rating. There are basically 4 types of load-ratings covered under this standard:light (green colour); medium (blue colour); heavy (red colour); and very heavy (yellow colour). The steel used by it are of the type ‘52SiCrNiV6 or 52SiCrNi5’ both of which give almost double spring life, as compaired to steel normally used by other types such as ‘CRV or CRSi’. To eliminate spurious material from being sold under its brand,and to maintain its genuineness, Bordignon springs are marked with laser with the brand name and the logo. The company produces springs also beyond the ISO-10243 range; in ‘extra-light’or in ‘super-heavy’ varieties. These springs are used in all sheetmetal dies.

Ind-Sphinx Precision Ltd offers AXIS range of carbide tools for micro machining application. The range caters to a wide variety of applications including aerospace components, horological components, precision dies, etc. These tools comprises of custom made tools as well as standard tools. With a view to complete the entire gamut of micro machining solutions, AXIS also provides special tools like step drills, flat drills, half moon drill for spot drilling, conical end mills, chamfering cutters, and countersunk drills. These tools are designed and produced to customer specifications.

PI-Tech Services

Hall 1 9 Stall A0

New Delhi Tel: 011-2651 3704, 2656 1687, Fax: 011-2651 2940, 2685 1390 Email: ptservices@hathway.com

Floor saving machine TV series is a revolutionary innovation product from YCM SUPERMAX in cutting-edge technology that demands rigidity & performance and is also patented. Because the X-axis underneath the Y-axis. It offers the smallest footprint and best chip disposal system, the unique T base structure design makes over hang free table movement and ensures best dynamic machining accuracy. For heavy duty machining, TV is powered up to 22 Kw spindle motor with 2 speed inbuilt gear available for various spindle speed up to 6000 rpm with low noise & delivers high rotational accuracy & maximum vibration damping characteristics. It also offer isolated direct drive spindle for 10000 rpm with ceramic bearings & thermal stability (best temperature controlled spindle for the best machining results). Z-axis counter is guided by guide bar that ensures the smoothest head stock movement & secures better surface finishing results. The axes are directly driven by powerful axis motor with backlash free & pre tensioned dual nut ball screw for the best positioning accuracy 0.004 mm & repeatability accuracy ± 0.003 mm, by combining the exceptional high performance hardware. S&T Engineers Coimbatore - Tamil Nadu Tel: 422-259 0810, Fax: 422-257 3629 Email: stengine@md3.vsnl.net.in

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Hall 1 & K01 4, F04 0 C Stall

Ind-Sphinx Precision Ltd Parwanoo - Himachal Pradesh Tel: 01792- 232860/960, Fax: 01792-232898 Email: axis@indsphinx.com

Angle head Nickunj Eximp offers wide range of angle head which is used for mill centre. These angle heads are manufactured by Alberti in Italy. Alberti heads are designed and manufactured in the billet style, which means that the bodies of each head are processed or manufactured from a single block of steel or high-tensile aluminium, providing the utmost strength and rigidity due to the integrity of the material being used, far more so in comparison with other manufacturers who use a casting process to produce the tool body. All Alberti angle heads are hermetically sealed to prevent contamination to the drive gears and bearings. The angle heads is enveloped with different like heat-treated and precision ground spiral bevel gears, resulting in low noise, reduced vibration level and high torque. Nickunj Eximp Enterprises Pvt Ltd Mumbai-Maharashtra Tel: 022-2219 0300, Fax: 022-022-2206 0424 Email: info@nickunjgroup.com

Hall 1 8 Stall D0

High-precision pinpoint gate bushing Punch Industry India offers high- precision pinpoint gate bushing; it is the part through which the resin runs from the runner into the molud. It is also the part where the runner and the moulded product are separated when one gate is opened. Dimensional deviations of this part will negatively affect the product’s quality; the gate diameter tolerance was changed to ± 0.01. Punch Industry India Pvt Ltd Chennai - Tamil Nadu Tel: 044-4201 8487, Fax: 044-4201 9487 Email: nakano-t@punch.co.jp

Hall 1 6 Stall B1


Product Showcase Stripper guide pin

Tool presetter machine

Punch Industry India offers stripper guide pin, it has designated clearance based on the measured diameter of stripper guide pins and bushings. It features the clearance between pin and bushing and can also be designated. One can select either a 1 pin + 1 bushing combination (CS type) or a 1 pin + 2 bushings combination (CW type).For the 2-bushing combination, the bushing length is selectable. Lineup High-precision 2 µm type pin & bushing combination (64 combinations) 3 µm type pin & bushing combination (48 combinations).

Nickunj Eximp offers tool presetter machine. The tool presetter machine is manufactured by Elbo Controlli in Italy. The tool presetting machine has an advantage of having their base and columns made of ground granite.Granite allows reaching flatness accuracy within ± 4 microns. This specific feature makes these machines more stable and assures one a highly repeatable performance over a long term directly on shop floor itself. The machine offers all the basic measurement & features such as diameter, length offset, angles, corner radius, multi point cutter. The maximum cutting function is performed through automatic (flying cross hair) and as well as manual (fixed cross hair) system with an analog image processing. One can operate the machine through pneumatic actuated handwheel for rapid movements of 2 mm/min and micromatic adjustment of fine positioning. The tool presetter machine is encompassed with the Italian design, stainless steel self adjustable structure, which is durable in nature.

Punch Industry India Pvt Ltd Chennai - Tamil Nadu Tel: 044-4201 8487, Fax: 044-4201 9487 Email: nakano-t@punch.co.jp

Hall 1 6 Stall B1

Micro tool Ind-Sphinx Precision offers a range of micro tools and ultra-micro tools for the highly demanding fields of watch making, electronics, aerospace, medical, automotive and host of other micromachining applications. The wide product range includes micro coolant hole drills, ultra micro drills (>0.040 mm), micro endmills (>0.100 mm), micro reamers and micro step tools with close tolerances and polished surfaces. Ind-Sphinx Precision Ltd Parwanoo - Himachal Pradesh Tel: 01792- 232860/960, Fax: 01792-232898 Email: axis@indsphinx.com

Hall 1 7 Stall E0

Co-ordinate measuring machine Mitutoyo offers SpinArm-Apex, a Co-ordinate Measuring Machine (CMM).This fully flexible portable three dimensional measuring device expands the possibility of measurement on the shop-floor. The seven axis movement allows user to approach the workpiece from any direction. It is equipped with rotation axis automatic braking mechanism which facilitates effortless handling. Non-contact line laser probe can be attached to the SpinArm for high speed scanning. This instrument can be applied in manufacturing large sheetmetal components, fabrications and welding/inspection fixtures. Mitutoyo South Asia Pvt Ltd New Delhi Tel: 011-26372090 Email: delhi@mitutoyoindia.com

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Hall 1 1 Stall C0

Nickunj Eximp Enterprises Pvt Ltd Mumbai - Maharashtra Tel: 022-2219 0300, Fax: 022-022-2206 0424 Email: info@nickunjgroup.com

Hall 1 8 Stall D0

Alloy steel flat bar Mould Steel Hotline Co offers alloy steel flat bars (type 1.2738) that have good polishability and photoetch performance. These bars also have good machinability and are suitable for surface treatment. They have good abrasion resistance and longer life for moulds. The alloy steel flat bars are suitable for large scale, required for even hardness, high toughness and good surface polishability. Also on offer are moulds of trash can and casting mould frames. Mould Steel Hotline Co, Ltd Shau Kei Wan - Hong Kong Tel: +86-757-26326691, Fax: +86-757-26326667 Email: gary.mouldsteel@gmail.com

Hall 2 0 Stall K1

The information published in this section is as per the details furnished by the respective manufacturer/ distributor. In any case, it does not represent the views of


Sector Watch

Hema Yadav & Nishant Kashyap

With India establishing itself firmly on the global manufacturing map, the local sheetmetal industry will be witnessing surge in demand. While manufacturers gear up to meet the resulting challenges, the sector is ready to take on international competition.

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Sector Watch

I

n the last two decades the sheetmetal manufacturing industry has advanced rapidly with the evolution and adaptation of smart technology and automation. Currently, the demand is for products having high productivity and flexibility. Manufacturers are veering towards numerical control systems like CNC machines, and machining centres for punching & cutting, which are more productive and provide better speed. As the Indian automobile and aerospace industries are growing rapidly, the demand to deliver better products at faster rate has increased. Manufacturers are looking at capping the maximum number of operations on a stamped component to four or five, which in turn challenges the tool makers in developing innovative tools and technology solutions. According to Ashutosh Singh, General Manager, Hind Tools India Pvt Ltd, “Currently, the demand is to adopt new technologies like automation, numeric control systems, etc. Companies in India are still lacking behind in providing proper machining solutions; some major automobile players are still importing equipment. So, the biggest challenge for the manufacturers in the country is to provide better solutions and grab the shoring demand.”

Automobile, automotive component, aerospace, railway, construction and electronics industries are the biggest users of sheetmetal. From business point of view this is an ideal time to be in India as we have sufficient local demand.

Ashutosh Singh,

General Manager, Hind Tools India Pvt Ltd

meet these requirements, the current generation of production technologies and CAD/CAM systems allows the user in optimising the manufacturing processes and ensuring greater productivity. “The development of latest sophisticated technologies like CNCs, machining centres and various methods of cutting have changed the way companies used to function. New technologies like software and automation have increased productivity & efficiency, and thus reducing time and cost,” avers Singh. Automobile makers and dies & tool makers are hard-pressed to cut down on lead time and optimise material & tooling costs to compete in this demanding market. New materials like High Strength Steel (HSS) have given new challenges owing to their behavioural changes when stamped. This has led to increase in the usage of sheetmetal formability software solutions to simulate the outcome of the

utilisation of new materials and processes, long before the dies are built or even designed.

Prominent software solutions The use of software in sheetmetal industry is the result of rapid globalisation. The automotive industry is one of the largest beneficiaries, wherein scope exists in catering to the wide range of vehicles from passenger to commercial segments. Santosh Venkata Subbaiah, President, data M Software India Pvt Ltd, explains, “The ability of the software to assist in virtual modelling of sheetmetal parts (CAD), verify the intended function (CAE), as an input data for rapid prototyping, verify the output quality of the tool design (CAE) and development of respective tooling (CAM) has facilitated faster research and development. The usage of software has helped in the evolution of new/alternative forming methods of sheetmetal to handle the complexity,

The development of new machines and applications plays a critical role in the growth of any industry. In the sheetmetal working sector, various advancements have taken place over the years, be it in cutting, bending, punching or forming. With the customers’ emphasis on quality and quantity increasing, companies are bound to shift from conventional systems to automated ones. However, those in the traditional fabrication domain are still utilising the conventional machines. In today’s scenario, companies are under constant pressure to improve efficiency, quality and reduce cost. To

Courtesy: A Innovative International Ltd

Machines & technology

Sheetmetal is used in various sectors such as automotive, aerospace, railways, etc

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Sector Watch The usage of software has helped in the evolution of new/ alternative forming methods of sheetmetal to handle the complexity, tolerance, production volume and control the cost as well.

Santosh Venkata Subbaiah,

President

data M Software India Pvt Ltd

tolerance, production volume and control the cost as well.” Sheetemtal industries in developed countries like Europe, Japan and the US have been at the forefront with extensive R&D, software development and usage. With the commercialisation of software technology for global usage, the application is gaining momentum in India as well. With continued utilisation of software solutions and local skills available for R&D, India is inching forward in the list of software enhanced countries.

Roll forming: The unexplored potential

Courtesy: data M Software India Pvt Ltd

Out of the many sheetmetal cold forming methods, roll forming has generated significant interest in the Indian sheetmetal industry. High-volume production, consistent product quality, less material handling, minimum labour utilisation are some of the advantages with cold roll forming process. Subbaiah avers, “Longitudinal welded tube made out of cold roll

forming process already exists in India. Considering the variety of products that are being roll formed worldwide, roll forming is still an unexplored opportunity in India. For instance, Indian railways has realised the advantages of roll forming process and has redesigned a few of the structural members of wagons. Stainless steel

importance in many industrial areas like construction, transport, appliances, oil & gas, civil engineering, etc.” The current trends have created three segments in cold roll forming industry: machine making, roll tool making and products manufacturing. The need for local roll forming in Asia is quite in demand due to its quality, cost, delivery time and after-sales services. Explains Subbaiah, “Manufacturing is at par with international standards with a demand to improve on delivery time. Local manufacturers are looking forward to produce specialty products such as large-diameter-low-thickness or small-diameter-high-thickness tubes,

Advantages of waterjet cutting

       

Heat is not generated Does not produce any dust or particles Kerf width is small Can be easily used to produce prototype parts efficiently Faster and cheaper Can be easily automated for production Does not leave a burr or a rough edge Eliminates other machining operations such as finishing and grinding

materials up to 12 mm thicknesses are now being roll formed as well. The automotive industry is already consuming a few roll formed parts and is on a constant look out for such parts as an alternative to press formed parts. Besides, roll forming is gaining

partitions, shop racks, etc, and also custom-made products, which are either being imported or made by alternative processes.” However, awareness of the technology needs to be increased among the consuming industry to experience the sustainable demand of roll formed products. The conventional roll forming of manufacturing longitudinally uniform parts has gained popularity. Companies who have mastered conventional roll forming are handling more challenges in terms of tolerances, new material, complex shapes, etc. The new trend has been to produce single piece longitudinally non-uniform parts.

Waterjet cutting

Forming sequence

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This cutting technology is gaining popularity for its quotient of green. Hardik Shah, Country Head – Sales & Marketing, A Innovative International Ltd, says, “Waterjet will play a crucial


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role in metal cutting industry as it is quite versatile. It can be utilised to cut both metal and non-metal up to the thickness of 300 mm, with a good finish and without any heat or burning effect.” Waterjet cutting is available for 2D cutting, 5-axis cutting with robot and combination with plasma and laser technology. It can be utilised in various industries as there is no hazardous waste produced in the case of waterjet cutting. Also, this type of cutting prevents unnecessary waste, as single large pieces of reusable material can be cut off easily. Shah explains, “Because of its versatility, waterjet job shops will always be in demand in the sheetmetal industry. The latest trend is to utilise waterjet for profile cutting of precious metals like S S, titanium, aluminium, copper, brass, marble, granite, etc.” However, he is of the view that lowcost conventional technology with less power consumption having high-cutting speed could pose a challenge in some applications of waterjet cutting for the sheetmetal sector.

Dieless NC forming Incremental forming is one of the technologies that have emerged as an alternative to conventional sheetmetal forming processes for mass customisation. Incremental sheetmetal forming has established its potential to form complex threedimensional parts without using a matching die. The process locally deforms sheetmetal utilising a moving tool head, achieving high-forming limits than those of conventional sheetmetal stamping processes. It is constantly adopted by the engineering community due to its flexibility and low cost. The dieless nature in incremental forming provides a competitive alternative for economically and effectively fabricating low-volume functional sheet products. Potential application areas include aerospace industries,

Courtesy: data M Software India Pvt Ltd

Sector Watch

Simulation of roll forming process

Low-cost conventional technology with less power consumption having high-cutting speed could pose a challenge in some applications of waterjet cutting for the sheetmetal sector.

Hardik Shah,

Country Head – Sales & Marketing, A Innovative International Ltd

customised products in biomedical applications and prototyping in the automotive industry. It is a numerically controlled incremental process that can produce complex shapes from various materials.

Gaining competitive edge in global market As Indian economy accelerates rapidly, the country is witnessing significant growth, with the manufacturing sector clocking exceptional progress. Many global players have set up manufacturing facilities in the country. Industries such as automotive and infrastructure are ahead in the race. The reflection of this can also be seen in sheetmetal working. Automobile and aerospace industries are the biggest consumers of the sheetmetal industry. It is estimated that automobile sector will grow almost fivefold to over ` 5,00,000 crore by 2020, while in the next five years the Indian aviation industry will grow at 10 per cent annually.

The Indian railways has also fuelled demand for sheetmetal manufacturing as it is one of the biggest railway networks in the world. The current railway budget and metro projects have created huge opportunity for sheetmetal manufacturers. The sheetmetal industry encompasses the suppliers and also the equipment manufacturers. Valuechain partnerships between suppliers and manufacturers are paramount to the success of the industry. Sheetmetal components are fabricated from carbon and stainless steel, as well as aluminium, brass and copper sheet. “Automobile, automotive component, aerospace, railway, construction and electronics industries are the biggest users of sheetmetal. From business point of view this is an ideal time to be in India as we have sufficient local demand,” says Singh. For international suppliers of sheetmetal machines, tools and systems, India is the market offering outstanding business opportunities.

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Courtesy: KUKA Robotics India Pvt Ltd

Industry Update

INDUSTRIAL ROBOTS

Shaping future trends Automation has become a popular trend in the machine tool industry, especially in sectors that require speed, precision and short lead times. The automotive and aerospace industries are at the forefront, as robotics offers the advantages of maximising the flexibility of operations, productivity and high performance. The latest features and functions in industrial robots are enabling the machine tool industry to gain a competitive edge over others. Rachita Jha

T

he usage of robots is on a rapid rise in the manufacturing industry, as industrial products have become increasingly individualised with quick time-to-market. This requires flexible automation. Robots, when once programmed, can easily switch from one process to the other

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and promise efficiency in production, flexibility and accuracy. With the rise in demand for robots, and constant design & development of these, the future will witness more automation on the shop-floor. However, the robotics industry still has to make tremendous efforts in developing user-friendly machines,


Industry Update

The age of robots Robots help in improving productivity. In the past, it was difficult to communicate with robots and make clear what was required of them. The recent years have seen the development of new strategies to make robot programming much easier. As per International Federation for Robotics (IFR), the year 2010 witnessed an upswing in the purchase of robots for industrial usage. The automotive industry topped as the biggest purchasers of robots. The report states that emerging markets like India have contributed effectively to this growth. So, the future of robotics business is on an upswing. Moving away from the conventionally-manned operations, manufacturing units today house the latest automation solutions and are investing in robotoperated processes. “We focus on improving the co-operation between robots and human operators with overlapping workspaces to achieve an optimal degree of automation. The ‘Safe Robot’ technology enables direct interaction with human operators. The advantage is that now the user is no longer forced to opt for, or against full automation, but can develop customised intermediate solutions. This makes automation also attractive for small- and medium-sized enterprises,” says Pradeep Shoran, AGM – Marketing, KUKA Robotics India Pvt Ltd.

The ‘Safe Robot’ technology enables direct interaction with human operators. The advantage is that now the user is no longer forced to opt for, or against full automation, but can develop customised intermediate solutions. This makes automation also attractive for small - and medium-sized enterprises.

Pradeep Shoran,

AGM-Marketing, KUKA Robotics India Pvt Ltd

Indian market is changing from a medium-quality market to high-quality products-oriented market, it is calling for high degree of quality, productivity and better flexibility. Not to mention the increasing labour cost and the availability of skilled labour,” says Tore Lindstrom, Business Unit Manger – Robotics, ABB Ltd. Health and safety of workforce are also major reasons behind increasing demand of robots. Robots can work in harsh conditions where the working temperature and the environment are beyond the normal tolerable human working conditions. “However, it is perceived that increasing cost of labour and availability of skilled labour are the main factors driving growth of robotics industry. On the contrary, the urge to match global quality standards and to surmount global competition

are the growth drivers of robotics industry in India,” adds Lindstrom.

Design and development Today, manufacturers are introducing technologies that make robots much easier to understand and operate. Clear command structures, a readily comprehensible program design, and extensive help functions make today’s robots much easier to program, even for the uninitiated. “The culmination of program design and development is the new ‘teaching by demonstration’ technology. With this method, the programmer shows the robot the movements & positions that it will need to execute during a production sequence. This method can be employed without any previous programming experience whatsoever. The robot controller automatically

Courtesy: KUKA Robotics India Pvt Ltd

which can perform expected tasks in the easiest possible way.

Growth drivers In view of high-order volume and state-of-the-art technology centres, production units have opted for the latest in automation solutions to deliver quality, performance and ontime delivery. “Robotics has been the key driver in the case of lowcost automation, with a high degree of flexibility and smaller Return On Investment (ROI) time period. As the

Manufacturing companies are investing heavily in automated solution

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Industry Update Robots in material handling Robotics has been the key driver in the case of low-cost automation, with a high degree of flexibility and smaller ROI time period. As the Indian market is changing from a mediumquality market to high-quality products-oriented market, it is calling for high degree of quality, productivity and better flexibility.

Tore Lindstrom,

Business Unit Manger - Robotics, ABB Ltd

saves the movements it has been shown, assigns them to a program number, and can utilise this program straightaway for production,” explains Shoran. This makes it much easier to program industrial robots, and the ‘teaching by demonstration’ method even requires absolutely no previous robot programming experience. Offline simulation tools and designer software takes robot programming to an optimum level, which increases manufacturing flexibility and cutdown installation periods. Moreover, today technology supports robots that can be monitored remotely with remote service as well. “Due to rapidly changing product variants, ‘hard automation’ is no longer a costeffective solution. The only viable approach is to employ highly flexible robotic technologies. For small- and medium-sized enterprises in particular, robots will play an increasingly important role in new areas of production, processing and handling, in the future,” avers Shoran.

Material handling Automation of machining centres is an upcoming trend. Many manufacturers are now utilising robots for placing and removal of job materials. A robot can transport heavy loads and is utilised in production for fullyautomatic machining of heavy castings and workpieces. When installed with a sensor-monitored changeover station, it allows the manufacturing system to be loaded and unloaded without interrupting the machining process. With automatically exchangeable grippers, robots can also directly handle the most varied workpieces with ease. Pallet handling and workpiece handling are thus possible in an ‘on-the-fly’ changeover, without the need for operator intervention. This flexibility allows the operator to convert the system quickly to meet new challenges, and the robot ensures optimal utilisation of the machining centre in a shift operation. Several kinds of technologies, including robotics have been employed to automate material

       

Picking, placing Palletising and de-palletising Material transfer Loading and unloading/ dispensing Inspection and sorting Material removal Packing, labelling and shipping Assembly, warehouse and distribution automation

Robotics for SMBs

     

Small-volume manufacturing Application specific operation Non-traditional manufacturing Novel application areas such as aerospace and unmanned automotive production Flexible automation Rapid deployment and simplified programming

handling processes for increasing efficiency, reducing cost and improving competitiveness. “The latest generation robots incorporate vision, mobility, autonomous navigation, complex manipulation, motion control and superior intelligence. These greatly enhance material handling productivity & quality level, and expands the scope of material handling to myriad applications including picking, placing, palletising & depalletising, material transfer, loading & unloading/dispensing, inspection, sorting, assembly, warehouse and distribution automation,” informs V Amaresh Gandhi, Jt General Manager – Automation Division, Bharat Fritz Werner Ltd.

Courtesy: Gudel India Pvt Ltd

Aerospace and automotive sectors

Robots are increasingly being used to handle job materials

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Innovative designs and features of industrial robots have become more popular in recent times. The introduction of robots with integrated vision and touch remarkably changes the speed & efficiency of new production and delivery systems. Robots have become accurate that


Industry Update 10 good reasons to invest in robots

         

Reduce operating costs Improve product quality & consistency Improve quality of work for employees Increase production output rates Increase product manufacturing flexibility Reduce material waste and increase yield Comply with safety rules and improve workplace health & safety Reduce labour turnover and difficulty of recruiting workers Reduce capital costs (inventory, work in progress) Save space in high-value manufacturing areas

they can be employed where manual operations are no longer a viable option. This are being increasingly used in applications, especially in aerospace and automotive sectors. “With rapidly increasing power of the microprocessor and artificial intelligence techniques, robots

Suppliers of industrial robotics solutions have expanded their product offerings to support the needs of Small-to-Medium Manufacturers (SMM), allowing them to improve productivity, cut costs and increase the quality of their products. Such systems are built around the needs of small-volume manufacturing, application-specific operation, etc.

V Amaresh Gandhi,

Jt General Manager-Automation Division,

Bharat Fritz Werner Ltd

have dramatically increased their potential as flexible automation tools. The latest usage of robotics is in applications demanding advanced intelligence such as the aerospace sector. Robotic technology is converging with a wide variety of complementary technologies – machine vision, force sensing (touch), speech recognition, advanced mechanics, operation & controls and remote governance. This has unveiled new levels of functionality for jobs that were earlier considered impractical for robots in aerospace and automotive sectors,” avers Gandhi. Hence, unmanned production is soon going to become the norm in the automotive sector.

Courtesy: KUKA Robotics India Pvt Ltd

Viable for SMBs

Unmanned production is the future for automotive sector

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Contrary to the drawback of being an expensive technology, a new range of robots designed for unique applications and flexibility comes as a viable and affordable option for the Small and Medium Businesses (SMBs). Robotic manufacturing solutions for SMBs are characteristically less in cost, quick to install, simple to operate, and easily reconfigurable to support small production volumes. “Suppliers of industrial robotics solutions have expanded their product offerings to support the needs of Small-to-Medium Manufacturers (SMM), allowing them to improve productivity, cut costs and increase the quality of their products. Such systems are built around the needs of small-volume manufacturing, application-specific operation, nontraditional manufacturing and novel

application areas such as aerospace and unmanned automotive production, flexible automation, rapid deployment and simplified programming,” says Gandhi.

Bright future The common challenge for all types of manufacturing companies is to constantly optimise their internal production processes, thereby saving energy, utilising few resources and effectively increasing the output per work cell. During the last downturn in the economic cycle, the standard reflex of the global procurement chain was to investigate the value of purchases and to look for more economical and efficient solutions. “Currently, the industry in India utilises robotics or any other automation solution only in a marginal manner. Manufacturers who have been in business for five decades and provide machining solutions based on individual, cell & line concepts, are including automation solutions as an additional vertical for their customers. Moreover, customers have started realising that automation not only leads to better ROI but also reduced Human Resource Development (HRD) hassles and saving in costs,” avers Gandhi. Automation is helping companies in every industry to become strong global competitors. The new-age robotic systems are far more userfriendly than their predecessors and are designed to improve efficiency & operational cost. Going with the trends, the future will witness more of Indian job shops shifting from manual to robot-driven systems.


Leaders Speak

Growth in world market depends on successful collaborations with local partners ...asserts Ayumu Ikezumi, President & Vice Chairman, Dijet Industrial Co Ltd. The company is a supplier of precision metal cutting tooling and high-impact custom cemented carbide. In an interaction with Hema Yadav, Ikezumi chalks out plan of action for gaining marketshare in India... Q What is the current scenario

in the cutting tool industry? In the past, the cutting tool industry of developed countries relied on automotive and related industries. In the recent years, car production in developed countries has decreased, affecting the cutting tool business in these nations, which has now shifted to the Asian markets to meet global demand. Infact, in India, Brazil and China, the demand for cars or automotive products is increasing, and many automotive manufacturing companies from Europe, Japan and the US are setting up their manufacturing units in these countries.

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Leaders Speak We are also planning to enter new markets, and industries like engineering, aerospace & power generation. Our R&D department has been developing tools for these industries. Currently, most of the organisations operate in a world of uncertainty, complexity and have to cope up with rapid changes. The main factors that have brought us into this situation is ‘intense competition’, ‘rapid technological change’ and ‘constant demand for high quality & better value in minimum time’. The Indian manufacturing industry is highly innovative and has registered phenomenal growth rate due to sudden surge in demand from the automobile, engineering, defence and aerospace sectors. The machine tool industry is also at its peak. Therefore, the scenario across the globe is optimistic.

Q Which of your products are

available in the Indian market? Our main focus in India is on dies & moulds machining and turbine machining industries. Our high-feed indexable tools, and roughing & finishing tools like indexable ball nose cutters are in demand, while some of the tools for automotive components machining are becoming popular too. Our unique method of offering customers a rigid & strong tool has given us, as well as our customers, the confidence to aim for high productivity in the existing machines. We believe that good quality cutting tools are worth than investing in additional machines for more productivity.

Q Elaborate on the kind of

technologies offered by the company. Our advantage is the consistent production from carbide. Also, we provide a wide range of modular tooling system, especially shanks, which are completely carbide-based (without steel) for threading parts. These tools assure accuracy not only during finishing, but also roughing.

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We do have our own R&D centre, and have been developing carbide raw materials, coatings, geometries, cutter body materials, etc on a continuous basis. Customers are increasingly seeking good quality tools of diverse range, which are cost-effective.

Q What is the mantra behind your

success in international markets like India? What is the tactic adopted to survive the everchanging market dynamics?

maintain long tool life as well. Our R&D department is developing such valuable tools for the market. Our production plants are equipped with innovative technologies that facilitate smooth and efficient production. Our R&D department develops new products based on the feedback from across the world. Therefore, the main task for the team is marketing and testing, including finding the after-market reaction & report of a product. This helps us in understanding the demand of the growing market. At Dijet, we have a relatively moderate approach. After the preliminary investigations (also based on field test report from endusers), we make necessary changes in our designs and manufacture it as per market requirement.

Although we manufacture and supply quality products for every market, we produce high-quality products only in Japan. ‘Rapid technological change’ has helped improve general efficiency, and resulted in substantial cost savings. And, we are continuously improving quality within a minimum timeframe. Our main objective is to never Q What are the factors that lose awareness of the changing support growth of metal customer needs. Our employees & cutting, endmill and highbusiness associates are well-trained impact custom-cemented to recognise & manage changes and carbide tool market? convert the threat of change into an The key should be how opportunity of growth. manufacturers of these segments We always strive towards product can supply to end-users across improvisation, client satisfaction the world on time. We strongly and on-time delivery of products. believe that if we have to retain our This has helped us consolidate our customers, we need to: position in the Indian market. Also,  Keep our promises our team of managers/engineers,  Be willing to help them along with our distributors, is  Inspire confidence continuously interacting/meeting  Treat customers as individuals customers and offering them  Make it easy for customers to do solutions on all types of machining business with us issues. We team with customers on Besides these, we need to keep productivity improvement and cost on developing dealers to sell our reduction projects, along with our products as well. Also, our wide end-users/customers. In a span of distributor network ensures timely three years, we have become a wellcompletion of the orders. known entity in the country.

Q How has the demand pattern Q Tell us about the R&D efforts

of your company. Heat-resistance alloy, titanium alloy, exotic materials such as Carbon Fibre-Reinforced Polymer (CFRP) are being utilised increasingly, which require tools that can machine these materials with high efficiency, and

from various verticals helped the metal cutting sector, and which are the emerging sectors that will drive demand? In the recent past, the technology of coating has improved considerably. It has helped the performance of cutting tools and contributed in improving


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MMT APR-2011 AD NAME: LMT PG NO. 108 MMT APR-2011 AD NAME: LMT PG NO. 108


Leaders Speak

The Indian manufacturing industry is highly innovative and has registered phenomenal growth rate due to sudden surge in demand from the automobile, engineering, defence and aerospace sectors.

productivity in different types of industries. Towards the need of preserving the environment, energy saving is gaining popularity across the world. Therefore, the demand for products that can find a fine balance between industry and environmental concerns will be on the rise. Industrially-developed countries world-over have created market niches on the back of well-developed and supportive machine tool industry. The demand for quality tools is increasing. In the same way requirement for good and expensive machines is rising. This is because output from these expensive machines decides the cost of manufacturing.

it helps him in informing our distributors, managers & engineers about the latest technologies & products, and also train them. The ultimate goal is to pass on the benefits to the customers and end-users.

Q What is the quality approach

/matrix adopted by the company to enhance efficiency?

expand our brand name because we are still new to the Indian market. We are focussing on our new products, tools, peripheral equipment as well as cutting-edge machining technologies & services, and conducting live machining demonstrations. At the same time, our team, along with our distributors, work hand-in-hand to reach maximum possible customers.

Q What are the challenges

faced by the company? The main materials for carbide like Tungsten Carbide (WC) and also additives like rare metal & earth are commodities that are not widely available. We understand that this trend will continue in the future as well. Therefore, the need is to develop new grades, which contain less of similar raw materials. We have been working on this subject with knowhow accumulated by our own R&D department and are gradually trying to achieve it. Economy is bound to grow and is expected to raise the demand for cutting tools from all sectors. Simultaneously, the challenges of producing costeffective tools, fast delivery of tools, meeting the expectations of clients are major challenges, and these will set the standard among global players.

We have acquired ISO9001, the international quality management system in 1997. We have also obtained environment management system ISO14001 in 2001. In 1992, we received ‘Ford Q1’, which is a quality certification from Ford Motors in the US. We strongly Q The company has recently believe – ‘Employees with the right attitude are vital resources who can commenced its Indian office. enable successful organisations to What are the reasons behind translate customer extension concepts deviating from the dealer/ into reality’. We provide state-of-thedistributor business model? art training to our employees, manage It is mainly to support our distributors. and reward them, so that they function We always work closely with local efficiently and enthusiastically. distributors and build strong, longterm relationship, as growth in each Superior quality is the primary market across the world depends focus at Dijet Toolings. We follow Q What are your plans for on successful collaborations with stringent quality control measures future growth in India? local partners. We believe, this is at every stage of our processing. Currently, our biggest export the best way to increase business Every task is handled with extra market is China. But, we expect in markets abroad. Along with Ravi care and safety measures. Also, the Indian market also to grow to Sane, Manager (Indian arm), we have we are expanding at a rapid pace of the same size within the next on board Yuichiro Hiyoshi, Manager and investing in new machines 10 years. At Dijet, we are mainly (in Japan), who are working towards & technologies, so our focus to focussing on the big sectors like building the company’s brand image. enhance the overall efficiency is dies & moulds, automobiles, Also, Sane is trained in Japan quite apparent. auto-ancillary, electronic parts, to deal with all applications and is aerospace, engineering, fabrication always connected with the latest Q How do you plan to reach parts, etc. Currently, an increase technological developments at the in imports of tools to the Indian more customers and meet Head Office. Since he is regularly market has been registered, which their requirements? updated on the technological and indicates the untapped potential to We are participating in as many other developments of the company, be explored in the country. exhibitions at different locations to

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Facility Visit

RENISHAW METROLOGY SYSTEMS PVT LTD

Where quality is priority With a vision to provide the best measurement, motion control and precision machining solutions, Renishaw believes that success comes from patented & innovative products, high quality manufacturing, and the ability to provide customer support in all its markets around the globe. Equipped with skilled manpower and highly sophisticated machines, the company’s Pune facility plays a pivotal role in its future growth strategy. Nishant Kashyap

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enishaw’s core strengths lie in its design and development capabilities, with a strong focus on innovation. The company’s products are globally well-known for applications, as diverse as machine tool automation, co-ordinate measurement, Raman spectroscopy, machine calibration, position feedback, CAD/CAM dentistry, stereotactic neurosurgery and medical diagnostics. In these areas, the company aims to be a long-term partner, offering superior products to meet customers’ needs. Renishaw Plc and its subsidiaries like the Pune facility are committed

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to conducting business in a socially responsible manner, with respect to the environment, its employees and everyone who deals with the company. The UK-based company has a strong global presence, with more than 50 branches in 31countries. Around 94 per cent of the sales are made outside the home country. Since its formation in 1973, the company has won numerous awards, including thirteen Queen’s Awards, recognising Technological Achievement, Export Achievement and Enterprise (Innovation). According to Suhas Cholkar, Director & Head –


Facility Visit Manufacturing Services Division (MSD), Renishaw Metrology Systems Pvt Ltd, “Quality is the priority for Renishaw, as majority of our customers are buying the product because of our reliability. Our team’s responsibility is to deliver product which is in line with the customer’s expectations. Our attempt is always to exceed expectation and deliver quality product.”

Role of Pune facility The facility started its operations in 2006. The manufacturing area was around 12,000 sq ft, which today has increased four-fold to 49,000 sq ft. The Pune facility plays a significant role in the company’s growth strategy, as most of the products manufactured here are exported. Currently, the facility has three product lines. Among them is cable sub assemblies (encoder, MTP, Raman, CMM, etc). The facility supplies various types of semi-finished products like cables to its parent company Renishaw Plc and/or to its sister entity Renishaw Ireland. Says Cholkar, “The assembly is carried out at Renishaw Plc. By 2012, we plan to manufacture the next line or integrated part, which is the ReadHead.” The facility has enough capacity for its second product line MCU’s. Accordingly, it assembles this product in its Pune facility. Also, the purchasing team is in the process for sourcing and developing the various parts locally, considering the cost and logistics benefits. The third product line is tool setting arms (MTP, CMM), which comes in two categories – standard and special arm – for which the facility has total manufacturing strength.

Quality is the priority for Renishaw, as majority of our customers are buying the product because of our reliability. Our team’s responsibility is to deliver product which is in line with the customer’s expectations. Our attempt is always to exceed expectation and deliver quality product.

Suhas Cholkar Director & Head of Manufacturing Services Division (MSD) - India

upgrading ourselves and improving current practices. Accordingly, we change the benchmarks, improving our business practices and addressing more customer requirement & expectations,” avers Cholkar. In the past, the company has made significant commitment to R&D, with around 18 per cent of annual sales invested in R&D and engineering. This has enabled the company to diversify into manufacturing sensors for CNC machine tools, which are utilised for automating machine setting operations & in-process part measurement, position encoders for accurate motion control, laser interferometry for machine performance evaluation, systems to produce dental crowns & bridges, Raman microscopes for spectral analysis of materials, medical devices for neurosurgical applications, and products to improve the diagnosis of human infectious diseases. In keeping with the surging demand of the market, the company has intensified its R&D activities.

Range of products The company has range of products for every kind of metrology solution. Especially for the industrial metrology solution it has CMM probe systems, machine tool probe systems, laser calibration, telescoping ballbar and gauge. The company is wellestablished in medical sector. It has also products like dental CAD/CAM, molecular diagnostics and stereotactic neurological systems. Renishaw recently introduced calibration tool QC20-W, new PH20 five-axis head for touch-trigger measurement on co-ordinate measuring machines and Equator a versatile gauging system. The company has a range of position encoders for special manufacturing needs, which includes magnetic encoders, optical incremental linear encoders, optical incremental rotary encoders, optical absolute encoders and laser interferometer encoders.

Skilled manpower As every organisation’s success is based

R&D effort The company’s success lies in its Research and Development (R&D) effort. With huge investments in R&D, the company has been able to develop new products and has been able to beat stiff competition. “Competition is growing day by day, so the challenge for us is to keep

Employee development is one of the main focus areas for the company

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Facility Visit

The facility is equipped with sophisticated equipment & technology

on its manpower, Renishaw’s Pune facility also has engineers with technical expertise, experienced management and skilled sales and marketing team. The company frequently provides training programmes for its employees. “Employee development is also our main focus area, because as per our policy regarding quality, we have maintained continuous developments. The demand changes each day, so we have to be ready to ensure that the products are ready for the situation, which are more efficient & cost-effective. I dedicate our success to the people in our organisation,” replies Cholkar. The Pune facility has 77 employee who work on the shop-floor and ensure efficiency & utilisation level. The facility has direct and indirect support staff, out of which around 21 function in departments like engineering, quality as well as purchasing. They maintain health of the plant and make sure quality manufacturing is carried out. It is a completely export-oriented unit. “We are exporting to our own subsidiaries across the globe and cables. Also, we have been producing quality products with the combination of sophisticated technology and quality engineers. Employees are our strength. When we started the plant, we set six engineers as trainees and sent them to Renishaw Plc and Renishaw Ireland

112 MODERN MACHINE TOOLS - April 2011

for vigorous training for six months,” reveals Cholkar.

Catering to international demand The biggest revenue generator for the facility remains international market. The Pune facility is equipped with extremely sophisticated equipment, censor and technology lab to cater to international standard and demand. In the facility Canban system are used for easy movement of the material. According to Cholkar, “Our Pune facility matches the international standards similar to Renishaw’s other facilities in Ireland and the UK. We have all kinds of equipment and facilities for manufacturing quality products. This is also due to the fact that we are manufacturing most of the products for international markets.” The logistic unit of the manufacturing division also manages the logistics of products as most of the products are for international market. He further adds, “For our logistics purpose, we have short-listed Expeditors, who handle our inbound and outbound logistics. Our workforce monitors and watches the logistics company for proper co-ordination, which improves the day-to-day situation.” As most of the R&D activities are carried out at Renishaw’s UK and Ireland facilities, The Pune plant plays the role of manufacturer.

Its manufacturing division has world-class technologies and experienced personnel to carry out all manufacturing-related activities. The company believes in setting up proper production facilities, putting in place operations, and catering to demands. The facility has a demo centre, which has CNC and Co-ordinate Measuring Machine (CMM) for training purposes of customers and employees. It can accommodate 30 customers at a time. It has a dedicated sales and marketing division which looks after requirments and supports from the Western region.

Growth ahead At Renishaw, most of the research is aimed towards improving productivity and processes. Based on the market trends and customer requirements, the company targets one segment after another to focus its R&D efforts in the required direction. Currently, it is focussing on upgrading and enhancing the motion control and measuring system. About future plans, Cholkar says, “There is a good opportunity in store for us because the products that we are manufacturing are labour-extensive and labouroriented ones. Since we are having adequate resources for manufacturing new products, we have plans to focus on different product lines like encoders, MTP, Raman, CMM, etc in our facility. In the future, if the demand increases, we may increase the range of products, along with our production capacity.” Keeping in line with the company’s image to provide the best technological solutions and quality products, the company is planning to grab the opportunities in India and abroad. Renishaw is in an expansion mode. With the support of a modern manufacturing facility, Renishaw India is now leveraging its capability to tap into the existing potential in the country and create opportunities to grow in the manufacturing domain.


Manufacturing Excellence TUBE DEBURRING BRUSHES

Courtesy: Valgro India Ltd

Lowering manufacturing costs Deburring is often a practical necessity after cut-off operations. Wire brushes provide low-cost and reliable tube deburring systems. These come with high-quality nylon wire, impregnated with abrasives for longer life and faster cutting action.

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ylon wire brush systems can be an ideal solution for cut-off applications that require deburring, but do not need the endfinishing of a chamfering blade. Unlike chamfering processes, brush deburring does not leave secondary micro burrs. Brush deburring is also more forgiving than chamfering with a blade, tolerating some imprecision in tool setup and slight variations in machine alignment and tube length. Automated brushing systems can be integrated with cut-off operations to eliminate work-in-process and increase throughput. Cycle times of less than five second per piece can be routinely achieved. Brush deburring can be applied to different types and sizes of tubing, bars and extrusions. Brushes can deburr stock of almost any shape, material and end-geometry. With brush deburring, it is also easy to quickly change from one configuration to another.

Brush selection for tube end deburring processes When selecting a brush for an application, a number of questions need to be addressed. First, what end is being pursued – for exmple,

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deburring, edge breaking, polishing, cleaning, etc? Second, what is the material that needs attention? For instance, if the goal is to deburr a stainless steel tube that was saw-cut, either an abrasive or stainless steel wire brush should be utilised to reduce contamination on the workpiece. A carbon wire brush would deburr the part faster, but it would also leave traces of carbon steel that would cause the part to oxidise. If the tube is harder than Rc 35, the only remaining option is the usage of abrasive filament. Depending on the equipment utilised, either a cup or radial brush will perform the job. Most automated deburring processes employ two wide-face brushes set perpendicular to the stock. The brushes deburr both ends simultaneously. The rotation of the brush is clockwise at one end and counter-clockwise at the other end, so that the brushes move across both ends in a downward direction. The high brush speed allows the system to perform with low-brush operating pressure and penetration. Excessive pressure and penetration prevent the wire tips from contacting the edge and causes filament breakage. The result is a reduction in brush life and deburring action.

Feed rate is dictated by the nature of the burrs to be removed. Heavier burr necessitates the removal of more material, and therefore, may require a longer time in front of the brushes. Lighter burr requires less time in front of the brushes. Adjustable feed rate allows the system to achieve an optimal combination of deburring action, throughput and brush life. Optimal matching of the brush to an application can extend brush life by three or four times. Choosing a brush that matches the particular application can be a challenge, because five variables must be addressed: brush diameter, brush length, wire size, type of wire and brush density.

Wire type Steel wire brush life is less and also has a effect on environmental safety. Wire will break during deburring and can damage human assets sometime. Using steel brushes on these materials will cause ‘after-rust’, which results from contamination with ferrous particles. Brush diameter is determined by the diameter of the tube to be processed. Since radius of curvature changes with brush diameter, large brushes are required to deburr tubes that are bigger.


Manufacturing Excellence High-brush speed and lowoperating pressure High-brush speed is critical to application success. Wire brushes function by delivering millions of wire tips to the burred edge each minute. These wire tips have a hardness of approximately 60 Rc and a striking velocity of more than 60 mph. This highimpact action separates the burr from the stock and leaves a smooth edge. Excessive pressure and penetration prevents the wire tips from contacting the edge and causes filament breakage. The result is a reduction in brush life and deburring action. Penetration of the tube-ends into the brush face should be limited to less than 1/8 inch. If the brushes are unable to remove the burrs when utilised at the recommended speed and penetration, a more aggressive brush is required.

Brush density Wire density refers to the number of

wires packed into a square inch of brush surface area. High brush density increases brush life and deburring action. For some applications, it is cost-effective for users to pay a premium for high-performance brushes with high-brush density. For other applications, brushes with one third the density are preferred. Users need a range of brush density to choose from, to optimise the economics of their specific process. For good performance and brush life, the ends of the stock should penetrate into the brush face less than 1/8 inch, a requirement that necessitates a stable centre of rotation. To ensure good balance, quality brush manufacturers will distribute filaments evenly, and test the balance during rotation, adding weights if necessary, in a process comparable to how automobile mechanics balance wheels. Brush systems offer a low-cost and reliable method of deburring cut-off

stock. By selecting high-quality brushes that are balanced and closely match the five parameters of their particular application, users can expect long brush life and trouble-free operation. Brush-tube orientation is designed to be utilised on portable tools and drill presses. It provides intense brush action for fast, thorough cleaning and finishing in such hard-to-reach places as small diameter holes, internallythreaded surfaces, and many otherwise inaccessible areas. Fill materials include steel, stainless steel, brass, nylon abrasive filament and nylon. Discs brush for flat surface solve many deburring, edge-radiusing and finishing problems. Their compliancy and filament nature accommodate part contours, prevent damage to value-added components, and make them ideal candidates for robotic and automated workstations. Courtesy: Valgro India Ltd

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Factory Fundamentals It has been our persistent effort to provide incremental value to our readers with ‘cuttingedge’ information. As a part of this endeavour, we have this feature - ‘From Modern Machine Shop’, in an exclusive arrangement with the premier metalworking and machine tool publication in North America. Modern Machine Shop (MMS), published by Gardner Publications, US, offers exceptionally high editorial features and circulation standards that have become a hallmark of its operating philosophy and worldwide reputation. We strongly believe that the information provided in this feature will keep our readers updated about the latest global developments in business strategies & technological innovations, the quintessential ingredients for competitive manufacturing.

Precision metrology supplier relies on HMC accuracy Global metrology supplier Quality Vision International produces critical measurement equipment components in-house to control quality and accuracy. Horizontal Machining Centres (HMCs) from Makino enabled the company to not only achieve the precision required for components of one multi-sensor system, but also significantly reduce cycle times.

M Aluminium comprises 90 per cent of the weight of the OGP SmartScope Flash 302, a multi-sensor system that combines video measurement with an optional Through-TheLens Laser (TTL), touch probe or microprobe. While the aluminium construction provides a high strength-to-weight ratio, it also creates difficulties with achieving tight tolerances required to produce critical components of the system

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anufacturers of precision-engineered, high-end products require sophisticated metrology equipment for effective quality control. To deliver the requisite precision, the metrology equipment often must be manufactured to standards that are even more stringent than those of the parts it measures. “We are fighting the same battle as our customers – always improving accuracy and manufacturing methods so we can deliver superior products,” says Stephen Flynn, President, Optical Gaging Products (OGP), a division of Quality Vision International (QVI). QVI contracts few jobs to manufacturing partners, but the company produces the most critical components at its in-house machine shop to control quality and accuracy. A few years ago, however, the tight tolerances and high production requirements of components for

one multi-sensor measuring system exceeded the capabilities of the shop’s manufacturing equipment. Two HMCs from Makino (Mason, Ohio) not only provided the precision needed to produce these parts, but also significantly reduced cycle times.

Customised solutions Founded in 1945 in Rochester, New York, QVI is a worldwide supplier of metrology equipment marketed under various brands, including OGP, VIEW Micro-Metrology, Quality Vision Services, RAM Optical Instrumentation and Certified Comparator Products. Through these brands, the company offers a diverse product range covering a wide spectrum of industries. Starting with a selection of 50 standard models, the company can also engineer customised measurement solutions for specific customer applications. For its part, OGP focusses on multisensor systems, which often include lasers, touch probes, microprobes


Modern Machine Tools (Apr-11) Insert 8 - Front-Pg 117


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Factory Fundamentals and other sensor types that work in conjunction with video measurement technology. In addition to providing extremely detailed measurements, such systems can inspect more part dimensions in a single setup than its more dedicated counterparts. “The sensors work throughout the system’s usable volume, so overall accuracy depends on the basemodel construction. That is why we manufacture base-model components here in Rochester,” explains David Wolf, Shop-floor Manager, QVI. A few years ago, two critical components for one particular multi-sensor system, the base plate and X-axis yoke, proved difficult to machine to specification. With a 300by 300- by 250-mm measuring volume, the SmartScope Flash 302 is the largest benchtop machine in OGP’s inventory. Aluminium comprises 90 per cent of its weight. “A key to manufacturing the 302 was a high strength-to-weight ratio,” Wolf explains. The shop soon found that meeting the tight tolerances required for the base plate and X-axis yoke was much more difficult in aluminium than the hardened, ground tool steel with which it was more accustomed to working. High production goals and the size of these parts, which necessitated a larger machine, further compounded the problem. “Most machine tools require a sacrifice in accuracy for a large work envelope, which we could not afford. Also, while profitable machining for us once meant utilising machine tools long after they were paid for, the 302 required capabilities that could be found only in modern, high-performance machining centres,” says Wolf.

Accurate machining QVI began its search for a solution by evaluating HMCs from several manufacturers based on the specific design and engineering requirements of the 302’s yoke, which moves in one axis and carries the sensors that move on it in a perpendicular axis (the third

axis moves across the base). Two of the yoke’s most critical features, a pair of identical bores located on opposite ends of the part, require bore accuracies of ±5 micron and location tolerances of ±2.5 micron. In assembly, the yoke must hold better than 1 arcsecond per inch of travel. The company settled on Makino’s a61. Whereas most HMCs utilise a vertical spindle on a horizontal plane, this model features a slantcolumn structure for a stronger Y axis that resists Z-direction cutting forces. Wolf explains, “Yaxis straightness travel of less than 10 arcseconds was required, and Makino was the only builder that immediately responded that this wouldn’t be a problem. In fact, when we measured the a61, we found it exceeded all the listed tolerances – including Y-axis straightness, which we measured at 4 arcseconds.” In addition, the machine’s 14,000rpm spindle enables the usage of high-speed tools and advanced toolholders that can achieve surface finishes of 0.8 RMS and roundness tolerances of 2 to 3 micron. The level of accuracy the machine provides has also prompted the shop to apply it to other jobs, particularly those involving prismatic components with tolerance requirements that necessitate single-setup production to eliminate stack-up error. Although QVI initially planned to purchase a $ 50,000 trunnion fixture to accomplish this task, the a61’s rotary table provides sufficient positioning accuracy to machine these parts without extra equipment. As for the requirement to produce parts fast enough to meet demand, says Wolf, “The a61’s rapid acceleration/deceleration rates and 0.9-second tool changes have helped reduced cycle times for the yoke by 50 per cent.” Another contributor to faster cycles is a multi-sided fixturing vise that enables machining of multiple sides of the part in a single

Tolerances as tight as ±5 microns were required to produce certain components of the SmartScope Flash 302, including the unit’s base plate

...and X-axis yoke

The a81 HMC’s two pallet system enables operators to fixture one base plate while the other is being machined

setup. He further adds that the machine’s robust construction keeps downtime to a minimum. “We had come to expect waycover replacements every two to three years, which often entailed long periods of machine downtime, but the a61’s way covers show no signs of degradation after two years of heavy usage.”

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Factory Fundamentals elements, specifically citing its rigid construction and features such as glass scales.

Significant contribution Using Etalon LaserTracer volumetric accuracy test equipment, Gesner was able to further tweak the machine to realise submicron positioning accuracies. The Etalon software outputs a Two of the yoke’s most critical features, a pair of identical bores located on opposite ends of the part, require bore volumetric error map that is accuracies of ±5 microns and location tolerances of downloaded to the machine’s ±2.5 microns. In assembly, the yoke must hold better Fanuc CNC, which features a than 1 arcsecond per inch of travel 3D error compensation option. Verification of the straightness errors after volumetric compensation Way covers are not the only showed a threefold improvement with components of the machine that have an average of less than 1 micron of held up over time. After a year of service, error in all axes. the company performed calibration However, a different Makino HMC, tests to qualify and verify the a61’s the a81, also contributed significantly accuracy. Results showed an average to accelerating production, especially straightness accuracy error for all axes for the 302’s base plate. The shop’s of less than 3 micron. Eric Gesner, previous machines took too long to Chief Metrologist, QVI, attributes that remove the large amount of metal performance to the machine’s design

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needed to produce this component, causing backlogs. Since installing the a81, roughing times have been reduced by almost 70 per cent while still achieving the 5-micron tolerances required for the part. Wolf says the a81’s two-pallet system, which enables fixturing additional base plates, helps further reduce out-of-cut time and increase throughput. “Improved roughing accuracy resulted in a faster final finishing process for the base plate, the slowest operation of all because of the straightness and perpendicularity of the 302’s structural supports. This has enabled the company to realise a much quicker return on its investment in the a81,” Wolf explains. “Being a leader in measurement equipment requires producing parts with accuracies beyond customers’ required specs. With the results we are seeing out of our a61 and a81, we are more excited than ever to push the envelope of measurement standards,” he concludes.


Factory Fundamentals

Machining for air quality Honing experts describe the significance of this machining process for meeting the most recent emissions standards affecting cars, trucks and other vehicles. Peter Zelinski

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akers of all types of engines have been under pressure for decades to reduce emissions. And for decades, they have done so. Not just car and truck makers, but also makers of engines for vehicles ranging from lawn mowers to locomotives – all have improved fuel efficiency and air-pollution performance to meet increasingly tight government standards. Today, though, the difference is not just a matter of degree, but also a matter of difficulty. Engines are now so efficient that their designers have to work that much harder to obtain further incremental efficiency gains.

A finished diesel engine cylinder liner sits beside a two-stage honing tool with an integrated air sizing system. On this tool, a first set of abrasives performs semi-finishing, with cycle time controlled by the air system. These abrasives then retract, and a second set of abrasives applies the finish by cutting down the peaks left by the first set. The resulting engineered crosshatch finish can be seen inside the completed liner

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Two witnesses to this are Dennis Westhoff and Rich Moellenberg with Sunnen, a company that specialises in bore honing systems and tooling. Perhaps more than any other machining process, honing is particularly important to the search for tight engine-emissions performance. “In the 1980s, all easier job was done,” says Westhoff, Global Business Development Manager, Sunnen. Straightforward improvements were made to vehicle engine designs that originally had not treated fuel efficiency or air quality as paramount concerns. The history of meeting emissions standards proceeded from these mechanical refinements to improved form and dimensional tolerances resulting from better machining, including improved accuracies for cylinder bore roundness and cylindricity. Today, engine makers seeking further refinements look to even more minute levels to meet current emissions requirements. Specifically, opportunities for winning better engine performance tend to focus not on dimensional form tolerances, but on the even smaller surface-finish characteristics of piston, injector and fuel pump bores. Honing is perhaps uniquely suited among machining process for repeatably achieving a desired finish on these bore IDs. Rich Moellenberg, Manager – System Sales, says, “Those modern engine-system surfaces are specified in ways that go well beyond the ‘Ra’ (average roughness) commonly utilised to describe finishes.” Parameters from


Factory Fundamentals surface that might be specified by an engine company’s tribologist (or specialist in interacting surfaces).

Holding oil Honing, for bores, is a process in which an expanding tool assembly with abrasive stones This roughness trace shows a surface that is smooth in terms of peak height, but with deeper valleys that were deliberately created in rotates inside the the semi-finishing step so that the surface would hold a lubricating bore, while the tool film of oil or part reciprocates. Because the cutting points of the honing abrasive are the ‘Rk’ family, for example, describe small and numerous, the heat & stress microscopic attributes including the produced in the workpiece are small. surface’s bearing-area curve and An outcome characteristic of honing its peak height under load, as well is a crosshatch pattern that facilitates as the capacity of troughs in the lubrication transfer along the length surface to retain oil. In honing, the of the bore. This crosshatch pattern is selection of stones and equipment another aspect of honing that can be – as well as the programmed precisely controlled. motion and the sequence of Lubrication transfer is one of the separate honing operations – can principal areas in which a cylinder be tailored to generate precisely the surface might be designed for improved emissions performance. Along the bore ID, if the surface itself can help to utilise oil efficiently and let it spread more easily, less oil will be needed in the cylinder. That means less oil will burn as the engine runs. “As much as possible, the goal is to get the cylinder dried up,” Moellenberg says. However, another goal in surface design is to reduce sliding friction – and this goal might compete with oil transfer. A surface that is ‘smoother’ in terms of sliding friction might be less effective at retaining and transferring even quantities of oil. Tribologists and other engine specialists seek to realise the right balance between aims such as these. The resulting surface design is Here is a superabrasive honing tool often complex, characterised by various alongside a through-bore fuel injector body. Manufacturers of parts such as this body are concerned with not only various specific surface finish parameters, but also the precise form of the bore, because clearances between the body and plunger in a modern fuel injection system are so tight

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surface-finish parameters with exacting meanings. The honing technology provider might then spend months developing a process to achieve this surface and proving that process for high-volume production. “They know what surface they want, but not how to machine it,” Westhoff says. In fact, he says the early stages of discussing a new process sometimes reveal that, from a machining perspective, certain surface callouts are mutually contradictory and cannot both be achieved.

Honing under load Beyond these surface characteristics, other capabilities of honing – including controlling dimensions such as bore size, roundness and taper – also remain important, he says. If manufacturing devotes less attention to these parameters today, that is only because they have long been tightly controlled in engine-related machining. However, in the pursuit of greater fuel efficiency, tolerances in these areas are becoming tighter as well, with clearances between moving parts shrinking micron by micron. One result that Sunnen sees is that practices from performance race car engine making are migrating into conventional automotive engine production. An example Moellenberg cites is torque-plate honing, in which torque is applied to a cylinder to simulate the cylinder’s eventual assembly into the engine block. The cylinder is honed in this loaded condition. The reason for machining in this state relates to how small clearance dimensions between moving parts have become. The specified fit between the piston and cylinder might now be so tight, he says, that just the tiny distortion of the cylinder resulting from its fit in the engine could prevent the piston from functioning.

Peter Zelinski is a Mechanical Engineer and the Senior Editor - Special Projects of Modern Machine Shop magazine in the US.


Curtain Raiser

Invigorating the Indian sheetmetal industry With Indian economy’s rapid progress, the country’s sheetmetal domain is experiencing increasing demand from the fields of automobiles and aerospace. The second edition of BLECH India is poised to capture the enthusiasm and provide impetus to this thriving vertical. Hema Yadav

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he booming Indian economy has resulted in large amount of investments to provide for the ever-increasing consumer demand and the reguired infrastructure. In particular, the automotive industry and its suppliers, construction, home electronics and white goods industries as well as the steel production industry have benefitted from this positive trend. Riding on the back of this strong momentum, the country’s sheetmetal industry is gearing up to meet the rising demand. The current edition of the event will be held at Bombay Exhibition and Convention Centre (BCEC), previously known as Bombay Exhibition Centre during April 14-17, 2011. For

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international suppliers of sheetmetal machines, tools and systems, India is a market that offers immense opportunities. BLECH India 2011 will present and promote this facet of the industry. It will prove to be a unique platform during India’s upswing, transforming into a central marketplace for everyone involved in sheetmetal working. The exhibition is considered to be the first choice when it comes to sourcing the right machinery, tools and materials. More than 120 exhibitors from all over the world will present their latest technologies to the industry’s key decision makers.

Hallmark of excellence Being a part of a series dedicated to sheetmetal working exhibitions in


MMT Apr-2011 Ad Name: Eng Expo Pg No. 127 MMT Apr-2011 Ad Name: Eng Expo Pg No. 127


MMT Apr-2011 Ad Name:Eng Expo Pg No. 128 MMT Apr-2011

Ad Name:Eng Expo

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Curtain Raiser growth markets, the event is organised by Inter Ads-Brooks, a joint venture between Mack Brooks Exhibitions, UK, and Inter Ads Exhibitions, India. The first BLECH India exhibition took place during November 18-20, 2009, at the Bombay Exhibition Centre in Mumbai. The trade exhibition focussing on sheetmetal working technology featured 50 exhibitors from eight countries, and attracted around 3,600 visitors, mainly from India. The exhibition analysis reflected that the key industry sectors to which the visitors belonged included sheetmetal products, components & assemblies (53 per cent), mechanical engineering (42 per cent), automotive industry (10 per cent), steel & aluminium construction (9 per cent) and iron & steel production (9 per cent). The exhibition proved as a platform to forge and consolidate

Visitor profile The trade show is designed for sheetmetal working specialists in sectors such as:  Mechanical engineering  Sheetmetal products  Steel and aluminium construction  The automotive industry and its suppliers  Heating/ventilation/air conditioning Electrical engineering  Electronics industry  Rolling mills   Iron and steel production  Precision engineering  Aerospace  Ship building

all levels, with majority being head of manufacturing or possessing managerial responsibilities.

Exhibitor profile

Concurrent event



Fastener Fair India 2011 will be held from April 16-17, 2011 at BCEC. It will be a highly focussed B2B event, offering a complete range of industrial fasteners and fixings technology. Many international and national exhibitors will present modern technology and solutions, helping industry professionals connect, network, update their knowledge and explore business prospects with the market leaders. Visitors will be able to directly access key insights about latest technologies & raw materials, meet suppliers, manufacturers, wholesalers and distributors, under one roof. The event will provide time and cost-effective opportunities to explore this sector in India, wherein the demand is likely to sky-rocket in the future. Dedicated to showcase the best of sheetmetal working in growth markets, these events will act as a convergent point for industry leaders and suppliers, facilitating technology and knowledge sharing.

                 

Sheetmetal, tube, sections (ferrous & non-ferrous) Finished products, components, assemblies Handling Separation/cutting Forming Flexible sheetmetal working Tube/section processing Machine elements Joining/welding/fastening Surface treatment of sheetmetal Automation and robotics Dies/tools Controlling/regulation/ measuring/testing Quality assurance CAD/CAM systems/data processing Factory and warehouse equipment Environment protection/ recycling Safety at work Research and development

business relations. As manufacturing with sheetmetal is an important and fast-growing industry in India, majority of the exhibiting companies at the show assessed the market for sheetmetal working in the country as positive in the coming years. The visitor profile included specialists at

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Events - National

AHMEDABAD

PUNE

CHENNAI

INDORE

Gujarat Oct 14-17, 2011

Maharastra Nov 18-21, 2011

Tamil Nadu Dec, 2011

Madhya Pradesh Jan 6-9, 2012

Gujarat University Exhibition Hall

Auto Cluster Exhibition Centre, Pimpri-Chinchwad

Chennai Trade Centre, Nandambakkam

Poddar Plaza, Nr Gandhi Hall

India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumactics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment. For details Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022 3003 4651 Fax: 022 3003 4499 • Email: engexpo@infomedia18.in

DIEMOULD India 2011 International exhibition for industries including dies & moulds, press tools and machine tools; April 7-10, 2011; at Chennai Trade Centre, Chennai For details contact: Tool & Gauge Manufacturers Association of India (TAGMA) A-33, NandJyot Industrial Estate Safed Pool, A K Road, Mumbai Tel: 022 2852 6876, 2850 8976 Fax: 022 2850 3273 Email: mumbai@tagmaindia.org Web: www.tagmaindia.org

BLECH India 2011 The event will be focussing on industrial technology, sheetmetal working, handling, cutting, forming, automation and robotics; April 14-17, 2011; at Bombay Exhibition Centre, Mumbai For details contact: Inter Ads - Brooks Exhibitions (India) Pvt Ltd Plot No 859, Phase-V, Udyog Vihar Gurgaon, Haryana Tel: 0124 475 1600 Fax: 0124 475 1601 Email: blech.india@iabex.com Web: www.blechindia.com/english

AutomationExpo 2011 The event will highlight automation in industrial process, factory & building, systems and solutions;

130 MODERN MACHINE TOOLS - April 2011

April 21-23, 2011; Chennai Trade Centre, Chennai For details contact: Intel Trade Fairs & Expositions Pvt Ltd 113, New Sonal Link Industrial Estate Link Road, Malad (W), Mumbai Tel: 022 28803977 Fax: 022 28819008 Email: intelexpo@vsnl.net Web: www.intelexpo.com

InterMachinery India The 5 th edition of InterMachinery India will be showcasing machinery & equipment, which will be attended by a large number of international exhibitors; June 9-11, 2011; at Bombay Exhibition Centre, Mumbai For details contact: Worldex India Exhibition & Promotion Pvt Ltd, 309, Parvati Premises Sun Mill Complex, Lower Parel, Mumbai Tel: 022 4037 6700 Fax: 022 2496 2297 Email: info@worldexindia.com Web: www.intermachineryindia.com

Plot No. F/11 & F/12, Camlin Fine, WICEL, Andheri (E), Mumbai Tel: 022 3201 9137 Fax: 022 2832 4404 Email: sales@focussedevents.com Web: www.focussedevents.com

MetEx India 2011 International exhibition on metal, metallurgical technologies, equipment and service; September 22-24, 2011; Bangalore International Exhibition Centre, Bengaluru For details contact: Koelnmesse YA Tradefair Pvt Ltd B 501/502, KEMP Plaza, Mind Space,Chincholi Bunder, Malad (W), Mumbai Tel: 022 42107804 Fax: 022 40034433 Email: n.seth@koelnmesse-india.com Web: www.metex-india.com

IA India International trade fair for process & production, automation and industrial building automation; December 6-9, 2011; Bangalore International Exhibition Centre, Bengaluru For details contact: Hannover Milano Fairs India Pvt Ltd B-303, Dynasty Business Park Andheri- Kurla Road, Chakala Andhrei East Tel: 022 40050681 Fax: 022 40050683 Email: info@hmf-india.com Web: www.ia-india.com

CeMAT India Internation trade fair for material handling and logistics; December 6-9, 2011; Bangalore International Exhibition Centre, Bengaluru

Automotive Engineering Show International exhibition on technologies for automotive manufacturing; June 10-12, 2011, at Chennai Trade Centre, Chennai For details contact: Focussed Event Management Pvt Ltd

For details contact: Hannover Milano Fairs India Pvt Ltd B-303, Andhrei (E), Mumbai Tel: 022 40050681 Email: info@hmf-india.com Web: www.cemat-india.com


Events - International PMTS 2011 An international event on precision machined parts manufacturing; April 19-21, 2011; Ohio, USA For details contact: Gardner Management Services 6915 Valley Avenue Cincinnati, Ohio, USA Tel: +1 800 950 8020 Fax: +1 513 527 8801 Email: allison@gardnerweb.com Web: www.pmts.com

JAPAN METAL STAMPING TECHNOLOGY EXHIBITION 2011 The exhibition will highlight the latest technologies in metal stamping, press forming machines, forging press machines and accessories & tools for forming machines; April 20-23, 2011; at Tokyo Big Sight, Japan For details contact: Japan Metal Stamping Association Shiba-koen 3-5-8 Kikai Shinko Kaikan 212 Minato-ku, Tokyo, Japan Phone: +03 3433 3730 Fax: +03 3433 7505 Email: jmsa@nikkin.or.jp Web: www.nikkin.or.jp

MOLDEXPO 2011 The event will highlight the latest technologies and developments in dies & moulds industry; May 10-12, 2011; at Feria de Zaragoza, Spain For details contact: Feria de Zaragoza Carretera Nacional II, km 311 50012 Zaragoza Spain Tel: +34 976 764 700 Fax: +34 976 330 649 Email: info@feriazaragoza.com Web: www.feriazaragoza.com

Chongqing Lijia International Machine Tool Exhibition The 12th West China’s leading international exhibition will showcase the latest development and technology in the industry; May 11-14, 2011; Chongqing, China For details contact: Chongqing Nanping Development Road, International Business Building, No. 31, Cole 28-5 Chongqing, China Tel: +86 23 86376088/311 Fax: +86 23 86376323, 86308310 Email: chinawmte@gmail.co Web: www.cwmte.com.cn

Fax: +49 7025 9206620 Email: info@schall-messen.de Web: www.blechexpo-messe.de

Atlantic Design & Manufacturing The international event will showcase advanced design & manufacturing; June 7-9, 2011; at Jacob K Javits Convention Center, USA For details contact: Canon Communications 11444 W Olympic Blvd Los Angeles, CA 90064 Tel: +310 445 4200 Fax: +310 445 4299 Email: info@ubm.com Web: www.ubmcanon.com

SHEETMETAL ASIA 2011 The 15th international exhibition will showcase the latest developments in sheetmetal fabrication technology and machinery; May 19-22, 2011; at Bangkok International Trade Exhibition and Convention Centre (BITEC), Thailand For details contact: UBM Asia (Thailand) Co Ltd 503/23 KSl Tower, Sri Ayuthaya Road Thanon Phayathai, Rajathewee Bangkok, Thailand Tel: +6600 2642 06911 Fax: +660 2642 6919-20 Email: info@sheetmetal-asia.com Web: www.sheetmetal-asia.com

Blechexpo International trade fair for sheetmetal processing; June 6-9, 2011; Stuttgart, Germany For details contact: P E Schall GmbH & Co KG Messeunternehmen Gustav-Werner-StraĂ&#x;e 6 D-72636 Frickenhausen Tel: +49 7025 92060

Machine Tools Vietnam 2011 20th Vietnam International Industrial fair will showcase a variety of machine tools; October 19-23, 2011; at Vietnam Exhibition and Fair Centre, Vietnam For details contact: Vietnam Exhibition Fair Centre (VEFAC) 148 Giangvo Road, Hanoi Vietnam Tel: +844 3834 5655 Fax: +844 3831 1228 Email: lien.hoaly@vefac.vn Web: www.vietnamindustrialfair.com

The information published in this section is as per the details furnished by the respective organisers. In any case, it does not represent the views of

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Report

ENGINEERING EXPO CHENNAI 2011

Channelising knowledge, building brands Keeping pace with the giant strides of the manufacturing sector in Tamil Nadu, the third edition of Engineering Expo Chennai created an aura for promoting interaction between various stakeholders in the industry. With technology and innovations as its core strengths, the Expo offered better commercial prospects for exhibitors and visitors alike. Annabel Dsouza

T

here is no denying that entrepreneurship and initiatives are integral to industrial success of companies as well as the entire trade ecosystem of a region. Facilitating this culture of business expansion through technological advancements, the third edition of Engineering Expo Chennai was held from March 11-13, 2011, at the Chennai Trade Centre, Nandambakkam. During the three days of intense networking, the city’s burgeoning engineering industry received a further impetus in terms of information upgradation as well as profitable partnerships. The event was marked by the presence of V Arumugam, Zonal GMSouth I & III, National Small Industries Corporation Ltd (NSICL); R Selvaraj, President, Ambattur Industrial Estate Manufacturers’ Association (AIEMA); and

Sunil Kaul, Senior GM, Power Transmission Division, Fenner India Ltd as Guests of Honour. The esteemed guests highlighted Chennai’s emergence as a manufacturing hub and sourcing base for India’s auto industry. Further, they emphasised on the pivotal role played by trade shows and exhibitions in supporting entrepreneurship in the region. Awareness and expertise go a long way in constructing the right environment for competitive businesses. As the global economic scenario converges to become more inclusive, local players have to compete with products and services in the international market for harnessing export demand. Selvaraj said, “Chennai is bestowed with abundant technical knowledge and skill sets. The educational initiatives of the State have yielded good results in tapping the vast human capital in

the region. However, industry collaboration is the need of the hour at student and professional level.” He further added, “Besides commercial gains, trade fairs offer entrepreneurs an opportunity to grasp technical developments and convert them into profitable business ventures.”

The knowledge factor This year’s edition of Expo performed exceptionally well in terms of business generation and networking prospects. Around 80,000 kg of machinery was displayed at the event while business leads worth ` 39.34 crore were generated. However, the key highlights were the knowledge and technology sharing offered by the 200 plus exhibitors at the event. As the famous adage goes, one cannot deliver today’s solutions with yesterday’s technology and expect to be

Chennai charms…

chnology

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tors ob rossed visi

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132 MODERN MACHINE TOOLS - April 2011

at its best

The city is emerging as a major player in the auto components and ancillaries industry. Its strategic location as a seaport city is reinforcing its status as a leading sourcing hub for most brands in the engineering industry. An abundance of skilled workforce and thriving economic culture attract industries to this city. With many large and small players from all spheres of the engineering world competing for market space, innovative technology and value-added services are going to be the key determining factors for success. Sunil Kaul, Senior GM, Power Transmission Division, Fenner India Ltd, asserted, “The Indian engineering industry is poised to grow immensely. As markets expand and demand increases, we look at competitors as partners in progress. There is plenty of scope for upgrading existing product portfolios, and companies should benchmark their products against international standards and not restrict themselves to local competition.”


Report

(L-R): Guests of Honour Sunil Kaul, Senior GM, Power Transmission Division, Fenner India Ltd; R Selvaraj, President, Ambattur Industrial Estate Manufacturers’ Association; and V Arumugam, Zonal GM-South I & III, National Small Industries Corporation Ltd at the inaugural function

in business tomorrow. Similarly, adopting the latest available technology in the market fosters a large number of start-ups and Small and Medium Enterprise (SME) initiatives. This is the most critical aspect of a self-sustaining economy. As Chennai emerges into mainstream auto components manufacturing, every effort is being made by the State Government to promote and support entrepreneurship. Arumugam said, “SMEs generate over 40 per cent of employment. Their share in the export market is more than 9 per cent. To further encourage SMEs’ excellence, there is a credit rating based on faster delivery with value-added services. Benefits are also extended towards sponsoring and promoting participation at international trade fairs.”

Business latitude All successful businesses understand the crucial role played by exhibitions and conferences in fostering opportunities. Engineering Expo has always been a

platform for branding and interacting with suppliers, OEMs, auxiliary service providers and end-users. Competitive acumen is another advantage offered by this Expo, which not only facilitates sales and marketing, but also supports decision makers in formulating future strategies. Kaul stated, “Engineering Expo offers a good opportunity for companies to share knowledge and expertise on processes & innovations. It promotes partnerships between industries and their ancillaries, which in turn plays a crucial role in technology transfer and R&D. Exhibitions and trade shows enable companies to collaborate with each other in seeking new opportunities and providing a learning curve on cost compression, quality circle, service improvement, energy-efficiency, etc. The Expo assures tremendous benefits for the parties involved and the industry at large.” Besides strengthening brands, this edition of Engineering Expo Chennai also witnessed companies building strong networks and collaborations. Suresh C K,

General Manager - Marketing, Surya Automotive & Plastics, said, “From a business perspective, this exhibition has enabled us to tap the enormous potential within the industry. Our products and services have evinced interests among our target audience. Moreover, at this exhibition, we received valuable feedback that helped us identify areas in and around Chennai where there is demand for our products.”

On an optimistic note Like its previous editions, this Expo redefined its benchmark of success. Reiterating the importance of the event to give a boost to the industrial scenario of Chennai, Kaul added, “The worth of a trade show in the league of Engineering Expo cannot be estimated only from a profitgaining perspective. Although immediate business gains are important, one should look at the larger perspective in terms of industry awareness, key strengths and overall brand building.” The Chennai Expo seemed to be a perfect culmination of the enterprising spirit of Engineering Expo as it brings down the curtains on this season. India’s engineering industry earnestly awaits the next season, with renewed vigour and enhanced prospects as the Expo returns to Chennai in December 2011.

Mission SME V Arumugam, Zonal GM-South I & III, National Small Industries Corporation Ltd (NSICL), said, “The technologies and solutions offered by local ancillaries in Tamil Nadu certainly meet international standards of quality and efficiency. Exhibitions like Engineering Expo allow companies to showcase their products effectively, while also garnering sales and revenues.” He further added, “We at NSICL do our best to encourage participation at trade shows, both at the national as well as international level. These expos also serve as a platform for awareness and exposure of innovative technology in the market.” A panoram ic view of pulsating India’s automobile industry consists of business at the Expo some of the world’s leading brands like Ford, Royal Enfield, Mitsubishi, Volkswagen, among others. In this context, Arumugam stated, “In terms of outsourcing, Multinational Companies (MNCs) cannot manufacture all components, and outsourcing is integral to their operations. Here, SMEs play an important role in MNC establishment in the State. SMEs help the region to become a major sourcing destination.” April 2011 - MODERN MACHINE TOOLS 133


Report

Total number of visitors: 15,550+ First-time exhibitors

Exhibitors’ insights

Rajul Gandhi, Director, Seion Watertech Pvt Ltd Chennai is a crucial market for our industry. However, there is a dearth of high-end solutions, and this exhibition has helped us reach out to local clients. We experianced considerable demand for our stateof-the-art products. This was evident from the impressive visitor turnout at the Engineering Expo and we have generated enquiries worth ` 1.5 crore.

Falgun Pandya, MD, Saimona Air-Mech Pvt Ltd We sold five machines during the first two days. This alone speaks for the market demand and the role of this exhibition in facilitating business. Besides, we look at trade shows like this as opportunities for interacting with our vendors, suppliers, distributors, etc. Such events enable us to boost our brand image and promote our products significantly.

Anand Kannan, VP- Marketing, Powerica Ltd I am quite satisfied with the quality and visitor turnout. Given that our technology has a unique edge in efficiency and pricing, we hope to leverage the enquiries and generate business. In terms of brand building as well, I would rate this Expo on the higher side.

Vipin Shah, Director, Electroweld Automations India Pvt Ltd Automation is critical to any engineering industry and we see tremendous potential for our products and services in Chennai. This edition of Engineering Expo has been successful in attracting the best companies from the industry, which in turn helped us in networking and building collaborations.

Bony Paul, MD - India & GCC Region, Trelleborg Sealing Solutions This exhibition has been a good experience in strengthening our business in Chennai. The visitor turnout and their interests in our solutions were quite encouraging. We were able to achieve our aim of brand building. C Kumarakrishnan, Assistant Manager Sales, Pepperl+Fuchs (India) Pvt Ltd The response that we received at this expo was heartening. Among the visitors, many were students, who were keen on exploring our world-class solutions. However, in terms of business prospects we will be utilising the key contacts generated at this Expo for future sales and revenue.

4,532

Total business leads generated

134 MODERN MACHINE TOOLS - April 2011

Ganesh Parthasarthy, CEO, Tussor Machine Tools India Pvt Ltd Our CNC solutions were well-received in the market for its high precision delivery as well as rough handling capacity. At this exhibition, we were able to leverage on our strong pricing advantage and also promote our brand among target visitors. Pavandeep Singh, Managing Partner, Engineering Hindustan The scale of this exhibition has grown manifold over the years, and we are glad to have participated this time as well. The quality of visitors has been quite satisfactory and we have received good feedback from potential clients. We hope to convert these into profitable partnerships in future.

80,000 kg

Total mach inery movement at the venue


Report

Total number of exhibitors: 200+

Total business generated: ` 39.34 crore

Innovative edge

Visionary visitors

Rajul Gandhi, Director, Seion Watertech Pvt Ltd Our industrial reverse osmosis solutions bring down the TDS count to 2,000 ppm. This portable water technology is ideally suitable for industries in Chennai. The saline water available in this region is not feasible for processing purposes. This technology has wide-scale applications in the pharmaceuticals, tanneries, electronics sectors, etc.

Vinod Kumar, Branch Manager, Wilson Sandhu Logistics India Ltd An exhibition with large participation from the SME sector is important for my company. Being from the logistics industry, I was glad to interact with several companies having large-scale importexport operations. This has also been a great knowledge gaining experience and I hope to follow-up with the leads generated here.

R J Subramanian, Deputy GM, Power Transmission Division, Fenner India Ltd The PowerTran belts are designed for heavy-duty applications in agriculture, mining, construction, etc. It offers power savings up to 40 per cent and also reduces drive cost. It is almost maintenance-free, with optimum tension throughout service life. Ameer Munaff, CEO, Fein Power Tools The powerful belt sander has been developed for machining welded seams on pipes and can be used to precisely smooth corners, edges, profiles and deburr sheetmetal. The tool features a header, which can be swivelled 1800, allowing for flexible and comfortable use even in complex applications. Sriram Subramonian, Country Manager, Boge Compressors (India) Pvt Ltd The C Series compressor has been launched recently in the Asian market. It is unique because 70 per cent of its components like pipes and connections have been reduced into a manifold block, making it compact and user-friendly.

78%

happy Exhibitors of with quality visitors

P Samba Murthy, Partner, Vimal Industries The construction and infrastructure market in Chennai is on the upswing, and such exhibitions bring to the fore the latest materials and machinery of world-class standards. I was able to source some ventilators for my construction business. Besides, I have also observed that products and services available here have a major price advantage, due to the intensely competitive environment, which promotes excellence. Mark Wei, Senior Business Manager, System Integration Outsourcing CEG, Huawei Technologies Company Ltd I am often on the look-out for electronic component suppliers for the telecom industry. I observed a large number of machine manufacturers and few from the electrical segment at the Expo. I met some potential suppliers and look forward to more exhibitions like these with international participation.

83%

Exhibito rs found Enginee ring Expo b etter than ot her trade e vents in Chenna i

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Product Update This section gives information about the national and international products available in the market

Rotary gear pump

Circular sawing machine

Rotofluid rotary gear pumps (FTX series) offered by Fluid Tech Systems. They are cost-effective, elegantly designed, reliable and more efficient in working, compared to other pumps of this type, according to the company. These pumps employ a pair of single helical profile gears shrunk fitted on hardened and ground shaft as impeller supported on either side on self-lubricated sintered bronze bush bearing. Casing and covers of the pumps are machines on CNC machine, being manufactured from closed grained CI, conforming to IS210 grade 20 materials. The rotary gear pumps are available in eight different sizes from 0.25 inch to 2.5 inch and maximum pressure of 10 kg/cm² with 2.5 LPM to 350 LPM flow capacity. These are ideally suitable for OEM applications like engine lubrication, pumping & heating unit, oil filtration cleaning systems, etc. They are highly suitable for pumping and transfer of corrosive chemicals, acids, dyes, resins, pigments, printing inks and various other liquids.

Indo Tech Machines offers circular sawing machine with auto loader. This sawing machine is utilised in diverse industry for cutting up bars and tubes. The machine is specially designed for high rate of production and more accuracy. Available in semiautomatic, fully automatic and numerically controlled versions, the circular sawing machine features simple controls and robust construction. Also, offered is circular sawing machine in different specifications based on the application related requirements of clients. Indo Tech Machines Pvt Ltd Indore - Madhya Pradesh Tel: 0731-4269777, Fax: 0731-4073814 Email: info@indotechmachines.com

Twin-spindle chucker Fluid Tech Systems

Jekshine hydraulic press brakes (PBR series) offered by Jekson Machinery, are manufactured for fabricating operations, which demand accuracy, quality and productivity in their shearing requirements. Twin cylinders mounted on the rear side of the machines are synchronised by a torsion tube exerting the bending tonnage through linkages. The press brakes are available in the range of 20 tonne to 400 tonne and working lengths from 1250 mm to 6500 mm. Monoblock welded steel frame made from ultra tested steel plates rigid to provide accurate bending and repetitive accuracy is within Âą0.03 mm. The complete hydraulic system is mounted between side columns. Components and equipment utilised are manufactured by internationally reputed manufacturers. The hydraulic press brakes are useful for manufacturing of textile machinery, steel furniture, door frames, control panel and auto parts. Also manufactured are NC stroke, NC backgauge press brake (Y & X axis) with LCD control.

Jyoti CNC Automation offers TS 120 twin-spindle chucker with gantry robot. This is an ideal solution for manufacturers looking for complete automation with mass productivity of chucker type components having diameter up to 120 mm. The structure of this machine consists of two headstocks with twin turret configuration and an efficient gantry robot. The basic design of the machine allows direct falling of chips in the chip removal tray/conveyor. Matching different requirements for different applications, the machine can be interfaced with auto job feeding system with gantry system. High torque servo turrets placed in quite proximity to the spindles and in parallel to the job holding provide favourable conditions for smooth cutting performance with faster approach. Side-by-side, high-speed spindles provide perfect cutting environment. Additional features include spindle purge preventing coolant and chips entering precision parts. The monoblock-designed structure provides better rigidity during full load condition. Special pre-loaded job conveyors enable long unattended production. Efficient chip removal system with free chip falls matches with production rate. Fast indexing servo turret with 8-station and machine for flexible machine utilisation of two identical operations or first and second operations with turnaround station are other important features.

Jekson Machinery Pvt Ltd

Jyoti CNC Automation Pvt Ltd

Ahmedabad - Gujarat Tel: 079-2290 1850, Fax: 079-2290 1851 Email: intro@jeksonmachinery.com

Rajkot - Gujarat Tel: 02827-287 081/2, Fax: 02827-287 811 Email: info@jyoti.co.in

Ahmedabad - Gujarat Tel: 079-2290 0100, Fax: 079-2290 0200 Email: rotofluid@dataone.in

Hydraulic press brake

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Modern Machine Tools (Apr-11) Insert 8 Back-Pg138


Product Update Lathe machine New Dilip Industries offers geared lathe machine, the model series ‘MDG’. It is ideal for all sliding, surfacing & screw cutting operations at optimum speed with high accuracy and unusual ease of operation. The spindle speed range is 71-1800 rpm in eight steps. The main bed of the machine is a 25 grade CI, heavily ribbed and robustly designed structure to sustain any deflection and vibration under heavy cuts. The carriage rigid tool-post is wide enough to maximise its load bearing capacity. A separate feed shaft along the lead screw supplied as a standard accessory which saves time as well as reduces the wear and tear of the lead screw nut. The Admit Between Centre (ABC) is available in three lengths: 1340, 1630 & 1770 mm & the height of centre is 205 mm. This is manufactured for minimal maintenance to boost your productivity and is offered with a range of standard and optional accessories. New Dilip Industries Rajkot - Gujarat Tel: 0281-238 8528, Fax: 0281-236 6552 Email: sales@newdilip.com

Mr Samir Gandhi Executive Director Gandhi Automations Pvt. Ltd. “We are pleased to be associated with SEARCH Magazine for many years now, it has provided us a steady return on our advertising and has helped us to expand our business. One must advertise here to experience growth in one’s business.”

sales@geapl.co.in

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Product Update Interchangeable insert holder Guhring offers HT800 WP, an interchangeable insert holder, which is available in diameter ranging from 11.5 mm to 25.99 mm and with cutting lengths of 1.5 x D, 3 x D, 5 x D, 7 x D and 10XD. The nickel-plated holder is equipped with rigid insert seat, and is optimised by flute profile, preventing chip congestion, especially in deep holes with coolant ducts opening on the flutes for better chip evacuation. Its interchangeable inserts are produced in ultra fine carbide grades. The overall construction of the holder has been made rigid and is also made simple-to-change the wear out inserts without damaging the holder after the usage in few seconds time. The application lies in steels, cast iron and aluminium machining. The interchangeable insert holder includes benefits such as high-cutting rates, timesaving, broad range of applications, cost-effective and quick delivery. Guhring India Pvt Ltd Bengaluru - Karnataka Tel: 080-2289 2500, Fax: 080-2289 2510 Email: info@guhringindia.com

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Dear Reader, ‘MODERN MACHINE TOOLS’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the machine industry. You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 3000 words, while that of a product write-up should not exceed 200 words. The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format. The final decision regarding the selection and publication of the articles shall rest solely with ‘MODERN MACHINE TOOLS’. Authors whose articles are published will receive a complimentary copy of that particular issue and an honorarium cheque. Published by Infomedia 18 Ltd, ‘MODERN MACHINE TOOLS’ is the leading monthly magazine exclusively meant for manufacturer and user fraternities of the machine trade. Well supported by a national readership of over 1.25 lakh and strong network of 25 branch offices across India, this magazine reaches out to key decision makers among the Indian manufacturers of machine products, machinery and allied sectors. Also, by virtue of tie-ups with global media majors, it ensures that advertisers are able to promote their products and services across the globe at no extra cost. So get going and rush your articles, write-ups, etc… Thanking you, Yours sincerely,

Manas R Bastia Editor Infomedia 18 Limited ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W) Mumbai 400 028 India

D +91 22 3003 4669 T +91 22 3024 5000 F +91 22 3003 4499 E manas@infomedia18.in W www.infomedia18.in


Product Update Shot blasting machine MEC Shot Blasting Equipments offers airless special 50 hp 6 W special shot blasting machine. This is a special-purpose heavy machine to clean truck frame rails & channels of high strength steel 110-130 KSI in a single pass only by high powered six wheels each 50 hp of diameter 21 x 5 inch blade width rotate at 2,250 revolution per min. Out of six wheels, two are kept inside the blast cabinet with open type wheel housing to achieve the surface finish SSPC-10 at workpiece speed 45 ft/min and SSPC-6 to SSPC-7 up to 60 ft/min by providing variable frequency drive to three roller conveyors. A special abrasive air wash system of approximately 5 m length is designed. The approximate weight of the machine is 40 tonne. Important safety features incorporated include: robust big maintenance platform along with safety railings at a level of 7.5 m height from floor, maintenance platform for wheels at a level of 1.5 m from floor, zero speed sensors, heavy duty silencers to the high-volume blower powered by 40 hp motors to control the noise level, compact but highly efficient cartridge type dust collector to control dust emission of 20 mg per normal cu m of filtered air and powder coated IP-55 protected control panel with efficiently programmed PLC. MEC Shot Blasting Equipments Pvt Ltd Jodhpur - Rajasthan Tel: 0291-274 0609, Fax: 0291-274 2409 Email: mail@mecshot.com

April 2011 - MODERN MACHINE TOOLS 143


Product Update Spring isolator Dynemech offers spring isolators for massive vibration & shock isolation of machines like power presses, shearing and bending machines, gensets, fans, blowers, centrifuges, test beds, textile machines, forging hammers, textile machines etc. The spring isolators are combined with viscous safety damping. The elastic plastic viscous safety damping ensures a high degree of isolation combined with a higher reduction of the movement of the machine. In most cases, viscous damping is required to limit excessive movement, which could occur as a machine operates at a speed near to or coinciding with the resonant frequencies. This happens during run-up and slowdown of the rotating machines as it passes through the resonant frequency of the machine foundation system. The springs are made of high-grade wire & finished with protective coatings thus ensuring trouble free service life. The benefits of spring isolators have high vibration and shock isolation, better structural safety, improved health protection of workers, installation of sensitive machinery and heavy machinery possible in the same shop, reduced foundation costs, improves service life of machines and tools. Dynemech Systems Pvt Ltd New Delhi Tel: 011-2786 2469, Fax: 011-2755 0116 Email: sales@dynemech.com

144 MODERN MACHINE TOOLS - April 2011


Product Update Portable grinding wheel balancer SBS Precision Systems offers a new version of the SB-4500 automatic grinding wheel balancer, a cost-effective solution to balancing a grinding wheel on the machine. The semi-automatic system comprises two-channel SB-4475M controller with standard vibration sensor and a proximity or photoelectric speed sensor. The controller tells the operator the exact angular position for the two or three weights on the flange of the grinding wheel. Balancing to less than 1 micron is normally achieved in three spins of the grinding wheel. The controller can be left on the machine to constantly monitor imbalance or move from grinder to grinder. Important features include: fast, more accurate than manual balancing methods, intuitive controls with clear text display in five languages, upgradeable to fully automatic balance system, expansion slot for AEMS-acoustic monitoring card if needed, proven high performance controller and sensor, automatic detection of spindle rotation direction, vibration sweep analysis function for basic machine vibration diagnosis, results can be exported to industry standard analysis or SPC programs, and can be supplied in an industrial carry case with magnetic base and photo speed sensor. SBS Precision Systems (India) Pvt Ltd Kolkata - West Bengal Tel: 033-3292 0078, Fax: 033-2400 3097 Email: rajesh@sbsindia.in

146 MODERN MACHINE TOOLS - April 2011


Pg No. 147 MMT Apr-2011 Ad Name:Tungaloy MMT Apr-2011 Ad Name:Tungaloy

Pg No. 147


MMT Apr-2011 Ad Name:Coatec Pg No. 148 MMT Apr-2011 Ad Name:Coatec

Pg No. 148


Product Update Precision tool holding collet Lexis Tooling Systems offers complete range of CNC tool holding collets such as ER collets, ER tap collets, internal/ external coolant delivery collets, internally cooled tap collets, ER clamping nuts and cylindrical chucks. Lexis also offers wide range of international standard collets such as RTX collets, Ortlieb collets, double angle collets, TG collets, and DF collets (interchangeable with universal acura-flex style collets) conforming to DIN standards. The company manufactures internal and external coolant delivery collets that are specially designed for coolant through machining applications. The coolant delivery collets enhance the performance of tool and machining process especially in automotive and aviation manufacturing. They can withstand the pressure up to 1,000 psi. Advantages of these collets include: high-performance, high accuracy & versatility, multiple applications, wide clamping range, long life, and tool extension capabilities. Lexis Tooling Systems Pvt Ltd Coimbatore - Tamil Nadu Tel: 0422-261 0571 Email: sales@lexisindia.com

150 MODERN MACHINE TOOLS - April 2011


Product Update Radial drilling machine Arsun Engineers offers AR series of radial drill machines, which are designed to offer rigidity, precision and easiness in operation. The model AR40 has drilling capacity of 40 mm in steel and 50 mm in cast iron. Its drilling motor comes with a power of 1.5 kw (2 HP) and arm lifting motor of 0.75 kw (1 HP). The machines are doublecolumn type having generously provided ribs and appropriate wall thickness for base-plate, arm, inner column and column sleeve. Its drill-head comprises an oil-filled sturdy gearbox and a powerful feed box, which offers 8-speeds and 5-auto feeds. Auto feed is fitted with a ball clutch, which disengages at preset drilling depth as well as against high drilling pressure, thus preventing breakages or damages of internal moving parts. Main specifications include: speed range 45 - 1,150 rpm, auto-feed range 0.05 - 0.25 mm/rev of spindle, 250 mm ram travel (drilling depth) and drilling radius is 500/1,175 mm. Its double-column design and wide clamping area of base-plate with ample rigidity of the machine makes it suitable for drilling, tapping and reaming operations. Applications are in engineering workshops, fabrication shops, dies, moulds & machinery manufacturing, automobile & shipbuilding industries, railways, defence etc. Arsun Engineers Bhavnagar - Gujarat Tel: 0278-251 4076, Fax: 0278-242 0132 Email: sales@arsun.com

152 MODERN MACHINE TOOLS - April 2011


Product Update Linear dust collector Prem Brothers offers Power Master linear dust collectors. These dust collectors in compact size 600 x 600 mm x desired length are specially designed for under work table/ conveyor applications. These are space saving and are used for collection of dry ferrous dust generated from grinding process such as surface grinders, profile grinders, off hand grinders & belt grinders etc. Grinding/cleaning/ polishing done in fine application, is convenient and direct application can proceed under the conveyor. Standard features include: low noise level, high filtering efficiency with cotton filtering sleeves (non-inflammable) and lower power consumption. Standard accessories can be: two suction inlet with connecting flexible pipe – 100 mm ID. It has a 2-hp 3-phase 2,800-rpm motor and is fitted with a manual shaker CFM – 1,070. Dust collectors are available in a range of 0.5 to 3 hp for various applications. Prem Brothers New Delhi Tel: 011-2811 7456, Fax: 011-2811 7464 Email: powrmstr@vsnl.com

154 MODERN MACHINE TOOLS - April 2011


Product Update Tool clamp Walsons & Company offers powRgrip速 tool-clamping system from REGO-FIX AG. This innovative system is available for tools with diameters up to 25.4 mm. High-tech powRgrip速 tool-holders are used in ultra-modern CNC machining centres in high productivity processing such as HPC or HSC. Due to its good vibration-dampening properties in combination with a very high clamping force, the PG10, PG15, PG25 and now also the PG32 powRgrip速 collet holders can be used to achieve maximum output from the newest processing strategies and machining tools. With powRgrip速 PG32, the user can now clamp tools with an even larger diameter than in the past. The PG32 collets cover a diameter range from 6 to 25.4 mm. This gives the machining centre operator a modern, flexible high-tech clamping system with tried-and-tested REGOFIX quality. This new development has led to an enormous expansion in the application range. The new system can be of particular interest for the aerospace and automotive industry, for mould making as well as for mechanical workshops with high quality requirements and high machining volumes with large machine tools. Walsons & Company Pune - Maharashtra Tel: 020-2433 1400/1900, Fax: 020-2433 1601 Email: info@walsonsindia.com

156 MODERN MACHINE TOOLS - April 2011


Product Update Arc welding transformer Canary Electricals offers Vulcan heavy-duty arc welding transformers. These are very effective for fast production, structural work, machine building & fabrication, filling jobs, worn-out machine parts repair and in arc cutting jobs. These shunt type machines are the swiftest to offer stepless variations in welding current to match all operations while the stud type machines outperform all in ruggedness heavy-duty applications. They yield quite higher performance to cost ratio compared to any other machines in the market (claims the company). The arc welding transformers are built with the latest trends in design & manufacturing, and are tested to the most stringent standards to offer years of trouble-free service. Design features include: modern looks & novel design concepts; epoxy powder-coated body for long life; and coil varnishing by vacuum pressurised impregnating varnishing system. Canary Electricals Ltd Morbi - Gujarat Tel: 02822-250 431, Fax: 02822-250 433 Email: info@vulcanwelding.com

The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any case, it does not represent the views of

158 MODERN MACHINE TOOLS - April 2011


International Products Large crankshaft gauge Adcole Corporation offers large crankshaft gauge. The model 1200-10 crankshaft gauge features a proprietary ball bearing spindle with <0.25 um for measuring crankshafts up to 4.572 m long, with a 559 mm swing diameter, that weigh up to two metric tonne. Utilising a laser interferometer, in combination with a contact follower having a 330 mm stroke, this high-precision gauge can measure 3, 600 data points on pin journals for roundness and straightness with 0.5 um accuracy. It is well-equipped with 483 mm touch-screen display and a Windows-based OS for ease of use and output flexibility. It is built on a base of structural steel main cabinets with a large 457.2 mm thick surface plate; this robust machine weighs 20 metric tonne. Its application are in industries like marine, diesel, oil field, power generation, locomotive engines and mining.

servo proportional valve equipped with on-board electronics ensures best hydraulic regulation and safety features. Integral digital driver and axis controller are designed for electro hydraulics motion control to improve performances. Digital servo actuators come with a new automation architecturebased on distributed intelligence and Fieldbus interfacing for direct integration into existing communication networks, ie, CANopen or Profibus-DP. These are independent units with two basic operational modes. The slave control performs in real-time the motion closed loop control, according to external analog or Fieldbus position reference signals. Motion cycle control carries out a pre-programmed position/time motion cycle with closed loop control. The machineâ&#x20AC;&#x2122;s electronic unit provides digital commands (start/stop/switchover) to synchronise the servo actuator to the overall machine working cycle. Atos SpA Sesto Calende - Italy Tel: +39-0331-918306 Email: info@atos.com

Adcole Corporation

Vertical turning lathe

Marlborough - USA Tel: +1-508-485 9100, Fax: +1-508-481 6142 Email: breece@adcole.com

You Ji Machine Industrial offers vertical turning lathe, YV-500ATC+G. The vertical turning lathe is specially designed to combine turning and grinding operations into one machine. The second spindle speed is upto 8,000 rpm, which provides better grinding accuracy and good performance. The convenience of workpiece loading on vertical tuning lathe elevates more machining accuracy and machining efficiency. Comparing the grinding speed of utilising vertical turning lathe for irregular workpiece is about 4-5 times quicker than the machine centre. To avoid workpiece dust into guideways and internal pollution, all guideways are designed with positive pressure. Spindle air blow curtain can prevent workpiece dust from entering spindle unit and extend the spindle life time. High rigidity machine feature design enhances customer high-machining accuracy and operation convenience to fulfill special materials machining demand such as quarts, ceramics and graphite.

Centreless grinding machine Palmary Machinery offers centreless grinding machine. The model FCL-18 is available from 12-24 inch and has CE, ISO 9001 certification. It consists of NC single axis feeding system, while the dressing and compensation system ranges from 1 to 8 axle. The loading & unloading system helps in increasing the production efficiency. Palmary Machinery Co Ltd Taichung County - Taiwan Tel: +886-4-2492 9799, Fax: +886-4-2492 9499 Email: palmary@grinding.com.tw

Digital servo actuator Atos offers new digital servo actuators, which provide electrohydraulic solution for easier subsystems configuration. These are smart actuators integrating many functions in a single, compact and programmable motion control unit. These include low-friction servo cylinder, with integral position and force transducers allow accurate movements with no stickslip phenomena coupled with high translation speeds. High-performance

160 MODERN MACHINE TOOLS - April 2011

You Ji Machine Industrial Company Ltd Kaohsiung City - Taiwan Tel: +886-7-6983068, Fax: +886-7-6983071 Email: youji@ms15.hinet.net

The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any case, it does not represent the views of


Product Index Sl. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

Product

Pg No

Ac drive ............................................................. 97 Adaptor.............................................................................143 Aerosol - multispray....................................................... 69 Air treatment ..................................................................151 Air-conditioner................................................................. 20 Airline fluid ........................................................................ 69 All-geared autofeed pillar drilling machine........115 Alloy steel flat bar....................................................81, 92 Aluminium endmill..................................................10, 11 Aluminium processing machine .............................145 Aluminum extrusion ....................................................140 Angle encoder.................................................................BIC Angle head ........................................................................ 90 Angle shearing machine ............................................161 Angular bevel gear.......................................................144 Antivibration tool............................................................ 98 APFC panel ........................................................................ 20 Arc welding transformer ............................................158 Assembly & high temperature grease .................... 69 Auto cap pad printing machine..............................120 Auto feed radial drilling machine...........................115 Auto feeder hydraulic press........................................ 32 Auto-diffmachine simulation multi-axis................. 67 Automation .....................................................................148 Automotion controller................................................171 Automotive oil ...............................................................125 Bags bailing press ............................................ 32 Bailing press...................................................................... 32 Ball screw .........................................................................139 Bed plate ..........................................................................146 Bellow coupling.............................................................139 Belt grinder........................................................................ 93 Bench grinding machine.............................................. 93 Billet shearing machine................................................ 12 Blade ..................................................................................121 Blanking lines .................................................................145 Bore gauge ........................................................................ 82 Boring & milling head unit........................................158 Boring bar .......................................................................... 67 Boring machine .............................................................146 Brake motor ....................................................................157 Brine chiller......................................................................150 BTA / ejector counter boring ...................................140 BTA / ejector drilling....................................................140 Building automation....................................................148 Burrs ..............................................................................10, 11 C frame power press ........................................ 12 Cable ..................................................................................157 Cable carrier....................................................................139 CAD/CAM/CAE solution................................................ 71 Carbide..............................................................................143 Carbide burr...............................................................10, 11 Carbide end mill.............................................................. 65 Carbide end mill tool.....................................................BC Carbide indexable grooving solution ..................BGF Carbide rod........................................................................ 45 Carbide routhing endmill .....................................10, 11 Carbide tool .................................... 10, 11, 90, 139, 143 Casting ...............................................................................FIC CE marked milling machine.......................................FIC

162 MODERN MACHINE TOOLS - April 2011

Sl. No 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121

Product

Pg No

CED coating machine..................................................148 Centerless grinder machine......................................160 Centre drill.......................................................................143 Chain oil.............................................................................. 69 Chemlok coating machine ........................................148 Chuck.................................................................................143 Circular sawing machine............................................136 Clamp ................................................................................154 Clamping collet..............................................................150 Clamping tool...................................................................BC Close frame hydraulic press........................................ 32 CMM..................................................................................... 92 CNC...................................................7, 14, 15, 21, 59, 137 CNC controller.................................................................. 21 CNC cutting machine ..................................................148 CNC desktop engraving machine............................. 80 CNC equipment............................................................... 19 CNC guillotine shear...................................................... 24 CNC horizontal machining centre................. FIC, 123 CNC hydraulic press brake .......................................... 24 CNC hydraulic turret punch press............................ 22 CNC laser cutting machine................................ 24, 148 CNC lathe ..............................................82, 117, 123, 138 CNC machine...................... 8, 9, 15, 59, 123, 156, 169 CNC machine centre..............................15, 59, 67, 123 CNC machine simulation ............................................. 67 CNC machine solution ........................................ 46, 118 CNC machine tool...............................................107, 154 CNC micro-mill engraving machine ........................ 79 CNC milling machine....................................................FIC CNC oxy fuel cutting machine.......................148, 161 CNC plasma cutting machine .................22, 148, 161 CNC plate punching machine..................................161 CNC precision lathe.............................................. 73, 123 CNC press brake .................................................... 22, 161 CNC punch press............................................................. 24 CNC synchro press brake............................................. 22 CNC tooling................................................. 139, 143, 161 CNC turning centre ................................14, 15, 59, 123 CNC turret punch press..............................................152 CNC vertical machining centre..........15, 59, 123,FIC CNC waterjet cutting machine ................................161 CNC wire ...........................................................................BC CNC/VMC machine...................................................33-36 Coating machine...........................................................148 Coating plant..................................................................148 Coating system ..............................................................148 Coin press .......................................................................... 32 Collet..................................................................................143 Collet chuck............................................................. 73, 143 Combination boring ...................................................... 98 Combined drills & countersinks .........................10, 11 Command panel system .......................................40, 41 Complete tooling solution .......................................BGF Composite application.................................................. 67 Compressor oil................................................................. 69 Connector .......................................................................... 83 Console system.........................................................40, 41 Contactors & bi-relays................................................... 21 Control cabinet................................................................ 83

Sl. No 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 170 171 172 173 174 175 176 177 178 179 180 181

Product

Pg No

Control panel.................................................................... 83 Control system................................................................. 83 Controlling machine tool............................................BIC Conventional precision lathe ...................................138 Cooling tower.................................................................151 Coromill ........................................................................... FGF Corothread ..................................................................... FGF Counters & power supplies......................................... 55 Countersink .........................10, 11, 31, 50, 51, Booklet Crane duty motor .........................................................157 Crimping machine.......................................................... 63 Cross shaft power press .............................................158 Crush blade .....................................................................147 Customised solution...................................................... 98 Cutter.................................................................................121 Cutter grinder................................................................... 56 Cutter/grinder verification & machine simulation..... 67 Cutting machine............................................................148 Cutting speed optimisation........................................ 67 Cutting tool ........................................................................... ...................27, 29, 45, 57, 65, 75-78, 84, 85, 139, 147 Cylindrical grinder ........................................................117 Deburring solution......................................... 113 Decimal endmill........................................................10, 11 Deep-drawing hydraulic press................................... 32 Deep-hole drilling machine ................................39,140 Deep-hole drilling solution ......................................BGF Demagnetiser................................................................... 16 Diamond cutting & processing system ................141 Diamond superfinishing tool ..................................BGF Diamond tool ...................................31, 50, 51, Booklet Didactic equipment ....................................................... 83 Die coater.........................................................................147 Die spring........................................................................... 79 Die/mould machine ................................................... COC Digital servo actuator..................................................160 Dip spin coating machine .........................................148 Distribution transformer .............................................. 20 Double column milling machine .......................... COC Double-column vertical machining centre........... 79 Drill ..................................................... 10, 11, 65, 115, 158 Drill chuck arbor............................................................143 Drill mill.............................................................................143 Drill tap centre .........................................................FIC, 84 Drill tool.............................. 31, 50, 51, 57, BC, Booklet Drilling & milling tool .................................................... 98 Drilling head unit..........................................................158 Drilling machine ..................................................115, 146 Drive technology............................................................BIC Drives.................................................................................171 Ductile iron casting......................................................140 Dust collector ................................................................... 93 Electric motor lamination system................. 145 Electro magnet separator ............................................ 16 Electro magnetic lifter................................................... 16 Electro permanent magnetic chuck ........................ 16 Enclosure cooling unit ...........................................40, 41 Enclosure system .....................................................40, 41 Encoder............................................................................... 55 End mill......................................................... 143, 153, 156


Product Index Sl. No 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241

Product

Pg No

Engineering component ............................................156 Engraving system..........................................................141 Exhibition - Engineering Expo .......................127, 128 Exhibition-Blech India 2011 ..........................87, 88, 89 Export interfaces ............................................................. 67 Exposed linear encoder...............................................BIC Factory automation ....................................... 148 Fan & filter unit.........................................................40, 41 Feed finger ......................................................................150 Ferrous casting/ non-ferrous casting ....................140 Files.....................................................................................139 Fine pitch bevel gear...................................................144 Fix frame hydraulic press............................................. 32 Fixture ...............................................................................154 Flange motor ..................................................................157 Floor saving machine.................................................... 90 Fluidised bed coating machine...............................148 Foot mounting motor.................................................157 Forged component ......................................................140 Forging block ................................................................... 86 Forging press.................................................................... 12 Friction drop hammer......................................... 12, 146 Friction screw press ....................................................... 12 Gas spring .............................................60, 61, 86 Gear cutting machine ............................................... COC Gear milling machine ..................................................113 Glide coating machine................................................148 Gold purity (xrf) system..............................................141 Gray iron casting ...........................................................140 Grease........................................................................ 69, 125 Grinder ................................................................................ 56 Grinding machine........................................................... 93 Grip plier...........................................................................154 Grooving & parting tool ............................................... 45 Ground spiral bevel......................................................144 Guide bushes..................................................................150 Guillotine shear................................................................ 24 Gun drilling machine...................................................140 Gun drills ............................................31, 50, 51, Booklet Gun reamers ...................................................................140 H frame power press........................................ 12 Hammer.................................................................... 12, 146 Hand deburring tool...................................................... 82 Hanlding system module............................................. 83 Hard cut end mill ............................................................ 65 Heavy duty CNC ............................................................152 Heavy duty lathe machine .......................................... 56 Helical bevel gear .........................................................144 High performance drill...........................................10, 11 High performance endmill...................................10, 11 High precision tool holder .......................................... 23 High speed drill .............................................................139 High-feed cutter .............................................................. 81 High-precision pinpoint gate bushing ................... 90 High-speed machining centre ............................15, 59 HMC...................................................................................... 14 HMI .....................................................................................171 Holemaking tool............................................................147 Hollow bar ......................................................................... 17 Horizontal boring mill............................................... COC

Sl. No 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301

Product

Pg No

Horizontal handle clamp............................................154 Horizontal height adjustable platform.................158 Horizontal hydraulic press........................................... 32 Horizontal milling machine..................................... COC Horizontal pipe & tube bending machine ..........173 Horizontal section bending machine....................173 Horizontel machining centre ........................................7 Hydraulic & gear oil........................................................ 69 Hydraulic angle noching machine .........................161 Hydraulic machinery....................................................120 Hydraulic press ...................................32, 120, 158, 161 Hydraulic press brake................22, 24, 120, 136, 161 Hydraulic press machine ..........................................173 Hydraulic punch presses............................................120 Hydraulic shear ..............................................................161 Hydraulic shearing machine............................. 22, 173 Hydroforming.................................................................145 Hypoid bevel gear ........................................................144 Imaging & vision system ............................... 148 Indexable tool .................................................................. 65 Inductin motor...............................................................171 Industrial control & sensing device ......................... 55 Industrial cooler.............................................................151 Industrial cooling system...........................................150 Industrial oil ....................................................................125 Industrial robot ..............................................................103 Integrated mill turn centre.......................................... 81 Interchangeable insert holder .................................140 Interface electronics......................................................BIC Invertor/variable frequency drive............................. 55 Iron & steel part.............................................................147 Iron worker .............................................................. 24, 173 ISO & milling inserts....................................................... 65 ISO turning inserts.......................................................... 65 Isolation transformer ..................................................... 20 JIG .................................................................... 154 Jobber length drill ...................................................10, 11 L-angle box ..................................................... 144 Large crankshaft gauge..............................................160 Large enclosure ........................................................40, 41 Large size machining centre .................................. COC Laser cutting machine ............................................ 24,63 Laser cutting system....................................................141 Laser system....................................................................145 Laser welding system..................................................141 Lathe ............................................................................... 7, 56 Lathe machine ...............................................................139 Length gauges ................................................................BIC Lens mould......................................................................147 Level controller................................................................ 55 Linear dust collector ....................................................154 Linear way vertical machining centre...................169 LM guide ways ...............................................................139 LV motors........................................................................... 97 Machine measurement ..................................BIC Machine simulation multi-axis system ................... 67 Machine tools accessories .........................................139 Machined component.................................................140 Magnetic crack detector .............................................. 16 Magnetic modular encoder .......................................BIC

Sl. No 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360

Product

Pg No

Magnets ............................................................................. 16 Manufacturing equipment........................................120 Marine oil .........................................................................125 MCC & PCC enclosure ............................................40, 41 Measured value acqusition and display system .....BIC Measuring & monitoring relay for 1ph/3ph ......... 55 Measuring software ....................................................... 79 Mechanical / hydraulic press brake .......................173 Mechanical press brake ................................................ 22 Mechanical shear ............................................................ 24 Mechanical/hydro mechanical section bending machine..........................................................173 Metal cutting tool........................................................... 13 Metal forming system .................................................120 Metal scrape baling press............................................ 32 Metering equipment ...................................................156 Metric endmill ...........................................................10, 11 Micro tool........................................................................... 92 Micron drill ......................................................................147 Miling tool........................................................................147 Mill/turn machining centre ......................................... 67 Milling centre....................................................... 7,57, BIC Milling cutter .............................31, 45, 50, 51, Booklet Milling grade.................................................................. FGF Milling machine..................................................... 56, 146 Milling tool ........................................................................BC Mobile cylinder hydraulic press ................................ 32 Model export interface ................................................. 67 Modmachine simulation multi-axis ......................... 67 Modular boring machine............................................. 98 Modular tooling system ...............31, 50, 51, Booklet Motion control system.................................................. 55 Motor .................................................................................157 Mould ................................................................................146 Mould component........................................................147 Multi-axis waterjet cutting operation ..................... 67 Multi-channel programming/synchronisation .... 67 Multifunctional tool ....................................................... 45 Multimedia union ....................................................60, 61 NC spotting drill .........................................10, 11 Oil / coolant .................................................... 150 Online B2B marketplace..................................... 91, 162 Optipath ............................................................................. 67 OR-laser welding system.............................................. 14 Over crank shearing machine .......................... 22, 158 Oxy-fuel cutting machine............................................ 22 Paint shop equipment ................................... 148 Paint shop machine .....................................................148 Panel air-conditioner ...................................................150 Parallel kinematics machine ....................................... 67 Part ejector ......................................................................163 PC enclosure ..............................................................40, 41 PCB drill.............................................................................147 Permanent magnet chuck........................................... 16 Permanent magnet tool............................................... 16 Permanent magnetic lifter .......................................... 16 Permanent magnetic separator ................................ 16 Photo electric sensor..................................................... 55 Pillar drilling machine .................................................115 Pillar type hydraulic press ........................................... 32

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164 MODERN MACHINE TOOLS - April 2011


Product Index Sl. No 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419

Product

Pg No

Piller type power press ...............................................158 Piston pump ..................................................................... 53 Planetary gear head.....................................................139 Planning machine.........................................................152 Plano milling machine ................................................152 Plasma cutting machine............................................... 24 Plastic injection mould ................................................. 81 Plate bending machine ........................................22,173 PLC........................................................................................ 97 PLC-operated hydraulic press .................................... 32 Pneumatic automation...............................................149 Pneumatic clutch power press ................................158 Pneumatic friction clutch & brake power press.....158 Polish tool ........................................................................156 Polishing machine .......................................................... 93 Portable coolant purifying system.........................163 Portable grinding wheel balancer..........................146 Portable oil skimmer ..................................................163 Portable roughness tester ........................................... 84 Position display unit .....................................................BIC Power chucking cylinder............................................117 Power distribution component..........................40, 41 Power press....................................................22, 158, 173 Power saver....................................................................... 20 Power sources ................................................................175 Powergrip system .........................................................144 Precision fabrication works.......................................154 Precision gear cutting tool...................................... COC Precision lock nut..........................................................139 Precision machining centre ......................................156 Precision tool holding collet.....................................150 Press brake machine........................... 22, 24, 120, 158 Pre-tereatment system ...............................................148 Printer machine .............................................................120 Process automation and cntrol equipment.......... 83 Product assemblies ......................................................140 Profile bending machine.............................................. 63 Program verification system....................................... 67 Programmable logic controller ................................. 55 Programmable terminal ............................................... 55 Programming of the tool axis using ijk tool axis vectors........................................................................ 67 Proximity sensor.............................................................. 55 Pull action ........................................................................154 Pull stud............................................................................143 Punch press.....................................................................152 Quantumike ...................................................... 80 Quick change collets ...................................................150 Radial............................................................... 146 Radial drill .......................................................................... 56 Radial drilling machine...................................... 115,152 Rapid prototyping service ........................................... 80 Reamer .............................31, 50, 51, 143, 156, Booklet Rear cylinder hydrualic press brake machine....158 RFID ...................................................................................... 55 Rotary machine...................................................................7 Robot .................................................................................103 Robotic plasma cutting machine............................161 Roll forming machine..................................................173 Roll turning lathe machine ......................................... 56

Sl. No 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 476 477 478

Product

Pg No

Rotary damper ..........................................................60, 61 Rotary encoder................................................................BIC Rotary gear pump.........................................................136 Rotary joints & union..............................................60, 61 Rotating union ..........................................................60, 61 Safety light curtain .......................................... 55 SCADA & DCS implimentaion ..................................148 Screw tap .........................................................................156 Sealed linear encoder...................................................BIC Section bending machine .........................................173 Sensitive part loading/unloading machine ........163 Servo motor ....................................................................171 Servo slide with linear guidway and ball screws158 Servo stabiliser (air cooled)......................................... 20 Servo stabiliser (oil cooled)......................................... 20 Shaft loading machine................................................163 Shaping machine ............................................................ 56 Shear series .....................................................................120 Shearing machine.........................................................120 Sheet metal forming machine.................................145 Shock absorber .........................................................60, 61 Shot blasting machine................................................143 Side lock adaptor ..........................................................143 Simatic HMI panel........................................................... 21 Siphon system...........................................................60, 61 Small hole sprue bushing............................................ 82 Small junction/distribution boxes.....................40, 41 SME car loan ...................................................................159 SME finance.....................................................................159 Solar cell scribing system...........................................141 Solenoid valve.................................................................. 53 Solid carbide drill ............................................................ 13 Solid carbide reamer ..................................................... 13 Solid carbide special drill............................................. 13 Solid carbide special mill ............................................. 13 Solid carbide special reamer ...................................... 13 Spade drill...................................................................10, 11 Special induction hardening machine..................175 Special purpose machine ................................. FIC, 152 Special refrigeration equipment.............................150 Special tool......................................................................143 Spindle nose tooling machine................................... 45 SPMS ..................................................................................140 Spring isolator................................................................144 Standard endmill......................................................10, 11 Standard induction hardening machine .............175 Standard pyramid plate bending machine ........173 Steel casting....................................................................140 Steel collets .....................................................................150 Straight bevel gear.......................................................144 Straight flute drill.....................................................10, 11 Straight line action clamp .........................................154 Stripper guide pin........................................................... 92 Stub length drill........................................................10, 11 Submersible hydraulic press....................................... 32 Superior collision checking system.......................... 67 Sustainability software.................................................. 86 Swiss precision tool......................................................144 Switching relay ................................................................ 55

Sl. No 479 480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 495 496 497 498 499 500 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 536 537

Product

Pg No

Tap .................................31, 50, 51, 139, Booklet Tapping head unit........................................................158 Telecom system/ services............................................ 20 Tempurature controller ................................................ 55 Thread milling cutter........................................... 66, 113 Thread rolling system..................................................108 Thread turning machine ............................................113 Thread whirling tool ................................................... FGF Threading insert .............................................................. 81 Threading solution .......................................................113 Threading tool..................................................................BC Timer.................................................................................... 55 Toggle action clamp....................................................154 Toggle press....................................................................154 Tool.....................................................................................143 Tool clamp.......................................................................156 Tool grinder....................................................................... 56 Tool-holder......................................................................144 Tool presetter machine ................................................ 92 Tooling system.................................................................BC Toolroom machine.......................................................169 Touch probes...................................................................BIC Transparent gel................................................................ 69 Tube bending machine ................................................ 63 Tubing accessories ......................................................... 83 Turned component ......................................................140 Turning centre ........................................................ 57, BIC Turning holder ................................................................. 45 Turning insert................................................................... 84 Turning operation........................................................... 67 Turning tool ............................................................147, BC Turnkey projects ............................................................ 20 Turret .................................................................................117 Turret punch press ........................................ 24, 63, 152 Twin spin bearing reducer ........................................139 Twin-spindle chucker ..................................................136 Twist drill..........................................................................143 Ultra high pressur apparatus........................ 147 Under crank shearing..................................................158 UPS ....................................................................................... 20 Valve..........................................................83, 156 Valve terminal .................................................................. 83 Vane pump........................................................................ 53 Variable rake hydraulic shear ...................................158 Velocity & feed controller .....................................60, 61 Vertical handle clamp..................................................154 Vertical lead screw slide.............................................158 Vertical machine............................................................146 Vertical machining centre ...................7, 80, 117, 155 Vertical turning lathe.........................................152, 160 Vision measuring system ............................................. 86 Vision sensor..................................................................... 55 VMC machine .................................................................123 V-tec double column VMC .......................................... 14 Water chiller.................................................... 150 Wear part............................................................................ 45 Wear resistant tool .......................................................147 Wire die spring................................................................. 90 Zerol bevel gear ............................................. 144

COMPLETE ENGINEERING UNDER ONE ROOF @ www.engg-expo.com

170 MODERN MACHINE TOOLS - April 2011


Advertisers’ List Advertiser’s Name & Contact Details ABB Ltd

Pg No 97

Advertiser’s Name & Contact Details

Pg No

Chamunda Equipment

154

Advertiser’s Name & Contact Details

Pg No

Electronica Hitech Engineering Pvt Ltd

T: +91-80-22949560

T: +91-79-27522437

T: +91-20-30435400

E: sanaj.natarajan@in.abb.com

E: clamp@chamundaequip.com

E: hitech@electronicahitech.com

W: www.abb.co.in

W: www.chamundaequip.com

W: www.electronicahitech.com

Ambica Agro Industries

158

Coatec India

148

Emuge India Pvt Ltd

T: +91-281-2363575

T: +91-172-5063436

T: +91-20-39310000

E: shriambikapress@yahoo.in

E: info@coatecindia.com

E: marketing@emugeindia.com

W: www.ambikapress.com

W: www.coatecindia.com

W: www.emugeindia.com

Autotech Machine Tools Sales & Services 8-9

Cobra Carbide

T: +91-20-25690044

T: +91-8110-415003

T: +91-9920401226

E: autocnc@vsnl.com

E: sales@cobracarbide.com

E: engexpo@infomedia18.in

W: www.autotechcnc.com

W: www.cobracarbide.com

W: www.engg-expo.com

Best Engineering Aids & Consultanci

71

T: +91-80-42457336 E: info@beacon-india.com W: www.beacon-india.com Bevel Gears India Pvt Ltd

144

T: +91-80-28410239 E: jamalgrp@vsnl.com W: www.bevelgearsindia.com Bharat Bijlee Ltd

171

T: +91-22-24306237 E: vishwajyoti.vengurlekar@bharatbijlee.com W: www.bharatbijlee.com

Cosmos Impex (India) Pvt Ltd

10-11

46, 118

FIC

Engineering Expo

127-128

Ermaksan Machine Ltd, Sti

24

T: +91-224-2947500

E: sales@cosmos.in

E: sinan.bilgin@ermaksan.com.tr

W: www.cosmos.in

W: www.ermaksan.com.tr 120

Ferrocare International

T: +886-2-2601-8661

T: +91-20-26830655

E: sales@spc.com.tw

E: info@ferrocare.com

W: www.deesgroup.com.tw

W: www. ferrocare.com

Dijet Industrial Co Ltd

65

T: +91-80-22894100

E: ravisane@dijet.co.jp

E: info_in@festo.com

W: www.dijet.co.jp

W: www.festo.com 123

53

Festo Controls Ltd

T: +91-22-40121231

DMG Deckel Maho Gildemeister (India) Bharat Fritz Werner Ltd

66

T: +91-265-3927000

Dees Hydraulic Industrial Co Ltd

83

Forging Machinery Manufacturing Co

T: +91-80-40896500

T: +91-161-5011755

T: +91-80-28395745

E: info@dmgmoriseiki.com

E: info@nkhammers.com

E: bfwmarketing@bfw.co.in

W: www.dmgmoriseiki.com

W: www.nkhhammers.com

63

12

W: www.bfwindia.com Dowel Machinery Pvt Ltd Big Daishowa Seiki Co. Ltd

23

32

G W Precision Tools India Pvt Ltd 13, Booklet

T: +91-281-2362465

T: +91-80-40431252

T: +81-729-828277

E: dowel@thedowel.com

E: info@gwindia.in

W: www.big-daishowa.com

W: www.thedowel.com

W: www.gwindia.in

Camozzi India Pvt Ltd

149

DT Technologies Cz S.R.O.

150

Gallus India

T: +91-120-4055252

T: +91-4122-3628701

T: +91-124-4141434

E: info@camozzi-india.com

E: info@dttechnologies.com

E: info@gallusindia.in

W: www.camozzi-india.com

W: www.dttechnologies.com

W: www.gallusindia.in

Ceratizit India Pvt Ltd

45

East Coast Magnets (P) Ltd

16

Gem Equipments Ltd

T: +91-33-24947146

T: +91-40-23098262

T: +91-22-3267800

E: info@ceratizitindia.co.in

E: info@sardamagnets.com

E: sales@geminida.com

W: www.ceratizit.com

W: www.sardamagnets.com

W: www.gemindia.com

Cgtech India Software Solutions (P)

67

EFD Induction Ltd

175

85

151

Godson Bending Systems Pvt Ltd

T: +91-9845212147

T: +91-80-7820404

T: +91-281-2361467

E: Info.India@cgtech.com

E: sales@efdgroup.net.

E: godsonindia@hotmail.com

W: www.cgtech.com

W: www.efd-induction.com

W: www.godson-india.com

173

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172 MODERN MACHINE TOOLS - April 2011


Advertisers’ List Advertiser’s Name & Contact Details

Pg No

Greenleaf Corp

153

Advertiser’s Name & Contact Details IMT Exim (India) Pvt Ltd

Pg No 14

Advertiser’s Name & Contact Details Maco Corporation (India) Pvt Ltd

T: +814-763-2915

T: +91-44-45540442

T: +91-33-24758371

W: www.greenleafglobalsupport.com

E: innoexim@gmail.com

E: rdutta@macocorporation.com

W: www.imtexindia.com

W: www.macocorporation.com

GSK CNC Equipment Co. Ltd

19

T: +91-9886835186

India Mart Intermesh Ltd

91, 162

Makino India Pvt Ltd

E: gskwang@hotmail.com

T: +1800-200-4444

T: +91-80-28419500

W: www.gsk.com.cn

E: pr@indiamart.com

E: slim@makino.co.in

Guhring India Pvt Ltd

31

T: +91-80-40322500

125

W: www.iocl.com Inter Ads - Brooks Exhibitions Pvt 87, 88, 89 7

T: +91-20-32935433

Hann Kuen Machinery & Hardware Co Ltd158 T: +886-4-2486-0602 E: hann.kuen@msa.hinet.net W: www.hardy.com.tw 157

T: +1800-11-0303 E: marketing@havells.com W: www.havells.com Heattrans Equipments Pvt Ltd

140

ISMT Ltd

Makson Machines Pvt Ltd

W: www.makwanaeng.com 117

T: +91-80-41492285 E: mmtblr@acemicromatic.com 17

W: www.acemicromatic.com

T: +91-20-41434100

Millitronics CNC Machines

E: sachin.joshi@ismt.co.in

T: +91-98-45902876

W: www.ismt.com

E: sales.india@milltronics.net

J P Machine Tools Pvt Ltd

115

T: +91-278-2446437

Micromatic Machine Tools

W: www.blechindia.com

W: www.HaasCNC.com

Havells India Ltd

T: +91-124-4524200 E: blech.india@interads.in

E: sales@haasindia.com

155

E: makwana_eng@yahoo.com

W: www.guhring.in Haas Automation India Pvt Ltd

56

169

W: www.milltronics.net

T: +91-161-2531156

Mitsubishi Heavy Industries India Pvt

E: info@jpmachinetools.com

T: +91-11-41021234

W: www.jpmachinetools.com

E: mtdsales@mhiindia.com

Jekson Machinery Pvt Ltd

60-61

W: www.makino.com

W: www.indiamart.com India Oil Corporation Ltd

E: info@guhring.in

Pg No

161

COC

W: www.mhiindia.com

T: +91-79-25840105

T: +91-79-22901850

NN Combined Engineering Agencies Pvt LtdBGF

E: info@heattrans.com

E: intro@jeksonmachinery.com

T: +91-40-27844279

W: www.heattrans.com

W: www.jeksonmachinery.com

E: mail@nncea.com

Heidenhain Optics & Electronics (I)

W: www.nncea.com BIC

Jyoti CNC Automation Pvt Ltd

T: +91-44-30234000

T: +91-2827-287081

E: info@heidenhain.in

E: info@jyoti.co.in

W: www.heidenhain.in

W: www.jyoti.co.in

Hong Ji Precision Machinery Ltd

39

Kuka Robotics (India) Pvt Ltd

T: +886-4-2422-1095

T: +91-124-4635774

E: hongji_jasonlin@hotmail.com

E: pradeep@kuka.in

W: www.hong-ji.com.tw

W: www.kuka.in

Huen Chen Machinery Co Ltd

146

Lin Tong Sheng Cutting Trading Co.,

15, 59 Omron Automation Pvt Ltd E: srirams@ap.omron.com W: www.omron-ap.com 103

Pramet Tools India Pvt Ltd E: pramet.info.in@pramet.com W: www.pramet.com

156

Precihole Machine Tools Pvt Ltd

T: +886-7-372-3988

E: huenda@huenchen.com.tw

T: +91-22-25836780

E: aaa@ts-cutting.com

W: www.huenda.com.tw

E: info@precihole.co.in

W: www.ts-cutting.com

W: www.precihole.co.in

107, 154

LMT India Pvt Ltd

57

T: +91-124-4703825

T: +886-4-2561-6338

Hyundai Wia India Pvt Ltd

55

T: +91-80-40726400

108

Prem Brothers

93

T: +91-9940653703

T: +91-44-24405137

E: mvhari@gmail.com

T: +91-11-28117456

E: sales@lmt-tools.co.in

W: www.hyundai-wia.com

E: powrmstr@vsnl.com

W: www.lmt-tools.co.in

W: www.powermaster-india.com

FINALIZE SUPPLIERS @ 174 MODERN MACHINE TOOLS - April 2011

140

www.engg-expo.com


Advertisers’ List Raj Petro Specialities Pvt Ltd

Pg No 69

Advertiser’s Name & Contact Details Servomax India Ltd

Pg No 20

Advertiser’s Name & Contact Details V. R. Valves Pvt Ltd

T: +91-44-42288900

T: +91-40-44436666

T: +91-9825028180

E: francis@rajgrp.com

E: dharmesh@servomax.net

E: vrvalves9801@yahoo.com

W: www.servomax.net

W: www.vrvalves.com

W: www.rajgrp.com Rajindra Machines (P) Ltd

146

T: +91-161-2223666

Siemens

21

40-41 Sigma Engineers

E: info@rittal-india.com

T: +91-240-6600606

W: www.rittal-india.com

E: info@sigmatoolings.com 143

T: +91-2827-287631 W: www.bloodtools.com Roto Linear Systems

139

98

Walson & Company

S&T Engineers

137

E: info@walsonindia.com

T: +1800-11-22-11

W: www.rego-fix.com

E: contactcentre@sbi.co.in

Walter Tools India Pvt Ltd

W: www.sbi.co.in

T: +91-20-27104800

Taegutec India Ltd

BC

T: +91-80-27839111

W: www.walter-tools.com Weldor Engineering Pvt Ltd

E: sales@stengineers.com

W: www.taegutec-india.com

T: +91-281-2360242

W: www.stengineers.com

TAGMA

Sahajanand Laser Technology Ltd

22

E: weldor@weldor.com 141

18

E: diemould@tagmaindia.org

E: marketing@sahajanadlaser.com

W: www.tagmaindia.org

Weldor Engineering Pvt Ltd

Takamatsu Machinery Co Ltd T: +91-20-27104725 E: coromantindia.communications@sandvik .com W: www.sandvik.coromant.com/in

E: mahesh.weldor@rediffmail.com 73

W: www.weldorpunchpress.com

T: +81-76-2741403

Werner Finley Pvt Ltd

E: h.nakagawa@takamaz.co.jp

T: +91-80-23289889

W: www.takamaz.co.jp

E: info@wernerfinley.com

Tungaloy Singapore (Pte) Ltd

152

T: +91-2827-252038

W: www.sahajanandlaser.com FGF

W: www.weldor.com

T: +91-22 28526876

T: +91-79-23287461

Sandvik Coromant India

27

E: service.in@walter-tools.com

E: sales@taegutec-india.com

T: +91-422-2590810

144

T: +91-20-24331400 159

T: +91-80-23572855 E: rotolinearindia@vsnl.net

E: prasad@vargusindia.com W: www.vargus.com

W: www.sigmatoolings.com State Bank of India

E: info@bloodtools.com

113

T: +91-9899073393

T: +91-80-23519792

Robin Precision Products Pvt Ltd

139

Vargus Ltd

W: www.siemens.com/simumerik Rittal India Pvt Ltd

Vardhaman Enterprise E: vardhamanenterprie@rediffmail.com

E: machinetool.india@siemens.com

W: www.nkhhammer.com

156

T: +91-9322490805

T: +91-22-24987529

E: info@forginghammer.com

Pg No

147

150

W: www.wernerfinley.com

T: +91-22-61248888

Yamazaki Mazak India Pvt Ltd

T: +91-1871-223893

E: info@tungaloyindia.com

T: +91-20-27351417

E: sarabsukhbatala@yahoo.co.in

W: www.tungaloy.co.jp.in

E: sudhir_patankar@mazakindia.com

Sarabsukh Machine Tools

152

W: www.mazak.com

W: www.sarabsukhmachines.com Schuler India Pvt Ltd

Tussor Machine Tools Ind Pvt Ltd 145

T: +91-22-66800300

138 YG Cutting Tools Corporation Pvt Ltd 50-51

T: +91-422-3200183

T: +91-80-43543636

E: info@tussorindia.com

E: info@schulerindia.com

E: admin@yg1india.com

W: www.pinachoindia.com

W: www.schulergroup.com Seco Tools India Pvt Ltd

33-36

29, 75-78

U-Tech Associates

W: www.yg1.co.kr 163

Zen Wu Zheng Sun Tool Co Ltd

T: +91-2137-667300

T: +91-80-23390309

T: +886-7-352-5743

E: seco.india@secotools.com

E: udaya@u-techindia.com

E: first@jsk-tools.com.tw

W: www.secotools.com/in

W: www.u-techindia.com

W: www.jsk-tools.com.tw

121

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176 MODERN MACHINE TOOLS - April 2011

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Modern Machine Tools - April 2011  
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