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Editorial

Importing Inspirations…Only he growing dependence on imports, especially in the metal working value chain, is a cause of worry from an overall economic health point of view. The acknowledgement, acceptance and the uneasiness felt by Indian players over this import dependence, on the other hand, indicates that we are at least cognisant of this reality. The overall economic damage apart, the fact that while we are shipping in more than shipping out, we are in fact damaging and minimising the prospects of indigenous products and services by opting to shop for the same in the global marketplace.

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This trend on import dependence and trait is not without reasons though. With India’s domestic market flourishing, the demand for machine tools is multiplying and the local machine tools companies are finding themselves underequipped to deal with the surging industry demand. This means that 70 per cent of the demand is met by imports from countries such as Germany & China and the industry acknowledges that, unless swift measures are taken, this trend could further strengthen.

Editorial Advisory Board Vikram Sirur President, IMTMA & Executive Chairman, Miven Machine Tools Ltd

L Krishnan Vice President, IMTMA & Managing Director, TaeguTec India P Ltd

Shailesh Sheth Media Chairman, IMTMA & Past President, IMTMA

M Lokeswara Rao Past President, IMTMA & MD, Lokesh Machines Ltd

N K Dhand Past President, IMTMA & CMD, Micromatic Grinding Technologies Ltd

R Srinivasan

Substantiating this fact, the 2012 World Machine-Tool Output & Consumption Survey by Gardner Publication, our partners, has rated India as the fourth highest importer in the world, while the country trails down to the bottom of the list at the 27th spot to become one of the lowest exporters. When we asked experts about this disparity in EXIM, they were of the opinion that the imports are in terms of high-end, high-accuracy and high-performance reliable machines. The local manufacturers are, however, producing high-volume low-cost machines. This is the reason why the Indian contribution to machine tools manufacturing is just 23 per cent, while 77 per cent is imported. The volume of imported machines is low, but the cost of high-end & high-accuracy machines is very high. There are three important things, which need to be changed. We primarily have to increase the technology and reliability of the machines so that we can make them fit for exporting. Secondly, the sub suppliers of critical parts, like ball screws, etc., are not available in India and we instead import the technology or the machine or import the components at high cost, which subsequently increases the cost of the final product. Thirdly, innovation is key. We cannot simply duplicate imported products. We instead have to come up with innovatively designed products, which are low cost and provide the same level of quality parameters. Then again, as per the same survey, India stands as the 7th largest consumer of machine tools, but finds itself down the list at the 16th spot for its production capacity, thereby making the demand-supply gap apparent and indicating an urgent need to scale up domestic production. If machine tools are the basic building blocks of manufacturing-based societies, then the rate at which a country installs new ones ought to say something about its pace of industrialisation. How the country controls its import dependence and lets the indigenous offerings rule the market will shape the future and fortunes. So, let’s import inspirations…only.

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

Archana Tiwari-Nayudu archana.nayudu@infomedia18.in

March 2012 - MODERN MACHINE TOOLS

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Contents Insights & Outlook Global Machine Tool Survey 2011 .................................... 102 One Q Many Views: Import Vs Export ............................ 106 One Q Many Views: Production Vs Consumption ........... 108 Business Dynamics ............................................................ 114 Advance Metrology Systems ............................................. 116

Insights & Outlook Global Machine Tool Survey 2011 & Metrology Equipment

Special Focus Die & Mould

101

49

Digital Optical Comparator .............................................. 118 Nanometrology .................................................................. 126

Facility Visit Precihole Machine Tools Pvt Ltd ..................................... 94

Special Focus

Automation Trends - Die & Mould Manufacturing

Die & Mould India 2012 ................................................... 50 Reducing Import Dependence ........................................... 52

Strategy - Strengthening Business

New Avenues ..................................................................... 62 Seamless Integration .......................................................... 64 Technology Trends ............................................................ 74 Micro Moulding ................................................................. 76 Additive Manufacturing ..................................................... 78 Tool Selection ..................................................................... 90

In Conversation With

Engineering Optimal Design Simulations ......................... 128

How a Global Builder Handles Changes Around the World? ........................................................................... 130

Tips & Tricks - Metrology Operations Optimising CMM Usage & Maintenance .......................... 132 Event Report - Aurangabad Creating Yet Another Success Story .................................... 136

Regular Sections Editorial ...................................................................... 15 News, Views & Analysis .............................................. 28

Volker Nesenhöner CEO, OPEN MIND Technologies AG ...

Technology & Innovation............................................ 38

42

Event List .................................................................. 134 Products .................................................................... 138 List of Products ........................................................ 163 List of Advertisers .....................................................167

Looking for a specific product? We will find the product for you. Just type MMT (space) Name of the Product and send it to 51818 eg, MMT (space) Lathe and send it to 51818.

NEXT EDITION HIGHLIGHTS Special Focus: Metal Forming Insights & Outlook: Grinding & Finishing

Cover illustration: Sanjay Dalvi

April 2012 - MODERN MACHINE TOOLS

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Printed by Mohan Gajria and published by Lakshmi Narasimhan on behalf of Infomedia 18 Ltd. Executive Editor: Archana Tiwari-Nayudu Printed at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Infomedia 18 Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai - 400 028. MODERN MACHINE TOOLS is registered with the Registrar of Newspapers of India under No. MAHENG / 2008 / 24347. Infomedia 18 Ltd does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition.

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MMT Apr-2012

Ad Name: BigDaishow Pg No. 23


MMT Apr-2012

Ad Name: Precihole Pg No. 24


MMT Apr-2012

Ad Name:Mitutoyo Pg No. 25


MMT Apr-2012

Ad Name: Fullton Pg No. 26


News, Views & Analysis

Karnataka Foundry Cluster Project To Be Revived

Bengaluru Hosts IFEX-2012 After 33 Years

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Danfoss-IIT Madras Collaboration To Enhance New Technologies in Climate & Energy

 Members of Indian Foundry Association meet exhibitors to

n an effort to promote the foundry industry in Karnataka, the State Government has decided to set up a ‘Foundry Cluster’ at Dobbspet, 50 kilometres from Bengaluru, over the next six months. The state has one of the largest deposits of iron ore in the country. Revealing the State Government’s plan, Murugesh Nirani, Minister for Industries, Government of Karnataka, said, “Earlier, we had proposed a Foundry Cluster near Dobbspet, but it did not pick up due to issues raised by the Karnataka State Pollution Control Board. We will address all those problems to revive the project at Dobbspet at the earliest by taking into consideration the growth prospects of the foundry industry.” The foundry cluster is one of the 14 such industry-specific clusters being developed in Karnataka. “We are in the process of acquiring land for these clusters. We will ensure that the Foundry Cluster becomes a reality in the next six months,” the minister added. Nirani also expressed the government’s commitment towards the growth of Micro, Small and Medium Enterprises (MSME) and to resolve the various problems that this industry faces. At the proposed Foundry Cluster, the IIF plans to set up a Centre for Innovation, including R&D facilities, with training and technology demonstrations for foundries. The government has agreed to allot 2 acre of land to IIF under a special plan. This will be the second industrial estate for foundries in Karnataka, apart from Belgaum. According to Sundara Murthy, President, IIF, the foundry industry in the country is growing at the rate of 22 per cent. Automobiles, aerospace and public infrastructure demand serve as strong growth indicators for the foundry industry. “India’s share in the global market is approximately 10 per cent of 91.67 million metric tonne. India is the second largest producer of foundry-based castings, while China is the market leader with 43 per cent of the total output,” Murthy added.

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anfoss has signed a Memorandum of Understanding (MoU) with IIT Madras, India, an education institute with research expertise in power electronics and power quality solutions. The collaboration will enhance new technologies in climate & energy. The research collaboration with IIT Madras will provide several unique long-term benefits for Danfoss, such as focussed problem-solving consulting for product improvement, patents enhancing Danfoss’ intellectual capital, quick and cost-effective access to advances in technology relevant to the power electronics business and exploring the possibility of Danfoss engineers joining Masters and PhD programs, etc. Jørgen M Clausen, Chairman, Danfoss A/S, who signed the MoU with IIT Madras, said, “A key enabler to realising our vision is building and leveraging external research collaborations with universities, like IIT Madras, who are experts in the field.”

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MODERN MACHINE TOOLS - April 2012

t took as long as 33 years for Bengaluru to bring back India’s largest and only foundry exhibition to the city. The 8th International Exhibition on Foundry Technology, Equipment and Supplies was organised concurrently with the 60th Indian Foundry Congress and was jointly organised by The Institute of Indian Foundrymen and Koelnmesse YA, Tradefair Pvt Ltd. The three-day exhibition hosted over 200 exhibitors from all corners of India and over 15 countries including China, Japan, Germany and Italy. The exhibition widened the scope to promote the foundry industry in Karnataka.

discuss the prospects that the industry offers.

DISA India Ltd Launches Two New Technologies

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ISA, India and Wheelabrator - the world’s leader in surface preparation technology and manufacturing - recently launched two high-tech indigenous machines, the DISA MATCH 20/24 horizontal flask-less moulding machine and the MB 500 metal belt tumb blast machine.


News, Views & Analysis

Training Program On CNC operation for SMEs

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o improve the knowledge and understating of CNC machines, IMTMA organised a five-day workshop in Bengaluru to give hands on training to operate these high-end machines. The workshop was an added benefit for participants from small and mid-sized companies who aim to upgrade their shop floors. “Every shop floor today is slowly graduating from conventional methods to CNC machines. We had participants who have never worked on a CNC machines and also those who wanted to know the ways to optimally use the machines,” said M Krishnamoorthy, Director - Training, IMTMA. Shared his experience, Nagendra Rao, a workshop participant and proprietor of New Cast Die Casting Ltd, said, “I took part in the workshop to understand the functionalities of CNC machines. I want to set up CNC machines in my shop floor and this program would help me choose the right machines to suit my manufacturing operations.”

Seminar To Improve Injection Mould Design Practices Organised

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iming to improve injection mould design practices and standards, IMTMA organised a ‘Seminar on Design & Processing of Injection Moulded Components’ in Pune. The seminar focussed on the technical details and basics of mould design providing case studies to discuss specific aspects of mould processing, finishing and production. The nature of the seminar was geared more to benefit aspiring mould design engineers and managers looking to be guided through mould manufacturing fundamentals in industrial component production. This seminar emphasised designing injection moulds for any product, correctly and reliably the first time, thus avoiding any redesign or concept changes. The key speakers at the seminar included N V Samant, Smart Consultants; S Raghavan, EUV Tech and R Kallorath, Digimold.

Empowering Industrial Automation Through PLC Technology

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he continuous demand for efficient manufacturing has made it necessary for high-quality and reliable control systems to be a part of the manufacturing process. Programmable Logic Controller (PLC), also called ‘The Work Horse’, is a key driver in automation, production and process planning in the manufacturing industry. A day-long event hosted by IMTMA Bengaluru discussed the various facets of Industrial Automation. The seminar was conducted by Anil Purohit, Director, Leonardo Automation (India) Pvt Ltd, who discussed the various facets of PLC right from the basic concepts to PLC and Human Machine Interface (HMI) and evaluation of PLC power and optimum selection.

IMTMA Training and Workshop Calendar for April 2012 Date

Topic

Venue

10-11 April 2012

Workshop on Form & Positional Errors and their Measurement

SKF College Campus, SKF India Ltd., Chinchwad, Pune

10-11 April 2012

Training Programme on Geometric Dimensioning and Tolerancing (GD & T) in Design Chennai through Manufacturing

11-12 April 2012

Workshop on Workholding and Fixturing Techniques for Productivity Improvement on CNC Machines

Technology Centre, BIEC, Bangalore

12 April 2012

Seminar on Design and Processing of Injection Moulded Components

Gurgaon

12 April 2012

Seminar on Value Engineering and Value Analysis

Technology Centre, BIEC, Bangalore

13-14 April 2012

Training Programme on Reducing Cycle Time & Machining Cost on CNC Machining Centres

Gurgaon

17-18 April 2012

Training Programme on New Product Development on CNC Machining Centres

SKF College Campus, SKF India Ltd., Chinchwad, Pune

18 April 2012

Workshop on Acceptance and Testing of CNC Machines

Gurgaon

20 April 2012

Seminar on Lasers in metal working

SKF College Campus, SKF India Ltd., Chinchwad, Pune

20-21 April 2012

Workshop on Failure Mode & Effects Analysis (FMEA)

Technology Centre, BIEC, Bangalore

24 April 2012

Seminar on Hydroforming and its applications

SKF College Campus, SKF India Ltd., Chinchwad, Pune

25 April 2012

Workshop on Calibration of CNC Machine Tools

Technology Centre, BIEC, Bangalore

26 - 27 April 2012 Seminar on Die & Mould Manufacturing

Hotel CAG Pride, Coimbatore

27-28 April 2012

Gurgaon

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Workshop on Measurement Systems Analysis

MODERN MACHINE TOOLS - April 2012


News, Views & Analysis

Pratt & Whitney To Enter MRO Segment In India

Creaform Completes

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he Canada-based company has completed a decade in the field of 3D portable optical measurement technologies and 3D engineering services. As a way ahead, Creaform’s quinquennial strategic plan is to increase its growth rate and strengthen its position as a major player in the industry of metrology. The company’s R&D program aims to lead the development and launch of several new technologies creating innovative, accurate, reliable and easy to use devices.

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auging the opportunities in the Maintenance, Repair And Overhaul (MRO) segment that India offers, leading aerospace engine supplier, Pratt & Whitney, plans to invest over $ 150 million in the next three years to set up an MRO and an aircraft engine components facility along with training centres. For the proposed MRO unit, which alone would require an investment close to $ 100 million, the company is considering places like Bengaluru and Hyderabad. The company is already holding talks with various Indian firms to set up a joint venture. Apart from India, the company is also considering a few other Southeast Asian countries for setting up the projects.

BIEMH Attracts Buyers In India

T

he presentation of the next edition of the Biennial Spanish Machine Tool Fair recently took place in Pune. The fair will be held in Bilbao from May 28 to June 2, 2012. Around 18 Spanish manufacturers of machine tools, accessories, component parts and tools will take part in the Basque Prime Minister Patxi Lopez’s trade mission to India. As part of this mission, the Spanish Association of Manufacturers of Machine Tools, Accessories, Component Parts and Tools, AFM and Advanced Manufacturing Technologies visited India between March 19 and 23, 2012, with a delegation of 18 companies. The main objective of the association in this trip was to promote the sector and the BIEMH, the Biennial Machine Tool fair. Over 1,000 firms from 25 countries have confirmed their attendance.

Pepperl+Fuchs Opens Factory Automation HQ At Gurgaon

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he company recently inaugurated the Indian headquarters for its factory automation division. After more than two decades of direct engagement with the Indian market, the company has come a long way in being part and parcel of imbibing the psyche and trends in automation for the manufacturing environment in India. In his inaugral address,  Dr Guenther Kegel, Managing Director and CEO, Pepperl+Fuchs Group of Companies inaugurated the new Dr Guenther Kegel, Managing facility Director and CEO, said that the new FA headquarters is a stateof-the-art facility with a well laid out office, combining testing, conferencing, integrated ERP and meeting facilities. This would help P+F bring higher quantity and quality support to the market, leveraging its staff to deliver the best to its customers. He said he believes that a country the size of India, with its legacy, has its own dynamics and the decade of engagement with India has been a good learning experience. 32

MODERN MACHINE TOOLS - April 2012

Carl Zeiss Sets Up New Tech Centre

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ttempting to get closer to customers, Carl Zeiss opened its third Tech Centre in Chennai. This is a technology and expertise-driven centre catering to the measurement needs of Indian industries. The application specialists in the centre would guide customers on specific solutions for improving part and component quality. The centre offers solutions for dimensional, form, surface finish and contour measurements, reverse engineering, measurement against CAD data, off-line programming, designing and building of fixtures, probes & accessories. The centre will also offer scheduled seminars on metrology, form and position, GD&Ts, surface roughness and measuring uncertainty.


News, Views & Analysis

SIMTOS 2012 To Stage Global Manufacturing Technology intelligent manufacturing he 15th Seoul International technology and existing main Manufacturing industries under the catch Technology Show 2012 phrase, ‘United SIMTOS to be hosted at KINTEX, Korea Manufacturing, United will raise the curtain from one of Manufacturing Technology the world’s biggest manufacturing with Machine Tools’ show. Organised by Korea Amid numerous countries Machine Tool Manufacturers’ participating in SIMTOS Association (KOMMA) between 2012, this year, India will rise April 17 and 22, 2012, the event as one of the main countries promises to be the best place to in the event and will have a get updated with the industry’s huge participation from the latest technologies. Indian machine tools industry To tap the overall manufacturing industry,  A survey conducted during SIMTOS 2010, showed that over both in terms of exhibitors 63.2 per cent of participants believed that the next edition would be double and buyers. KOMMA this year has upgraded the size. SIMTOS- 2012 has met that target Engineering Export the event from being just a Promotion Council (EEPC) India will organise an Indian ‘Machine Tool Show’ and instead becoming a ‘Manufacturing pavilion at SIMTOS 2012 to mark its unprecedented presence Technology Show’. With this, the event will spread out to amid its Asian competitors. Along with this, KOMMA has also be twice its original size and will expand its product exhibits invited the Indian Machine Tool Manufacturers’ Association to new categories such as welding machines, CAD/CAM (IMTMA) to the event showing the growing importance of equipments and machine tools as well. This year’s edition will the country. provide a new paradigm to the convergence of next generation

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Fluke Corporation Acquires TTL Technologies Pvt Ltd

Vikram Solar Ltd Commissions 2 New PV Power Plants In India

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A

luke Corporation, the global leader in portable electronic test and measurement technology, has acquired TTL Technologies Pvt Ltd, for an undisclosed amount. TTL has represented Fluke in India since 2001 as a master distributor. The new business combines TTL’s many years of experience in the Indian test and measurement market, its national distribution network, its renowned customer care, and accredited calibration labs with Fluke technological innovation, manufacturing excellence and world-class business processes. “We are excited to welcome TTL to the Fluke family,” said Peter Van Den Broek, President – Emerging Markets, Fluke Corporation. “TTL has been a great partner and now, together we will substantially increase our overall customer offering. This agreement reinforces our commitment to our customers in India and positions us for rapid growth in an important market.” TTL businesses and employees will be integrated into the Fluke organisation. There are no plans for changes in staffing or facility locations. “Our top priority is our customers and meeting their needs,” added Van Den Broek. “Our goal is for the transition to be as seamless as possible.” “TTL’s acquisition by Fluke is a huge step forward. We will utilise this new strength to widen and deepen our reach to customers across India, creating tremendous excitement and growth,” said Joey Joseph, CEO & Managing Director, TTL Technologies.

Kolkata-based Indian multinational and leading solar module manufacturer, announced the commissioning of two new power plants – one each in Gujarat and Rourkela, Orissa. The Gujarat power plant is a 5-MW facility and the second plant in Orissa is capable of producing 1 MW power. The project in Gujarat is sponsored by Konark Gujarat Pvt Ltd and the plant is located at Bachchau in Gujarat. The second power plant in Orissa is sponsored by Molisati Vinimay Pvt Ltd and located at Ranja village, Deogargh district. Speaking on the occasion Gyanesh Chaudhury, Managing Director, Vikram Solar Ltd, said, “We are pleased to promote new, clean, cost-effective in-state electricity generation with the establishment of two new power plants. We are committed to protecting and encouraging better use of natural resources in our country by implementing better technologies.”

April 2012 - MODERN MACHINE TOOLS

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News, Views & Analysis

In brief... 

AMT (The Association For Manufacturing Technology) and AMTDA (The American Machine Tool Distributors’ Association) have announced a merger that will integrate their products and services to serve the members of both associations better.



Rockwell Automation has purchased the assets of SoftSwitching Technologies, a leading provider of industrial power quality detection and protection systems, located in Middleton, Wis.



Honda Motorcycle and Scooter India (HMSI) will set up a fourth plant in Narasapur, Bengaluru. The company will invest ` 800 crore in this unit to raise their total capacity to nearly 6 million units.



The Institute of Indian Foundrymen (IIF), is keen on setting up a one-of-a-kind foundry innovation centre in Bengaluru. The centre will be equipped with an R&D lab, a small foundry to test inputs and raw material, and a training centre.



Chennai hosted Automotive Testing Expo India 2012. The three day long expo had over 150 exhibitors from across the globe, including ABS Instruments Pvt Ltd, ANSYS Software Pvt Ltd, Bruel + Kjaer – Josts, National Instruments and MOOG among others. The event exhibited wide range of technology like test simulation, NVH analysis, engine / emissions testing, vehicle dynamics testing etc.



Honeywell Technology Solutions, the R&D arm of global technology major, is setting up a new centre in Bengaluru. The company has received approval from the Karnataka government for setting up the facility which entails an investment of ` 402 crore



China’s FAW Foundry aims to enter the automotive casting business in India. “We want to know the nature of automotive casting sector in India and want to partner with a local company in the country,” said Sun Feng, President, FAW Foundry Company

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MODERN MACHINE TOOLS - April 2012

China-India Plan To Maintain Dominance Over Global Foundry Castings

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hina and India together, account for approximately 50 per cent of foundry castings made globally and they plan to maintain this position over their competitors through rapid expansion and enhanced production over the next three years. Their combined production of castings is expected to reach 65 million metric tonne by 2015. At the second Asian Foundry Forum (AFF), hosted during the 60th Indian Foundry Congress (IFC), the representatives of the foundry industries from China, India, Japan, Taiwan and Mongolia, deliberated extensively on enhancing production of castings through sustainable technology. “China intends to increase production of castings to 50 million metric tonne by 2015 from the existing 35 million metric tonne. Similarly, India plans to enhance production of castings from 9 million metric tonne to 15 million metric tonne by 2015. Asia will continue to dominate the world foundry industry,” said B N Krishna Samaraj, Chairman, Organising Committee, and 2nd AFF. The key objectives of the AFF are to consolidate Asian foundries by improving competitiveness and promoting sustainable development through cooperation along with platforms for idea exchange.

Industry, Academia Partner To Raise The Next Generation Of Indian Engineers

I

n an effort to bolster the opportunities available to aspiring engineering students, Vishwakarma Institute of Technology, Pune, collaborated with the State University of New York at Binghamton (Binghamton University) and Anveshak Technology and Knowledge Solutions, and recently hosted the 1st International Conference on ‘Research Trends in Design, Analysis and Manufacturing of Mechanical Systems’ at VIT, Pune. The conference provided a platform for the industry and academia to collaborate on an international level, to discuss research trends & the needs and challenges in the manufacturing sector. The panel of speakers, comprising of Dr Bala Bharadvaj (MD, Boeing Research & Technology, India), Prof K Srihari (Distinguished Professor and Dean, Watson School of Engineering and Applied Science at SUNY Binghamton), Devdutta Chandavarkar (Director at Mercedes-Benz India), Sanjay Sharma (CEO of MESTECH Services) and Prof Nitin Afzulpurkar (Dean, Engineering and Technology, Asia Institute of Technology), discussed the ‘Needs and Challenges for Industry-Academia Collaboration in India’. The development of skilled engineers sorely requires such efforts, which have previously been difficult due to Intellectual Property issues, process hurdles and industry perception of academia as slow and cumbersome. VIT, however, plans to provide 3-6 month internships, in conjunction with the industry, for students in India and abroad during their tenure of 4 years at the institute. Students from mechanical, industrial and production engineering backgrounds were given an excellent overview of state-of-the-art applied manufacturing and had the chance to network with industry professionals. Speaking about the partnership with VIT, Prof Bahgat Sammakia, VP, Research at Binghamton University, said, “It has become increasingly important for students to be equipped with diverse skill sets in order to serve the global economy. Hence, we are pleased to partner with Vishwakarma Institute of Technology in their endeavour to provide the students with enhanced academic experience and an opportunity to work on cutting-edge projects made available by our industry partners in US and Europe”


TECHNOLOGY & INNOVATION Tool and Mould Making

Tool and mould making emerge at the crossroads of burgeoning product diversity and simultaneously plummeting product cycle times. Reducing throughput times is highest on the order of priorities while simultaneously driving down manufacturing expenditures is only possible by redesigning the entire process chain.

Creating Cost-Effective and Time-Saving Environment

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xtensive analyses of production routines form the basis for discovering potential enhancements and laying the basis for creating further production and machine designs. The method applied is broken down into :  Analyzing the process chain in order to indentify all of the interrelationships and dependencies  Derivation of potential for optimization including documentation of effects  Coming up with new ideas for mechanical production including upstream and downstream steps in the process  Rough and detailed planning of technological processes and 38

MODERN MACHINE TOOLS - April 2012



Dimensioning processing machines

Optimisation of Machining Time It is not only necessary to apply the effects of state if the art technology and the potential of cutting materials to downsize production times in metal cutting production. It is also necessary to analyse and enhance the current production process. We can discover time reverses by enhancing technology, engineering and organization. The points of concentration in relation to the analyses are:  Analyzing the technological routines in mechanical production  Evaluating and enhancing specific stages of production in terms of the options of reduced main and



secondary processing times and Reduction in machine loading times

Machine Analysis There is a heated debate going on these days on the potential for boosting productivity and accuracy in tool and mould making. The entire manufacturing process is dominated by the cost and time needed for mechanical machining due to the major proportion for free forming geometries and predominant small scale and job lot production. Beyond this, the accuracy of production defines the effort required for working. Furthermore, finishing is extremely important both because of the great amount of time it requires and as a basis for subsequent breaking in and


Tool and Mould Making adjustment work. Since the machining velocities to be achieved with the performance of the cutting material used are limited, the greatest potential is to be found in enhancing the dynamic properties of the processing machines. And indeed, aligning CAM tolerances, NC control tolerances and dynamic NC control settings can save as much as 20 per cent in time without even changing the machining strategy. Of course, this requires a holistic analysis of machining process and adapting the parameters in the process to the machining job. That means we can make statements on the working precisions of tool machines under various process and environmental conditions based upon a comprehensive analysis of the impact of faults along the mechanical machining process chain. They offer users and tool machine manufacturers the point of departures for improvements in producing tools or designing machine elements.

5- Axis Machining The amount of machining effort and time required for manufacturing free form surfaces in tool manufacture is very high so that it is necessary to find alternatives to conventional 3 axis milling machining for fast and economical tool production. Using efficient 5-axis chip removal technologies enables us to substantially scale back machining time. For example, we can measurably reduce the aspect ratio of tools when machining cavities and similar topological shaping, thus guaranteeing reliable process production conditions. On the other hand using 5 axis machining strategies for planning and pre finishing machining makes it possible to substitute ball headed milling tools with more efficient torus milling tools. The major characteristic of surfaces made by 5 axis machining is slight values for scallop-height and roughness because the machining tool is excellently aligned to the work piece surface. This is the reason why reworking effort can be reduced to the minimum while boosting 40

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sintered hard metals, although they require a final finishing in spite of a high level of dimensional accuracy. 100 A new and even highly economical machining option is 80 36,05% milling thermally sprayed hard 36,05% metals where setting up the process 60 and selecting tools in alignment with the technique make it possible 41,28% 40 30,52% to measurably boost economy and flexibility. We were able to 20 5,67% 5,67% document a 60 per cent reduction in 9,45% 9,45% cost for hard metal machining with 7,56% 7,56% % geometrically intricate contours Process time - current Process time - optimised in comparison to conventional Time saved by using high-performance techniques (such as contour tools: approx. 10% grinding or electrical discharge Milling Organisation Tool Changing machining (EDM). Finally, milling Drilling Set-up of hard metal with super hard cutting materials not only generates a virtually damage free edge zone, but the tool’s contact width and substantially also excellent surface qualities. driving down the machine time. There are major demands made of the machine equipment used especially with Rough Drilling 5 axis machining of tool components The production of deep cavities in made of cast iron and steel materials. mould making involves a very high level And the oscillating axes of machining of machining and expenditure in terms centres need a very high level of retention of time. In order to cope with the need moments in position regulated operation for rapid tool production, alternatives especially with roughing down and to conventional milling need to be pre-finishing operations. Adapting the considered here too. machining strategies, to the machine’s Making use of rough drilling specific characteristics enables us to means that the rough machining can achieve major benefits. be optimised to a considerable extent. The process is based on machining operations acting exclusively in the Milling Thermally Sprayed Hard direction of the axis of the spindle, the Metal use of optimised tool as well as a high Using hard metal in tool and mould level of productivity due to an extended making frequently appears to be radial machining distance. uneconomical due to the high level of The advantages of machining material and machining cost. Previous strategy are: options have not offered any form of efficient or economic hard metal  Reduction of machining time by machining with complex contour up to 30 per cent by comparison to geometries. conventional processes. State of the art production techniques  Boosting the rate of metal removal. such as high velocity oxy fuel (HVOF)  Reducing the radial machining enable us to apply the hard metal forces. material onto highly stressed tool zones  Reduction in the rise of component which makes it possible to measurably temperature as a result of targeted improve protection against wear and chip discharge. tear. These layers have hardnesses  Increase in process reliability. in excess of 1,000 HV, giving them Courtesy: Fraunhofer Institute for Machine Tools and approximately the same properties as Time reserves based on the use of modern tools

Forming Technology IWU


IN CONVERSATION WITH Volker Nesenhöner

High technology, visionary strategies & motivated personnel— ingredients for sure success… … is what Volker Nesenhöner, CEO, OPEN MIND Technologies AG, feels as technology advancements have made the world a global network. Talking to Debarati Basu, he delved on the changing dynamics of the European markets and the transition of simulation technology over the years. Q Industry Transitions Over the last decade, the machine tools industry has grown tremendously. The CAD/CAM industry, especially, has shifted gears to make simulating software, which can now produce parts in a more productive and competitive way. The industry too, has diversified into various segments like aerospace, moulds and dies, automotive machinery, etc. The improvements have also aided in reducing 42

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time cycles. With technology, we can now produce parts which were considered impossible to produce 15 years ago.

Q Indigenous Market Overview The Indian market is not very different from the global market. Indigenous companies today are not just producing for the Indian industry, but also for the global market. With this growth, the Indian market needs

to provide solutions—high in quality, at competitive prices and with ontime delivery. While the markets in Europe, the US and Japan are slightly saturated, the Indian market is booming. A decade ago, the situation of the Indian industry was different. The industry has achieved this level because of its adaptability to the global markets and standards. There are some


Volker Nesenhöner discrepancies, but this segment will certainly grow to a level where it will be at par with global standards. India has a few advantages over other markets. Unlike the Japanese or Chinese markets, it is easy to communicate with the Indian industry. However, there are a couple of things that need to be improved. Precious time is lost in commutation owing to poor infrastructure. However, despite the odds faced, I am impressed to see the way some companies function. This is just the tip of the iceberg; India is on the right path to become a great player.

Q India’s Strengths India, China and Russia are the booming markets and each market is different from the other. However, India has already entered a niche sector—the aerospace segment. The aerospace market today is booming and the commercial airtravel sector has witnessed huge growth. Every major aviation giant has forayed into the Indian market. History is proof that it takes time to establish a successful industry segment in any nation. India is a huge country and growth in this segment might take a decade or two, but all it needs is highly motivated skilled personnel, a stabilised economy and the right political environment. We believe in the strength of the Indian market and that is the precise reason why we decided to enter this industry.

Q Euro Crisis There is a wrong notion about European businesses. Everyone is talking about Greece and Portugal. However, compared to the big businesses in Europe, this is quite insignificant. Greece is a very tiny part of the entire European business. The European market is slightly unstable due to high labour costs and saturated markets. On the other hand, India and China have established a huge consumer market and this is the reason why many European companies are moving to Asian countries. The focus is not to simply get parts assembled, but to customise technology to suit the needs of the market.

UP CLOSE & PERSONAL What defines the growth of a company? High technology, with a good strategy and vision coupled with a motivated group of personnel, are the ingredients for sure success. It is very important to have a clear vision and know the direction. As a CEO, I need to look after my employees and provide them with an environment that keeps them motivated, well trained and interested in the work they do, so that they can make value additions. Employees define 50 per cent of the company’s success. Also, it is important to be focussed and clear about what you want to achieve. Since the beginning, we have only focussed on milling processes. We have many competitors who are into several things at the same time. But we prefer to concentrate on one area, explore its dimensions and excel in it.

What it takes to get the right employee on board? I look for the right behaviour and attitude in my employees. We are an international company and so, we have to think globally. It is very important that the character fits in our culture. Skills and experience obviously follow suit. But more than that, it is important that my employee knows the market. Selling a product is just one part of the job. They should also understand the process and speak the language of the customer.

What does it take to know the market? I travel to various places to understand the market culture and the work. Feeling the pulse of the shop floor and understanding the problems first hand are highly beneficial. Everything cannot be positive and we would want to see both the aspects of the function to understand the things which would make the process better.

Message for budding entrepreneurs Entrepreneurs today, need to understand the market, its customers and the different cultures, because several companies which are providing solutions only to the local markets today might become global players tomorrow. A lot of companies have failed because they could not understand the culture and its different mentalities. You have to provide solutions for a small world and if you want to be successful, you always have to be a step ahead of others.

Q Forecast for CAD/CAM We foresee a consolidation in the CAM industry. Today, there are around 40-50 companies producing CAM solutions worldwide. However, I believe that in the next five years, there will be less than 10 global players. Most companies will either merge or disappear. The same trend was followed by the CAD industry two decades back, and the same is predicted for the CAM industry as well. To survive in this race, there needs to be a unique strategy. Our plan in the next five years is to double our revenue and market share. In terms of the world ranking of all CAM companies, we currently stand seventh;

while among independent companies, we rank fourth—we will try to bag the second slot in the next five years. We have updated our technology to suit modern needs. We have always been a trend-setter in introducing technology; and the market looks up to us as a company which is at least five years ahead of its time. This is our advantage. We try to understand the industry needs, demands and changes that it will undergo over the next two years. The market today demands complete solutions having a consolidated CAM environment with better functionality and easy user interface. debarati.basu@infomedia18.in

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SPECIAL FOCUS DIE & MOULD 50

Die & Mould India 2012

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Reducing Import Dependence

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New Avenues

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Moulding Exuberant Opportunities Enhancing Made In India Prowess

Finding Opportunities Beyond The Conventional

Seamless Integration

Transitioning Mould To Perfection

Technology Trends

Die & Mould Technology: Innovations For Expansion

Micro Moulding

Moulding Miniatures

Additive Manufacturing

Additions In Manufacturing

Tool Selection

Tooling Solutions For Machining Optimisation

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SPECIAL FOCUS Die & Mould India 2012

MOULDing Exuberant Opportunities With fast-paced changes taking place in the manufacturing sector, the need for die mould cannot be undermined. As India is catching up on the adoption of the latest technology solutions, manufacturing will soon witness a dramatic change in the way it is being operated currently. Aimed at offering a platform to meet perspective buyers and increase the know-how within the industry, Die & Mould India 2012 is all set to provide a fertile ground for GenX manufacturing. Nishant Kashyap reports...

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he booming Indian economy has resulted in large amount of investments to provide for the everincreasing consumer demand and the required 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 die mould industry is gearing up to meet the rising demand. In recent years the industry has found many new customers such as plastic products, energy, medical, auto ancillary, consumer durables, etc.

Exhibitors Profile          50

Dies & moulds manufacturers, press tools Mould base & standard parts Hot runner system Tool Steel CAD/CAM system related to Dies & Moulds Die spotting Rapid prototyping & modeling Moulding machine/ die casting machine Accessories for machine tools

MODERN MACHINE TOOLS - April 2012

The 8th Biennial - Die & Mould India International Exhibition is scheduled at Bombay Exhibition Centre, Goregaon Mumbai from April 19-22, 2012. The exhibition provides an ideal opportunity for the dies and moulds industry to upgrade its know how and keep pace with the latest developments in this segment. It also provides unique opportunity for the dies and moulds & the entire tooling related industry to witness the latest technologies in this niche sector.

Visitors Profile         

Machine tools Dies & moulds Total tooling Measuring instruments & gauges Mechanical engineering Sheetmetal products Auto ancillary Automation provide Plastics

Hallmark of Success

P N Surendranath, Executive Director, TAGMA

This edition of die & mould India will expose Indian tool rooms and solutions providers to the latest innovations and trends, which will help manufacturers keep pace with higher growth rates in the manufacturing sector. Tool rooms today, are under tremendous pressure from shrinking budgets and production cycle times. The solution lies in concerted team effort of software technologists, tool-cutting engineers and machinery manufacturers.

Organised by Tool & Gauge Manufacturers Association of India (TAGMA), the 1st edition of the exhibition was held in Mumbai in the year 1998. Since then the event has today steadily grown to become the largest ‘Die Mould Exhibition’ spread over an area of 20,000 sq mts with international participation from over 25 countries. The 2010 edition of Die & Mould India witnessed a total of 25,400 visitors and the categories of interest were 34 per cent, 35 per cent and 20 per cent for the machine tools, dies & moulds and total tooling industries, respectively. The event has become the one stop platform for die & mould manufacturers. It has become the place to meet prospective customer and showcase the latest technology. Being the biggest die mould focused event, the


Die & Mould India 2012 exhibition leaves no stone unturned in consistently meeting the expectations of both exhibitors and visitors alike. The event enables manufacturers and traders from India and other countries to showcase their products and services, thereby gaining brand recognition & additional customers. Also, many visitors to these exhibitions, have gained appropriate knowledge and solutions to meet their specific requirements.

Concurrent Event The event has always been a highly focused B2B event and this year will be no exception in offering a complete range of die mould related technologies such as die/mould polishing machines, injection moulding, hot runner system, press tool and latest automation and measuring technologies. 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. As demonstrated during the last seven editions, Die & Mould India 2012 has all the prerequisites – participants and visitors who mean business, excellent infrastructure, organiser with a repute etc – to make it a thumping success even this year.

What Exhibitors Say…

Vinod M Sutariya, Head-Marketing, Indo-German Tool Room – Ahmedabad This edition of die & mould India will expose Indian tool rooms and solutions providers to the latest innovations and trends, which will help manufacturers keep pace with higher growth rates in the manufacturing sector. Tool rooms today, are under tremendous pressure from shrinking budgets and production cycle times. The solution lies in concerted team effort of software technologists, toolcutting engineers and machinery manufacturers.

Sambit Pradhan, Manager - Business Developement-Asia Pacific, Geometric Ltd Joseph Killukan, Managing Director, Jergens India Pvt Ltd We are participating in die & mould India as it will offer us the opportunity to connect with machine-tool manufacturers and metal and plastics tooling manufacturers on a single platform. At the exhibition, we will be showcasing our die-mould clamps, workholding products, specialty fasteners, swivel hoist rings to prospective customers and users.

Die Mould India 2012 plays a vital role in drawing attention of global investors towards Indian die and mould industry. It helps us reach prospective customers and showcase our capablities. This year we will be showcasing design and manufacturing automation technologies for the die and mould industry as well as technologies like VoluMill for high speed roughing and ElectrodeWorks for electrode extraction that will help us focus on the potential audience. During the event, we have planned for series of CAMWorks and DFMPro product demonstrations to suit the target buyers requirements. Initial communication for this has been sent via mailers to the prospective buyers.

nishant.kashyap@infomedia18.in

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SPECIAL FOCUS Reducing Import Dependence

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I E D MA

Enhancing

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The progression in the industry dynamics and technological upgradation has hiked the graph of quality parameters. However, when it comes to the core of all manufacturing procedures, the mould and dies industry in India is still crushed under the dependence of imports. Is it just the cost factor which the industry is trying to evade or has this dependence moulded the entire attitude of industrial growth? Debarati Basu talks to industry experts to find out ways in which the country can become self dependent.

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he die casting and moulding industry invariably forms the mother of all manufacturing processes. A firm foundation in place is what ensures the automatic progression of the industry towards quality and reliability. However, the Indian industry is largely dependent on neighbouring nations for imports related to this segment. Judging by the statistics, the Indian industry projects a high growth rate in manufacturing segments; this will automatically create immense growth requirements in the die and mould sector. “The Automotive Component Manufacturers Association of India 52

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(ACMA) has alone projected a growth of 40 per cent year on year and the main constraint for them is the supply for castings from India. We have the capability and the technology, but we do not have the required infrastructure,” said Dr Sundara Murthy, President – Institute of Indian Foundrymen (IIF). India today, is the second largest in casting production around the globe with 9.05 million tonnes of casting produced annually. The country comes second only to China which has over 40 million tonnes of casting annually. Keeping pace with the production, IIF projects a growth of 15 million tonnes by 2015 and 24 million tonnes by 2020.

“Export of foundry machinery to India in 2011 was worth € 85 million from Germany, China, Italy, Korea and Japan. The steel melting unit has a total export to India worth € 300 million. The dependence has not just been on China and Taiwan, but also on European countries,” reveals Rajesh Nath, Managing Director – German Engineering Federation (VDMA). There are several reasons for the strong dependence on imports in this segment; however, the changing requirements leading to growth of this industry clearly indicate that the Indian mould makers need to strengthen their prowess.


Reducing Import Dependence Cost Efficiencies Reducing costs is the major prerogative of every manufacturer today. However, bringing down the cost has its own repercussions, especially on maintaining the same level of quality. Importing has instead become the most viable option for manufacturers to maintain quality with lower investment. “Better quality moulds require investment to obtain right expertise and personnel, right from designing to the mould assembly. As an alternative, the industry finds it easier to import the mould which will evade the investment on upgrading the infrastructure. The perception however is now changing because the production volume for internal consumption is increasing,” explains Kaushik Bhattacharjee, Country General Manager – AgieCharmilles (South East Asia)

Techno Tussles This segment of the industry has always been dominated by manual operations. According to Viraj Naidu, Managing Director – DISA India, out of the 5,000 foundries in India, only 100 use high end automated solutions. “Around 4,000 foundries depend on manual operations with very low productivity and of the 1,000 which are considering automation; only about 100 are using high end technologies. Even with this disparity, India ranks second largest globally. This highlights the tremendous opportunities of growth in the industry. Imports only add to the cost. The general expectation is that, India in the next five years will see similar type of growth that China has experienced over the last ten years. This cannot be achieved manually. We have to upgrade ourselves to automated systems and the casting industry requires a lot of assistance,” reflects Naidu. With the growing competition, the industry now needs to make a quantum shift to automate its operations and increase production. “We are still 1/5th of China in terms of casting production; and India today has to double its capacity to meet the demand, but at the same time we have to be cost effective. 54

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Manning Skill Set Dr Sundara Murthy, President – Institute of Indian Foundrymen (IIF) Why should we import when we have the capability and the technology? All we need is proper infrastructure. Innovation is the only way for any quantum development.

Viraj Naidu, Managing Director – DISA India The Chinese and Indian way of working is different. China invests in capacity first and then the business follows. This is more adventurous, but is possible because of low currency cost. Indian industry follows an incremental or gradual growth approach and expands as business flows in. This industry needs a quantum jump.

Kaushik Bhattacharjee, Country General Manager – AgieCharmilles (South East Asia) Quality is not to be compromised for cost. Cost competitiveness should come from efficient management of manufacturing process and right management of resources. Industry can grow only when generating the right quality becomes a norm. This should be backed by the right resources & right ROI.

The domestic technologies available today are all out date and if we continue buying casts and machines from Europe, it would only add to the manufacturing costs,” points out Manish Kothari, Managing Director – Rhino Machines.

Acquiring high-end machines is not the solution to the issue. Strengthening the production base has to be complimented with acquiring the skill set and adequate know-how of the technology along with the high-precision machines. This segment of the industry is dominated by the small and mid-sized industries, which makes it labour centric. As the industry pitches to step up to the podium of technological advancements to be at par with the international demand, the know-how of the industry also need to be in sync. The industry needs to evolve from its conventional methods and adapt to the new mould making and casting technologies which is ruling the industry.

Supporting the SMEs Being dominated by the small and the medium scale companies, the entire equation rolls back to the cost factor. Heavy investments do not come to the smaller companies by choice, but more as an obligation. To boost the overall production capacity of the country and compete with the global production, the weaker links of the industry need to be strengthened. These can be strengthened not just by adequate government aid, but also with the assistance from the industry itself. “The institute is coming up with several courses ranging from ITI module to a degree course. We are developing clusters all across the country to impart skill sets. The industry today needs to innovate and grow,” explains Dr Murthy. A collective and focussed effort needs to be applied to empower the mould makers and the industry as a whole to reduce the dependence on imports. This can be made possible only if this segment is given central position around which the foundation of the entire industry growth is entrusted on. Strengthening this foundation will only ensure a strong presence of all the other industries in the global arena. debarati.basu@infomedia18.in


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SPECIAL FOCUS New Avenues

FINDING OPPORTUNITIES BEYOND THE CONVENTIONAL Progression is the key to growth. The automotive industry, for decades has governed the growth graph of the Indian manufacturing industry. But it is time now that the industry spreads its wings and tests new terrains. For the die and mould industry, the growth of new segments in the industry has come up with altogether a different set of challenges which this industry needs to conquer. Debarati Basu explores the ebbs of opportunity that awaits this industry segment.

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ie and mould is ubiquitously found in every segment. How well these segments are explored is what defines growth prospects. Even as the Indian industry has comfortably proved its mettle in the automotive industry, it is time that the industry climbs the ladder to find of new terrains where die and mould industry can grow. “Out of the 90 million tonnes casting produced worldwide, about 1/3rd of it goes into the automotive industry. In India it is slightly higher as the growth that this industry has encountered over the recent years has been huge. However, keeping pace with the growth of the automotive industry is something which the Indian foundry industry has not been able to do primarily because of slower rate of mechanisation trends. This brings in immense opportunity of growth for this segment alone,” said Viraj Naidu, Managing Director, DISA India Limited. However, here are to list some of the new avenues where the Indian die and mould industry can expect to find growth opportunities over the next decade.

Railways While 45 per cent of the casting production is consumed by the 62

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automotive industry, railway would form the second largest segment. The ever expanding railway network in India offers a cauldron of growth opportunity for the industry. While manufacturing of railway tracks and coaches which will rise tremendously, the railways division is working towards lowering the weight of the coaches. “Railways have been the lifeline of the country and with the increase in the passengers, there is also a lot of emphasis on the cargo transportation. There is a vigorous attempt to make the railway coaches lighter in weight so that it can carry heavier load maintaining the balance at the same time,” said S K Sharma, Addl Member Mechanical (PU), Railway Board, Ministry of Railways. This had led to experimentation with new low weight –high strength materials and die and mould makers of railway coaches has to meet up with new set of challenges in moulding such materials. From malleable iron to cast iron to the use of ductile iron, the variety in the new types of material is ever changing. Along with this the rail flaw detection instrumentation and probing devices would also emerge as an important segment to curtail the derailment possibilities, ensuring the balance between low coach weight and high load carrying possibility.

Infrastructure and Construction Equipment Urbanisation has brought in a high rate of development in infrastructure and construction segment. The government of India plans to incorporate additional investments over the next few years in upgrading and modernising the country’s infrastructure. For the die and mould industry, equipments required for road constructions and other heavy engineering machineries will be of prime importance. Requirements for machineries with new designs, multipurpose utility with high strength will be the need of the hour. As more number of Indian players are slowly entering this segment, castings for the engines of the construction equipments will be more crucial both in terms of quantity and heavy duty reliability. Currently, the Indian companies face abundant competition from global players and the Indian companies are working towards bringing out construction equipments with new features like Dozer Shovels, Dumpers, loaders, compactors etc.


New Avenues Municipal Casting While the industry eyes at the bigger chucks of development and investment, smaller and unconventional segments of the industry also lays out a lot of scope for growth. Odd enough, but the developments in the municipal constructions has always been ignored. “A manhole cover is a huge industry in itself but has always gone unnoticed. In a city’s drainage system, every half a kilometer needs an access. Multiply that with the length and width of the country and it would show how huge this industry is. It is technically a very simple casting. These covers are made manually and also do not need high end finishing accuracy. In India many casting suppliers are exporting these manhole castings. Since it is so simple a work, the mature markets do not want to take it up and the production instead comes to the emerging markets like India and China. With the urbanisation, the volumes have grown and it is no longer feasible to depend on manual operations. The Howrah belt of West Bengal specialises in this casting with around 500 foundries is this particular business,” explains Naidu. This segment calls for an organised set up and high level of automation for more business to flow in.

FMCG and Electronics Industry This is by far the fastest growing segment in the world today. With a rampant growth in the utility of electronic gadgets like mobile phone, laptops and innumerable new designs in the consumer durable products like television, refrigerator, washing machines etc, the scope of growth for the mould and dies industry is immense. However, experts in the industry feel that India is too late to enter the race. With the fast paced change that the FMCG and electronic device industry is caught up with, the Indian industry is far from making a mark of its own in this industry. But, that is no reason why the industry should stop their attempt to enter this market in a big way. Assessing the market potential, the die and mould industry can bank on the opportunity especially in the small mould parts. This

Rajesh Nath, Managing Director, VDMA, German Engineering Federation. Manual operations have its limitation. The level of automation in India is low but there will be a strong boost in future as automation application is spread across industrial areas. Better quality equipment is cost effective when we look at its value.

Kaushik Bhattacharjee, Country General Manager, AgieCharmilles (South East Asia) Pte Ltd. India has not looked into FMCG and consumer durable industry seriously and now it is an oversaturated industry and we cannot do much in terms of great innovation in this segment now to become the world leader. The industry moved to China because they are now the experts in terms of volume and mass production. Our infrastructure never encouraged such mass production.

is a segment which is still in its infancy in this segment and plastic moulded parts for electronic gadgets, is an area which can be explored and excelled in by the industry.

Aerospace and Medical Equipment The aviation sector has brought India to the center stage of global market. While the country has entered this industry at the right time displaying the right attitude needed to be a potential player in this segment, this is the time when the ancillary industry segments can grab the opportunity and grow in their respective fields. Die and mould being one among them. With every major global OEM entering the Indian market with joint ventures, this is the time of knowledge sharing. The need for high precision and accuracy in moulds and die casting will change the dynamics of the industry. Adopting new technology in the process will only add on to the value that this industry offers to the globe. This segment will demand for

aero parts and components which are both large and small and requires high accuracy. Moulding new materials in itself will bring in challenges and providing high finishing accuracies and intricacies will be what the mould makers needs to excel in. The field of medical equipment manufacturing is yet another field which has yet not progressed much in the Indian domain yet it offers an important role for the Mould and dies industry. With a handful of Indian companies now entering this industry, this would open up new domains for the mould and die industry in the making of surgical machines and equipments and transplant parts.

Textile and Agriculture Machinery These are two industries which has for long gone unnoticed of automation. The agriculture centric country and the textile pockets still traditionally in a large way prefer to have manual operations. However, the trend is now changing and with the growing demand for volume most farmers and textile merchants are making way for the automated operations. “The rate of mechanisation in these fields is very low in India. But with the importance given to the agriculture industry, the mechanisation is increasing and this will give a boost to the industry,” said Rajesh Nath, Managing Director, VDMA, German Engineering Federation.

Pumps /Valves and House Construction Equipment A huge amount of casting is required in this particular segment right from taps and the water piping in a building to pumps and valves required in various sector segments. This industry too needs to emerge from the manual mode of operation to automation. Apart from these, the rise in the demand for earth moving equipments, trucks and tractors also have opened up potential avenues for the growth for this industry. Now, it only depends on the how much the Indian die and mould industry can bank on. debarati.basu@infomedia18.in

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SPECIAL FOCUS Seamless Integration

Simply identifying potential business is not where the challenges end; the industry needs to go through a quantum transition in order to seamlessly incorporate new manufacturing nuances. Debarati Basu tries to find out the missing links in the industry’s growth and ways in which these gaps can be plugged so that the conventional industry can easily evolve to the next level of manufacturing operations.

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he level of competition both at the domestic and the international market has reached a threshold which involves an entirely different set of challenges. In such a situation, is it enough to take a risk and plug into untested terrains? Should the industry instead be conscious in its investment activities and take measured steps ahead? What are the things which need to be upgraded in developing India so as to integrate it into the global industrial evolution? These are some of the questions which the industry ponders upon today, as it finds itself caught in the midst of age-old methods followed traditionally and the sudden surge in technological advancements being incorporated universally. Discussed below is a list of the do’s and don’ts for the Indian industry as it transitions to the next level: 64

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Change in Attitude This is probably the first step in the entire process of progression. The industry needs to change its basic attitude towards change itself. The industry needs to assess itself in a new light in comparison to the changes which are happening worldwide. With the rate at which the global industry is progressing in terms of technology, investment and industrial know-how, it is too late for the Indian industry to continue with the ‘chalta hai’ (it’s okay) attitude. The global market only wants perfection with not a micron out of place. Hence, the country needs to strive to enter that league of manufacturing capability. “New technology is the need. We can no longer do it the conventional way, and more Indian companies are inculcating this trend fast. This has resulted in an increase in the skill and knowledge in the industry to operate

these machines,” explains Viraj Naidu, Managing Director – DISA India

Create a Niche In an age of tough competition, the Indian industry needs to define its own identity and carve its own niche. If Europe today stands for precision, Japan for innovation and China for its mass production, where should India create its domain? We can no longer only be identified as low-cost outsourcing destination for global OEMs. Getting into a niche market or domain probably may not be a feasible option in terms of return on investment. But the industry needs to look beyond the horizon and calculate the value in it, which would pay back in the longer run. “India is well advised to stay on its path of domestic growth and prosperity rather than try to excel


Seamless Integration Change in Work Culture Christian Kleeberg, Managing Director – MAGMA Engineering Asia Pacific. You have everything in this country for it to grow. But despite very strong receptiveness of the Indian industry, the willing to adapt the best technology is very low here. People talk about improvement but they do not improve. Cost is not the factor hindering technological advancements, and whoever says so has not done a professional ROI or cost-benefit calculation.

everywhere. Focus on your core areas, make them strong and be independent of fluctuations worldwide,” reflects Christian Kleeberg, Managing Director – MAGMA Engineering Asia Pacific PTE Ltd.

Generate Volume To justify the investment, it is invariably important to generate the volumes. Most investment and expansion plans fail because of the lack of initial demand in the market. However, by the time the volumes rise, India will find itself lagging behind the others in the race. The industry needs to confront the reality and dare to plug into new terrains and create the need and expand the market.

Change in Buyer Attitude High-end manufacturing, investment in latest technology, and precision in production, all goes down the drains as soon as the buyer demands reduction in the cost of the final product. The main prerogative of every buyer today is to cut down on cost. Given the competition, every business house would bag the contract by lowering the cost of the product but this eventually trickles down to cost cutting in the manufacturing process compromising quality. This brings the industry back to square one—that is ensuring quality. 66

MODERN MACHINE TOOLS - April 2012

It is difficult to change habits. The conventional work culture has seeped in too deep and for too long for it to change. But the world has moved on. The global market, along with quality demands on time delivery and professionalism in approach. With upgradation in technology, it is now imperative to upgrade the working environment that we provide. “Indian foundries do not mind having 15 per cent rejection but they avoid adopting better technology which can drastically bring down the rejection levels. They are satisfied if one machine is able to S Subbarayan, Deputy General Manager (Die Mould), Makino India. Market is the driving force. You can get technology when you have volumes to justify it and you have volumes when you have the capability. It is a vicious circle.

meet the current demand instead of investing in a technology which can double the production. The issue here is also with the lack of human resource, training the available resource and then retaining them,” points out Kleeberg.

Do Your Homework With so much variety in products in offer and new demands being generated by the market continuously, the avenues for investment in the industry have also opened up. It is now upto the industry to assess the demand trends and emerging opportunities in the market. The onus lies on the intensity of homework done, along with assessing the return on the investments. Avenues are many, but selection of the right path and excelling in it makes all the difference.

Research Initiatives The area where the Indian industry lacks is its inclination towards research. With some of the premier technical institutes

generating waves in the global circuit, the domestic market fails to benefit out of it. There is a dire need to encourage research initiatives in the industry and excel in generating innovative designs and technologies instead of manufacturing prototypes.

Grow and Let Grow The Indian industry is a blend of larger OEMs and small and mid-sized companies. Each category has its own forte of expertise. But today, each segment of the industry has its own path of functioning. What the market instead needs is amalgamation of strengths and expertise from every sector and grow as one industry.

Sense of Competition In an age of cut throat global competition, every country, no matter how big or small, has an outward outlook. Every country has grown big by creating a global image for itself. The Indian industry too should strive to put

Dr Sundara Murthy, President, Institute of Indian Foundrymen (IIF). The industry has not yet considered investment in the niche market. Magnesium, aluminum and lithium alloys have tremendous opportunity which we have not yet explored. We have to enter these niche areas, explore and innovate.

the ‘Made in India’ brand on the global map. It is not just the Tata’s or the Mahindra’s, but the ‘Brand India’ which the global industry should acknowledge and accept with reverence. This is just the beginning. With time, the Indian industry would itself grow out of its groove to amalgamate into the global way of operation and functioning. The only prerogative is that the time taken should not be a bit too long. debarati.basu@infomedia18.in


MMT Apr-2012 Ad Name: Blaser Pg No. 69


MMT Apr-2012 Ad Name: Object Pg No. 70


MMT Apr-2012 Ad Name: Samkrish Machine Pg No. 71


MMT Apr-2012 Ad Name: Shuter Pg No. 72


SPECIAL FOCUS Technology Trends

DIE & MOULD TECHNOLOGY:

INNOVATIONS FOR EXPANSION Rapid technological advancements in global die & mould manufacturing are rising in relevance, particularly in India, where unprecedented growth in demand raises challenges in production and capacity. Tarun Tampi looks into the Indian machine tools industry in the grip of these advances.

T

Courtesy: Hwacheon Machine Tool Co., Ltd.

he manufacturing industry in India is primed to grow by more than 15 per cent in 2012. For the die and mould sector, an industry fundamental to manufacturing, this growth comes at a crucial time. Approximately 70 per cent of demand is met through imports in a rapidly slowing global economy, despite the Indian manufacturing sector rising when it was expected to slide. Government policies are attempting to bolster manufacturing to 25 per cent of GDP by 2025 through initiatives such as technology funds, training centers, subsidies and policies regarding joint ventures with foreign manufacturers. Such collaborations are being encouraged to bridge the gap in technology and manufacturing practices, all at a time when indigenous demand is expected to climb by 40 per cent. There is a relative shortage of capacity, innovation, in-house development and technical talent in Indian manufacturing companies who are increasingly dependent on foreign machining centres and rely heavily on high-tech component imports. Domestic manufacturing has a market share of just 33 per cent at present. In this regard, die

74

MODERN MACHINE TOOLS - April 2012

and molud manufacturers need to invest in equipment and technical know-how to exploit the hightech product market since that is where the scope and scale of future manufacturing exists. The following technological trends serve to guide the Indian mold manufacturer through prominent developments and recent innovations in the industry. Overall, the trends point towards faster production cycles, shorter lead times, more precise tolerances and higher quality surface finishes while molds increase in size and complexity. These lead to machines with increasing capabilities like higher spindle rpm’s, higher multiaxis velocity and acceleration, control systems for greater positional accuracy and micro-tolerances. Advances in hard-milling and multi-functional molds as well are empowering mold manufacturers to diversify and maximise the quality of their products.

Rapid Tooling Rapid tooling advances are currently responsible for reducing cycle times by 40 per cent as compared to conventional machining. Conformal cooling, bimetal layering and better mold materials, like aluminium, allow


Technology Trends for quicker thermal conductivity in molds and rapid processes allow for production of inserts and mold tooling in less than 48 hours. Mixed metal and gradient tools are also produced using Rapid Solidification Processes (RSP), Direct Metal Laser Sintering (DMLS) and Selective Laser Sintering (SLS). Rapid processes are capable of easily producing modifications in the tool, like undercuts or side-action. They can be used to make high-volume parts in large sizes and even transparent parts in most engineering grade materials. Rapid technologies can output moulds in twothree weeks and can even be used to reverse engineer parts or repair and rebuild molds. With the development of vinyl tooling gel coats and zeroshrinkage resins, it is possible to build within a day, durable molds with high surface finish. Further, rapid tooling, since it is based off a CAD file, offers the option of customised production, flexible design and standardisation of parts. This is increasingly relevant since mold designers have to often modify their molds because of part re-design.

Hot Runner Technology Hot runners are vital in delivering the melt material from the injection nozzle into the cavity and their application helps illustrate the effect of gate quality on overall part quality. Developments in hot-runner technology has seen vast improvements in thermal uniformity, melt homogeneity, wall thickness, output capacity and automated electric valve gating. Electronically controlled gating systems using servo control are replacing hydraulic and pneumatic actuation. Electric systems are more precise, cleaner in function and can optimise every parameter in the functioning of upto 64 valves, improving melt pressure and flow at each gate. Better process controls, like in thermocouple controlled nozzles and improved hot-runner nozzles allow for easier application and simple maintenance of hot-runner systems. These advances have a direct impact on the part quality, cycle times and costs. They reduce resin costs and introduce

direct gating where cold-runners were used, allowing for more cavities in a single mold.

Aluminium Moulds It has long been understood and proven that aluminium tooling is capable of reliable high-volume production. The effects of wear, hardening, machining, finishing and cycle time are all better for aluminium tooling as compared to traditional steel tooling, although aluminium moulds must be built to the same standard and design expectation of steel molds. Aluminium moulds can be half to one-third the weight of traditional steel molds, reducing wear

Die and molud manufacturers need to invest in equipment and technical know-how to exploit the high-tech product market since that is where the scope and scale of future manufacturing exists and tear and have far better thermal conductivity. The cycle times are reduced by 30 to 50 per cent allowing for greater production volume, costs savings on production tooling as well as lead times reduced by 10 per cent. There is also reduced distrotion, internal stresses and shrinkage. Such molds, although they require more care and adaptive techniques to design since the material is aluminium, are also better suited thermally to hot runner systems. Hence, in terms of quality, time and cost, these advances reorient the view on aluminium, particularly aircraft-grade aluminium, as a high performance, large volume production material for molds and not just for soft tooling.

High-speed Machining High-speed Machining (HSM) has had a significant impact on the mould manufacturing process. EDM has long

been the choice technology for cavity cutting and hard steel machining, however, HSM has improved over the years to match EDM in surface finish and accuracy. HSM has several inherent advantages, like higher cutting speeds and feed rates, better surface quality and accuracy. This also leads to lesser tool loads, lower mould temperatures, better thermal conductivity and reduced machining costs. HSM reduces the workload and costs of producing high precision surface finishes. Tool life is extended although care must be taken to carefully tailor and balance the tool and HSM machine according to the requirement since spindle rates are very high. Sharp internal corners and 90 Degree cuts are still possible only with EDM, but mold manufacturers could also look into complementing EDM with HSM as and when possible. Mould development is rapidly shifting towards large-scale production. To meet these challenges, larger molds with better material properties need to be developed. Multi-axis cutting and deep-hole cavities need to be improved to efficiently machine more complex parts. Compound processing, where multiple machining processes can be done on a single machine, is still to be realised at a level where mould processing, mechanical, electro-chemical and ultrasonic processing can all be carried out on the same machine. There is a 30 per cent growth in demand expected in the machine tool industry this year, with present demand standing at about ` 10,000 crore. Largescale expansion in the automotive, defense and railway sectors are primarily responsible for this surge in machine tool demand. To match this, small and large manufacturers need to increase their production capacities, invest more in R&D and take advantage of joint venture opportunities. Coupled with the adoption and optimisation of the latest technologies, the industry could easily meet and surpass IMTMA’s projected market size of ` 23,000 crore by 2020. tarun.tampi@infomedia18.in

April 2012 - MODERN MACHINE TOOLS

75


SPECIAL FOCUS Micro Moulding

OULDING The word ‘micro’ has seeped deep into the manufacturing industry and with the rising demand for small and sleek products, machining such intricacies is an expensive challenge. Micro moulding, however, has rose as a cost-effective alternative for the industry. Debarati Basu finds out the nuances that this technology offers to the industry.

E

ven as the manufacturing industry itself has taken a leap towards higher level of precision, most manufacturers are trying to cut down on the machining costs. To top it up, miniaturisation is a trend which is catching up across all the industrial verticles throughout the world. With the rise in micro components, machining parts at the sub micron level has always posed to be a great challenge. As an alternative, technological advancement has brought in micro moulding as a cost effective option to micro machining which can deftly produce miniature parts supplying similar precision and reducing the overall cost of production and manufacturing at the same time. However, given the adversities that the Indian industry faces, will this technology be able to seep in as a costeffective option for the manufacturers?

Micro-level Moulding As the domain of manufacturing processes has expanded over the years, the next criterion of immense importance is on bringing down the cost of manufacturing. Micro machining has traditionally been the benchmark of precision machining 76

MODERN MACHINE TOOLS - April 2012

especially in industries which demand for high intricacies and complex designing parameters. However, as the soaring volumes for such components are in demand, the industry has deftly accommodated new technology justifying mass production. Micro moulding, today can offer a range of cost-effective alternatives for components that are miniature, complex and require high-precision tolerances. In precision micro moulding of a component, manufacturers have to consider the mould tool design, the micro moulding equipment used and ensuring the quality of the final product. Any component which is smaller than one micron and has high-precision tolerances are components which can be micro moulded effectively. Additionally, this technology can play an important role for components made of metal, ceramic, glass or plastic with high degree of design complexity. However, the ability to produce acceptable metering accuracy and homogeneity of very small quantities of plastic melt is in itself a key challenge in the micro moulding process.

Why Micro Mould? Along

with

bringing

down

the

manufacturing costs; this process also saves time in production processes as compared to that spent on machining the parts. This has been found highly effective especially in the segments which demands parts in high volumes. The advancement in this technology has also guaranteed precision of parts which has automatically brought down the need for surface finishing. As the trend for smaller components is rising, it might become more difficult to machine complex geometries. Hence, micro moulding comes in as a viable option as this technology gives more freedom to designers to include intricate features in the products thereby enabling easy manufacturing of complex designs easily.

Applying Micro Moulding The rising complexities in the field of medical equipments have generated opportunities for micro moulding. Here are some areas of medical equipments manufacturing made of plastics where micro moulding can play a bigger role along with other manufacturing segments where it has already make a mark:  Some of the medical devices require


Micro Moulding visibility under an X-ray and are typically made of metal. The density of the material provides the contrast needed to accurately locate the position of the device inside the body during the procedure. Plastic resins filled with radiopaque compounds can be visible under x-ray imaging and can be used to replace metal components.  Medical devices that carry current need to be isolated from the main body of the instrument. This additional component increases the diameter of the product. Switching to a moulded plastic component can remove the need to add isolation to metal components thereby reducing the size of the device.  Plastic with metal or ceramic filler can be a suitable replacement for metal injection moulding (MIM) as it eliminates the need for secondary operations associated with MIM technology.  Micro moulding can be vertically integrated into an entire manufacturing assembly process that may include stamping, insert moulding, bonding or conventional. With the rise in the use of complex parts in the field of medical, defence and automotive industry, increasing number of components are manufactured so as to integrate them in the process of micro moulding. Hence, in this process, mould tooling is also an important aspect. Micro moulding is an extremely complex process compared to conventional moulding. At micron level of moulding, the need for the right tool increases due to tighter tolerances and higher intricacies. Since this process needs to guarantee similar level of precision, as offered by micro machining, jeopardising the quality of mould tool would ultimately lead to low quality product and loss of time in surface finishing the component to the required specifications. Also high grade quality inspection equipment plays a very important role in the entire process to assess the

S Subbarayan Deputy General Manager (Die Mould), Makino India. Micro moulding and micro machining, both have their own relevance. One cannot replace the other but in industries demanding mass production; micro moulding becomes a more practical, cost effective option. After micro, people have started talking at the nano level today.

quality parameters of the final product which need to be measured for its precision and perfection at the micron level. Measuring a micro moulded part which is as small as 0.01 mm is not a simple task. Every aspect in the entire process forms a critical ingredient to manufacture a perfectly micro moulded component.

Advantages of Micro Moulding

    

Low cost solution Incorporates intricate and complex geometries Reduces particle contamination Gives better surface finish. Decreases cycle time

adopt this technology, will redefine its manufacturing parameters with this technology. The only roadblock remains the fear of the unknown as this technology is still in its infancy and most manufacturers and buyers need to understand the dynamics of this process. It is now upon the manufacturers not just to develop the skills of micro moulding but also to generate the demand in this sector as a high quality low cost alternative. debarati.basu@infomedia18.in

Gearing Up M i c r o moulding, if performed to achieve the exact parameters of accuracy required in highly critical s e g m e n t s like medical, electronic devices and defence, can prove to be an excellent lower cost alternative to micro machining. The criticality of this process will only increase with time and the need for even smaller and intricate designs. India, which is on its way to April 2012 - MODERN MACHINE TOOLS

77


ADDITIONS IN MANUFACTURING

Courtesy: Fraunhofer Institute for Laser Technology ILT

SPECIAL FOCUS Additive Manufacturing

The late Steve Jobs observed that, “The overall point is that new technology will not necessarily replace old technology, but it will date it. By definition. Eventually, it will replace it. But it’s like people who had black and white TVs when colour became available, they eventually decided whether or not the new technology was worth the investment.” For the die and mould industry, Tarun Tampi takes a contemporary look at how additive manufacturing is worth the investment today.

A

dditive Manufacturing (AM), a technology that is a few decades old, has long been viewed by the industry with scepticism. Just a few years ago, less than 22 per cent of mould makers had adopted rapid prototyping, let alone rapid tooling or manufacturing. There is a reluctance to embrace AM techniques as the next step in manufacturing even though these techniques have since outgrown their infancy and are rapidly amassing potential to revolutionise how we manufacture. Doubts linger; ‘Is the technology fundamentally disruptive?’, ‘Would it really eliminate the need for moulds and tooling?’, ‘Can it match conventional manufacturing in product quality, cycle times, costs?’ The mould industry is fundamental to manufacturing and having seen tremendous growth recently, mould makers are increasingly looking for ways to diversify their markets, extend their capacities and bolster the competitiveness of their businesses.

Processes and Classification: AM can satisfy each of these needs considering recent improvements, and 78

MODERN MACHINE TOOLS - April 2012

its progressing ability to work with plastic, ceramic, metal and composite materials. Its applications can be sifted into three broad categories: Rapid Prototyping (RP): produces functional prototypes with properties similar to the product. Fit and form testing, assembly compatibility and design iterations can all be performed, thus allowing for huge savings of time and cost within the design stage itself. Further, the manufacturing process cycle can be optimised, having studied the prototype. Samples may be quickly made for cosmetics, marketing, safety standards and conceptualisation. Rapid Tooling (RT): is used to create patterns and mould tooling, either directly or indirectly, for low-medium volume production. Although it trails conventional mould-making methods in surface finish, durability and part size, RT allows for complex geometries to be made using multiple materials while reducing lead times for tooling, reducing initial costs and improving the versatility of the design since the CAD file is all that needs to be modified. Rapid Manufacturing (RM): involves medium-high volume production of end-

user parts. For high volume production, savings on tooling and skilled labour still do not sufficiently offset the short production cycles, high accuracy and tolerances of conventional methods. For these applications, there are a host of processes and technologies unique to AM. Depending on the form of the raw material used, there are:  Liquid – Sterelithography (SLA), Jetted Photopolymer, Inkjet Printing  Powder – Selective Laser Sintering (SLS), Direct Metal Laser Sintering (DMLS), 3-D Printing (3DP)  Solid – Laminated Object Manufacturing (LOM), Fused Deposition Modelling (FDM) All of these processes share a similar process structure in that a CAD model of the desired part is made and then converted into an STL file. The STL file is sliced into layers or voxels (volumetric units) and the machine builds the part according to the STL file, after which any post processing is done if required.

Benefits of AM Since there is no inherent tooling required or any setup time, lead times


Additive Manufacturing to manufacture a part or prototype are greatly reduced. Parts of almost limitless complexity can be made using materials of any type, as long as they are available in the required form, which can be combined to provide the desired mechanical properties. Further, since manufacture is directly linked to the CAD file, mass customisation at low-volume production is highly cost effective and extremely versatile, which is why the medical and jewellery industry are already benefiting from the use of AM technology. For rapid tooling, like indirect silicon rubber moulding or epoxy tooling, various features, moulding parameters and tooling changes can all be evaluated in a matter of days. FDM and laser sintering could be used for thermoformed tooling as these processes yield parts with porosity that can be used to draw a vacuum through the tool. These technologies give the mould maker the ability to design and quickly build his own moulds, cavities, inserts, die casting tooling etc, thus reducing his dependence on expensive imports. Rapid metal mould technology is a priority for metal-casters and toolmakers in this regard. In addition, jigs and fixtures can be designed, customised and produced in-house without the need for any special tooling. Similarly, since AM can add material where needed, it is useful in the repair and modification of existing parts as well. A significant advantage AM brings is conformal cooling technology for mouldmaking. Previously, mould makers were restricted in their ability to build cooling channels into the mould due to the limitations of tool and drill geometry. But with AM, cooling channels can be built in to conform to the shape of the mould, allowing for a variety of mould configurations, faster cooling, better quality parts and reduced production time. Conformal cooling also allows the mould to last longer, thus extending its production volume for parts. Since it successively adds material in small quantities to build the part, only as much raw material is used as the part requires, allowing for savings in material requirement and consumption. This is 80

MODERN MACHINE TOOLS - April 2012

“If you can think it, we can make it! Additive Manufacturing, the future of the next Industrial revolution, has come here to stay!” – G K Rao, CEO, Imaginarium (India) Pvt Ltd

in contrast to conventional machining, where large amounts of scrap are generated after a part has been machined out of stock. Hence, accounting for the design, manufacturers using the additive approach could reduce 50 – 80 per cent of the raw material used to make a part, which would mean extracting twenty-six times less material from the earth.

Applications of AM, in Descending Popularity

      

Functional Models Direct Part Production Fit, Fixtures, Assembly Presentation & Visual Aids Patterns for Prototype tooling Patterns for metal casting Tooling components

Challenges: Only a Matter of Time Limitations still remain as the technology grows to fit the size of its potential. Part size, surface finish, accuracy, mechanical properties, and tolerance are all areas where AM needs drastic improvement if it is to match conventional machining. “There are three main challenges; firstly, the huge capital investment in the machinery. Secondly, the expensive consumable cost which, over the years, could overtake the capital invested. Thirdly, the lack of a good ecosystem of service providers, well-informed users and attractive government policies.” – explains G K Rao, CEO, Imaginarium (India) Pvt Ltd. Further, in terms of production, AM is still suitable only at low-medium volume since it still does not match the cycle times, part quality, tool life and overall costs of conventional machining at high volume. Today however, AM techniques can effectively produce

volumes of 10,000 – 15,000 parts. As the practical application of AM grows, a number of these disadvantages will be resolved to make AM practical and cost-effective in the future.

Adding the Future The nature of additive processes is such that it alters our fundamentals about manufacturing in terms of design, investment, supply chains and equipment. Materials available today for AM processes, such as powdered metal alloys, polyamides, nano-resins etc are increasing in variety and quality. The processes are more robust and highly customisable with new processes being developed as well. Today improvements and innovations in DMLS, Laminate tooling, Laser sintering and Laser-cusing are expanding their scope and application to produce enduser parts throughout the industry, in aerospace, automotive, medical, defence and general engineering sectors. A growing offshoot of these technologies is hybrid manufacturing, a combination of additive and subtractive (conventional) manufacturing processes. Rao believes that “One cannot replace traditional tools and dies as a route to large volume manufacture. RP will more than complement them acting as a derisking tool for design validation while highlighting costly errors at fractional cost, thereby averting costly rework and loss of precious time.” Complex parts may be built using additive technologies and finished or post-processed using conventional machining, thus using the best process where needed. This brings with it the benefits of both manufacturing techniques and is easier to assimilate into existing business models. With annual growth in the AM’s twenty-three year history at 26.2 per cent and with 100 per cent of all future development expected to focus on manufacturing, the prospects are limitless. The point is to see where this technology can be applied cost-effectively and creatively by the manufacturing industry. tarun.tampi@infomedia18.in


Modern Machine Tools (Apr-2012) Insert 9 - Front-Pg 81


Modern Machine Tools (Apr-2012) Insert 9-Pg82


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Modern Machine Tools (Apr-2012) Insert 10 - Front-Pg 87


Modern Machine Tools (Apr-2012) Insert 10-Pg88


SPECIAL FOCUS Tool Selection

S N O I T U tion L

O S ING

g L n i O n i O T r Mach

a s i m i Opt

Fo

There are different types of dies & moulds which require different approaches and strategies while selecting cutting tools. So, how does one choose the most appropriate cutting tools for machining moulds and dies? Some considerations that need to be take into account while selecting tools‌

O

ne should understand the need and importance of the product before finalising on the right cutting tools. For instance, if you have to make a mould for a circuit-breaker, cutting tool selection becomes crucial as the tolerances to be maintained will be very tight. To produce more accurate parts, one should select precisely ground cutting tools, sophisticated machines and appropriate CAD/ CAM systems. For sheet metal dies, you need big diameter tools like dia 80 bull nose or ball nose and so on. A form tool needs to be machined with high-speed machines for smaller groove areas and requires smaller tools (as small as 0.1mm). While machining mould bases finishing and accuracy are the top priorities. Material Type – (soft steel, steel up to 50 HRc, steel more than 50 HRc, stainless steel, aluminium, etc) 90

MODERN MACHINE TOOLS - April 2012

Tool life plays a major role once you have harder material more than 52 HRc and soft materials like aluminium. The tools selected for hardened steel will not perform efficiently if used for softer materials. Also, to machine electrodes in copper, you need a sharper tool and a thin PVD coating. In the case of graphite, you need a sharper tool with diamond coating that can withstand its abrasiveness; otherwise, one will struggle to get the net shape within optimised time.

Hence, while using bigger diameters on HSM machines, it is important to consult your cutting tools suppliers or machine tools suppliers to understand the limitation. Similarly, if you want to machine with higher depth of cut with conventional feed and RPM, you should have a robust machine spindle which may not have a high RPM. In such a scenario, you need to synchronise your need and availability to select the appropriate tools considering the machine type as well as the resources available.

Type of Machines It is also very important to understand the type of machines. For example, if you want to machine hardened steel, HSM technology is required to cut the steel more efficiently. However, most HSM machines may not be able to deliver the high torque required for high depth of cut in case of bigger size tools

Strategising After deciding on the material and machine, one needs to focus on selecting an appropriate machining strategy. There are several strategies which can be used for efficient machining like, HSM, High Feed Machining (HFM), High Performance Machining (HPM),


Tool Selection Table 1: Traditional Tool Selections - Roughing /finishing Operation

Tool type (Seco)

dia (mm)

Cutting speed (M/Min)

Feed per tooth (mm)

RPM (per min)

Roughing-1 Roughing-2

Dia 25R2 high feed-2

25

200

0.7

2544

0.7

75%

3

5342

Dia 16R2 High feed-2 Ball end-mill dia 6R3

16

200

0.7

3975

0.7

75%

2

5565

6

200

0.1

10600

4%

35%

2

2120

Dia 12 ball -JH111 (standard length up to 45 mm)

12

220

0.15

5830

scallop=0.010

2

1749

Finishing-2

Dia 12 ball –JH-111 (From 45 mm to 57 mm)

12

200

0.12

5300

scallop=0.010

2

1272

Finishing3(corner)

Ball end-mill 6R3JH111 ball

6

200

0.07

10600

scallop=0.010

2

1484

Rest Roughing Finishing-1

micro machining and conventional machining. Tools selection example: Let us take an example of one forging die having the following dimensionsEnvelope size – 500x250x60 Minimum radii to be achieved – 3.0 mm Maximum depth to be machined – 57 mm, this requires a minimum of 60 – 65 mm overhang Hardness of material – 55 HRc

Pointers for Consideration While doing the roughing, the first question is—which type of tools (eg ball nose, bull type or sharp end-mills) will be more efficient? The answer is—“It depends upon the shape of the die or mould,” says Sashi Menon, DGM – Technical Support, Seco Tools India. He adds, “In other words, if you have a bigger shape to be cut like 500X200X100 with hardened steel of 55 HRc—go for high feed tools as they are an economical way of cutting the material faster.” If you have normal P20 steel for a bottle mould with a size of 100X100X50, go for ball nose end mill directly and carry out high speed machining roughing. To rough out a forming die in aluminium, you need sharper tools with two flutes for easy removal of chips, for eg Seco –Jabro 400 Series. By using this, you can achieve even 0.5mm thickness of 92

MODERN MACHINE TOOLS - April 2012

Depth of cut Step over No of Table feed (mm) (mm) teeth (mm/min) (Zn)

wall with 30.0 mm height. If you do not have the right tool in this case, you will have to struggle to get the net shape and surface finish required.

Tool Holding This is another important factor that requires consideration since the adaptor is the key link between the cutting edge and the spindle nose. Using sub-standard holding devices or a damaged pull stud (retention knob) may result in damaged machines or improper dimensions and forms. Balanced adaptors and tools are inevitable while machining using the HSM strategy or when the RPM is higher than 12,000. A well balanced adaptor with minimum unbalance of 3g.mm/kg is a highly recommended HSM.

the NC programme and use overhangs which will enable you to use optimised parameters. Anti-vibration adaptors like Steadyline from Seco are highly recommended while machining larger depths, like mould bases, for instance.

Parameters for Finishing ap (depth of cut), ae (step over) depend upon surface roughness requirements. These may vary in case of precision moulds to forging dies. So, using proper ap and ae will reflect on the surface finish, tool life and the cycle time. ap and ae, which are lower than the recommendations, may result in poor surface finish and bad tool life since every cutting tool also needs to have sufficient material to cut.

L/D Ratio

Stock Material

This is another major factor that has to be considered. Tool life and cutting parameters are greatly influenced by the overhang factor. It is always advisable to use the lowest overhang possible and while machining longer depths, divide

This plays a vital role while finishing. Enough material has to be left for finishing cut. Parts with very low stock may result in rubbing the tool on part. At the same time, excess material may result in bending of the tool, which may spoil the net shape and surface finish.

Types of Dies and Moulds

   

Injection and compression moulding Die casting Forging Sheet metal forming and cutting

Vipin Rajput, Product ManagerJabro Products, Seco tools India Pvt Ltd, Pune


FACILITY VISIT Precihole Machine Tools Pvt Ltd

PIONEERING CUSTOMISED DRILLING SOLUTIONS Spearheading deep hole drilling technology, with customised machines as their forte, Prechihole Machine Tools Pvt Ltd is a groundbreaking establishment that is relentless in pursuing sustainable innovation, functionally and reliably. During a visit to the company’s facilities, Nishant Kashyap & Tarun Tampi, take a look at the latest manufacturing technologies.

A

fter gaining extensive experience and expertise in Deep Hole Drilling Machines (DHDMs) from overseas, Precihole is credited for bringing this highly specialised, yet much-needed niche technology to Indian job shops. Deep hole drilling practically defines a drilling operation at a depth which is 10 times the diameter of the hole. It is a technology that comes with its own unique possibilities and challenges. This Indian company has come a long way from being an indigenous manufacturer of gun-drilling machines to becoming an exporter of quality DHDMs to Austria, Canada, Brazil and the US, to name a few.

Production Capability The company manufactures a vast range of DHDMs. These machines are available as per clients’ specific demand. And to 94

MODERN MACHINE TOOLS - April 2012

meet this demand, the facility never sleeps. The company has two different facilities in Thane that reliably run three shifts, round the clock, throughout the week, transporting at a high throughput rate to its clients. Machines are widely appreciated for their greater functionality and reliability. The cycle time for the production of a single standard machine is approximately four months while for more complex or Special Purpose Machines (SPMs), it takes around six months. An average of five machines is completed each month and Precihole is on its way to double its production capacity. For a machine, depending on the specification and design need of the customer, while about 25 engineers and technicians engage themselves in the manufacturing and assembling process. In terms of specifications, drilling machines are built to handle components of diameters ranging between 1.5250 mm typically. Machines can be

automated if required and customised to the component or part it is needed for. Training for machine operation is also provided for and usually takes a few days. International standards are maintained at every step, right from shop floor practices to component and end-product quality. Further, every machine is an improvement or innovation in one way or another.

Product Range The company houses India’s largest state of the art deep hole drilling manufacturing centre. It houses three distinct sections of the business – conventional machining tools, subcontract assembly areas and Gun or BTA drilling stations - all complementing each other. Engineering challenges are plenty and varied in deep hole drilling. The company manufactures single axis gun drilling machines, 3-axis gun drilling machines, BTA and STS drilling machines, X-Y BTA deep hole drilling machines, skiving and burnishing


Precihole Machine Tools Pvt Ltd

A A Qazi, Director Prechihole Machine Tools Pvt Ltd We have incorporated lean manufacturing in our system, which is not only helping us reduce and identify unnecessary waste processes, but is helping us increase the volume of products being manufactured at our plant without any added cost or investment.

machines for deep hole drilling equiment available in the world.

Challenges Encountered

 Applying international standards in lubrication & machining techniques.

machines. Apart from this, the company also manufactures SPM’s. Precihole has several hundred machines implemented successfully at several large and medium sized businesses around the world. With giants like Honda, TATA, BOSCH, Escorts, Godrej, L&T, Cummins, Premier Ltd and Mahindra as its key customers, the company has made its mark in offering state-of-theart technology at affordable costs. The machines are well designed with the customers’ need in mind. The machine tool range offered by the company covers most materials and hole diameters applied in the industry. The company has designed and manufactured all types of

Precihole was considered more of a local player during its initial days of operation, but it implemented the necessary technology and applications to go beyond the standard product offering. When the market was growing, the company’s think tanks were under the pressure to make the most of this promising environment. Gradually, the company matured in terms of trained manpower and applied technology to meet these requirements. A A Qazi, Director, Precihole Machine Tools Pvt Ltd observes, “The main challenge was to optimise the process which we followed and expand the training of our employees. We have incorporated lean manufacturing in our system, which is not only helping us reduce and identify unnecessary waste processes, but is helping us increase the volume of products being manufactured at our plant without any added cost or investment.” As one of Precihole’s engineers explained during the visit, there are several challenges that arise when you are pioneering customised machines in a niche segment like DHDM. For example, when guard plates were made for gundrilling and BTA-drilling machines, a curved design was given to add a visual uniqueness to the product. However, the curved plates were difficult to manufacture and hence, the design had to be changed to reduce the curve only to the corners, making the plates more rectangular or linear and thus, easier to manufacture.

In essence, the Thane facility has a well trained team, headed by experts with over 20 years of experience in quality systems and industry procedures. To meet the complex specifications of the petrochemical industry, the company’s design team has successfully upgraded their systems constantly working to enhance product quality.

Future Outlook From ramping up their marketing to reenergising their branding, extending into larger facilities to applying the latest in production strategy, Precihole is primed to take-off in the global DMDH market. The company’s new facility situated in Kalyan, around 35 kms outside Mumbai, is in its final stage of completion. Regarding the expansion plan, Qazi explains, “The new facility, spread over more than one lakh sq ft, will help us double our capacity. We are planning to manufacture around 10 machines per month at our new facility. Apart from this, we are aggressively looking at overseas markets as well. There are some customers in the European market who are happy with our products and services and this has prompted us to focus on this market.” He further adds, “During the recession, many companies in the international market prioritised cost effective products, which was a very tough task in developed markets. That situation became an opportunity for us; we provided them with the same quality product at lower cost. Now they are placing repeat orders. We have skilled manpower who can deliver the same quality product at parity with global standards. Also, when we deliver the product to customers, we send our applications engineers to their plant ensuring proper installation.” Carving its future course, Precihole has already charted out its growth strategies and is now stepping ahead into an era promising exponential success. True to character, the company persistently strives to hone its technology through innovation and guarantees its customers top quality bang for their buck! nishant.kashyap@infomedia18.in tarun.tampi@infomedia18.in

April 2012 - MODERN MACHINE TOOLS

95


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Ad Name: Ceratazit Pg No. 97


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INSIGHTS & OUTLOOK GLOBAL MACHINE TOOL SURVEY 2011 & METROLOGY EQUIPMENT 102 Global Machine Tool Survey 2011 The World Survey at a Glance

106 One Q Many Views

Import Vs Export: Can India Ever Bridge This Gap?

108 One Q Many Views

Production Vs Consumption: Is India ready to be Among the Top Ten Global Machine Tool Producers?

114 Business Dynamics

Gauging the Metrological Momentum

116 Advance Metrology Systems Aiding Accuracy... Adding ‘Measurable’ Advantage

118 Digital Optical Comparator Fully Automated Part-to-CAD Measurement Verification

126 Nanometrology

Enabling Nanoscale Productivity

101 MODERN MACHINE TOOLS - April 2012


INSIGHTS & OUTLOOK Global Machine Tool Survey 2011

THE WORLD

D

ollar-volume production of machine tools around the world during 2011 grew at 35 per cent. Output by the 28 principal producing countries was $ 92.7 billion. That represents a gain from 2010’s $ 68.8-billion, which in turn had been an increase of one-quarter from 2009. The hole caused by the deep worldwide recession in 2009 was being filled. Biggest percentage increases in production came from Japan, Germany, France, China, the US, South Korea, and the UK, when measured in their own

AT A GLANCE currencies. Many showed even steeper year-to-year percentage increases when their output is converted to US dollars. China’s 32 per cent boost in shipments cements its place as numberone producer. At $ 27.7 billion in estimated output in 2011, China is more than $ 9.3-billion ahead of second-place Japan. Germany ranks third among producing countries. Output from those top three account for 64 per cent of 2011’s total world output measured in this survey. The US had a solid 25 per cent gain in production, which increased to $ 4.1

Rebound Complete

Production 1. 2. 3. 4. 5.

Country China Japan Germany Italy Korea, Rep. of

6. 7. 8. 9. 10.

Taiwan United States Switzerland Spain Austria

11. 12. 13. 14. 15.

2011 (est.) $-Millions Cut-Form 27,680.0 69-31% 18,353.1 89-11% 13,494.7 74-26% 6,232.6 49-51% 5,641.0 69-31%

2010 (rev.) $-Millions 20,910.0 11,971.4 9,488.8 5,017.9 4,498.0

Change in Change in local currency U.S. dollars $ 32% 39% 53% 35% 42% 18% 24% $ 25%

5,000.0 4,161.1 3,462.7 1,053.3 1,001.8

80-20% 73-27% 84-16% 64-36% 54-46%

3,877.0 3,340.1 2,395.2 836.9 844.0

29% $ 23% 20% 13%

29% 25% 45% 26% 19%

France Brazil Turkey United Kingdom Canada

930.7 873.4 668.0 658.0 c639.3

61-39% 81-19% 25-75% 72-28% 60-40%

662.2 837.4 555.0 507.2 c546.8

34% $ 20% 25% 17%

41% 4% 20% 30% 17%

16. 17. 18. 19. 20.

India Czech Republic Netherlands Belgium Russia

576.0 446.0 400.7 375.6 263.0

87-13% 80-20% 20-80% 20-80% 41-59%

512.0 372.0 317.8 298.0 219.0

13% 20% 20% 20% 20%

13% 20% 26% 26% 20%

21. 22. 23. 24. 25.

Sweden Finland Mexico Australia Denmark

218.4 166.9 c122.4 100.9 76.5

38-62% 20-80% 58-42% 86-14% 40-60%

207.9 135.1 c165.5 113.6 72.8

0% 18% $ $ 0%

5% 24% -26% -11% 5%

26. Portugal 27. Romania 28. Argentina

73.7 u42.5 32.3

21-79% 71-29% 50-50%

66.2 42.5 29.0

6% $ $

11% 0% 11%

Total

$92,744.7

$68,839.3

u = unrevised from previous year but converted at current rates c = circa; rough estimate from fragmentary reports. $ = reported in U.S. dollars. % = ratio of cutting/forming in some cases estimated from previous reports Source: Gardner Publications, Inc.

102 MODERN MACHINE TOOLS - April 2012

billion in 2011. Consumption grew at an even faster pace, up 53 per cent, as imports also zoomed. Largest consuming country in the world continues to be China, which installed an almost-unbelievable $ 38.4 billion worth of machine tools, one-third of it in imports. Looking at consumption on a per-capita basis China, with its huge population, in the past had ranked low. Now, with burgeoning local production and a continued low export pace, its expenditure per capita of $ 29/person/ year puts it in the middle of the pack, with the likes of Canada and Belgium.

35%

Taken as a whole, the global machinetool-producing industry finished making its comeback from the precipitous decline of 2009, in which some countries saw production fall by half. In 2011, total shipments by the national industries that participate in this World Machine Tool Output & Consumption Survey amounted to $ 92.7 billion, an increase of 35 per centover the $ 68.8 billion for 2010 (table, left). Moreover, that 2010 figure in turn represented a 26 per cent gain over the dismal sum of $ 54.7 billion for 2009. So, last year’s output just surpassed the total for 2008 when the downward slide started. But what may be true for producers at large does not necessarily apply evenly across the board. Calamitous drops and subsequent rebounds never treat all participants equally. Some weren’t hit by the recession as hard as others. China is the classic case in point: between 2008 and 2009, when every other country in the survey saw output decline, China’s increased 10 per cent, and its market share thus climbed (graph, below).


Global Machine Tool Survey 2011 Europe production shares shifted to 61 per cent and 32 per cent, respectively, and in 2011 the same percentages were seen (bar chart, above).

The China Factor

Another aspect has been the rate of recovery—call it the “bounce-back” factor. In the 2008-to-2009 comparison, six countries suffered production crashes of 50 per centor more. Of those, Japan and Taiwan subsequently have been able to post substantial increases (see last columns in Production table); France and the Czech Republic have showed only moderate resilience; and Finland and Denmark continued to have slumps and only in the past year have been able to post increases. United States production in that ’08-’09 crash dropped almost as precipitously—down 44 per cent—but it’s managed a 50 per cent comeback in 2010 and another 25 per cent gain last year. Other countries in the Americas have not been able to regain production rates as quickly however. One result of this uneven response to global market turmoil is a geographical shift in where most cutting and forming machine tools are made. During the recessionary 2009 and for several years prior, Asian countries produced around 48 per centof total world output while the 15 Western European countries in the CECIMO consortium built around 46 per cent. In 2010 those Asia/

The 13th-century travelogue of Marco Polo’s experiences in China gained avid attention in Europe. But after the first transcription its publisher quickly renamed it Il Milione (“The Million”), in a nod to his audience. European readers, it seems, couldn’t grasp the size and scope of the culture Polo described, so the title reflected the notion it was full of a ‘million’ lies. Westerners today sometimes

raise eyebrows at the pace of Chinese machine-tool expansion. Statistics here are reported in US dollars rather than yuan renminbi by the national builders’ trade association, and they reflect a continuing expansion of an industry strained to meet voracious domestic demand. China has been the world’s biggest consumer of machine tools since 2002; back then imports satisfied much of its requirements. Inevitably Chinese production of factory equipment grew as indigenous entities like Shenyang and Dalian MT Group integrated and expanded smaller factories and as builders in Taiwan, Japan and elsewhere opened Chinese facilities. For 2011, Chinese output of machine tools is estimated at $ 27.7billion, or more than the combined shipments of Italy, Korea, Taiwan, the

Exports Country

2011 (est.) $-Millions

2010 (rev.) $-Millions

Change in Change in Exports * as local U.S. dol% of 2011 currency lars Pdtn 37% 51% 62% 34% 41% 70% 30% 37% 71% 35% 35% 80% 22% 44% 85%

11,380.6 9,460.2 4,451.9 4,000.0 2,955.1

7,517.2 6,721.0 3,260.5 2,960.0 2,058.7

2,380.0 2,301.0 1,874.0 918.9 870.9

1,850.0 1,678.0 1,559.6 641.2 642.3

$ $ $ 36% 29%

29% 37% 20% 43% 36%

9% 41% 45% 87% 232%

820.3 818.5 747.1 484.1 473.0

743.6 629.7 513.8 401.3 441.0

5% 25% 38% 15% 7%

10% 30% 45% 21% 7%

82% 124% 80% 121% 106%

413.0 c266.2 179.5 139.1 107.8

380.8 c264.6 213.2 112.6 100.4

8% $ -20% 18% $

8% 1% -16% 24% 7%

62% 42% 82% 83% 12%

1. 2. 3. 4. 5.

Japan Germany Italy Taiwan Switzerland

6. 7. 8. 9. 10.

China, Peoples Rep. Korea, Rep. of United States Spain Belgium

11. 12. 13. 14. 15.

Austria United Kingdom France Netherlands Czech Republic

16. 17. 18. 19. 20.

Turkey Canada Sweden Finland Brazil

21. 22. 23. 24. 25.

Denmark Romania Australia Russia Portugal

96.0 u85.2 78.0 64.0 50.1

91.4 85.2 87.7 60.0 43.7

0% $ $ $ 9%

5% 0% -11% 7% 15%

125% 200% 77% 4% 68%

26. 27. 28.

Mexico India Argentina

c30.6 28.0 10.4

c41.4 22.0 11.0

$ 27% $

-26% 27% -5%

25% 5% 32%

* = includes re-exported machines u = unrevised from previous year but converted at current rates. c = circa; rough estimate from fragmentary reports. $ = reported in U.S. dollars. Source: Gardner Publications, Inc. April 2012 - MODERN MACHINE TOOLS 103


Global Machine Tool Survey 2011 US, Switzerland, Spain, and Austria. A different view of the global machine-tool scene comes from looking at consumption. For the purposes of this survey, consumption is defined as a country’s domestic production, less its exports, and plus its imports. It represents machines that have been installed. In 2011 the US showed the fastest growth rate in equipment consumption among all major indusrtrialised countries, with a 53 per cent increase in installations compared to 2010. It remains a solid fourth in the world in machine-tool consumption, after China, Japan, and Germany. It should be said, however, that

Consumption Country

2011 (est.)

2010 (rev.)

1. 2. 3. 4. 5.

China Japan Germany United States Korea, Rep. of

38,370.0 7,620.5 6,956.0 6,611.9 5,131.0

28,480.0 4,889.8 4,677.5 4,313.4 4,264.0

6. 7. 8. 9. 10.

Italy India Brazil Taiwan Mexico

2,963.3 2,352.0 1,990.0 1,800.0 c1,360.9

2,672.5 1,775.0 1,861.3 1,623.0 c1,060.4

11. 12. 13. 14. 15.

Russia Turkey Switzerland France Canada

1,317.0 1,285.0 1,240.7 1,182.5 c1,143.6

1,165.0 864.9 850.5 850.2 c848.8

16. 17. 18. 19. 20.

Austria United Kingdom Spain Sweden Netherlands

632.2 561.7 451.5 372.8 328.3

446.3 422.1 473.4 259.6 256.9

21. 22. 23. 24. 25.

Belgium Czech Republic Romania Argentina Australia

301.9 291.0 u243.0 211.5 167.0

252.9 130.0 243.0 146.3 220.9

26. 27. 28.

Finland Portugal Denmark

128.0 104.3 43.1

108.6 115.2 41.1

the growth rates, both in production and in consumption, may be starting to retreat from their catch-up pace of the past two years. Recent reports from trade associations that measure orders for new machines show a slackening in the pace of bookings, as pent-up demand is starting to become satisfied.

Asia’s Share Grows Total World Production $100-B $80-B $60-B $40-B $20-B

Trade Increases Whether output will continue at the current pace is unknown. What the WMTO&C Survey shows, however, is that imports and export activities in the past year have regained momentum. Japan and G e r m a n y continue as the Change Change in leading exporters in local U.S. currency dollars of machine $ 35% tools, but their 41% 56% percentage 42% 49% gains in 2011 $ 53% $ 20% exports were matched by the 6% 11% French, Koreans, $ 33% $ 7% Spaniards, 11% 11% Taiwanese, and $ 28% several others. 13% 13% American exports $ 49% grew 20 per cent. 24% 46% The top five 32% 39% $ 35% countries on the Exports table all 35% 42% 28% 33% show a very high -9% -5% ratio of exports to 37% 44% production. That 22% 28% metric, the last 14% 19% column in the $ 124% table, can provide 0% 0% $ 45% an interesting $

-24%

12% -14% 0%

18% -9% 5%

Apparent Consumption = local Production, less Exports, plus Imports u = unrevised from previous year but converted at current rates. c = circa; rough estimate from fragmentary reports. $ = reported in U.S. dollars. Source: Gardner Publications, Inc.

104 MODERN MACHINE TOOLS - April 2012

World Output by Region

2009 Asia

2010 W. Europe

2011 Americas

Asia excl Austr; W. Europe = CECIMO Source: WMTO&CS; Gardner Publications, Inc.

perspective on a nation’s reputation as a major supplier to outside countries. China, on the other hand, hardly exports at all; despite placing at sixth position with 2011 exports of nearly $ 2.4 billion, its shipments outside China are less than one-tenth of its production. The ratios must be viewed with caution, though. Some entrepôt nations like Belgium, Denmark, and Holland traditionally have exports that are far in excess of their production as they ship out machines that had been taken in for re-export. Similarly, the last column in the Imports table, which tracks imports as a percent of local consumption, can in some cases reflect port activity as much as import penetration. Nevertheless, survey figures provide insight to each country’s proclivity toward offshore sourcing. The United States with its very open market—showing an import penetration of 65 per cent—ranks number two in dollar-volume imports behind China. American equipment consumption grew 53% last year, and its 71 per cent change in imports suggests that much of that demand was filled from overseas. High import-penetration rates are also evident in Mexico, Russia, France, Turkey, and India during 2011. American dependence on foreign suppliers for its factory-equipment demand is also seen in its balance


Global Machine Tool Survey 2011 Patterns of Consumption

Per-Capita Consumption Country

1. 2. 3. 4. 5.

Switzerland Korea, Rep. of Germany Taiwan Austria

6. 7. 8. 9. 10.

Japan Italy Sweden Canada China

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

2011 Population Spend Consumption 000s $/capita $-Millions 1,240.7 7,604 $163.16 5,131.0 48,508 $105.78 6,956.0 82,329 $84.49 1,800.0 22,974 $78.35 632.2 8,215 $76.95 7,620.5 2,963.3 372.8 1,143.6 38,370.0

127,078 58,126 9,059 33,487 1,323,591

$59.97 $50.98 $41.16 $34.15 $28.99

Belgium Czech Republic Finland United States Netherlands

301.9 291.0 128.0 6,611.9 328.3

10,414 10,211 5,250 307,212 16,715

$28.99 $28.50 $24.38 $21.52 $19.64

France Turkey Mexico Spain Romania

1,182.5 1,285.0 1,360.9 451.5 243.0

64,420 76,805 111,211 40,525 22,215

$18.36 $16.73 $12.24 $11.14 $10.94

21. 22. 23. 24. 25.

Brazil Portugal Russia United Kingdom Australia

1,990.0 104.3 1,317.0 561.7 167.0

198,739 10,707 140,041 61,113 21,262

$10.01 $9.75 $9.40 $9.19 $7.85

26. 27. 28.

Denmark Argentina India

43.1 211.5 2,352.0

5,500 40,913 1,156,897

$7.84 $5.17 $2.03

Source: Gardner Publications, Inc.

of trade in machine tools. The largest exporters typically top the trade-balance rankings, and the largest importers are at the bottom. At a minus-$ 2.5 billion for 2011, American trade balance worsened dramatically from a negative-$ 975 million in 2010. The US has the second-poorest balance after China among countries that have domestic machine-toolproducing industries. Dollar-volume balance in machine-tool trade for 2011 is seen in the table below. Compared to 2010, the largest increases in positive trade balance were made by usual-leader Japan and by Germany, Switzerland, and Taiwan.

Another, perhaps more subtle, pattern emerges: one of consolidation. In 2011 the top five consumer countries accounted for installing 70 per cent of surveyed world output. By contrast, in 1995 the top five—namely the US, Germany, Japan, China, and Italy, in that order—purchased only 55 per cent of total surveyed output. One more way of looking at consumption is the amount each country spends compared to its population (right). Switzerland, at $163/Swiss, tops the list and has led for decades. China, with 1.3-billion people, not long ago had ranked with India at the bottom and now is in the middle.

If machine tools are the basic building blocks of manufacturing-based societies, then the rate at which a country installs new ones ought to say something about its pace of industrialization. For the past decade China has led the world in acquisition. For 2011 the pattern continues, and as the pie chart above shows, more than two-fifths of the output by value of the world’s machine-tool producers has been put in place on Chinese factory floors.

Source: Gardner Publications, Inc.

Imports Country

2011 (est.) $-Millions

2010 (rev.) $-Millions

Change in local currency

Change in U.S. dollars

Imports* as % of ‘11 cnsmptn

1. 2. 3. 4. 5.

China, Peoples Rep. United States Germany India Korea, Rep. of

13,070.0 4,324.8 2,921.5 1,804.0 1,791.0

9,420.0 2,532.9 1,909.7 1,285.0 1,444.0

$ $ 46% 40% $

39% 71% 53% 40% 24%

34% 65% 42% 77% 35%

6. 7. 8. 9. 10.

Mexico Brazil Italy Russia Turkey

c1,269.1 1,224.4 1,182.5 1,118.0 1,030.0

c936.3 1,124.3 915.1 1,006.0 690.7

$ $ 23% 11% 49%

36% 9% 29% 11% 49%

93% 62% 40% 85% 80%

11. 12. 13. 14. 15.

France Taiwan Belgium Canada Switzerland

998.9 800.0 797.2 c770.5 733.1

701.9 706.0 597.3 c566.5 514.0

35% 13% 27% $ 21%

42% 13% 33% 36% 43%

84% 44% 264% 67% 59%

16. 17. 18. 19. 20.

United Kingdom Japan Austria Netherlands Sweden

722.2 648.0 450.6 411.8 333.9

544.6 435.6 345.9 340.4 264.9

28% 35% 24% 15% 20%

33% 49% 30% 21% 26%

129% 9% 71% 125% 90%

21. 22. 23. 24. 25.

Czech Republic Spain Romania Argentina Australia

318.0 317.2 u285.7 189.6 144.0

199.0 277.7 285.7 128.3 195.1

60% 9% $ $ $

60% 14% 0% 48% -26%

109% 70% 118% 90% 86%

100.2 80.7 62.6

86.1 92.7 59.6

11% -17% 0%

16% -13% 5%

78% 77% 145%

26. Finland 27. Portugal 28. Denmark

* = includes machines imported for re-export u = unrevised from previous year but converted at current rates. c = circa; rough estimate from fragmentary reports. $ = reported in U.S. dollars. Source: Gardner Publications, Inc.

April 2012 - MODERN MACHINE TOOLS 105


ONE Q MANY VIEWS Import Vs Export

CAN INDIA EVER

THIS GAP?

With so big a nation, the Indian industry has forever been caught in the dilemma of ways to meet the domestic demand. Failing to meet the requirement, the country’s dependence on imports has consistently gone up. The 2012 World Machine Tool Output & Consumption Survey by Gardner Publication has rated India as the fourth highest importer in the world while the country trails down at the bottom of the list at the 27th spot to become one of the lowest exporters. Debarati Basu asks the industry leaders to point out the measures which need to be taken to bridge this gap and indulge in exports. Here is what they said…

Vikram Sirur, President, Indian Machine Tool Maufacturers’ Association

Tosher Hormusjee, Director, G W Precision Tools India Ltd. Indian machine tool as a capital sector is bound to be higher in import than in export level. If you want to make world class products you would require world class machine tools as well. There is not a single machine manufacturer in the country who can provide the standard that is required. Also, the metrology equipments which is required to ensure quality is not there. The quality required is not available in the country and therefore there is no choice but to import this. Against this, the local demand is so huge that all that is manufactured is consumed internally and the local requirement is not necessarily of export quality. For high production and high efficiency, we require machine tools specific to the requirement. Whereas, India mostly has generic tools. One measure which needs to be taken is to strengthen the small scale industries. We can have many Bosch, Mahindras and Tatas, but ultimately it is the SMEs who support them. We have to create an atmosphere and a situation in which SMEs’ growth is treated as paramount and proper infrastructure should be provided to them.

The main reason is the technological gap because of which we still have to depend on import and this is the reason why our machines are not fit for export as it does not match the quality parameters set according to the global standards. We also need to work closely with the government so that certain things can be put in place and we too will be able to garner the quality and quantity required for reducing the dependence on imports. The industry is working in this direction so that in the next 15 years we can match the level of quality required by the global market.

Verdict The industry certainly needs to indulge in more research activities to create new technology and increase the quality products which are fit for exports. And all of this will only be possible when the small scale industries see a balanced growth and support to double its contribution in adding numbers to domestic manufacturing.

Sreekanteswar S, President- India Sales and Operations, Korber Schleifring GmbH The imports happening are in terms of high end, high accuracy high performance reliable machines. The local manufacturers are however producing high volume low cost machines. This is the reason why the Indian contribution to the machine tool manufacturing is just 23 percent and 77 percent is imported. The volume of imported machine is low but the cost of high end machines, high accuracy machines are very high. There are three important things which need to be changed. We primarily have to increase the technology and reliability of the machines so that we can make it fit for exporting them in a big way. Secondly, the sub suppliers of critical parts like ball screws etc is not available in India and we instead import the technology or the machine or import the components at high cost which subsequently increases the cost of the final product. Third, innovation is the key. We cannot simply duplicate imported products. We instead have to come up with innovatively designed products which are low in cost and provide the same level of quality parameters.

debarati.basu@infomedia18.in

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ONE Q MANY VIEWS Production Vs Consumption

IS INDIA READY TO BE AMONG THE TOP TEN

GLOBAL MACHINE TOOL PRODUCERS

?

According to the latest global machine tools industry survey, India stands as the 7th largest consumer of machine tools but finds itself down the list at the 16th spot for its production capacity. This clearly quantifies the huge demand-supply gap and the urgent need to scale up domestic production. Nishant Kashyap talks to leaders in the Indian machine tools industry to find out ways in which India can balance this demand-supply gap. Nikhil Nayak, Managing Director, NN Combined Engineering Agencies Pvt Ltd

It is a fact that the consumption of imports is fast increasing in the industry and this is a reflection on the growing maturity of the industry. As the industry matures, the need for quality and reliability becomes more important. Indian industries today are increasingly linked to higher quality standards either as a result of international companies participating in the India growth story or as they seek to participate in the global supply chain. In order to meet the growing demands of the industry, Indian manufacturing has to efficiently “scale� up production and quality. Government policy is a very important factor and the National Manufacturing Policy is a very big step in that direction. The programs detailed in the policy have to be implemented efficiently to help us move forward in this area. Quite simply, if manufacturing growth is a priority then all that industry and government have to do is identify the factors impending growth and find ways to alleviate the problems. A lot can be learned from the gains made by the IT industry in this area.

Ramesan Kallorath, Managing Partner, Digi Mold, India

To bridge the widening chasm between surging demand and indigenous production, there are several areas where solutions need to be implemented. Government support in terms of policies, subsidies, technology transfers and facilities is poor in India. Further, customers in India lack the technical know-how in design and production to understand what is possible for mould manufacturers, leading to constant re-design of the component, hindering the need for shorter runs and turn-around times. There is also a fundamental shortage of capacity which until satisfied, results in orders being turned down. Resolving these hurdles would leave nothing in the way of Indian manufacturers realising their global potential.

Anil Kumar, Vice President - Marketing & Technology Services, CERATIZIT India Pvt Ltd

Demand is very high for machine tools in India and that is the reason we are in the top ten rankings. Demand for the machines mainly depends on the fact that consumers want high quality machines at low cost. When it comes to low cost machines, we are lagging behind China, Korea and Taiwan and when it comes to high quality machines within India, there are not many options besides German and Japanese technology. Indian companies need to invest much more in research and development. They should intensify focus on design activities. Skilled manpower is also one of the biggest concerns in India so they should invest in training and development activities as well.

Verdict The manufacturing sector in India was largely unaffected by the global economic recession as demand and orders in domestic as well as international markets grew steadily. Domestic manufacturers are aiming to achieve 50 per cent market share by 2017, despite fierce global competition, and in order to do that, several initiatives need to be taken in tandem, by the government and native manufacturing companies. nishant.kashyap@infomedia18.in

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INSIGHTS & OUTLOOK Business Dynamics

The field of industrial metrology relies heavily on the Coordinate Measuring Machine (CMM) to verify the precision, reliability and accuracy of manufactured products. As Indian manufacturers focus on exports, the quality checkups at every stage become very important. Nishant Kashyap tracks the rise of home grown metrology companies and how it will change the overall dynamics of the quality in the Indian manufacturing

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pcoming sectors like infrastructure, nuclear, aerospace, defence equipment, energy, medical and power are fuelling the demand for high precision metrology systems in the country. Many metrology technologies like CMM, portable CMMs, laser probe technology are gaining acceptance and applicability within the industry.

Demand Trend The biggest growth factor for CMMs is India’s ‘Manufacturing Hub’ tag. Ever since global companies have setup their base in the country, the demand for CMMs is on the rise. To make the product at par with the global standards every component and equipment provider has to deliver the product with high precision and after passing all quality checkups. Apart from the traditional customers like automobile and heavy engineering, other sectors like medical equipment, energy, aerospace, electrical & electronics, etc have entered into India in a big way. All these industries require very small components, which needs to be manufactured using cutting age technologies. As inspection and 114 MODERN MACHINE TOOLS - April 2012

measurement is one of the key processes to ensure the product quality, CMMs become the most essential apparatus in any products manufacturing process. On the demand trend, M Kumara Giri, Regional Manager – FARO Business Technologies India explains “Currently the demand for laser technology has increased. But 10 years back we all used parts which were positions oriented. Now most of the parts are profile oriented and very critical. Die and mould manufacturers prefer laser technology. If you consider any big die and mould manufacturer, once the part is semi finished they validate the part before final finish. It is not just in India, worldwide the demand for the laser tech is on the rise.”

Adoption of CMMs Earlier Indian companies were always focussed on high volume manufacturing; to achieve this, quality was not given much attention. Indian companies were not really concerned about investing on quality control machines and techniques. Lately all companies have realised that to be competitive and to become a global player they have to have a proper quality control systems in place. To accomplish

the quality standard and increase productivity many Indian companies including SMEs have installed proper measuring and inspection instrument into their systems. “Today, along with Tier I companies, the Tier II and Tier III customers are also gearing up to adopt CMMs. Apart from this, there are many global players coming into market and they insist on quality, so we follow and have to fulfil the customers expectations.” avers Giri. Many Indian manufacturing companies have started exporting products worldwide, which is one of the main reasons for adoption of CMMs, as they have to match the global standards. Apart from the global companies; Indian customers have also become more demanding and are forcing companies to adopt CMMs and have proper quality control procedure.

Adding Productivity Reduction of errors and increasing repeatability has been the core focus areas of metrology system manufacturers for better customer satisfaction. These features help them add quality and trust factor in their products. Connecting highly reliable measuring instruments to machining lines has helped manufacturing companies to address the challenge of delivering high-quality products, which are at par with global standards. Commitment to quality is a continuous process. New technology, equipment, products and applications have led to a continuous change in the manufacturing line across machine tool industry. As India strengthens its base as an automotive hub, with concurrent steps


Business Dynamics towards increasing volume of business coming in from the aerospace and medical industry, digital inspection process significantly advances the performance benchmarks of CMM productivity. The manufacturers of metrology products have joined hands with the industry leaders and standardsetting organisations to work out an open metrology technology platform that allow unhindered interoperability between different makes & kinds of CMMs and other inspection equipment to avoid huge capital investments in replacing obsolete metrology equipment.

Changing Dynamics Indian manufacturers were always dependent on global OEMs for high precision metrology devices. However, today there are new domestic players entering the market and gearing up to be in sync with the global parameters of accuracy and precision especially in cost effectiveness. This has not only increased the access of high precision metrology

Reasons to Invest in CMM    

Tap global market requirements with quality at par with global standards Improve existing measurement system’s efficiency to achieve the highest possible accuracy Identify and rectify smallest uncertainty in measurements Monitor the process with suitable measurement systems

system for SMEs, but is also helping them in productivity enhancement. As yet, many SMEs have not installed CMMs on their shop floor, and using the manual and conventional measuring methods. Simply, the reason is high investment, skill manpower and special maintenance. Not having a proper measuring system also affects the overall productivity. Sensing the demand from the SMEs, few Indian companies have started manufacturing CMMs and providing other cost effective metrology solutions. The

result of home grown metrology system can directly be seen as growth and productivity enhancement of Indian SMEs.

Future Outlook As the manufacturing industry is bullish on the future growth prospects, the optimism also spills over to the metrology industry. The key factor that sets one company apart from the other continues to be of quality and trust in the brand & products that promise to help companies reduce their time and money spent on quality checks. Factors like standardisation and globalisation have increased the level of precision needs in the country. India is gradually establishing its image as one of the biggest economies of the world, and this has positively affected the sale of CMMs. With new avenues like aerospace and wind power giving the metrology industry a shot in the arm, the future looks positive for metrology solution providers. nishant.kashyap@infomedia18.in

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Courtesy: Renishaw Plc.

INSIGHTS & OUTLOOK Advance Metrology Systems

Aiding Accuracy... Adding ‘Measurable’ Advantage Is the manufacturing process undergoing a transition? The demand for better metrology systems which can effectively provide multi axis measurements is rising. Tarun Tampi finds out how new metrology systems like 3D coordinate machines, laser tool probing and improved sensors are trying to make the measurement process extremely quick, increasing precision and accuracy in measurement.

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etrology is fundamentally driven by the need for information; the need to know every measurable aspect of a product for certain and to make decisions based on this certainty. The evolution of metrology has come a long way since hands and feet were units of measurement. Today with nanometrology, we are beginning to accurately measure what we can’t see, from the atomic to the macroscopic. Advances in metrology are primarily driven by factors of speed, accuracy, measurement size, environmental control and lower costs. This article will talk about the emerging technologies on the very edge.

Metro-tomography This is an application of computer tomography, where X-rays are used to scan a rotating part to obtain an accurate 3-D model. This 3-D model can be converted 116 MODERN MACHINE TOOLS - April 2012

into various formats, including CAD, for part analysis. This non-destructive measurement of a component allows, in addition to traditional evaluation, for material and assembly inspection as well as porosity, damage and defect analysis. Parts with interiors or very complex parts can be measured completely, quickly and easily. The process is highly automated and requires minimal training. While providing vast amounts of information in a single scan it allows for reverse engineering applications, geometry comparisons and process optimisation.

used along with lasers or infrared light to measure objects at distances of a few hundred feet. No calibration or custom fixtures are needed, unlike traditional CMM’s. Rapid digital data collection is possible using PCMM software and the user can also compare dimensional data to a CAD file directly. This does away with the use of hand tools, gauges and single dimension measurement devices. PCMM’s are increasingly robust and only limited by the reach of the articulated arm, although it can be repositioned as required, such is its flexibility. It can also be combined with laser scanning to provide 3D measurements.

Portable Coordinate Measuring Machine (PCMM)

Multi-sensor Measuring

Unlike traditional stationary CMM’s, portable CMM’s allow for versatile use of a CMM anywhere on the shop floor or industrial site, at any stage of production. A touch probe is mounted on the end of a highly articulated, lightweight arm. It has six degrees of freedom and can be

These involve the use of more than one sensor in one machine that is automated and uses software to manage the sensors. It can involve the use of chromatic point sensors, confocal microscopes, white light interferometers, film thickness sensors and atomic force microscopes.


Advance Metrology Systems There are vision sensors, touch-trigger probes, analog scanners and laser sensors which can all be used now on a common platform using a single software package. In some cases, over 20,000 data points can be gathered per second. If there is a conflict between sensors, for example, a trade-off in accuracy and speed between laser and analog scanning, multi-sensor machines can be programmed to switch automatically to optimise the measurement, minimising cost per measurement. They also save time by combining measurement processes, like video metrology with a touch probe, thus eliminating the need for repeated calibration and reducing the need for multiple measurement fixtures. With improved integration of sensors, between themselves and with CAD models, multisensor measuring machines are the way of the future, increasing choice and potential in productivity and inspection quality.

Lasers Tracking This technology has come a long way since its inception. It involves the use of laser

beams to measure objects within the accuracy of a few microns within a range of tens of meters. The beam follows a retro-reflective target, placed wherever a measurement is needed on the part, and records distance, azimuth and elevation which are converted into cartesian coordinates. The tracker is easy to use, can measure large parts, requires only a single operator and can quickly provide high value measurements. Laser trackers can be integrated with robotics or be made part of the assembly line as a metrology tool. Another great example is Equator, a radical new gauging system developed and patented by Renishaw. It combines the flexibility and versatility of CMM’s with the quick accuracy of hard gauges. A production line part can be directly used as a master part through the calibration file from a CMM. It uses a parallel kinematic structure which greatly reduces time spent in setup and calibration while maintaining stiffness for repeatability. Several parts, from different machines, can be measured in a matter of minutes with a comparison

accuracy of 0.002 mm. The stylus can be quickly reconfigured in an integrated stylus changing rack, allowing for high speed comparative gauging of high volume production parts. Since it can be calibrated for thermal measurements as well, it can be used directly on the shop floor with customisable measuring software thus reducing waiting time and gauge costs. This technology was developed in collaboration with and for use in automotive, aerospace, medical and other component manufacturing industries. As non-contact sensors and vision inspection systems develop further, software is being improved to integrate several such sensors and interface with the design to compare geometries and ensure accuracy. Reducing inspection time and costs at a stage where parts are becoming smaller, more complex and more precise, is becoming easier as point-cloud software meets multisensor technology, as retrofitted sensor technology meets CMM’s and as particlemicroscopes meet nanometrology. tarun.tampi@infomedia18.in

April 2012 - MODERN MACHINE TOOLS 117


INSIGHTS & OUTLOOK Digital Optical Comparator

 The VisionGauge digital optical comparator uses a highresolution digital camera and a low-distortion telecentric lens to capture a high resolution image that exactly matches the part geometrically

Fully Automated PART-TO-CAD MEASUREMENT

VERIFICATION The complex geometries of parts that are produced in today’s shops are known to have tight tolerances that require highly detailed measurement for quality control. But to stay competitive, shops need to make sure these inspection operations do not add unnecessary time to the production process.

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ptical comparators, or profile or contour projectors, are often used to verify that these manufactured parts are within tolerance. They provide a comparison between a part and its drawing to allow the operator to make an overall pass/fail determination. These instruments are easy to use and are well suited for use on the shop floor as well as in metrology and QC labs. While these measuring tools are generally considered to be versatile and cost effective, their dependence on an overlay (also called a template or Mylar) can be viewed as a drawback. 118 MODERN MACHINE TOOLS - April 2012

Besides the added cost and time for printing, calibration and setup, these overlays can increase the likelihood of operator error.

Going Digital The VisionGauge digital optical comparator was designed to alleviate possible concerns with traditional optical comparators. Developed by VISIONx and distributed in North America by Methods Machine Tools Inc, the instrument uses a high resolution digital camera and a low-distortion telecentric lens to capture a high resolution image that exactly matches the part geometrically. The instrument’s software

then projects the images, along with the part’s CAD overlay, onto a quad monitor display. The software’s Auto-Align tool automatically aligns the CAD data to the part. The tool typically takes less than two seconds to produce its result, and its operation is very straightforward. Auto-Align produce repeatable and accurate results that are completely operator-independent. It supports both XY and XY-rotation alignment of the CAD drawing to the part. The automated functionality helps users to reduce inspection times and obtain increased accuracy, lining the CAD drawing up with the part along one or


Digital Optical Comparator

 The Auto-Align tool allows users to reduce inspection times and obtain increased accuracy by lining up the CAD drawing with the part along one or multiple data points

multiple data points or doing an overall ‘best fit’ alignment. The auto pass/fail tool automatically determines, accurately and in real-time, if a part is within tolerance. It can be point-based or can consider complete geometric entities, and it can perform both operations simultaneously on the same part. In point-based mode, the part’s deviation from nominal is evaluated at precise user-specified crosssections to verify that the part is within tolerance at all of these locations. The geometry-based auto pass/fail tool verifies that the part is within tolerance over complete geometric entities. It supports bi-directional tolerances and imposes no restrictions on the

tolerance values. Therefore, tolerances can be either the standard “plus/minus” tolerances or “minus/minus” and “plus/ plus” tolerances. “We are very excited about the release of these new CAD Auto-Align and Auto Pass-Fail tools to enable the fully automated verification of a part against its CAD data,” says Patrick Beauchemin, VISIONx president. “These innovative new tools have been extensively validated at key customer sites, and all of the early adopters are delighted with the benefits that these new tools provide.”

Saving Time The digital optical comparator can act

 The digital optical comparator is designed for precision part verification in a range of industries including orthopedics, medical device manufacturing, automotive, aerospace and energy

120 MODERN MACHINE TOOLS - April 2012

as a fully digital, drop-in replacement for a traditional optical comparator. It works directly with the part’s CAD data and does not require any overlays, Mylars or templates. The comparators are available in industry standard 5×, 10×, 20×, 50× and 100× magnifications. Systems are Windows based and deliver a network-ready “rolling cart” configuration for ease of use on the shop floor. Built for speed and accuracy, the comparators can be set up to automatically collect complete electronic documentation and device history. Because the systems are software driven, all operations can be automated. As a result, it is possible to operate the system using only a bar code reader and a joystick, increasing productivity. The digital optical comparator’s camera produces a digital image that is sent to the system’s on-board computer. The software can then carry out further corrections on the image to eliminate the last minute geometric distortions and inaccuracies. The mathematical corrections to the image make it virtually perfect. Like traditional optical comparators, the VisionGauge uses collimated back illumination to produce clear and crisp images with sharp edge profiles. But instead of halogen bulbs, this system uses longer lasting LED technology that can provide stable illumination for as much as 10 years. As with traditional optical comparators, front illumination is also available for operations such as surface inspection. Since its introduction in September 2009, this innovative digital optical comparator has found its way into a range of industries, including medical device and orthopedic manufacturing, aerospace, cutting tool manufacturing, automotive and general machining. It is also appropriate for higher magnification and very high accuracy applications such as Micro ElectroMechanical Systems (MEMS) device manufacturing, electronics and semiconductor. Courtesy: MMS Magazine


MMT APR-2012 AD NAME: KOREA PG NO. 123


MMT APR-2012 AD NAME: PREMBROTHER

PG NO. 124


MMT Apr-2012 Ad Name:Samkrish Pg No. 121


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INSIGHTS & OUTLOOK Nanometrology

Enabling NANOSCALE Productivity

This is the era of microtechnology to nanotechnology, which require special metrologies and production methods for the realisation of manufacturing accuracies in the nanometric range. Nishant Kashyap takes a look at some of the application areas and importance of nanometrology.

Courtesy: Renishaw Plc.

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anometrology essentially refers to the science of measurement at a nanoscale level. Nanometrology has a vital role in manufacturing technology—producing nanomaterials and devices where the requirements are highly demanding and challenging. Moving from manufacturing, nanometrology now encompasses measurement of species or events on a nano-scale also. After the end of the 20th century, the development in the metrology field has reached nanometrology and will further proceed to picometrology. The past 40 years have noted the increasing importance of computeraided production metrology as a means to control industrial manufacturing, to test technical products with high accuracy on the basis of geometrical product specifications and verification, and to improve the quality of all kinds of products and processes. Therefore a sophisticated measurement technique must be considered as a very crucial requirement for the production of industrial goods of controlled and optimised quality. 126 MODERN MACHINE TOOLS - April 2012

Why Nanometrology? The problems of the work piece accuracy in modern industrial production technique gained increased importance in the last few years through constantly increasing demands on the quality of the parts produced. As the tolerances of workpieces and their features decrease the interaction and correlation between the dimensional tolerances and surface finish becomes more important, which demand for nanometrology. Consumer products like pocket cellular telephones, air bags, fax machines, video game players require length measurements many times finer than human eyes can observe, all these products required precision measurements of length voltage, frequency, velocity, pressure, radiation and temperature. Apart from this, medical equipment device and semiconductor industry and chip manufacturers have also created huge demand for nanometrology.

Mechanical Nanometrology This is a key technology required to support the important industrial sector of thin films and coatings in

industrial applications. It is also important for the development of micro and nanotechnology devices and components. Nano-indentation, or nanoscale instrumented indentation testing is one of the very few techniques that can measure both the elastic and plastic properties of very small volumes of materials and so, this is one of the most useful test methods for determining the mechanical properties of nanosized elements of materials or coatings. Nano-indentation allows for the measurement of other properties such as modulus, creep and viscoelasticity as well as hardness. Besides, applications in material research, nanoindentation is now widely used for quality assurance in industry, mainly in the microelectronics industry and microsystems technology.

Electrical Nanometrology This technique became increasingly important during the last two decades. This is mostly due to the semiconductor industry where failure analysis and optimisation of nanoelectronic devices demand knowledge of their electrical properties.


Nanometrology nanotubes, nanowires, etc has drastically increased the demands for the nanometrology. The characterisation of materials is an important part in these objects development process and it serves two broad purposes. Firstly, as part of the R&D into new processes, materials and products, and secondly as quality control and assurance during the pilot plant and manufacturing stages. There are numerous techniques used to determine the dimensional properties of nanoparticles. However, the techniques can be broadly broken down into three groups. The first group is ensemble techniques where a large number of particles are analysed simultaneously, for example Dynamic Light Scattering (DLS) and small angle x-ray scattering. The second group is imaging techniques that analyse individual particles using high-powered microscopic techniques (such as SPM or electron microscopy), where a large amount of information can be obtained on small numbers of particles (typically 200–1000) out of a sample size of many millions. The third group covers the methods that perform a classification of the nanoparticles in terms of their (apparent) size. These techniques are now well accepted in the development of new materials.

Electrical industry has become one of the biggest customers of nanometrology in recent years, as the demand from consumer’s for devices such as mobile, television, camera, computers, etc have increased substantially. All these electronic devices have several nano components, which demand nanometrology and micromachining systems. Laser probing systems and portable CMMs have been well accepted by this industry for measuring small components like chip, semiconductors, power supply unit, processor, motherboard, memory card, video card, etc that needs special attention while producing.

Nanometrology of Structured Materials Nanostructured materials have internal or surface structure at the nanoscale. Whilst these types of material have been produced for many years, recent advances in manufacturing now mean that nanostructured materials with new properties are being produced. It is important to fully characterise these materials on the nanoscale and build a relationship between this and the macroscale. The manufacturing route for the nanoscale component is, to be produced separately from the final material as nano-objects and then incorporated into the final structure. Measurement of nano-objects such as nanoparticles, ACHIEVABLE ACCURACY 0.1mm 0.01mm lμm 0.lμm 0.0lμm 0.00lμm (1nm) 0.3nm

Future Trends According to industry sources, the global market for nanotechnology Measuring instruments

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Mechanical Comparators

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 Achievable manufacturing accuracy and dimensional metrology and measuring instruments respectively

is predicted to reach $ 1 trillion by 2015. However, without the ability to measure and characterise molecules at the resolution of a nanometre level, much of the predicted potential of nanotechnology will not be achievable. The current global measurement infrastructure is rapidly extending into the nanoscale and beyond, to bring nanotechnology based products or manufacturing processes successfully and safely into the marketplace. It must provide the ability to measure in three dimensions with atomic resolution over large areas. For industrial application this must be achieved at a suitable speed/throughput. In the future, this industry is likely to see rise in demand for nanometrology. In coming years the science and innovation programme in nanometrology will find new directions to help shape the future areas of importance in nanomedicine and the design of new structural materials, while facilitating knowledge transfer into the healthcare, chemical, semiconductor and instrumentation industries. To meet the needs of this emerging manufacturing community it is important to boost and scale-up the research of nanotechnology for high rate production, reliability, robustness, yield, efficiency and cost issues for manufacturing products and services. To achieve this, new research directions must include a systems approach that encompasses nanoscale materials and structures, fabrication and integration processes, production equipment and characterisation of instrumentation and control tools, biomimetic design and integration of multi-scale functional systems, three dimensional nanoscale metrology, production-hardened metrology, and other areas driven by industrial applications. The impact is expected in energy systems, electronics, medical/health, transportation, pharmaceutical, chemicals, defense and aerospace sectors. nishant.kashyap@infomedia18.in

April 2012 - MODERN MACHINE TOOLS 127


AUTOMATION TRENDS Die & Mould Manufacturing

Engineering

ptimal Design Simulations Registering a phenomenal growth, the die & mould sector is garnering user attention with its latest technological advancements, especially engineering simulation and design optimisation. Nishant Kashyap traces latest software developments in sheet metal and mould making process and how it has changed the way dies and moulds are manufactured.

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he automation industry has witnessed a surge in the recent past, with the increased importance in design, especially in the manufacturing and Architecture, Engineering & Construction (AEC) verticals. Any company—large or small—looking to stay ahead in a highly dynamic and competitive ecosystem needs to deploy the latest CAD/CAM and simulation solutions in their systems. Also, such solutions provide a competitive edge for companies to outinnovate their competitors and deliver products faster, command marketshare and maximise a product’s potential. As dies and moulds are the back bone of many industries, there have been many automated technologies developed which are helping manufacturers to produce the product in high speed with better productivity. In today’s fast paced world, the automation systems have become an essential element in die mould manufacturing companies. Mould makers faces many challenges in the competitive business environment and it’s very crucial for them to upgrade technologically to survive global competition, which has resulted in the development of many die 128 MODERN MACHINE TOOLS - April 2012

& mould related software’s and adoption of these solutions by the die & mould manufacturers.

The Evolution Machining complicate shapes with high accuracy was the most challenging task in the early years for the dies & moulds industry. It is now moving towards automation to achieve high end machining. The implementation of automation in the dies and moulds industry is driven by many factors, including shortage of skilled labour and high labour cost. There is a need to reduce lead time, and achieve higher level of accuracy & repeatability. Automating Sambit Pradhan, Manager Business Developement (Asia Pacific), Geometric Ltd Complete process of die & mould from design to manufacturing can be automated, tools can be developed to map the organisation standards practices of design and manufacturing processes and take help of the latest technologies to automate it

the recent developments in automation provide significant benefits for HighPerformance Machining (HPM) of electrodes and steel mould components. In earlier days die & mould were manufactured using traditional methods and conventional machines which required highly skilled manpower and domain experts. This leads to inconsistency in productivity & quality as skilled manpower & domain experts were not readily available. “Currently Automation has helped in getting rid of the earlier issues and helps in automating the complete process of die & mould manufacturing which includes mould CAD designing & CAM process without any manual intervention. Now things are changing because of latest technologies and development in hi tech machineries and CAD/CAM tools. It helps in automating the manufacturing process , reducing time to market, and consistency in quality”, says, Sambit Pradhan, Manager - Business Developement (Asia Pacific), Geometric Ltd. The use of highly accurate palletising for work pieces and electrodes on HPM and EDM machines is widely credited with reducing the set-up times on machines


Die & Mould Manufacturing and improving the overall tolerance levels. The use of these systems enables high levels of throughput and significant improvements in accuracy & repeatability across components. The standardisation of these palletising units also allows jobs to be targeted for a range of different machines within the shop. This flexibility can significantly increase throughput while reducing the scheduling complexity.

Benefits of Automation Today, mould manufacturers need to develop mould designs that are more accurate, save time, and improve profitability. With newly developed software solutions, not only does one have the ability to define mould geometry, but one can also have access to a wide range of automated mould design tools. As a result, it is possible to validate critical aspects of mould designs before releasing them for production. Further, one can automatically identify undercuts, complete side cores, verify draft angles, define parting lines, create parting surfaces, assess proper fill characteristics, and ensure mould durability. The role of software today, goes hand in hand with the manufacturing industry. 3D simulation not only eliminates errors, but also gives the manufacturer an opportunity to visualise the path and act according to fastest machining. Pradhan says, “Complete process of die & mould from design to manufacturing can be automated, tools can be developed to map the organisation standards practices of design and manufacturing processes and take help of the latest technologies to automate it. For example Once the CAD design is ready automation can help in getting the die design done automatically and then move into manufacturing where the CAM process is automated using the best practices of the organisation. Other intermediate process also can be mapped and linked to the automation tool so that the complete process operates seamlessly.� The output of dies is tremendously complemented as it reduces the trial and error method and advances the scope of manufacturing and time taken for the output of a die or mould. Tool & die makers are hard-pressed to cut down on lead times and optimise the material/tool costs to compete in this demanding market. This has led to increased use of software solutions to simulate the outcome of the processes, long before the dies are built or even designed.

Forecast In the era of delivering quality in products, there is no limit in the speed of machining and production. The definition of high speed machining has changed. With the right automation solution companies can achieve every parameter to be perfect solution provider. The die & mould industry will continue to demand more advanced softwares that cost less than the existing ones. Industry will need more efforts to develop better quality mould parts economically and locally. In future higher productivity and efficiency will depend on the collaboration of both the industries. nishant.kashyap@infomedia18.in

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STRATEGY Strengthening Business

How a Global Builder Handles

?

CHANGES AROUND THE WORLD

In a bid to counter the yen’s strength versus the US dollar, Yamazaki Mazak Corp (Oguchi, Aichi, Japan) has chosen two means: imports from America and price hikes (widely seen as taboo in China’s emerging market).

T

he US unit of Mazak had raised prices in June 2011, following a similar move by competitor Okuma America. Then came the plan to have Mazak Corp (Florence, Ky) export a total of 15-20 units per month of more low-end compact, and medium-size lathe models in October. According to the Mazak Group, the reverse imports, as the Japanese call such an arrangement, were in the past intended to help meet temporary excessive demand from Japanese users. In addition, the US subsidiary will soon, for the first time, export to South America and Asia outside of Japan, starting at about ten units per month of two compact lathe models. 130 MODERN MACHINE TOOLS - April 2012

Meanwhile, for the first time since it began production in 2000, Yamazaki’s Little Giant Machine Tool Corp Ltd (Yinchuan, Ningxia Hui Autonomous Region, China) raised by 5 per cent its prices for Chinese users. That was possible because of the strong demand for all the plant’s machines, including two horizontal-spindle machining centers added in 2011, according to President, Tomohisa Yamazaki at the parent company. He also predicted that the original Chinese unit’s capacity would rise to 270 units per month, up 70 per cent, alleviating the fourto five-month wait that Chinese users typically encounter. Yamazaki Mazak also has started construction of its newest plant,

choosing Dalian in China’s Liaoning Province, the city that already houses Dalian Machine Tool Group, the country’s largest builder. Some 200 joined in the Oct. 19 groundbreaking; the Mazak facility will be run by a new unit-Yamazaki Mazak Machine Tool (Liaoning) Co. Ltd. Completion is slated for the end of 2012. A year later it is expected to assemble 100 units per month of small lathes and machining centers. Mazak invested $ 65-million including land, plant and equipment as well as parts facilities. The Dalian project includes parts and components to be used by Mazak plants worldwide. (The company nine factory complexes around the world include five in Japan.) For Chinese customers, it will offer


Strengthening Business post-sales services including repair of main spindles, which to date have had to be done in Japan, incurring shipping costs and added time. Mazak expects the Dalian factory will slash parts production costs and counter the yen’s quick rise versus currencies in the US and other countries. According to Motohiko Yokoyama, JTEKT Corp, Chairman and current chairman of the Japan Machine Tool Builders’ Association, currency problems are faced not only by Yamazaki Mazak but other Japanese builders. He adds that some of his group’s members also faced continuing power shortages from the earthquake/tsunami earlier in the year. The builder also plans expansion at its Yamazaki Mazak Singapore Pte Ltd. location founded in 1988 in that state’s Jurong Industrial District, with the construction of a new factory building adjacent to its existing one. The original, 200,000 sq.ft. plant produces 70 compact lathes per month; the new one will assemble 50 machining centers per month. The Singapore enterprise is seen internally as an entrée to markets in India and throughout the tennation ASEAN (Association of Southeast Asian Nations) bloc. That strategy originally had been forged back in 2008, President Tomohisa Yamazaki allowed, adding that year’s global financial crisis (the Lehman Brothers Shock, as the Japanese call it) forced Mazak to put it aside. But in 2010 Singapore and India signed a tariffreducing free-trade agreement at the same time demand from the automotive sector recovered, yielding for Japanese producers a kind of ‘divine wind’.

Principles of Management at Yamazaki, by Yamazaki Several reporters in the room at the 1974 northern-Kentucky press conference announcing the launch of a Yamazaki factory in the US recognised that the man taking questions was not your run-of-the-mill corporate type. Given that the plant was being located practically across the Ohio River from the world seat of power in machine tools, some of those present probably thought this competitor to be an upstart, even cheeky. ‘Visionary’ would have been a far better depiction. A couple of years before he died in September at age 82, Teruyuki Yamazaki published a book commemorating his company’s 88th anniversary, Mazak’s Management Principles. In it, he outlined some 75 guiding beliefs he said helped him manage the family-held company he chaired for decades into becoming the largest machine-tool builder in the world. Here are some: If we manufacture machines based on sales forecasts, only 30 per cent would meet customers’ specifications.

We should develop our own unique products and use those new advanced machines for our production. A Kimono (formal dress) must be accompanied with the Haori (mid-length coat), Obi (belt), Zori (sandals), and all other required accessories. We gain customer trust by being a total systems developer. Our challenge is to focus on increasing market share more so than the sales volume.

Machine-tool manufacturers enjoy a high ratio of profit to net sales, but they suffer from an extremely low ratio of profit when compared to total assets.

We do not seek to be listed on the stock exchange because no considerable benefit is realised, and we want to maintain autonomy.

We have been derided as being a party-loving company. However, we consider such activity to be a necessary investment to promote better communication.

We act as a doctor in the factory-automation industry. A good doctor always carries a stethoscope.

A machine-tool manufacturer must continue to exist so that it can be responsible for its own machines. The best way to pick mushrooms is to patiently keep looking in the same area. (After learning of the exporting strictures that would be caused by the 1980s Voluntary Restraint Agreements between the U.S. and Japan.) I am saddened that many top manufacturers in Western countries have disappeared oneby-one. I remind myself of their mistakes from time to time.

Courtesy: Gardner Publication Inc

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TIPS & TRICKS Metrology Operations

Optimising CMM Usage & Maintenance In any manufacturing system, quality control is one of the most critical aspects in ensuring that the finished product conforms to the specifications or demands of the customers. Thus, optimum use of metrology equipment becomes the need of the hour to ensure the quality parameters. Nishant Kashyap provides pointers for optimum utilisation of Coordinate Measuring Machine (CMM). 1 It is advisable to carry out the annual calibration of CMM by OEM/service engineers during night time as temperature variation is lower.

2 CMMs should be ideally run in all axes at least five times daily. CMM probe should be calibrated at least once daily before starting to avoid any possible flaw during the operation due to any prior miss handling of the system.

3 Always buy pneumatic compressor and air-dryer from reputed brand. Place pneumatic compressor/air-dryer outside CMM room to reduce noise levels/temperature rise.

4 CMM should be cleaned daily to make it dust free; especially the path, through which air-bearings travel. It should be ensured that this passage is free from scratches, dust, scrap, oil, moisture, etc.

5

6

Pneumatic air pressure as advised by OEM must be maintained and accordingly a pneumatic compressor with higher rating & tank size should be used, else compressor will run continuously and get heated quickly. Additional filters should be used to filter off oil and moisture from atmosphere/air. Also regular checks should be carried out to drain off the oil/water from filters. Generally CMM is placed near shop floors. It should be ensured that the layout where CMM is placed is isolated from vibrations.

7 CMM should be placed in a dust free, temperature controlled (about 20 – 21 Degrees symbol Celsius) environment.

8 Extra caution needs to be taken while programming with special probes or star probes. Length/diameter ratio of probes should be taken extreme care of as advised by OEM.

9

10

It is necessary to dry-run the new or unproven programs and not place any components/ parts/ fixtures on CMM table during dry-run. Also, if you are using simulation software it is advisable to check before dry-run. Axes motor magnets should be periodically checked and cleaned for carbon deposits. Also it should be ensured that magnets are placed back in the same orientation. nishant.kashyap@infomedia18.in

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Event List - National

AHMEDABAD Gujarat Oct 5-8, 2012

PUNE

CHENNAI LUDHIANA INDORE

Madhya Pradesh Punjab Maharastra Tamil Nadu Nov 2-5, 2012 Nov 22-25, 2012 Dec 21-24, 2012 Jan 11-14, 2013

AURANGABAD Maharastra Feb 1-4, 2013

RUDRAPUR Uttarakhand Feb 23-26, 2013

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. Mob: 09819552270 Fax: 022 3003 4499 • Email: engexpo@infomedia18.in • Web: www.engg-expo.com

Modern Machine Shop The event offers an ultimate platform to demonstrate potential and futuristic technologies in the product segment to a large cross-section of business visitors, from the entire engineering industry; April 5-8, 2012; India Expo Mart, Greater Noida For details contact: Indian Machine Tool Manufacturers’ Association Bangalore International Exhibition Centre, 10th Mile, Tumkur Road, Madavara Post, Bengaluru Tel: +91 80 6624 6600 Fax: +91 80 6624 6661 Email: info@imtma.in Web: www.imtma.in

DIEMOULD India 2012 The 8th edition of this international exhibition will provide an ideal opportunity for the die & mould industry to upgrade its know how and keep pace with the latest developments in this segment; April 19 – 22, 2012; Bombay Exhibition Centre, NSE Complex, Goregaon, Mumbai. For details contact: Tool & Gauge Manufacturers Association of India (TAGMA) A-33, NandJyot Industrial Estate, Safed Pool, A K Road Mumbai - 400 072

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Tel: +91 22 28526876 / 28508976 Fax: +91 22 28503273 Email: mumbai@tagmaindia.org Website: http://www.tagmaindia.org

Automotive Engineering Show 2012 The premier event on automotive components will demonstrate the latest technology in the automotives segment; April 26-28, 2012; Auto Cluster Exhibition Centre, Chinchwad, Pune. For details contact: Focussed Event Management Pvt Ltd, Head Office : Plot No. F/11 & F/12, Camlin Fine,WICEL Compound, Opp. SEEPZ Main Gate, Andheri (East), Mumbai – 400 093 Tel: 91-22-3201 9137 Fax: 91-22-2832 4404 Email: info@focussedevents.com

ACMEE 2012 The event will showcase various innovations made in automobile and engineering industries over the past few years and act as a forum for exchanging diverse product information, technical details and development of new business contacts; June 14 -18, 2012; Chennai Trade Centre, Chennai For details contact ACMEE 2012- AIEMA Technology Centre,

1st Cross Road, Ambattur Industrial Estate, Chennai 600 058 Tel: +91 44 2625 8619 Fax: +91 44 2652 0814 Email: info@acmee.in Website: www.acmee.in

AMTEX 2012 AMTEX (Asian Machine Tools Exhibition) has constantly strengthened its position as one of the largest shows of machine tools, machineries and manufacturing technologies in the Asian region. The event will showcase the latest advances in machine tools and manufacturing solutions; July 27-30, 2012; Pragati Maidan, New Delhi. For details contact Triune Exhibitors Pvt Ltd 25, 3rd Floor, 8th Main Road Vasanthnagar, Bangalore 560 052 Tel: +91 80 4330 7474 Fax: +91 80 2235 2772 Email: info@triuneexhibitors.com Web: www.triuneexhibitors.com

Automation 2012 The seventh international automation exhibition and conference will be held at the Bombay Exhibition Centre, Mumbai; between September 7 – 10, 2012. Automation Exhibition will showcase the power of collaboration between solution providers i.e. vendors, engineering companies and actual users of the technology. The conference held during the course of the event also provides an excellent insight in the latest practices. For details contact IED Communications Ltd, 243, Shiv Shakti Industrial Estate, Marol, Andheri Kurla Road, Opp Mittal Estate, Andheri (E), Mumbai 400059. Tel: 28505138/ 28514673


Event List - International MACH 2012 MACH organised by the Manufacturing Technologies Association (MTA), attracts almost 450 exhibitors and over 20,000 visitors who will showcase some of the best innovations and latest developments from the manufacturing technologies sector; April 11 – 16, 2012; NEC Birmingham, UK For details contact The Manufacturing Technologies Association 62 Bayswater Road, London, W2 3PS, United Kingdom Tel: +44 (0) 20 7298 6400 Fax: +44 (0) 20 7298 6430 Email: info@mta.org.uk Web: www.mta.org.uk

China CNC Machine Tool Fair China CNC Machine Tool Fair (CCMT) has been successfully held since 2000 in Shanghai every year. It has developed into one of China’s biggest machine tool and metal-working exhibitions; April 16 -20, 2012; Nanjing International Expo Center, China. For details contact: IMAG - Internationaler Messe - und Ausstellungsdienst GmbH Am Messesee 2, 81829, München Germany Tel: +49-89 9492 2113 Fax: + +49-89 9492 2114 Email: reinhard.willenbuecher@imag.de Web: www.imag-db.de

SIMTOS 2012 SIMTOS 2012 will be divided into six brand pavilions by exhibit product ie metal cutting and die & mould working, press & metal forming, cutting-off & welding tools & related equipment, CAD/CAM, measuring system & robotics and motion controls; April 17 – 22, 2012; Korea International Exhibition Center (KINTEX), Seoul Korea. For details contact: 4th Fl Tower Crystal Building, 1008-1 Daechi-dong, Kangnam-gu, Seoul, 135-280, South Korea Tel: +82-2-3453-2721

Fax: +82-2-6280-2721 Email: intl@simtos.org Web: www.simtos.org

Tel: 34 94 40 40 000 Fax: 34 94 40 40 001 Email: bec@bec.eu Web: www.biemh.com

AUSTECH 2012 The show exhibits with new manufacturing technologies and techniques to cut costs. More than 10,000 decision-makers regularly attend Austech and National Manufacturing Week to get ideas, find innovative ways of making things and solve manufacturing problems; May 8 - 11 2012, Sydney Showground Sydney Olympic Park, Australia. For details contact AMTIL Suite 1, 673 Boronia Road Wantirna, 3152, Victoria, Australia Tel: +61 3 9800 3666 Fax: +61 3 9800 3436 Email: kwarren@amtil.com.au Web: www.amtil.com.au

MTA VIETNAM 2012 The 10th exhibition will serve as a platform to network with pioneers from machine tools, precision engineering and metalworking technology sector; July 3 – 6, 2012; at Saigon exhibition & Convention Centre, Ho Chi Minh City, Vietnam For details contact: Singapore Exhibition Services Pte Ltd 1 Jalan Kilang Timor 09-02 Pacific Tech Centre Singapore 159303 Tel: +65 6233 6638, Fax: +65 6233 6633 Email: mta@sesallworld.com Web: www.mtavietnam.com

IMTS 2012 INTERMACH 2012 The show focuses exclusively on industrial machinery and aims at introducing the latest high-tech machinery and cutting edge technology from around the world; May 1720, 2012; at Bangkok International Trade & Exhibition Centre (BITEC), Thailand.

America’s largest manufacturing show—the International Manufacturing Technology Show (IMTS) 2012—is one of the largest global industrial trade shows, with over 1,100 exhibitors & 82,000 visitors; September 10 – 15, 2012, at McCormick Place, Chicago, USA.

For details contact: UBM Asia (Thailand) Co Ltd 503/23 K S L Tower 14th Floor Sri Ayuthaya Road, Kwaeng Thanon Phayathai, Khet Rajathewee, Bangkok 10400 Thailand Tel: +66 0 2642 6911 Fax: +66 0 2642 6919 E-mail: info-th@ubm.com Web: www.ubmthailand.com

For details contact: The Association for Manufacturing Technology John Krisko, AMT Director - Exhibitions 7901 Westpark Drive, McLean, VA 22102-4206 USA. Tel: 703-827-5252 Fax: 703-827-5250 Email: jkrisko@amtonline.org Web: www.imts.com

BIEMH The 27th edition of the event will showcase latest developments and technologies from leading companies in their specialty; may 28 – June 2, 2012; Bilbao Exhibition Centre, Bilbao, Spain. For details contact: Bilbao Exhibition Centre Ronda de Azkue 1, 48902 AnsioBarakaldo

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

April 2012 - MODERN MACHINE TOOLS 135


Event Report Aurangabad 17-20 February, 2012 Ayodhya Nagari

Creating yet another SUCCESS STORY The maiden edition of Engineering Expo held at Aurangabad was a runaway hit among the growing manufacturing and general engineering sector, as well as SMEs based in and around the historical city. The Expo had a positive impact on the developing manufacturing industry in Aurangabad and is poised to come back with more offerings and opportunities for exhibitors and visitors in the next edition. Nishi Rath reports...

I

n this era of ‘glocalisation’ where every leading company is trying to establish its footprint in regional markets and create a stronghold, sensing the pulse of customers is one of the old and most powerful adages. In order to explore the tremendous opportunities to get established in regional markets, trade shows play a very critical role. Holding the fort in organising multilocation trade shows, Engineering Expo is a brand to reckon with. Keeping up with its rich tradition and a fresh vigour & enthusiasm, the maiden edition of Engineering Expo Aurangabad portrayed the poised locational advantages to the manufacturing community. The latest edition of Engineering Expo, an established trade show from the stable of Network18, with support from Aurangabad Industrial Suppliers Association (AISA), held from February 17-20, 2012, turned out to be a huge success in terms of its quest towards bringing out the message to the entire Indian manufacturing fraternity of an emerging manufacturing hub – Aurangabad.

Expo takes off on a high note Dignitaries including Mukund Kulkarni, President, CMIA and MD, Expert 136 MODERN MACHINE TOOLS - April 2012

 Dignitaries unveiling the exhibitors’ directory during the inaugural ceremony

No of exhibitors 250+ Business visitors 18,013+ Exhibiton area 1,00,000 sq ft Business transacted ` 70 crore Business leads generated 17,000+ Products displayed 6,250+ More than 1,10,000 kg machinery moved in for display

Group Solutions; Millind Kelkar, Owner, Grind Master; Jayant Soni, President, AISA; Ravindra Naidu, Joint President, Birla Precision Technologies and Sunil Daga, Sr VP – Business Banking, Kotak Mahindra Bank along with Sudhanva Jategaonkar, Associate Vice President, Infomedia 18, were present at the Expo’s inauguration function. Elaborating on how Engineering Expo is all set to offer a fillip to the trade prospects of Aurangabad, Naidu said, “This is one of the largest SME gathering in Aurangabad. As we all know the potential this place has, this Expo comes across as a catalyst that will further boost its growth. It is a matter of pride for Aurangabad. Earlier, it was only known as a historic city; but now, it is also known as an automobile hub.”

Complementing Naidu’s views, coorganiser, Soni added, “We were looking for a platform in Aurangabad and now, with Engineering Expo, we found the best and one of the most preferred platforms. We can say that with this maiden edition, Engineering Expo has brought an international standard show to the doorstep of users. The small and medium business units will reap a lot of benefits from the Expo.” Offering a financial perspective, Virat Diwanji, Executive Vice President & Head – Branch Banking, Kotak Mahindra Bank said, “We are delighted to be associated with Engineering Expo. SMEs are the backbone of India’s economy. The sector has played a critical role in achieving wide measures of industrial growth, and is instrumental in generating large-scale employment across the country. We, at Kotak Mahindra Bank, believe that with the right mix of capital, technology and innovative ideas, SMEs have the potential to push India’s growth to the next level. Our customised business solutions, backed with customer friendly service, are designed to meet the challenges and growing requirements of this sector.”


Event Report Engineering Expo opens account at Aurangabad The latest edition of Engineering Expo highlighted the potential that a new and developing place like Aurangabad has to offer. The fast-paced industrial growth in Aurangabad will not only improve the employment avenues, but will also raise the standard of living in this city, opined Kulkarni. He added, “An Engineering Expo, like this, is vital for the competitiveness of industry, especially for SMEs.” Offering an organiser’s perspective on the choice of a new location for organising Engineering Expo, Jategaonkar said, “Engineering Expo has come a long way by becoming one of India’s largest multilocation trade shows (other places include Ahmedabad, Chennai, Indore, Pune, Rudrapur and now, Aurangabad). Over the years, it has successfully delivered its goal of becoming a preferred destination for SMEs, manufacturing and engineering companies to connect, transact & leverage ideas to foster the growth of organisations as well as that of the industry at large.”

Exhibitors attract audience Engineering Expo Aurangabad, held during February 17-20, 2012, boasted of huge industry participation from various manufacturing areas, including machine tools & accessories, material handling equipment, hydraulics and pneumatics, automation & instrumentation, light and medium engineering, safety & security and packaging machinery, among others. Elaborating on the excellent response generated at Engineering Expo Aurangabad, SJ

Delegations who visited the Expo…        

Varroc Engineering Forbes & Company Larsen & Toubro NRB Bearings Videocon Wipro Crompton Greaves Bajaj Auto

Gijare, GM – Equipment Division, CTR Mfg India, articulated, “Engineering Expo is definitely not below expectation. It has helped the SME sector, which is fast growing in Aurangabad, find potential customers. We showcased some of our best products here and even received very good response. CTR already has a strong presence in the segment and by participating in this Expo, we want to retain that position in the years to come.” Discussing the scope Aurangabad has to offer, Aniket Nanajkar, Profit Centre Manager – Mechanical Division, Phoenix Mecano, explained, “Engineering Expo has provided us a good platform to understand the market demands here. We were delighted to find potential customers visiting our stall at the Expo.”

meet global standards. The Expo has been organised very well and is a huge success among visitors. Trade shows of this stature will help this growing manufacturing hub,” said Satish Adsul, AGM – Corporate Purchase, Endurance Technologies (Casting Division). Rajesh Baheti, DGM – Corp Materials & VEPL – Head, Varroc Engineering, who was also present at the Expo, visited stalls and interacted with various exhibitors. “In its first edition itself, the Expo has become a huge success. We saw various companies showcasing their best products and solutions here. This will definitely help the SMEs located in and around Aurangabad. Considering the fact that Aurangabad is developing, organising such events will definitely offer a boost to the growth prospects of this region,” Baheti added. Engineering Expo Aurangabad also attracted overseas visitors. Russell Small, Sales Manager, Asia Pacific, Precision Polymer Engineering, England, was in Aurangabad mainly to attend the Expo. “I saw some of the best automation products displayed here by quality exhibitors. Such trade shows can be very helpful for a developing place like Aurangabad,” he exclaimed.

Promising times ahead Visitors in AWE The responses from visitors were encouraging as well. Most visitors emphasised that more such events should be organised in future. “Engineering Expo provides companies an excellent platform to know more about new technologies. It helps local manufacturers

INITIATIVES AROUND ENGINEERING EXPO AURANGABAD Panel discussion on ‘Shifting Status From Why Aurangabad To Why Not Aurangabad?’ The panel discussion was jointly organised by Infomedia 18 and in association with Aurangabad Industrial Suppliers Association (AISA) recently. The endeavour was a part of its value additions intended to bring the manufacturing and dealers community of Aurangabad to talk about the critical issues related to the growth of the region with an aim and intent to position Aurangabad and in and around areas a most sought after manufacturing hub. SME Meet: An informal discussion on the pain and gain areas of SMEs: A large gathering of SMEs shared their pain & gain areas of working in & around Aurangabad. Some of the major issues discussed during the meet were banking & government policies, availability & procurement of land, which deters expansion, and most importantly, the shortage of skilled labour in & around the region. The major solutions that were arrived at include amendments in regulatory laws and a clear exit policy to change the product line.

With various other companies looking forward to investing in Aurangabad, the region is set to witness further growth over the coming years. The huge turnout at the Expo is proof enough of the increasing awareness among local businessmen about new technologies and their value-added benefits. With an optimistic outlook, Jategaonkar informed, “As we look forward to making further value additions for an even better experience and reach to the target audience, we welcome large, medium and small industries in the manufacturing and servicing sectors to be a part of the Expo in its exciting journey.” With this huge success, Engineering Expo is slated to make it even bigger in the next edition with more promising opportunities to be tapped and more areas to be covered. nisi.rath@infomedia18.in

April 2012 - MODERN MACHINE TOOLS 137


Products - National

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

Die and mould machine The Sirius-Ul+ is a high-speed die and mould machine with a rapid speed of 40 m/min in all axis and spindle speed of 20,000 rpm. This machine has built-in spindle motor of capacity 22/18.5 kW. It has bridge-type column structure having Z-axis with 6-LM blocks on two guideways. The spindle is designed with oil jet lubrication system to minimise its thermal deformation. The machine has a 30-station ATC, which is servo driven and comes with arm-type of changer. Hwacheon made Optima cutting feed optimisation system is provided for unbeatable reliability. Also included is 3D simulated and FEM analysed frame design. Stitch Overseas Pvt Ltd Gurgaon - Haryana Tel: 0124-4755400, Mob: 09313361202 Email: stitch@vsnl.com Website: www.stitchtools.com

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Products - National Vertical honing machine The hydraulic auto stroking vertical honing machine improves bore geometry of medium and heavy jobs. The spindle rotation and reciprocation is mechanical. Honing mandrels are linked with spindles by universal joints. The stroke length is adjustable depending upon the length of the jobs. This honing machine has very compact design with all the features of auto-stroking machine having high productivity. The machine is very useful for honing large varieties of components, like cylinder liners, hydraulic valves, pneumatic valves, brake cylinders, rocker arms and con rods, etc. Khushbu Engineers Kolhapur - Maharashtra Tel: 0230-2468859, Mob: 09371658016 Email: honing@khushbuindia.com Website: www.khushbuindia.com

Angle grinders The models BG7 and BG9 high-speed angle grinders are available in 180 mm and 230 mm with 2200 W motors. These angle grinders maintain their rated output even under the most

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Products - National exacting heavy-duty conditions. Both the grinders find applications in all heavy weld dressing work, foundry grinding and in cutting off risers and runners. The angle grinders are especially useful where fast cutting is required and are capable of handling continuous production grinding and cutting work. Both the machines are 100 per cent indigenous so that all parts are locally available. Nippon Electrical Industries Ahmedabad - Gujarat Tel: 079-22822750, Mob: 09376710401 Email: marketing@nipponpowertools.com Website: www.nipponpowertools.com

CNC lathe This CNC lathe is suitable for machining small-sized parts. It has a compact foot print, cartridge spindle with maximum speed up to 6,000 rpm, rapid rates of 20 m/min on both axes, and a rigid bed. This machine lends itself well for cell manufacturing. Other features include saddle (Z) with V and flat guide ways, cross slide (X) with dovetail guide ways, special execution with load/unload system, etc. Maximum turning

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MMT Apr-2012 Ad Name:Hundai Pg No.141


MMT Apr-2012

Ad Name:Igus Pg No. 142


MMT Apr-2012 Ad Name:Femco

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MMT Apr-2012 Ad Name:Hwacheon

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Products - National diameter is 140 mm, maximum turning length is 200 mm, chuck size 135 mm, and spindle power is 5.5 kW. Ace Designers Ltd Bengaluru - Karnataka Tel: 080-22186700 Email: acesales@acemicromatic.com Website: www.acemicromatic.com

Drilling-cum-milling machine The model SI-6DMU geared pillar-type drilling-cum-milling machine is used for drilling, milling, tapping, lapping and counter boring. Drilling capacity of the machines is 40 mm, with face mill capacity of 25 mm, tapping capacity of 22 mm in cast iron, and drilling capacity of 35 mm in mild steel. Quill spacers are made of steel while the main spindles are made of EN steel with six slots. With a spindle speed of eight gears, the product is made from the best quality material and is helical teethed for smooth and noiseless running. Siddhapura Industries Bhavnagar - Gujarat Tel: 0278-2445048, Mob: 09924241999 Email: bipin@siddhapuradrills.com Website: www.siddhapuradrills.com

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Products - National Micro grain carbides The micro grain carbides are used for aluminum alloy processing end mills. These are suitable for copper, aluminum, aluminum alloy, copper alloy, nickel alloy, titanium alloy and plastic processing. The micro grain carbides are highperformance tools with 5-axis CNC grinding machines. Zen Wu Zheng Sun Tool Co Ltd Kaoshiung City - Taiwan Tel: +886-7-3525743 Email: first@jsk-tools.com.tw Website: www.jsk-tools.com.tw

Tilting rotary table The model DDT-125 NC tilting rotary table comes with twin-shaft connect and direct drive motor. This rotary table is available to match European controllers, such as Heindenhain, Siemens, Fagor, etc. It is suitable for engraving machines, modular manufacture, optical manufacture, etc. The tilting rotary table features high-speed and no backlash. Spintop Machinery Co, Ltd Taiwan - China Tel: +884-4-25682975 Email: cnc588588-5@yahoo.com Website: www.spintop.com

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Products - National Surface grinding machines The Sumo series surface grinding machines are available in various models, such as GSH-8, GSH-50, GSH-75, GSH-100 and in NC/CNC versions. These machines have robust base structure and have internationally accepted fixed column design. The heavy box type column casting with honey-combed ribbing is rigidly clamped to heavy base casting. The spindle housing supports cartridge-type spindle unit and is assembled with super precision bearings grease packed with imported grease to have long trouble-free service. The table drive is hydraulic with soft reversal device. Pinnacle Engineering Enterprise Surendranagar - Gujarat Tel: 02752-230552, Mob: 09879190585 Email: mail@pinnaclegrinder.com Website: www.pinnaclegrinder.com

Tool trolleys A wide range of tool trolleys for various types of application such as machining centres, CNC machines, automobile workshop,

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Products - National wiring, etc, is available. Also offered are customised systems for specific requirements and specified tools cabinet to serve as cassette type tool cabinets for safely storing of press brake tools. Salient features include spacious storage facility with ease in mobility, innovative designs that fits customers every single need, easy access for machine solutions, adjustable drawer as per customer need, superior quality at less price and stateof-the-art & user-friendly, etc. Basic Engineers Ahmedabad - Gujarat Tel: 079-25831575, Mob: 09825344527 Email: info@basicengineers.in Website: www.basiengineers.com

Radial drilling machine The all-geared auto-feed radial drilling machine (40 mm capacity) has gearbox of 9-speed with all 9-gears of EN9 steel and hardened up to 50 HRC. Oil bath gearbox and hardened gear gives very long life to the drilling machines. Auto-feed gears are also hardened. All the gears in the machine are supported through good quality bearings and not the bushes. The machine is supplied with complete electrical panel board with five push-button switches and one limit switch and two ISI electrical motors. Rotation and easy sliding of gears in bearings give very high reliability. Prakash Engineers Bhavnagar - Gujarat Tel: 0278-2438241, Mob: 09852356226 Email: pmwbvn@dataone.in Website: www.prakashmachines.co.in

Super-abrasive diamond and CBN grinding wheels The super-abrasive diamond and CBN grinding wheels and tools are high-power equipments that enable easy, efficient and economical redressing of worn-out buttons on tungsten carbide button drill bits at drilling site. The effectiveness of the equipment results in minimising the regrinding time of worn-out button bits. These equipments redress the tungsten carbide buttons and grind the steel portion of

the body of button bits for the relief. The pneumatically operated equipments are very compact in operation and usage. Wendt India Ltd Hosur, Tamil Nadu Tel: +91-4334-276851 Email: vijayvernekar@wendtindia.com Website: www.wendtgroup.com

Boring tool system The large diameter boring tool system combines various technical feature like super light execution, which ensures minor stress for operators and presetter spindles. With full HSC capability, it renders highest precision and performance. The system is based on aluminium extension slides of different lengths, which supports variety of aluminium and steel components for roughing and finishing tool assemblies. The mounting component is pinned to fit specific locations on the slides and is secured with steel bolts. The precise location of the components on the slide along with incremental adjustment scales for insert holders permit diameter and lengths setting without a tool presetter. Quattro Engineering India Ltd Coimbatore, Tamil Nadu Tel: 0422-257 1606,098947 88663 Email: coimbatore@quattroengg.com Website: www.microtoolings.com

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Products - National Tensioner nuts & bolts The tensioner nuts and bolts are multi hex-head clamping screws, a direct replacement of hex nut. These can be threaded directly on to an existing bolt/ stud/threaded rod or shaft. The washer rests on load bearing surface of parts which needs to be clamped and is protected. Tightening force (torque) is also distributed due to multi-clamping screws. The tensioner nuts and bolts allow usage even in the restricted and constrained space. NMTG Mechtrans Techniques Pvt Ltd Ahmedabad - Gujarat Tel: 079-22821527, Mob: 09328271660 Email: nmtg@nmtgindia.com Website: www.nmtgindia.com

Reversible tapping attachments These are low-weight, high-speed reversible tapping attachments that are suitable for use with standard HSS taps on any drilling machine vertically or horizontally, for right or left hand tapping

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Products - National of blind or through holes. Made of alloy steels with all moving parts hardened and ground to precision. The tapping attachments are available in capacities ranging from 2-3 mm. An ultra-sensitive and smooth operating ball-clutch protects the tap against breakage when, tap is bottomed in a blind hole or core hole is shallow or tap is dull. Tools & Appliances Corporation Ahmedabad - Gujarat Tel: 079-22740375, Mob: 09825126659 Email: taco@imitoolsindia.com Website: www.imitoolsindia.com

Radial drilling machine The model SMT 40/1000 DC double-column radial drilling machine is used for drilling, tapping, lapping, screwing and counter boring operation. This radial drilling machine is also used for screwing in cast iron, steel, plastics and other materials. Drilling capacity is about 40 mm and spindle nosed is of MT-4. The double-column is ground by German-make cylindrical grinder.

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Products - National Headstock is bored on imported boring machine (TOSS). Accuracy conforms to IS-2425 standards. The radial drilling machine is useful for every toolroom and maintenance purpose. Syndicate Industrial Corporation Bhavnagar - Gujarat Tel: 0278-2445148, Mob: 09426207129 Email: dinesh_siddhapura@smt.firm.in

Tapping chuck The QCSL non-reversible tapping chuck is specially developed for builders of heavy machinery, turbines, motors, nuclear reactors and other such types of heavy equipment. Capacity of the tapping chuck ranges from M30 to M200. It is available in Morse Taper, ISO taper or in special shanks. The chuck is suitable for heavy jobs and are suitable for tapping on higher diameter. This chuck is provided with length compensation features that allow the tap to act as its own lead screw. IMI Machine Tools Pvt Ltd Ahmedabad - Gujarat Tel: 02764-233983, Mob: 09825146659 Email: imi@imitoolsindia.com Website: www.imitoolsindia.com

Universal drilling system Rigid construction of the innovative tool makes maximum feed rates for lengths up to 5 x D possible. It notably increases productivity while maintaining process security through the optimally designed chip pockets and controlled drill deviation thanks to the special insert position. In combination with the recently developed universal grade CTPP430, the new drilling system MaxiDrill 900 is an unbeatable new product which finds optimum application in all fields of mechanical engineering. Ceratizit India Pvt Ltd Kolkata - West Bengal Tel: 033-24940581 Email: info.india@ceratizit.com Website: www.ceratizit.com

High-speed spindle unit The BEX-15 high-speed spindle unit is designed for spindle speeds up to 20000 rpm.Standard spindle and tool holder options are ER 25, ISO 30, HSK, ABS and Weldon. All spindle options are available with coolant through the spindle applications.

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Products - National With five different tool holder options, many drilling and milling applications are possible. Advantages are make real use of carbide tools, less vibrations and high precision, long life time in view of sturdy design and reinforced bearing option, deep hole drilling operations, etc. Suhner India Pvt Ltd Bengaluru - Karnataka Tel: 080-27831108 Email: blroffice.in@suhner.com Website: www.suhner.com

Radial drilling machine The model 38-PRD universal radial drilling machine is available in 38 mm capacity with fine-feed or auto-feed arrangements. This drilling machine comprises of latest technology and well-designed parts made up of special materials. The spindles and rams are made up of material EN-8 and also hardened to increase the hardness. All gears are made of EN-8 and cut helically to achieve perfect transmission ratio. Safety clutch is provided for autofeed mechanism. Its

April 2012 - MODERN MACHINE TOOLS 153


Products - National design prevents the damage of gears in case of wrong operating condition. Powermatic Engineers Ahmedabad - Gujarat Tel: 079-25620703, Mob: 09727100033 Email: response@drillmachineindia.com Website: www.drillmachineindia.com

Shot blasting machine This mega shot blasting machine has 16wheel station and is used for heavy fabricated structures in the automobile industry. The job is loaded on load bar of automatic trolleys having auto hoisting arrangement. Two trolleys are coupled through load bar for loading of heavy structures. These loaded trolleys carry the job into blast chamber where the 16-wheel stations are located strategically at descaling angle. The job pass through the high velocity stream of abrasive thrown by blast wheel stations resulting into thorough single-pass cleaning of job. The cleaned job comes out from the outlet vestibule of blast cabinet. Surface Finishing Equipment Company Jodhpur - Rajasthan Tel: 0291-2740128, Mob: 09829022624 Email: sfec@sify.com Website: www.surfacefinishing.org

Pillar drilling machine The model AP-40 all-geared pillar drilling machine has spindle gearbox with 8 mechanical speeds, which ranges from 90 to 885 rpm. The gear is made from steel. Totally enclosed 2 HP motor is directly coupled with gearbox. The levers for changing the speed are avoided by means of providing special gear system. Change in speed is possible while the operation is still on. Feed gearbox has two feeds 0.05 and 0.1, for the vertical movement of the ram. The drill spindle is made from the best quality steel. Poly Kraft Machines Ahmedabad - Gujarat Tel: 079-22743639 Mob: 09898003625

154 MODERN MACHINE TOOLS - April 2012


Products - National Email: pkmdrill@gmail.com Website: www.polykraftmachines.com

CNC milling machine The model OM-1 CNC milling machine is an ultra-compact milling machine designed for office environment. This machine brings highperformance and reliability to industries that are unable to fit a normal CNC machines into their facility. Designed for high-production or rapid prototyping of small, precision 2D or 3D parts, the milling machine fits through a standard 36” door and into most freight elevators. Features include full enclosure, 50,000 RPM electric spindle, high-speed machining software, coolant system, 4th axis drive, 25 mm precision ball screws, ¼” collet maximum capacity, 757 IPM rapids, and quick disconnect cord. Haas Automation, Inc California - USA Tel: +1-805-2781800 Email: sales@mtscnc.com Website: www.haascnc.com

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Products - International Vertical machining centre The model VMC-850 CNC vertical machining centre is installed with high accuracy C3 level ball screws with special structure pre-pulled, rapid and accurate. Salient features include: main structure with highlevel casting, stable & high quality, box guideway design provides high rigidity & stable structure, Y-axis supported by 4 rails provides the best carrying capacity of workpiece, dual speed gearbox provides ability of heavy cutting, spindle head with boon-structure provides stable support for the spindle, umbrella type ATC system, full enclosed guard cover keeps safe & clear working surrounding for operator, auto-lube system provides lubrication of railways and the ball screws, oil skimmer device keeps using time of coolant, etc. You Ji Machine Industrial Company Ltd Kaohsiung Hsien - Taiwan Tel: +886-7-6983068 Email: youji@ms15.hinet.net Website: www.youji.com

Vertical machining centre The model WV108A vertical machining centre is structurally designed for heavy and rough machining requirements with ultra wide machine base and column. The ultra wide machine base structure provides most stable construction rigidity which assures the overall machine performance and accuracy. Modular headstock design offers both IDD spindle design ideal for high-speed machining and 2-speed gear head for heavy machining requirements. The unique IDD spindle design offers low spindle vibration and optimal heat isolation that results in excellent surface finish while maximising both spindle and tool life under hard milling conditions. Yeong Chin Machinery Industries Co, Ltd Taichung - Taiwan Tel: +886-4-2562 3211 Email: yc@supermax.com.tw Website: www.supermax.com.tw

Boring heads A wide range of rough and finish boring heads producing diameters from 8 mm up to 500 mm plus all different couplings and accessories are offered. There are 3 basic boring heads, viz, micro boring heads fitting indexable boring bars with carbide insert pockets; finish boring heads; and rough boring heads with a synchronised adjustment. All the boring heads are radially adjustable for boring different diameters. The first two models feature a micrometer adjustment with 0.002 mm increments. Rough boring heads do feature

156 MODERN MACHINE TOOLS - April 2012


Products - International simultaneous adjustment of the slide blocks. Couplings are available in several executions to suit the most popular machine spindles. Pinzbohr Boring System Barcelona - Spain Tel: +34-93-5720873 Email: pinzbohr@pinzbohr.com Website: www.pinzbohr.com

Hydraulic cylindrical grinder The model PUI-450 hydraulic cylindrical grinder is a light heavy-duty machine meant for high-precision grinding of gauges, dies and punches for toolroom applications, with an accuracy on dia 0.002 micron. The one-piece machine body is made from close grain casting with maximum grinding length of 450 mm, and center height at 125 mm. Table is flat on one side and V-grooved on other side, with Turcite-B linear material coating and precision handscraped to match corresponding surface of the guideways. Pitroda Utility Industries Wadhwan - Gujarat Tel: 02752-243795, Mob: 09825416108 Email: response@pitrodautilityindia.com Website: www.pitrodautilityindia.com

April 2012 - MODERN MACHINE TOOLS 157


Products - International CNC vertical grinder Palmary CNC vertical internal, end face and external composite grinder offers more choice when need to grind internal, end face and external diameter at one time setting. Honeycomb type Meehanite cast iron machine bed structure is used to assure the best possible rigidity and stability with high quality. The 2nd axis angle auto off-centering function is used to grind the sleeve type or gear type internal taper hole. For the controller Mitsubishi M70, it is developed together with the supplier with the user-friendly control panel frame system in order to reduce the input mistake. Palmary Machinery Co Ltd Taichung County - Taiwan Tel: +886-4-24929799 Email: palmary@grinding.com.tw Website: www.palmary.com.tw

Copper alloy wires and rods These copper alloy wires include commercial bronze wire, low-silicon wire, and high-silicon wire. The commercial bronze wires are used industries such as architectural (etching bronze grill work, screen cloth, weather stripping), hardware (escutcheons, kick plates, line clamps, marine hardware, rivets, screws, screw shells, munitions: (primer caps, rotating bands), miscellaneous: compacts, lipstick cases, costume jewellery, ornamental trim, screen wire, base for vitreous enamel wave guides, etc. Low-silicon and high-silicon wires are used in aircrafts, hardware, industrial applications, marine industry, etc. Yuang Hsian Metal Industrial Corp Changhua City - Taiwan Tel: +886-4-7612689 Email: info@yhm.com.tw

Inverter chiller The high-precision inverter chiller is used in CNC vertical and horizontal machine centre, CNC wire cutting machine, CNC highprecision grinding machine, CNC machining centre (5 surface), optoelectronics, semiconductor and solar energy industries. This high-precision inverter chiller is individually designed for LCD control panel and temperature precision could maintain ¹0.1°C. Using inverter compressor keeps electric current smoothly and saves energy 33 per cent. The energy saving and high precision are from the operation of low load. It reduces the temperature rise and

158 MODERN MACHINE TOOLS - April 2012


Products - International maintains the precision during process. Filling the high-efficiency environmental refrigerant is without pollution. Wexten Precise Industries Co, Ltd Taichung City - Taiwan Tel: +886-4-24180799 Email: service@wexten.com.tw Website: www.wexten.com.tw

Robotic assembly system The Syfast robotic assembly system is used for medium volume production. It is specially suited for medium volume production, complex products with four or more components or assembly process, large numbers of variants, quick changeover times, progressive investment in assembly equipment, etc. Features include: standard platform with movable guarding; mineral casting for the machine frame; industrial PC cell control; clean-room 10,000 compatible; scara robot; and basic software management package. Mikron Tool SA Agno Bioggio - Switzerland Tel: +41-91-6106500 Email: mto@mikron.com Website: www.mikron.com

April 2012 - MODERN MACHINE TOOLS 159


Products - International Precision machine vice The precision machine vice body is made of ductile iron FCD60. Down thrust with semi-sphere prevents workpiece lift. The vice has side-lock to work (perpendicular of side lock 90-degrees = 0.015/100 mm). Vice bed is hardened to HRC45-degrees and maintain accuracy for long. The vice slide-chunk can be taken out, as it is convenient to clean away chips inside of vice. Vice bed height-size and guide block side are all made with full control along with 2.3 or 4 vices to perform a job at a time is available. Jin Year Precision Co, Ltd Taichung City - Taiwan Tel: +886-4-25232817 Email: liu0930@ms58.hinet.net Website: www.jinyear.com.tw

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

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MMTApr-2012 Ad Name: L&T Pg No. 161


MMTApr-2012 Ad Name: L&T Pg No. 162


List of Products To know more about the products featured in this magazine, fax us on 022-3003 4499 or tear and post to us the ‘Product Inquiry Card’ by following the 5 easy steps given there. Alternatively, you may also write to us at michael@infomedia18.in or call us on 022-3003 4684, and we will send your inquiries to the advertisers/companies directly to help you source better.

Sl. No Product 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

Pg No

3-axes high-speed machining centre ............. 99 3D printing system ......................................................... 70 4-column hydraulic press .............................. 145 5-axes high speed machining centre ............. 99 5-axes machining centre .................................... 61, 143 5-face double column milling machine ............. COC Abrasive belt grinder ..................................... 157 Accessories ..............................................................Booklet Adapter ..................................................................... 81, 138 All-geared planning machine...................................148 Angle encoder .................................................................BIC Angle grinders................................................................139 Appliance switch ............................................................. 27 Application and precision component machining ................................................................Booklet Auto-feeder hydraulic press .....................................145 Automatic grinding machine ...................................155 Automation ....................................................60, 151, 153 Bags bailing press .......................................... 145 Balancing machine .......................................................109 Balancing system .........................................................BGF Baling press .....................................................................145 Ball bearing ....................................................................... 55 Bar feeder ........................................................................... 82 Bearing ..............................................................................142 Belt grinder......................................................................124 Bench grinder .................................................................157 Bench grinder-cum-polisher .....................................157 Bench grinding machine............................................124 Bench polisher ...............................................................157 Boring machine .............................................................148 Boring tool system .......................................................149 Broaching machine .................................................18, 20 BTA/ejector counter boring machine ..................... 24 BTA/ejector drilling machne ....................................... 24 Cabinet .............................................................. 72 Cable and hose carrier ................................................129 Cable carrier ....................................................................142 Cable conduit ................................................................... 27 Cable connector ............................................................142 CAD/CAM software......................................................... 10 CAM follower ..................................................................146 Carbide end mill tool.....................................................BC Carbide end mill .............................................................. 58 Carbide rod........................................................................ 97 Carbide tool...........................................91, 138, 161-162 Carbide ..............................................................................138 Casting ................................................................................ 87 CBD .....................................................................................133 Centre drill .............................................................122, 138 Centreless grinding machine .........................149, 157 Ceramics ...........................................................................169 Cermets .............................................................................169 Chain ..................................................................................142 Chuck jaw........................................................................... 60 Chuck ......................................................................... 82, 138 CI casting ..........................................................................148 Clamp.................................................................................139

Sl. No Product 58 59 60 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 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111

Pg No

Clamping tool...................................................................BC Close-frame hydraulic press......................................145 CMMs .................................................................................147 CNC double-column machining centre ................. 14 CNC equipment ............................................................... 29 CNC grinding machine ...............................................155 CNC horizontal borer..................................................... 61 CNC horizontal boring and milling machine14, 143 CNC horizontal machining centre ............................ 14 CNC horizontal turning centre................................... 14 CNC lathe .................................................39, 61, 100, 140 CNC machine tool .................................................booklet CNC machine .......................8-9, 71, 99, 107, 141, 144 CNC machining centre ...........................................58, 99 CNC multi-tasking centre............................................. 14 CNC precision lathe........................................................ 41 CNC small machining centre ...................................... 58 CNC system ....................................................................... 89 CNC tooling .....................................................................138 CNC turning centre .............................................. 99, 107 CNC turning machine .................................................... 71 CNC turn-mill centre ...................................................... 14 CNC vertical machining centre ................. 14, 99, 107 CNC vertical turning lathe ........................................... 14 CNCs ............................................................... 7, 88, 99, 107 CNC-type 3D co-ordinate measuring machine ................................................................151, 153 CNC-type video measuring machine ..........151, 153 Coin press ........................................................................145 Collet chuck............................................................. 41, 138 Collets ................................................................................138 Connector .............................................67, 142, 151, 153 Control cabinet ................................................................ 67 Control panel accessories ............................................ 27 Control panel .................................................................... 67 Control system ................................................................. 67 Controlling machine tool ............................................BIC Conventional precision lathe ...................................100 Coolant pump ................................................................157 Coolants .............................................................................. 69 Coro mill .......................................................................... FGF Coro thread .................................................................... FGF Corrosion preventives ................................................... 47 Counter sink ....................................................... FIC, 12-13 Crush blade ....................................................................... 45 Cutting oil .......................................................................... 69 Cutting tap ......................................................................112 Cutting tool ........................ 21, 31, 45, 58, 91, 97, 123, ................................................................... 161-162, Booklet Cutting tools carbide metal working tool ...........169 Cycle time reduction and programming software for CNC for milling.......................................................... 57 Cycle time reduction and programming software for CNC for turning......................................................... 57 Cylindrical and internal grinding machine .........111 Cylindrical grinder machine.............................. 11, 149 Deep-drawing hydraulic press ...................... 145 Deep-hole drilling machine ........................................ 24

Sl. No Product 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168

Pg No

Deep-hole drilling sub-contracts .............................. 24 Desktop printer................................................................ 70 Diamond lapping and polishing systems...........BGF Diamond tool .................................................... FIC, 12-13 Didactic equipment for training ............................... 67 Die and mould machine.............................................138 Die coater ........................................................................... 45 Die/mould machine ................................................... COC DNC system for networking CNC machine........... 57 Drill chuck arbour .........................................................138 Drill mill.............................................................................138 Drill tool ..............................................................................BC Drill ................................................................................58, 81 Drilling and milling machine ....................................125 Drilling machine ............................................................125 Drilling tool.............. FIC, 12-13, 31, 91, 123, 161-162 Drilling-cum-milling machine ..................................146 Drive technology............................................................BIC Dust collectors ...............................................................124 Electrical connectivity ............................151, 153 Element shrink disc ......................................................146 End mill ...................................................................122, 138 Engineer’s files ...............................................................122 Exhibition - Acmee ......................................................... 56 Exhibition - Modern Machine Shop-2012 ............. 16 Expandable monoblock reamer ................................ 81 Exposed linear encoder ...............................................BIC Extruding system ............................................................ 87 Filtration unit.................................................... 20 Fix frame hydraulic press ...........................................145 Fixtures..............................................................................139 Flexible shaft grinder...................................................157 Floor plate........................................................................148 Form measurement........................................................ 25 Forming tap ....................................................................112 Freewheel-oneway-clutches .....................................146 Gantry and NC boring and milling machines 39 Gear cutting machine................................................ COC Gear hobbing machine ................................................. 79 Gear milling solution for CNC milling/turn-mill machine .............................................................................. 93 Gomet bearing ................................................................. 55 Grinding machine ..............................46, 124, 149, 155 Grip plier...........................................................................139 Grooving and parting tool .......................................... 97 Gun drill ............................................................... FIC, 12-13 Gun drilling and reaming machine.......................... 24 Handling system module................................. 67 Handy probe ...................................................................133 Handy scan ......................................................................133 Hard cut end mill ............................................................ 58 Heat exchanger machine ...........................................125 Heavy-duty bearing ....................................................... 55 Heavy-duty CNC machine..........................................140 High-precision tool holder .......................................... 23 High-pressure hydraulic clamping system.........BGF High-speed drill tap centre ......................................... 61 High-speed spindle unit .............................................152

April 2012 - MODERN MACHINE TOOLS 163


List of Products Sl. No Product 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229

Pg No

HMCs ..................................................................................125 Hold back .........................................................................146 Hole-making tool ............................................................ 45 Horizontal boring mill ............................................... COC Horizontal CNC machine ............................................107 Horizontal handle clamp............................................139 Horizontal hydraulic press .........................................145 Horizontal machining centre................ 7, 61, 99, 107 Horizontal milling machine..................................... COC Hydraulic centerless grinding machine................149 Hydraulic cylinder ....................................................18, 20 Hydraulic cylindrical grinder.....................................155 Hydraulic cylindrical grinding machine ...............149 Hydraulic equipment..................................................... 18 Hydraulic internal grinding machine ....................149 Hydraulic machine.......................................................... 82 Hydraulic power pack ............................................18, 20 Hydraulic press................................................ 18, 20, 145 Hydraulic surface grinding machine .....................155 HyperCAD .......................................................................... 10 IMTMA - AMTTF ................................................ 22 IMTMA - Finishing School Summit ........................... 96 IMTMA - Productivity Summit.................................... 44 Incremental rolling dies................................................ 73 Indexable tool .................................................................. 58 Induction seal/wad .............................................151, 153 Inductive proximity switch.......................................... 27 Industrial data logger and bespoke solution .....140 Industrial grinding and cutting machine .............. 87 Industrial packing machine.......................................151 INO and battenfeld hydraulic composite press 115 Integrated machine safety solution.......................113 Intelligent Ethernet system .......................................140 Interface electronics......................................................BIC Interference-free PC board ........................................140 Internal grinding machine.........................................149 Iron and steel parts ........................................................ 45 ISO and milling insert .................................................... 58 ISO turning insert ............................................................ 58 Jewellery polisher .......................................... 157 Jigs ......................................................................................139 Keyless transmission element....................... 146 Large part drilling and milling machine ...... 125 Large size machining centre .................................. COC Lathe chuck ....................................................................... 60 Lathe machine................................................................148 Lathe .......................................................................................7 LED........................................................................................ 27 Length gauge ..................................................................BIC Lens mould ........................................................................ 45 Linear drive laser cutting machine .......................... 48 Linear encoders and scale ...............................151, 153 Linear motor thread and gear grinder ................... 77 Load break switch........................................................... 27 Lube ..................................................................................... 69 Lubricant ............................................................................ 47 Machine measurement ...................................BIC Machine tool protection system ............................BGF Machine vice ..................................................................BGF Machining centre ............................................................ 79 Magnescale technology .............................................121

164 MODERN MACHINE TOOLS - April 2012

Sl. No Product 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290

Pg No

Magnetic modular encoder .......................................BIC Masonry drill ...................................................................122 Material testing machine ............................................. 25 Maxshot ............................................................................133 Measured value acquisition and display...............BIC Measurement equipment ............................................ 25 Measuring instrument.................................................109 Metal cutting tool ........................................................... 59 Metal scrape baling press ..........................................145 Metal working fluid ........................................................ 47 Metrascan.........................................................................133 Metrology equipment ................................................... 25 Metrology instrument and solution ......................147 Micro grain carbides ....................................................147 Micron drill ........................................................................ 45 Milling centre.......................................................................7 Milling cutter ..............................................FIC, 12-13, 97 Milling grade.................................................................. FGF Milling machine ...................................31, 123, 125, BIC Milling tool .......................................45, 91, 161-162, BC Mobile cylinder hydraulic press ..............................145 Modular tooling system ................................ FIC, 12-13 Mould component.......................................................... 45 Monitoring of grinding systems.............................BGF Motor protection circuit breaker .............................. 27 Motors and control..................................................18, 20 Moulding machine ......................................................... 87 Multi-functional tool ...................................................... 97 Multi-functional turret................................................... 82 Multi-media software for learning CNC milling and turning technology ............................................... 57 Needle roller bearing ....................................... 55 Optical measurement ...................................... 25 Other automation accessories ................................... 89 Packaging solutions ...............................151, 153 Packaging test equipment ..............................151, 153 Paint spray system........................................................115 PCB drill............................................................................... 45 PCD and carbide reamers ............................................ 81 PCD and CBN tool .........................................................169 Pedestal grinder ............................................................157 Pedistar buffer ................................................................157 Persico forming..............................................................115 Pillar drilling machine .................................................154 Pillar-type hydraulic press .........................................145 Pilot light ............................................................................ 27 Planning machine ..................................... 140, 148, 157 Plano-miller ...........................................................148, 157 Plano-milling machines ..............................................140 PLC-operated hydraulic press ..................................145 Plug and socket ............................................................... 27 Pneumatic .......................................................................... 82 Polishing machine ........................................................124 Position display unit .....................................................BIC Post processor .................................................................. 10 Power source .................................................................... 65 Precision bearing ..........................................................163 Precision fabrication work .........................................139 Precision gear cutting tool ...................................... COC Precision grinder ............................................................. 11 Precision switch ............................................................... 27 Precision universal cylindrical machine ...............149

Sl. No Product 291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349

Pg No

Process automation and control equipment ....... 67 Productivity tracking system for CNC machine .. 57 Profile projector ...................................................151, 153 Pull stud ............................................................................138 Pull-action clamp ..........................................................139 Pump.............................................................................18, 20 Punching and laminating presses ..........................115 Push button....................................................................... 27 Rack rolling dies ............................................... 73 Rack ...................................................................................... 72 Rack-type spline rolling machine ............................. 73 Radial drilling machine ..................148, 149, 151, 153 Real-time Ethernet system for Ethercat and Profinet ....................................................................140 Real-time open source PAC system .......................140 Reamer ..............................................FIC, 12-13, 122, 138 Reversible tapping attachments .............................150 Robot .................................................................................115 Rotary encoder................................................................BIC Rotary indexing table .................................................BGF Rotary machine ...................................................................7 Rotary switch .................................................................... 27 Rotating electrical connector .........................151, 153 Safety protection device ................................. 27 Scanning white-light interferometry microscope ............................................................151, 153 Schleicher automatic sandwich line ......................115 Schleicher robotic waterjet cutter..........................115 Sealed linear encoder...................................................BIC Servo motor and drive .................................................. 89 Shaping machine ..........................................................148 Shot blasting machine ................................................154 Shrinking technology ..................................................109 Side lock adaptor ..........................................................138 Single and double column vertical machining centre ............................................................ 61 Single and multiple precision switch ...................... 27 Single limit switches ...................................................... 27 Sinking EDM ....................................................................169 Slant/flat bed .................................................................... 61 Sleeve bearing.................................................................. 55 Small size ball bearings ................................................ 55 Solder paste ..........................................................151, 153 Solid carbide drill .....................................................59, 81 Solid carbide mill ............................................................ 59 Solid carbide reamer...................................................... 59 Solid carbide special drill and mill ........................... 59 Solid carbide special reamer ...................................... 59 Solid monoblock reamer.............................................. 81 Special boring bar........................................................... 81 Special fine boring tool ................................................ 81 Special hydraulic expansion technology ............... 60 Special induction hardening machine.................... 65 Special line boring tool................................................. 81 Special purpose machine................................... 79, 140 Special reaming tool ...................................................... 81 Special thread milling tool .......................................... 81 Special tool ......................................................................138 Spindle nose tooling...................................................... 97 Spline rolling machine .................................................. 73 SPMs ..................................................................................... 24 Standard and special PCD tools ................................ 81


List of Products Sl. No Product 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400 401 402 403 404 405 406 407 408

Pg No

Standard fine boring tools .......................................... 81 Standard induction hardening machine................ 65 Standard thread milling tool ...................................... 81 Stationary work holding............................................... 60 Stepper motor and drive ............................................. 89 Straightening machine ...............................................157 Straight-line action clamp .........................................139 Submersible hydraulic press.....................................145 Super precision bearing ............................................... 55 Super-abrasive diamond and CBN grinding wheels ...............................................................................149 Surface and profile grinding machine ..................111 Surface grinder....................................................... 61, 155 Surface grinding machine ...............................148, 155 Surface plate ...................................................................148 Tap ................................... FIC, 12-13, 81, 98, 122 Tapping chuck................................................................152 Tensioner nut .................................................................146 Tensioner nuts and bolts ...........................................150 Thread mill......................................................................... 93 Thread rolling machine ................................................ 73 Thread whirling tool ................................................... FGF Threading tool...........................................................81, BC Thrush ball bearing ........................................................ 55 Tilting rotary table ........................................................147 Toggle action clamp ....................................................139 Toggle press....................................................................139 Tool bits ............................................................................122 Tool grinding machine ...............................................111 Tool holder ......................................................................109 Tool holding system ...................................................... 60 Tool logistics system....................................................109 Tool monitoring system ............................................BGF Tool path simulator for CNC milling and turning..... 57 Tool trolleys.....................................................................148 Tool.....................................................................................138 Tooling system ..........................................................81, BC Tool-maker microscope ....................................151, 153 Touch probe.....................................................................BIC Track roller .......................................................................146 Tubing accessory............................................................. 67 Turn mill centre .............................................................143 Turning holder ................................................................. 97 Turning machine ...........................................31, 123, BIC Turning tool ...............................................................45, BC Turnkey solution.............................................................. 81 Twist drill ................................................................122, 138 Two-solvent spray line ................................................115 Ultra-high pressure apparatus........................ 45 Universal drilling system ............................................152 Vacuum chuck................................................... 82 Validation of packs .............................................151, 153 Valve terminal .................................................................. 67 Valve..................................................................................... 67 Vertical and horizontal machining centre ............. 39 Vertical boring machine .............................................148 Vertical handle clamp..................................................139 Vertical honing machine ............................................139 Vertical lathe machine ................................................143 Vertical machining centre....................................... 7, 61

Sl. No Product 409 410 411 412 413 414 415 416

Pg No

Vertical turn mill centre ................................................ 79 Vertical turning lathe ...................................................140 Vertical turning machine ................................... 79, 148 Vertical turret lathe ........................................................ 26 Wear parts ......................................................... 97 Wear resistant tool ......................................................... 45 Wire cut EDM ..................................................................169 Work-holding solutions .............................................BGF INTERNATIONAL PRODUCTS

417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463

Battery-type lifting magnetic chuck ............ 150 Bites ....................................................................................138 Boring heads ...................................................................156 CAM-type permanent lifting magnetic chuck.. 150 Centerless machine ......................................................159 Chuck controller ............................................................150 CIMES-2012........................................................................ 68 Circular cold saw ...........................................................148 CNC cylindrical roll grinder .......................................156 CNC machine .................................................................... 53 CNC milling machine .........................................155, 157 CNC plunge/angular cylindrical grinder ..............156 CNC rotary table ............................................................152 CNC vertical grinder.....................................................158 Copper alloy wires and rods .....................................158 Cutting machine............................................................160 Cutting tool .....................................................................154 Cylindrical grinder ........................................................159 Deep-hole drilling machine............................. 37 Demagnetiser .................................................................150 Diamond circular saw..................................................138 Diamond core bit ..........................................................138 Diamond dresser ...........................................................138 Diamond grinding wheels for LCD glasses.........138 Diamond scribers for sapphires ..............................138 Diamond tools for semiconductors .......................138 Diamond tools for silica tile industry ....................138 Diamond/CBN electroplated tools .........................138 Electro magnetic chuck.................................. 150 End mill cutter ................................................................158 End mill .............................................................................154 Fine-pole permanent magnetic chuck ......... 150 For precision grinding wheel ...................................138 Forming milling cutter ................................................158 Fully-automatic circular sawing machine............148 Fully-automatic tungsten carbide sawing machine.....148 Grinding machine ........................................... 159 Hard alloy turning cutter............................... 158 Heat treatment steel cutting machine .................148 High-speed double column milling machining center...119 Horizontal band .............................................................163 Hydraulic angle lock vise ...........................................150 Hydraulic automatic-type aluminum copper.....148 Hydraulic automatic-type metal sawing machine ...148 Hydraulic machinery ....................................................146 Hydraulic press brake ..................................................146 Hydraulic press...............................................................146

Sl. No Product

Pg No

464 Hydraulic punch presses ............................................146 465 IMTS-2012 - International Manufacturing Technology Show ........................................... 117 466 Industrial cleaning automation ...............................160 467 Internal grinding machine.........................................159 468 Inverter chiller ................................................................158 469 Iron fillings separator...................................................150 470 Knocking cylinder........................................... 160 471 Machine tools ................................................. 160 472 Magnetic block unit .....................................................150 473 Magnetic induction block..........................................150 474 Magnetic roller ...............................................................150 475 Magnetic separator ......................................................150 476 Magnetic steel sheet separator ...............................150 477 Manufacturing equipment ........................................146 478 Metal circular pipe/bar stock end chamfering machine....................................................148 479 Metal forming machine ..............................................146 480 Milling cutter ..................................................................158 481 Mororised rotary magnetic chuck ..........................150 482 Natural/polycrystalline/single crystal diamond dies ... 138 483 NC cylindrical grinder ..................................................156 484 On/off permanent lifting magnetic chuck ... 150 485 PCD multi-edged blades for PCB industry ... 138 486 Permanent magnetic chuck......................................150 487 Precision cutting wheels ............................................138 488 Precision machine vice ...............................................160 489 Press brake.......................................................................146 490 Professional high-speed machine ..........................119 491 Robotic assembly system .............................. 159 492 Rolling machine .............................................................159 493 Rotary permanent magnetic chuck .......................150 494 Saw blade sharpener ..................................... 148 495 Saw .....................................................................................163 496 Sawing machine ............................................................163 497 Shaft ...................................................................................159 498 Shear ..................................................................................146 499 Shearing machines .......................................................146 500 Spindle ..............................................................................139 501 Standard (powerful) magnetic base ......................150 502 Standard (powerful) permanent magnetic chuck ....150 503 Thread ............................................................. 159 504 Traditional cylindrical grinder ..................................156 505 Tunnel-type magnetizer .............................................150 506 Universal cylindrical grinder .....................................156 507 Universal machine ........................................................159 508 Vacuum system..............................................................150 509 Various types of wear-resistant parts ....................138 510 Vertical machining centre................................119, 156 511 Waterjet machine..........................................................160

Looking for a speciďŹ c product? We will ďŹ nd the product for you. Just type MMT (space) Name of the Product and send it to 51818 eg, MMT (space) Lathe and send it to 51818.

COC - Cover on Cover FGF - Front Gate Fold FIC - Front Inside Cover BIC - Back Inside Cover BGF - Back Gate Fold BC - Back Cover 166 MODERN MACHINE TOOLS - April 2012


List of Advertisers Advertiser’s Name & Contact Details Aiema Technology Centre T: +91-44-26258731 E: info@acmee.in W: www.acmee.in

Pg No 56

Asso For Manufacturing Technology T: +703-827-5270 W: www.imts.com

117

Autotech Machine Tools Sales & Services T: +91-20-25690044 E: autocnc@vsnl.com W: www.autotechcnc.com

8-9

Bei Jyu Precision Machine Co Ltd T: +886-4-2350-1280 E: SY3736@hibox.hinet.net W: www.beijyu.com.tw

160

Advertiser’s Name & Contact Details Dees Hydraulic Industrial Co Ltd T: +886-2-2601-8661 E: sales@spc.com.tw W: www.spc.com.tw

Pg No 146

160

148

Fong Ho Machinery Industry Co., Ltd T: +886-4-2406-6769 E: fongho@ms26.hinet.net W: www.fongho.com.tw

Doosan Infracore India Pvt Ltd T: +91-80-42660122 E: sandesh.kumar@doosan.com W: www.doosaninfracore.com

14

Fullton Machinery Co., Ltd T: +86-411-82767678 E: fullton@fulltontech.com W: www.fulltontech.com

26

G W Precision Tools India Pvt Ltd T: +91-80-40431252 E: info@gwindia.in W: www.gwindia.in

59

23

77

Blaser Swisslube India Pvt Ltd T: +91-124-4994000 E: india@blaser.com W: www.blaser.com

69

Drake Manufacturing T: +330-847-7291 W: www.drakemfg.com

CADEM Technologies Pvt Ltd T: +91-80-26634767 E: sales@cadem.com W: www.cadem.com

57

Durga Bearing Pvt Ltd T: +91-22-6876073 E: inquiry@durgabearings.com W: www.durgabearings.com

Castrol T: +91-44-42198885 E: CustomerService.India@castrol.com W: www.castrol.com/industrial Ceratizit India Pvt Ltd T: +91-33-24947146 E: info@ceratizitindia.co.in W: www.ceratizit.com

145

152

55

Ganro Industrial Corp T: +886-4-2537-6266 E: sdp@ganro.com.tw W: www.ganro.com.tw

119

65

98

Ermaksan Sheet Metal Working Machinery T: +90-224-2947500 E: sinan.bilgin@ermaksan.com.tr W: www.ermaksan.com.tr

48

GSK CNC Equipment Co. Ltd T: +91-9886835186 E: gskwang@hotmail.com W: www.gsk.com.cn

29

97

Emuge India Pvt Ltd T: +91-20-39310000 E: marketing@emugeindia.com W: www.emugeindia.com

Goindustry (Uk) Ltd T: +44-20-70983700 E: ailene.castro@go-dove.com W: www.go-dove.com

115

47

EFD Induction Ltd T: +91-80-7820404 E: sales@efdgroup.net. W: www.efd-induction.com

Gentiger Machinery Industrial Co Ltd T: +886-4-2683-6919 E: jay@gentiger.com.tw W: www.gentiger.com.tw

150

Erwin Junker T: +91-20-26053896 E: info@junker.in W: www.junker.in

46

Guang Dar Mangnet Industrial Ltd T: +886-4-2436-0757 E: guangdar@ms32.hinet.net W: www.guangdar.com

FIC

Essor International Inc W: www.essor.com.tw

153

Guhring India Pvt Ltd T: +91-80-40322500 E: info@guhring.in W: www.guhring.in

139

Booklet

Crane-Bel International Pvt Ltd T: +91-120-3263281 E: office@crane-bel.com W: www.crane-bel.com

18

Everising Machine Co. T: +886-4-2359-3178 E: evrs@everising.com.tw W: www.everising.com

163

Crane-Bel International Pvt Ltd T: +91-120-3263281 E: office@crane-bel.com W: www.crane-bel.com

20

Femco India T: +91-20-40147870 E: sales@femcoindia.com W: www.femco.com.tw

143

Creaform India T: +91-11-65022218 E: india@creaform3d.com W: www.creaform3d.com

Flow Asia Corporation T: +91-9343-340-001 E: inquiry-asia@flowcorp.com W: www.flowasia.com

58

Big Daishowa Seiki Co. Ltd T: +81-729-828277 W: www.big-daishowa.com

Cosmos Impex (India) Pvt Ltd T: +91-265-3927000 E: mediasupport@cosmos.in W: www.cosmos.in

Pg No

Dijet Industrial Co Ltd T: +91-22-40121231 E: ravisane@dijet.co.jp W: www.dijet.co.jp

Dowel Machinery Pvt Ltd T: +91-281-2362465 E: dowel@thedowel.com W: www.thedowel.com

Chamunda Equipments T: +91-79-27522437 E: clamp@chamundaequip.com W: www.chamundaequip.com

Advertiser’s Name & Contact Details

133

Festo Controls Ltd T: +91-80-22894100 E: info_in@festo.com W: www.festo.com

67

Haas Automation India Pvt Ltd T: +91-20-32935433 E: sales@haasindia.com W: www.HaasCNC.com Haimer India Pvt Ltd T: +91-9890153568 E: haimer@haimer.in W: www.haimer.com Heidenhain Optics & Electronics (I) T: +91-44-30234000 E: info@heidenhain.in W: www.heidenhain.in

7

109

BIC

April 2012 - MODERN MACHINE TOOLS 167


List of Advertisers Advertiser’s Name & Contact Details

Pg No

HG Technology Co Ltd T: +886-4-7362-725 E: hg.tech@msa.hinet.net W: www.hgt.com.tw Hong Ji Precision Machinery Ltd. T: +886-4-2422-1095 E: hongji_jasonlin@hotmail.com W: www.hong-ji.com.tw Hwacheon Asia Pacific Pte Ltd T: +91-20-30429140 E: sales@hwacheonindia.com W: www.hwacheaon.com Hyundai Wia T: +91-9940653703 E: mvhari@gmail.com W: www.hyundai-wia.com Igus India Pvt Ltd T: +91-80-39127800 E: info@igus.in W: www.igus.in

154

37

144

141

142

Indiam Machine Tools Manf - AMTTF T: +91-80-22731625 E: director@amttf.in W: www.amttf.in

22

Indiam Machine Tools Manf - Finishing School T: +91-80-66246600 E: augustin@imtma.in W: www.imtma.in

96

Indiam Machine Tools Manf - MMS T: +91-80-66246600 E: info@imtma.in W: www.mmsinfo.in

16

Indiam Machine Tools Manf Productivity Summit T: +91-80-66246600 E: augustin@imtma.in W: www.imtma.in Indian Tool Manufacturers T: +91-22-25852559 E: ltmth@hathway.com W: www.indiantool.com ISGEC Heavy Engineering Ltd T: +91-120-3301 001 E: trading@isgec.com W: www.isgec.com

44

122

61

Jagdeep Foundry (Regd.) T: +91-1871-242750 E: jagdeepfoundry@rediffmail.com W: www.jagdeepfoundry.in

148

Jainnher Machine Co., Ltd T: +886-4-2358-5299 E: saledep@jainnher.com.tw W: www.jainnher.com.tw

156

168 MODERN MACHINE TOOLS - April 2012

Advertiser’s Name & Contact Details

Pg No

Jin Year Precision Co Ltd T: +886-4-2523-2817 E: liu0930@ms58.hinet.net W: www.jinyear.com.tw

150

Jyoti CNC Automation Pvt Ltd T: +91-2827-287081 E: info@jyoti.co.in W: www.jyoti.co.in

99

Kabel Schlepp India Pvt Ltd T: +91-80-41158997 E: gm@kabelschlepp.in W: www.kabelschlepp.com

129

Kim Union Industrial Co. Ltd T: +886-4-2533-1131 E: kimunion@kimunion.com W: www.threadrolling.com.tw

159

Komet Precision Tool India Pvt Ltd T: +91-80-280780000 E: info.in@kometgroup.com

81

Advertiser’s Name & Contact Details

Pg No

Mitutoyo South Asia Pvt Ltd T: +91-11-26372090 E: delhi@mitutoyoindia.com W: www.mitutoyoindia.com Montfort Shanghai Co Ltd T: +860-21/52136600 E: g.zhang@montfortshanghai.com

25

35-36

MTE Industries Pvt Ltd T: +91-40-23777571 E: info@mteindustries.com W: www.mteindustries.com

73

Neri Engineering T: +91-80-28374885 E: sales@nerigroup.in W: www.nerigroup.in

89

Neway CNC Equipment (Suzhou) Co., Ltd T: +91-281-276-7100 E: newaycnc@gmail.com W: www.newaycnc.com

39

Korber Schleifring Gmbh T: +91-80-41554601 E: sales@schleifring.in W: www.schleifring.in

111

Nikon India Pvt Ltd T: +91-124-4688 500 E: nind.Inst@nikonoa.net W: www.nikon-instruments.jp/eng/

147

Korloy Inc. T: +82-2-2522-3181 E: export@korloy.com W: www.korloy.com

123

NMTG Mechtrans Techniques Pvt Ltd T: +91-79-22821527 E: nmtg@nmtgindia.com W: www.nmtgindia.com

146

Larsen & Toubro Ltd T: +91-22-67051093 E: sm.haridas@larsentoubro.com W: www.larsentoubro.com

91, 161-162

Macpower CNC Machinery Pvt Ltd T: +91-2827-287930 E: sales@macpowercnc.com W: www.macpowercnc.com

107

Marox Tools Industrial Co Ltd T: +886-4-2278-0167 E: service@marox.com.tw W: www.marox.com.tw

158

Metrol Corporation India Branch Off T: +91-80-42105031 E: sales@metrolindia.com W: www.toolsensor.com

58

Micromatic Grinding Technologies Ltd T: +91-120-2712137 E: info@micromaticgrinding.com W: www.micromaticgrinding.com

11

Milltronics CNC Machines T: +91-98-45902876 E: sales.india@milltronics.net W: www.milltronics.net

53

Mitsubishi Heavy Industries India Pvt Ltd T: +91-11-41021234 E: mtdsales@mhiindia.com W: www.mhiindia.com

COC

NN Combined Engineering Agencies Pvt Ltd BGF T: +91-40-27844279 E: mail@nncea.com W: www.nncea.com Objet Ap Ltd T: +852-2174 0111 E: info@objet.com W: www.objet.com OM Manufactures T: +91-281-2384444 E: info@ommanufacturers.com W: www.ommanufacturers.com

70

151

Openmind Cadcam Technologies (I) Pvt Ltd T: +91-80-30504647 E: Info.India@openmind-tech.com W: www.openmind-tech.com

10

OSG India Pvt Ltd T: +91-20-66304407 W: www.osg-india.com

87

P R Sales Corporation T: +91-20-25437591 E: info@prsales.in W: www.prsales.in

112

Palmary Machinery Co., Ltd T: +886-4-2492-9799 E: Roger@grinding.com.tw W: www.grinding.com.tw

159


List of Advertisers Pg No

Advertiser’s Name & Contact Details

Para Mill Precision Machinery Co Ltd T: +886-4-2680-0678 E: para.mill@msa.hinet.net W: www.paramill.com

155

Royal Precision Tools Corporation T: +886-4-2338-2068 E: oliver@royal-spindles.com.tw W: www.royal-spindles.com.tw

Pinnacle Engineering Enterprise T: +91-2752-230552 E: mail@pinnaclegrinder.com W: www.pinnaclegrinder.com

155

S&T Engineers T: +91-422-2590810 E: sales@stengineers.com W: www.stengineers.com

Pitroda Utility Industries T: +91-2752-243795 E: response@pitrodautilityindia.com W: www.pitrodautilityindia.com

149

Pramet Tools India Pvt Ltd T: +91-124-4703825 E: pramet.info.in@pramet.com W: www.pramet.com

31

Precihole Machine Tools Pvt Ltd T: +91-22-25836780 E: info@precihole.co.in W: www.precihole.co.in

24

Precision Industrial Co. T: +91-22-23436717 E: precisionranjit@hotmail.com

163

Prem Brothers T: +91-11-28117456 E: powermaster59@gmail.com W: www.powermaster-india.com

124

Premier Ltd T: +91-22-61179009 E: ericadesouza@premier.co.in W: www.premier.co.in Progressive Engineers T: +91-22-32944289 E: info@progressiveengineers.net W: www.hangsterfers.com Quickmil T: +705-745-2961 E: info@quickmill.com W: www.quickmill.com

79

151, 153

125

Riat Brothers (India) T: +91-161-2530805 E: riatbrothers@gmail.com W: www.riatbrothers.com

157

Robin Precision Products Pvt Ltd T: +91-2827-287631 E: info@bloodtools.com W: www.bloodtools.com

138

Rockwell Automation Pvt Ltd T: +91-120-4671694 E: dghosh@ra.rockwell.com W: www.rockwellautomation.com

113

Samkrish T: +91-44-23612310 E: info@samkrish.com W: www.samkrish.com Samkrish Machine Tools T: +91-44-23612310 E: info@samkrishmachinetools.com W: www.samkrishmachinetools.com

Pg No 139

88

121

71

Sandvik Coromant India FGF T: +91-20-27104725 E: coromantindia.communications@sandvik.com W: www.sandvik.coromant.com/in Sarabsukh Machine Tools T: +91-1871-223893 E: sarabsukhbatala@yahoo.co.in W: www.sarabsukhmachines.com

140

Schunk Intec India Pvt Ltd T: +91-80-41277361 E: info@in.schunk.com W: www.schunk.com

60

Seco Tools India Pvt Ltd T: +91-2137-667300 E: seco.india@secotools.com W: www.secotools.com/in

21

Shanghai Reed Exhibition Co Ltd. Beijing Office 68 T: +86-10-5933-9080 E: boris.benesch@reedhuayin.com.cn W: www.cimes.net.cn Shuter Enterprises T: +91-44-32407116 E: 32407116@shuter.in W: www.shuter.in

72

SLN Technologies Pvt Ltd T: +91-80-26651659 E: anil@slntechnologies.com W: www.slntechnologies.com

140

Taegutec India Ltd T: +91-80-27839111 E: sales@taegutec-india.com W: www.taegutec-india.com

BC

Advertiser’s Name & Contact Details

Pg No

Taiwan Diamond Industrial Co., Ltd T: +886-3-363-6971 E: Lai@taiwandiamond.com W: www.taiwandiamond.com

138

Takamatsu Machinery Co Ltd T: +81-76-2741403 E: h.nakagawa@takamaz.co.jp W: www.takamaz.co.jp

41

Teknic T: +91-22-26592392 E: teknic@vsnl.com W: www.tecknic.co.in

27

Tungaloy India Pvt Ltd T: +91-22-61248888 E: info@tungaloyindia.com W: www.tungaloy.co.jp.in

45

Tussor Machine Tools India Pvt Ltd T: +91-422-3200183 E: info@tussorindia.com W: www.pinachoindia.com Vargus Ltd T: +91-9730028248 E: vishal@vargusindia.com W: www.vargus.com Vijay Machine Tools Pvt Ltd T: +91-22-24950886 E: elmeco@elmacovijay.co.in W: www.elmacovijay.com Weizmann Engineering Ltd T: +91-44-22280595 E: weizmann_engg@yahoo.com W: www.weizmann.in Wexper India Ltd T: +91-124-2210020 E: rajan.vaid@wexper.com W: www.wexper.com YG Cutting Tools Corporation Pvt Ltd T: +91-80-43543636 E: admin@yg1india.com W: www.yg1.co.kr

93

157

82

169

12-13

Looking for a specific product? We will find the product for you. Just type MMT (space) Name of the Product and send it to 51818 eg, MMT (space) Lathe and send it to 51818.

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BGF - Back Gate Fold BC - Back Cover

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April 2012


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April 2012


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Reg No: MH / MR / WEST / 235 / 2012 – 2014 RNI No: MAHENG / 2008 / 24347 Licence to Post at Mumbai Patrika Channel Sorting Office, Mumbai GPO., Mumbai 400 001 Date Of Posting 1ST & 2ND Of Every Month / English & Monthly. Date Of Publication: 28th of Every Month

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Modern Machine Tools - April 2012