DMI-Mar 2018 issue

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w w w. m es h m i x m ed i a . co m

‘WELCOME TO THE NEW DIGITAL CNC WORLD’

Make In India

Is In Our DNA A deep dive into the strategy and leadership vision of Gautam Maini, MD, Maini Precision Products, who has led MPP to place it firmly on the world’s precision-engineering map.

OLIVER LORENZ Head of Market Asia ORDERFOX

MEASUREMENT ERROR

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

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Volume 2–Issue 2 M a r /Apr 2 0 1 8

CONTENTS 12

36

20 40

14 28

5

Vo l u m e 2 – Is s u e 2 M a r /Apr 2 0 1 8

42

47 48 56

60

58

Industry News Aerotech Balluff

Breakthrough Dietrich Kennametal Renishaw

Events NORD Drivesystems EMO

Outlook Carl Zeiss

Cover Story MAINI Precision Products

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12 13 14 40 58 47 48 38 20

Interview ORDERFOX

Case Study DMG MORI

Product News ELESA+GANTER BAUMER Interrol Seco Tools Haimer

Budget Impact VDMA VDW

Success Story

34

Jyoti CNC Automation

42

HMS Industrial Networks B P Poddar

18 31 36 64 68 32 33

Primer

MoU NORD Drivesystems

Special Feature Schuler

Vision Make In India MAGAL - INGYU

28 17 64 46 56 60

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Volume 2–Issue 2 M a r /Apr 2 0 1 8

Message | EDITOR’S LETTER

It’s Not About Jobs

Y

ou would notice in our interviews that we put one particular question before all the industry leaders: “What should be the ultimate aim of Mission Make in India – should it be the creation of jobs or making India a global manufacturing hub?” As you see, it is a leading question, that is, it already contains two options for the interviewee to pick one or both. It is a telltale sign of the hubris that we in the Indian media are afflicted with – we think that no one outside media has a mind of his or her own. Hubris is a big reason why the Indian media – be it business or mainstream – is struggling for survival and thankfully so because we need that much-needed churn. But I digress.

We have been asking people the aforesaid question for a particular reason. We want to understand why the slogan of Mission Make in India, despite its noble intent, is not able to deliver the desired effect. All the indicators tell us that growth in the manufacturing industry in the last few years has been stagnant at best and tumultuous at worst. The IIP (India Industrial Index) and PMI (Purchasing Manger Index) have shown some respectable numbers lately but they have not been steady – we see higher growth one month, followed by a slump in the next one. Globally, as per the latest OECD numbers, India’s industrial production growth lags behind that of Indonesia, Turkey and Estonia. As per the World Bank, industry’s MVA (Manufacturing Value Added) as a percentage of GDP has stayed in the same vicinity over the last many years – 16-17 percent.

In short, we have the right intent but we lack in spirit. In my opinion, an important way to understand the problem is to look at the ‘why’ of Make in India: Why must we make it a success? What is the ultimate purpose? When we put the same question to the manufacturing industry leaders, voila, we are invariably given the right answer. Surprise, surprise, it is neither of the two alternatives – it neither about jobs and nor the making of a global hub; it’s global competitiveness. India’s manufacturing industry must be able to compete with the world’s top industrially advanced countries like Germany, Japan and the UK on innovation and productivity.

Only would someone oblivious of the way a globalised world functions propose that India, or for that matter any one country, can become the global manufacturing hub in any area, be it in aviation or automotive. Creation of jobs, on its part, is also not a desired outcome.

It is an established fact that as a country becomes more industrialised, the manufacturing sector ceases to be a big provider of jobs for the obvious reason – competitiveness is about finding ways to do more for less. It is the other industries such as services and construction that provide the bulk of the jobs. The manufacturing industry in a developed country contributes in terms of innovation, trade and productivity to the GDP, not employment.

In essence, I believe that the whole Mission Make in India campaign should be refocused and realigned around global competitiveness for people in the industry to truly rally behind it. Because people already know the ‘what’; they need to believe the ‘why’.

Here’s wishing you successful 2018.

Write to me at editorial@meshmixmedia.com

ANAND PANDEY Editor Meshmix Media

IN-EM-2017-Win.indd 1

2/27/2017 10:13:53 AM

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Volume 2–Issue 2 M a r /Apr 2 0 1 8

Message | PUBLISHER’S LETTER

Inspired and Humbled

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ur fifth edition is here and we are jubilant and humbled at once with all the support, the praise, constructive criticism, and the interest we have received for the last four issues of Dynamic Manufacturing India.

We have endeavored to bring to you useful lessons shared by industry leaders in every edition. In our fourth issue, we covered the Aerospace Industry and got the opportunity to speak with Mr Shekar N, President, AIDAT (Aerospace Industry Development Association of Tamil Nadu) about how Tamil Nadu has emerged as a strong contender for the aerospace manufacturing business that is growing on a fast clip globally.

In our current edition, we had to opportunity to interview Mr Gautam Maini, MD, Maini Precision Products, who has been instrumental in putting MPP on a fast growth track particularly in the recent few years. MPP’s alliance with Safran Aircraft Engines for supply of precision machined components for the LEAP engines is truly a milestone for India’s precision-engineering growth story.

Overall, India’s economy is witnessing the start of a period of fast growth as evidenced from the latest industry reports. According to MOSPI, the manufacturing sector grew at a CAGR of 7.32 per cent between FY12 and FY17. India’s GDP increased 7.1 per cent in 201617 and is expected to reach a growth rate of 7 per cent by September 2018. Also, India has improved its ranking in the World Bank’s Doing Business Report by 30 spots over its 2017 ranking and is ranked 100 among 190 countries in 2018 edition of the report.

The primary aim of Dynamic Manufacturing India is to create awareness and encourage innovation and growth in the manufacturing sector as well as create a positive environment for emerging technologies. I thank you for your valuable suggestions and unbiased feedback, and look forward to your views on the current issue. We thank our advertisers for their continued support and faith in us. Your unwavering support has given has all the courage and resilience to be able to strive further.

Check out our website www.machineinsider.com for e-copy of our magazine and latest industry updates.

Do please write to me at preeti.m@meshmixmedia.com

PREETI MISHRA Publisher Meshmix Media

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Volume 2–Issue 2 M a r /Apr 2 0 1 8

Message | NOTES FROM THE FIELD

Going Global

O

ur manufacturing industry stands at the cusp of fast growth – the IIP beat market expectation in January when it rose by 7.5 percent year on year, with manufacturing output clocking a higher growth rate of 8.7 percent compared to December 2017. The sector appears to be well on its way to achieve the Make in India vision of contributing 25 percent, up from the current 16 percent, to India’s GDP.

In our small way, we at DMI, are doing what we can to push and promote the Make in India vision through our interactions with industry representatives. In the coming months, we plan to go deeper – you will see a lot of new initiatives from our side to reach out to the MSME sector, especially in the tier-2 and tier 3 cities in India. We have received great response and suggestions from our readers for this endeavour and we urge you to keep sending us feedback that helps us move forth in this direction.

Meshmix Media completed one year in February 2018 – it has been an eventful year for us, replete with learnings and small successes. Enthused by the response of our readers, we are taking the idea global. In the coming months, we will make sure that DMI, both through the readership and alliances, reaches global audiences across countries like Germany, China, Taiwan, Japan, Czech Republic, and of course, the USA. Our publication aspires to take Indian manufacturing to the global audiences.

I am grateful to Mr Gautam Maini, MD, Maini Precision Product who has shared his views with our publication that gave to us one of the best conversation pieces we have published in DMI thus far.

Happy Reading.

Write to me at advertise@meshmixmedia.com

DINESH MISHRA Senior VP – Strategy Meshmix Media

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Product News | AEROTECH

Featuring anti-creep crossedroller bearings and a precisionground, fine-pitch ball-screw, the ATX series boasts of excellent geometric performance.

Picture: Aerotech

Aerotech’s Linear Stages Ideal for High-Precision Tasks With anti-creep crossed-roller bearings and travel lengths to 250 mm, Aerotech’s ATX series linear positioning stages enable convenient integration into larger machines. It can also be used as stand-alone positioning axes. Vacuum and cleanroom-compatible versions are available in the market while ThermoComp ensures reliable performance in changing environments.

A

erotech’s ATX series linear positioning stages combine the performance capabilities of a highprecision crossed-roller-bearing positioner with the convenience and simplicity of a ball-screw drive mechanism. Outstanding motion performance and a variety of advanced options and features offer superb value and make the ATX series an excellent choice for use in highperformance applications.

Superior Motion Performance Featuring anti-creep crossed-roller bearings

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Product News | BALLUFF and a precision-ground, fine-pitch ball-screw, the ATX series boasts excellent geometric performance and minimal angular error motion.

With up to 250 mm of nominal travel, these linear stages offer superior minimum incremental step size and in-position stability compared to other stages that utilize recirculating ball bearings. This makes the ATX series ideal for many high-precision tasks such as vertical positioning of sensors and cameras, optics focusing, and beamline measurement and manipulation applications.

Linear Encoder Option ATX stages offer an integral center-mounted linear encoder to provide direct position measurement at the stage’s moving carriage. The typical effects of backlash commonly associated with screw drives are virtually eliminated when using the linear encoder as a position feedback device. Applications that require exacting workpoint performance benefit greatly from the direct linear encoder. Options are available with either incremental (1 Vpp and digital TTL) or absolute output signals.

Design and Integration Flexibility The ATX series is designed with a variety of standard features and options allowing them to be easily integrated into a larger subsystem or machine, or to serve as a stand-alone positioning axis. They mount to both metric and English optical tables and feature a versatile customer mounting interface on the moving carriage to which other positioning stages or equipment can be mounted. Brushless, slotless servomotors, with or without a holding brake, as well as stepper motors are available. The ATX series can be equipped with an optional motor foldback kit in order to reduce the overall length of the stage. This is particularly useful in vertical-axis applications where space is limited. Vacuum- and cleanroom-compatible variants are also offered.

Mitigate Thermal Errors with ThermoComp Temperature changes and thermal effects are often the most detrimental sources of error in precision machines, and screw drives are particularly susceptible. All ATX-series stages are available with Aerotech’s ThermoComp feature, an integrated temperature compensation solution that delivers accurate and dependable positioning performance in the presence of thermal disturbances. It protects the stage from the effects of variable-temperature environments and friction-induced self-heating, ultimately providing stability to the user’s process even in extreme industrial environments.

Capacitive Sensor Head by Balluff

The sensor is designed for use with type BAE sensor amplifiers from Balluff.

Picture: Balluff

Balluff offers a self-adhesive, capacitive sensor head with IP 64 protection for noncontact, continuous level detection on nonconductive vessel or pipe outer walls made of glass, plastic or ceramic.

T

he flexible sensor head with a maximum detection range of up to 850 mm in length can be individually trimmed to length (minimum 108 mm) and easily attached to container walls without additional accessories using the integrated adhesive surface.

For polar, aqueous media the wall thickness may be between 2 and 6 mm, or up to 2 mm for non-conductive media such as oil or bulk materials.

The sensor is designed for use with type BAE sensor amplifiers from Balluff. The optional amplifier allows levels to be continually detected over the entire measuring range as analog values (0...10 V, 4...20 mA) or via IO-Link or as minimum or maximum value exceeding. Both the IO-Link and the analog convenience amplifier feature versatile setting possibilities.

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Volume 2–Issue 2 M a r /Apr 2 0 1 8

Breakthrough | DIETRICH

De Dietrich Process Systems Successfully Implements Hygienic Drying in a Vacuum Spherical dryers are the ideal dryers in the production of high valuable products like pharmaceutical ingredients. From pure drying up to mixing and granulation the Rosenmund spherical dryer can cover a wide range of applications.

W

hen manufacturing takes place by wet chemical processes, Active Pharmaceutical Ingred­ ients are precipitated or crystallized from the solvent. The subsequent steps are usually isolation and drying. Hygienic drying in a vacuum requires a lot of attributes.

The innovative spherical dryer design provides the highest performance according to process control and the latest GMP standards. De Dietrich Process Systems is currently delivering several units in that field. The Spherical Dryer is available in the Rosenmund design.

Important advantages at a glance: • Fast drying, mixing and granulation • Easy cleaning (WIP/CIP) • Total product discharge • Short drying time due to high heat transfer design • Easy to inspect by quick lock opening • Explosion pressure shock resistant design • Compact design allows easy installation in existing production buildings

The innovative Rosenmund spherical dryer design provides the highest performance according to process control and the latest GMP standards.

Picture: Dietrich

The lower half of the sphere is removable either by pivoting or dropping. This allows total and full visual along with manual access to the process area. Accessibility, cleanability and fast as well as residue-free discharge are the most important prerequisites for the production of high-quality products. Effective trouble free washing and cleaning (WIP/CIP) is required to

Vo l u m e 2 – Is s u e 2 M a r /Apr 2 0 1 8

maintain the systems in order to meet strict hygienic standards. These conditions are a real challenge to agitated vacuum dryers and are met by the characteristics of the patented top driven Rosenmund Spherical Dryer design.

Superior Mixing with Three Arm Agitator The spherical dryer achieves a high grade of mixing via a three arm agitator specially designed to conform the spherical wall. The agitator drive together with the shaft seal mounted on the upper sphere. For sealing the rotation either gas or liquid lubricated double acting mechanical seals are supplied.

By heating the agitator at a high rational speed, the heat exchange can be increased. A reduced clearance between the body and the agitator improves the heat transfer and prevents wet goods from being baked onto the hub and blades. These are ideal conditions for excellent solid mixing in contact with the heated wall surface which results in short drying times and reproducible drying results. To prevent the formation of agglomerates, a high speed chopper can break up the lumps and assist the removal of moisture from within.

Fully Dischargeable At the center and lowest point of the sphere, a dead-space free design of valve allows the product to flow without restriction and the risk of building bulk bridges. With this free passage and a gentle rotating agitator valuable products can be fully discharged without being jammed.

Pack Off System For the packing of the discharged product the dryer can be supplied with a pack off system.

These systems are regularly supplied with a continuous liner to prevent active ingredients being exposed to the ambient. With a weighing scale and a permanent actuated discharge valve the product can be dosed to a preset value. A mill can also be placed between the discharge valve and the pack off system as an integrated part to achieve smaller particle sizes.

Cleaned in a Flash In the pharmaceutical industries federal agencies set requirements for cleaning process equipment. These good manufacturing practices are regulations put in place to ensure equipment is maintained in a clean and orderly fashion. The main concerns is to avoid contamination of the product and cross-contamination (by improper cleaning, bad maintenance) both of which can lead to product call-backs.

Picture: Dietrich

Key Highlight: Accessibility, cleanability and fast as well as residuefree discharge are the most important prerequisites for the production of highquality products.

Effective trouble free washing and cleaning (WIP/CIP) is required to maintain the systems in order to meet strict hygienic standards.

Due to the spherical design and the location of critical parts like the mechanical seal above the product level, washing and cleaning in place (WIP/CIP) procedures can be carried out efficiently with minimum quantity of detergents.

Moving and retractable cleaning ARD- Nozzles (Aftertreatment Regeneration Device) with rotating spray heads enter by pressure of the cleaning liquid from the vessel wall to the center of the sphere and enable a good coverage of the detergents on the product contacted surfaces.

When the spraying is completed, the ARD nozzles retract themselves under spring load to be flushed with the inner surface of the vessel, thus closing free of dead spaces.

Due to the slope in direction to the outlet valve, cleaning fluids and dissolved product residues are drained at the lowest point of the vessel. For the purpose of conducting a qualitative coverage test of the spray devices, a riboflavin test can be performed to measure the accuracy of the cleaning. The results of this procedure can be useful in the development of cleaning validation protocols.

Easy Access for Inspection To allow a quick inspection at any time the Rosenmund top driven spherical dryer can be opened easily by swiveling the lower half of the sphere. This operation is simply achieved by a hydraulic driven quick lock bayonet at the main flange and a hinge at the joint of the two spheres.

A further advantage of this partition into two halves is the possibility to install the dryer between two floors. The product discharge area with its lower part of the sphere can be located in a classified clean room whereby the upper part of the sphere is separated in the technical area.

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Breakthrough | DIETRICH

The innovative Rosenmund spherical dryer design provides the highest performance according to process control and the latest GMP standards.

Picture: Dietrich

Key Highlight: The size ranges from 100 to 4´000l net volume. The vessel is fully jacketed, insulated and covered by welded metal sheeting.

Normally the dryer comes along with skids for heating / cooling and vacuum including a condensation of the vapours.

Module

Description

1000

Sphere

1025

Discharge valve

1100

Quick lock (bayonet)

1300

Sampling valve

1700

Hydraulic actuated hinge

2000

Drive unit/Agitator

4500

Mechanical seal

7500

Chopper

7600

Spray balls (ARD nozzles)

8000

Dust filter

Versatile Design Features and Sizes Since dryers are usually designed for vacuum operation, the risk of thermal decomposition or dust explosion requires them to be designed for higher pressures in many cases. The spherical shape with maximum volume and minimum surface is the ideal geometry for an explosion containing shock resistant design.

The dryer can be manufactured either in stainless steel or, for high corrosive applications, in nickel alloys with high resistance to acids. The size ranges from 100 to 4´000l net volume. The vessel is fully jacketed, insulated and covered by welded metal sheeting. Normally the dryer comes along with skids for heating / cooling and vacuum including a condensation of the vapours. Particle

fines which can be fluidized during drying are withheld by a dust filter with cartridges whereby the filtration media can either be made of a textile cloth or by a sintered wire mesh. To optimize the performance it is important to adjust the peripheral equipment like heating / cooling and condensing / vacuum to match the specific requirements of the drying performance.

For heating / cooling mostly indirect loop systems are used in which a thermal liquid such as water, a glycol-water mixture, or thermal oil circulates through the dryer jacket. This liquid passes through a heat exchanger that respectively transfers the heat from the heat source (e.g. steam). Sensitive products may require rapid cooling at the end of the drying process in order to maintain product quality. Hence, care must be taken to ensure that heat from the product is removed by the coolant.

Condensers, typically shell-and-tube type, are used mostly to recover valuable process solvents which are evaporated during drying. Condensers used with dryers are operated in a way that vapours are condensed inside the tubes instead of outside. The advantage is that the straight tube bundles can be cleaned more efficiently. For fast and gentle drying at a reduced evaporation temperature, a vacuum system is required. A wide range of pumps are available in the market whereby screw or liquid ring vacuum pumps are generally used.

Optimizing and Scaling Up the Drying Process Either to optimize existing processes or to develop the best possible process parameters for new or modified products, trials are recommended. The Rosenmund spherical dryers cover a wide range of applications. From pure drying to combined processes with mixing and granulation, the results on drying and product quality can be optimized. Therefore pilot scale machines are installed at the site of the pharmaceutical manufacturer in order to implement the spherical dryer in the running process.

To summarize: Spherical dryers are the ideal dryers in the production of high valuable products like pharmaceutical ingredients. The spherical design allows full discharge and cleaning can also be performed easily to avoid the risk of cross contamination. From pure drying up to mixing and granulation the Rosenmund spherical dryer can cover a wide range of applications. Due to the high heat transfer and optimized peripheral equipment the drying time can be reduced significantly.

Vo l u m e 2 – Is s u e 2 M a r /Apr 2 0 1 8

Primer | HMS INDUSTRIAL NETWORKS

IIoT Gateway and Remote Access Router HMS Industrial Networks announces the release of its advanced IIoT Gateway and Remote Access router, eWON Flexy205.

T

he eWON Flexy 205 is a versatile Industrial Internet of Things (IIoT) gateway and remote access router designed for machine builders. In addition to VPN remote access with eWON Talk2M remote connectivity services, it allows you to enable alarm notifications, machine data reading, historical logging in order to monitor and collect vital key performance indicators (KPIs) for analysis and predictive maintenance.

On top of these functionalities, it can be tailored to meet your specific connectivity needs by adding extension cards, now or when a future need arises. You can make it as simple or full-featured as you need it to be. In addition, it is also possible to integrate data into your own systems or cloud platforms using the Talk2M application programing interface (API), HTTPs scripting or MQTT to name a few protocols that are supported.

“Machine builders are now looking to include value-added services by collecting data in addition to remote access. At the same time, it needs to have a compact form factor to fit inside their electrical cabinet” says Jon Jacobsen, Marketing Manager for the eWON Business Unit. “Combined with the selection of extension cards and the compatibility with major PLC brands, it makes this device the ideal IIoT gateway for machine builders”.

HMS and eWON are also proud to team up with world-class IIoT Software partners to provide turnkey, secure and powerful IIoT solutions for performance monitoring, reporting, analytics and maintenance features in order to give sense to data collected from industrial equipment. All these IIoT partner software are tested and verified to be used with eWON Flexy 205.

HMS and eWON team up with world-class IIoT Software partners to provide turnkey, secure and powerful IIoT solutions.

Picture: HMS Industrial Networks

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Product News | ELESA+GANTER

IP Protected and Weatherproof Latches ELESA+GANTER has added a new CSMH latch along with a compression handle to its existing range of latches.

P

articularly suitable for applications on power generators, machine protections and panelling, the CSMH latch can also been used for outdoor uses. Thanks to the packing ring made of silicone, the CSMH latch ensures an IP65 protection class, thus protecting the latch against the intrusion of solid foreign bodies, dust, water jets and steam. Hence, safeguarding the content of the compartment on which it is installed.

The latch is constituted by a handle in die-cast zinc alloy (grey or black colour) and is provided with a hole for the insertion of a padlock and a spindle that can be actuated by overturning the handle. The lock is available with 400 different combinations (CSMH) or with one combination (CSMH-U), and it is provided with a dustcover made out of acetal resin based (POM) technopolymer in red colour. In addition, it is possible to install a microswitch for remote signaling of closing and opening operations of the handle.

The CSMH latch ensures an IP65 protection class, thus protecting the latch against the intrusion of solid foreign bodies, dust, water jets and steam.

Picture: ELESA+GANTER

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Volume 2–Issue 2 M a r /Apr 2 0 1 8

Cover Story | MAINI PRECISION PRODUCTS

Make In India

Is In Our DNA A deep dive into the strategy and leadership vision of Gautam Maini, MD, Maini Precision Products, who has led MPP to place it firmly on the world’s precision-engineering map.

M

aini Precision Products (MPP), the leading manufacturer and supplier of high-precision components to automotive, industrial and aerospace companies, is one of the fasted growing Maini Group companies. In May 2017, a Maini Group statement said that it expects to achieve Rs 1,000 crore turnover annually in the next three years, a significant part of which will come from MPP’s automobile and aerospace businesses. In November, 2017, MPP crossed another milestone when it inaugurated its new dedicated aerospace manufacturing plant at Bommasandra Industrial Estate, Bengaluru. DMI got the opportunity to interact with Gautam Maini, Managing Director, Maini Precision Products, who has led MPP to position it on the world’s precision engineering map. We spoke with Mr Maini on a range of subjects, including his growth strategy which has proved phenomenally successful, his

partner selection process, his views on Industry 4.0 and Make in India, among others. Presenting, edited excerpts.

To what factors do you attribute MPP’s fast growth and the fact that it has been able to secure long-term partnership with leading industry names such as Marshall Aerospace and Safran Aircraft Engines?

MPP has been a highly customer-centric and quality-focused company, like the rest of the Maini Group companies. Our tagline in our logo ‘Value delivered. Always’ signifies our approach by which we deliver value and solutions to customers; not just a product or a service. We have constantly endeavored to bring higher value to our customers. Our core competence is our one-stop approach for any Build-to-Print requirement which has enabled us to form long-term partnerships with many of the industry leaders.

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Your growth strategy has proven to be very successful. You have stated that you believe in creating a partner ecosystem rather than having a captive ancillary type of a setup – could you elaborate on this strategy, and how it is paying off.

The basic difference it is that we do not approach customers with products; we approach the customer with solutions.

What kind of solutions are the customers looking for? Most customers are looking for very reliable, onestop shop, efficient manufacturing units that are competitive and great on quality. They don’t want to deal with hundreds of suppliers; they want to deal with three or four very good suppliers who can give them everything they want. That means that we should be able to handle a wide variety of products, because if I made just one or two products, then the customer knows that I may be offering a great product or two, but I am not offering a solution. The right strategy is to offer the customer a solution which means I go back and say: “We have suppliers who makes casting for us, do forging, die-casting, shellmoulding, heat-treatment service and so on – We have suppliers who can give us all of these. In a sense, we don’t have to go back to invest in a lot on these facilities because of our relationships with suppliers built over many years. This is the advantage of having these ecosystems. Now I can ask my customer: “What do you want?”

They would say: “I want 20 different part numbers, some casting, some forging, assemblies, I want it kitted, I want just-in-time delivered anywhere in the world.” They can come to us and we can provide all the advantages of these ecosystems that we created over the last 44 years. Then finally give them a reliable product on time, delivered JIT anywhere in the world.

Therefore we offer strategic solutions where we can give customers a wide variety of solutions, not just a few products.

Gautam Maini Managing Director Maini Precision Products Picture: Maini Precision Products

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Cover Story | MAINI PRECISION PRODUCTS

In May 2017, a Maini Group statement said that it expects to achieve Rs 1,000 crore turnover annually in the next 3 years, a significant part of which will come from MPP’s automobile and aerospace businesses. Could you please share with us a roadmap of how MPP aims to achieve the stated goal in terms of expansions and initiatives?

In aerospace MPP has systematically worked in the three verticals of Engine Components, Aircraft Systems and Aircraft Structures. Towards our target of reaching turnover Rs.1,000 Crore in the next 3 years, we have continuously invested in not only new machinery and equipment but also in creating new production facilities in anticipation of growth opportunities. As an example, we have just finished completion of Phase I of our new factory dedicated for aerospace.

After completion of Phase II in the Q II of 2018, the aerospace facility will have a dedicated plant area of appx. 1 lakh sq. ft. Our focused approach in each of the vertical is signified by the recent long term contract with Safran Aircraft Engines for the Nozzle Guide Vanes of Low Pressure Turbine for the state-of-the-art LEAP engines. We have also Expanded our Automotive and Industrial side of the business by adding a 75000 Sq Foot Facilty which will allow for a Higher Rate of growth.

Besides MPP; Maini Materials, Maini Plastics, and Composites and Virya Mobility all have strong growth plans to help the group achieve its growth objectives.

You have said in an interview that, at your new manufacturing plant at Bommasandra, you have invested in technologies which would be introduced for the first time in the India private sector. What are those technologies? Did you refer to technologies such as stelliting, vacuum brazing, etc.?

We are introducing new technologies like Stelliting, Creep Feed Grinding, Vacuum Brazing and EDM Erosion on honeycomb assemblies and other allied technologies. These are helping us to build the manufacturing ecosystem for the new Leap Engine from Safran, which as you know is a major breakthrough for a private firm in Indian aviation industry. These technologies enable us to equip ourselves to manufacture mission critical parts that form flow path of an aero engine. That clearly signals the path that we want to take. The Bommasandra plant is a dedicated facility for Aerospace having high potential to add on more advance technologies to expend its horizon on Aero products.

In the interview you refer to, I was talking about a new facility for Automotive and Industrial manufacturing. We opened two new facilities in November last year. The Automotive and Industrial plant that I mentioned in the interview was opened at Peenya, Bengaluru.

What is your perspective, in terms of implementation and adaptability, of the paradigm of industry 4.0 – where leading manufacturers like Siemens and Bosch are making their factories smarter with the use of industry 4.0 technologies such as additive manufacturing, Internet of Things and cognitive computing etc. In other words, does MPP have industry 4.0 in the cross-hairs?

MPP has always believed in having strong systems at its core. Industry 4.0 is something that has to be

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Key Highlight: The whole idea of having a digital 4.0 in my opinion is to make a factory which is connected in terms of efficiency, inventory, tool management, fixture management, decision-making process, basically everything that you need to make the factory progressive.

New plant of Maini Precision Products Picture: Maini Precision Products

adopted over a period of time. At MPP we have been running prototypes for many months now and we are at the point where we are selecting our partners to take us through the journey.

We strongly believe that a Connected Factory will benefit hugely in terms of competitiveness as well as customer satisfaction and customer delight.

Key Highlight: Towards our target of reaching turnover Rs.1,000 Crore in the next 3 years, we have continuously invested in not only new machinery and equipment but also in creating new production facilities in anticipation of growth opportunities.

What types of prototypes are being developed and provided at MPP and what are the kind of partners you looking at to be a part of these innovations?

Although I can’t name the particular projects [due to commercial confidentiality] but I would like to say that we have reached a stage where we are planning 50 new parts every month. In order to do that you have to have very robust systems so that the team is effective. We have implemented an Aero Lean System with a partner which gives us the accuracy and speed while developing new Parts. These parts now have to be successfully transitioned to ramp up to production volumes.

When you have a complex machine shop, it’s not easy to monitor and control all of the operations from one point. What we have done is, connect to the level of each individual machine. One can

monitor each machine and its efficiency online – whether it is loaded or not. When a machine is about to run out of material, typically [at other plants] the operator punches in a code that goes to the supervisor who will then take it to the manager and so on. In our case, the message will go directly to the phone of the purchase guy who is responsible for that material. When you talk about a connected factory, you make sure that the decisions are quick and simultaneous.

And not create a hierarchical structure that typically is found in an Indian organization today, where it will go all the way up, then sideways, and will come all the way down by which time the damage would’ve already been done. The whole idea of having a digital 4.0 in my opinion is to make a factory which is connected in terms of efficiency, inventory, tool management, fixture management, decision-making process, basically everything that you need to make the factory progressive.

In terms of quality we are looking at how we can automatically capture the information. So we have a [manufacturing plant] gate which has Bluetooth that automatically captures information. We are working with partners where we can get our run-charts online. We don’t

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Cover Story | MAINI PRECISION PRODUCTS

a particular size and scale. Those are the real challenges. [About partnering with companies on prototypes] The rule should be that you give your potential partner a thorough idea of your background, your thought process and your budget, which can vary.

want a system where operators have to handle the machines manually and then pick up a pen and start writing or reading the charts. That’s an added cost, that’s not added value. We pilot such projects in one of the units before we take it to another; it’s a long but a beneficial process.

To me, Industry 4.0 is not just a term. It evolves from everyday learning, about how it can be adopted and implemented in a company of

Can you give us an idea of the collaborative process which follows the selection of partners?

As far as Industry 4.0 is concerned, we went through at least eight to ten partners before we decided on prototyping with three of them.

We did a high level of due diligence on trying to understand the product, understand the budget, and understand the viable process of implementation like a regular process.

For instance, you have the Ace Micromatic that has a division that runs a TPM track. So you have a

Picture: Maini Precision Products

Vo l u m e 2 – Is s u e 2 M a r /Apr 2 0 1 8

programs for training the technical personnel.

The technical university of one of our major customer organizations has applauded our training system. Apart from in-house training exposure, for our supervisory and managerial staff as well as technicians, we arrange on-the-job skill enhancement at the plants of our customers, associates, and a wider circle of machinery manufacturers. Aside from these essential elements, we have always believed in creating a professionally challenging environment to keep the team highly motivated. We maintain a very flat organization structure and the personnel are enabled a high level of decision making freedom, maintaining an invigorating professional climate.

“Since we started about twelve years ago, we have progressed to a level where we are starting to take more and more complex work in all the different categories. So Make in India is in our DNA whether it’s for export or localization.”

Picture: Maini Precision Products

Key Highlight: We have always believed in Make in India – you know as a company till 2003, we only had Bosch as an Indian customer because their quality standards were really high and we learnt a lot from them since our inception in 1973.

module that you have to see how it connects into a Fanuc system or any given system. So we did all of that to understand duly how this connectivity happens. You also have Zeiss that integrates Quality systems very effectively. Our prototypes are still running and very shortly we will take a final decision.

Ensuring continued success in the automobile and aircraft high-precision components business requires availability of highly skilled engineers. Could you share with us best practices you use for hiring of best tech minds, and their training and skill development?

Our Human Resource has always been the prime asset in helping us build a consistent growth. We have in place very structured internal world-class

How do you view the progress of mission Make in India and the new Defence Procurement Procedure (DPP) policy in that context?

We have always believed in Make in India – you know as a company till 2003, we only had Bosch as an Indian customer because their quality standards were really high and we learnt a lot from them since our inception in 1973.

Our model has been very simple and clear; we follow an export-oriented and an importsubstitution model. We only like to do things that are challenging, whether it’s in automotive or industrial or aerospace. We like to be in the more difficult areas of these spaces so that we are not one of the hundreds that are trying to do something, but we are among the few which could possibly do it. Obviously aerospace has a big learning curve. Since we started about twelve years ago, we have progressed to a level where we are starting to take more and more complex work in all the different categories. So Make in India is in our DNA whether it’s for export or localization.

Obviously it opens us more opportunity because you have already dealt with customers, you markets have been set, your quality of your products have been well established , they know you are capable of making complex product and now all of a sudden they have an incentive to place more business with you. So that makes life much easier for companies like us where the government is incentivizing that it has to be made in India. To that extent definitely it will help all of us, because the policy supports Companies for Make in India and therefore it will only lead to better times. I do think that the government is in the right direction offering the right level of incentives and engagement.

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Cover Story | MAINI PRECISION PRODUCTS

The Maini group also contributes towards the Govt. Policy making process actively through the industry associations. The DPP has evolved well since its inception and it is encouraging the Government has shown willingness to incorporate industry view points and suggestions for improvements.

How do you see your role in India’s indigenous defence industry in light of the new DPP policy?

Maini Precision product is very aligned to the aerospace manufacturing. What helps is that the volume of business coming from commercial aerospace customers from all over the world is very high. Therefore we are very happy and progressing in that area. As far as the defence sector is concerned, Maini Materials Movement is playing a very significant role thanks to our background in off-road electric vehicles and the fact that today we are supplying a lot of locallybuilt vehicles for the forces in many areas. We are able to utilize the knowledge and abilities of our products in material handling and racking and handling complex projects with electric-vehicles

Vo l u m e 2 – Is s u e 2 M a r /Apr 2 0 1 8

Key Highlight: Maini Precision product is very aligned to the aerospace manufacturing.

What helps is that the volume of business coming from commercial aerospace customers from all over the world is very high.

Pictures: Maini Precision Products

technology built into it. We see a very promising future in this area. Today all the airports are working to go Green; we are the only indigenous manufacturer of the electric Tow Trucks which is used to pull the baggage or pull lighter aircraft and helicopters. Also when you see the golf carts– or buggies as some people call them – at the airports; these are all Maini buggies which is again a manifestation of the strength that we have in the off-road electric vehicles space. If you go to places like the Bengaluru railway station, you will see Maini buggies in operation. So wherever the last mile has to be electric, whether it’s at the airport or a railway station, we are very much involved in ushering in the sustainability revolution.

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Success Story | JYOTI CNC AUTOMATION

Our Suppliers Are Our Growth Partners T

he success of Jyoti CNC Automation Ltd has been phenomenal – having started as a maker of gear boxes for machines to presently making sophisticated CNC machine solutions for buyers across the world, Jyoti CNC continues to take giant strides in machining tech. DMI interacted with Parakram Jadeja, CMD, Jyoti CNC Automation Ltd, who has not only shaped his company’s success, but has also led his company into the Industry 4.0 paradigm in Europe with notable success. Edited excerpts.

Vo l u m e 2 – Is s u e 2 M a r /Apr 2 0 1 8

The biggest factor that can be attributed to Jyoti CNC’s phenomenal success is its ability to spot opportunities ahead of the curve, be it seeing the potential of 5-axes machining technology that led to the Huron acquisition, or the launch of MTX 300, a multi-tasker, or foray into industry 4.0 in Europe. How have you acquired the ability to see the next big thing – is it your passion for of the game of Chess that you took up as a youngster?

Yes of course, in certain way you can say it so, very interestingly Chess is blend of art, science and sports. The act of “move” is the motive of life as well as chess. We learn little from victory and

Parakram Jadeja CMD Jyoti CNC Automation Ltd

much from defeat. Making a decision is enough to define your position. When you see a good move, you look for a better one. One bad move doesn’t mean the end of the game. Never give up.

Chess is not always about winning – sometimes it is only about learning.

Bringing advanced innovation to our business is big challenge and it has paid off through positioning us among leading machine tool builders in the country. We are the first one to bring contemporary trends and innovation in machine building making us a true technological leader in India. Introducing linear motor technology and manufacturing 5-axis CNC machines in India aligned us towards manufacturing excellence.

The Huron acquisition was much strategic in terms of learning, adopting and growing towards being world-class manufacturer and to prove our quality capabilities in the European market. To meet advance research requirement of aerospace and defence we have developed India’s first multitasking MTX 300 for service of nation, drawing attention of global manufacturers towards India. We are the first one to establish the R&D trend in machine-tool building in India through the Leonardo da Vinci R&D center.

Since the inception of Jyoti, it has been our dream to stay ahead of time through technology which also defines our mission of ‘Propelling Technology Prospering Life’. We call our factory as the ‘Temple of Technology’. We were the first to adopt backward integration which reduced our dependencies and made us a dominant CNC machine manufacturer.

Jyoti’s MTX 300 holds the distinction of being India’s first multitasking machine capable of doing many machining applications such as turning, milling, and additive manufacturing. Can you share with us the market response to the machine in India and Europe and the way ahead for this technology at Jyoti?

Developing MTX was very much an emotional decision as we wanted to show not only Jyoti’s capability but India’s capability to produce worldclass manufacturing potential, which would lead to a reduced dependency on technology from abroad. Our aim was to dedicate this facility to defence and aerospace research to strengthen the nation’s position. The First MTX 300 was supplied to Indian Institute of Technology Madras (IITM). We received FIE Foundation Trust Award at IMTEX’17 Bangalore for designing and developing the first-ever Indian multi-tasking Machine.

Thus far we have got an encouraging response from domestic as well as European market. We

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Success Story | JYOTI CNC dominating factors for export orders. Our “nvu” series machines are reflections of the same. As we are aligning with all our targets, we are confident to meet our projected targets in the export business too.

call it our first step of success and we expect to advance consistently in the multitasking field.

To meet up focused demand of fastest drilltap in Automobile, Surgical and Telecom industries Jyoti has developed high speed drill-tap center known as Tachyon Series.

Given the upsurge in the smart-phone space in India particularly, how has been the response for the Tachyon series and how do you see it evolving?

The name Tachyon was dedicated to the contribution of two Indian scientists named V. K. Deshpande & E. C. G. Sudarshan for their research on Tachyon Particles which are theoretically postulated particles that travel faster than light.

Similarly, the machine is superior in speed and performance in its class. Since conceptualization, Tachyon is focused for the global market to match the present need of manufacturing world for highly reliable and highspeed performance.

Tachyon, which symbolizes speed to achieve excellent cycle time with almost nil loading-unloading time, is the need of booming smart phone and electronics market.

The share of exports in Jyoti’s business turnover is about 20 percent. The target that you’ve set according to your recent media quotes is about 30 to 40 percent and more. What are your plans and strategy to achieve and surpass the target?

Export business requires market presence to gain confidence of customers. Along with Europe, we have our market presence in all the continents either through direct dealing or with our channel partner. Our recent openings in the USA and China were big moves taken to expand our business network to these territories.

Export demands much quality and performance orientation. As Jyoti is a conscious corporation, we have raised our own quality standards time and again to meet our customers’ needs. We have developed a special assembly line for all the export orders. Sophistication and safety criteria are exactly match-to-order. We have fulfilled CE certification requirement for export machines.

Machine appearance and aesthetics are also

It is very tough for machine technology MNCs based in India to establish and expand their export footprint in Europe. However, in a short span of time, Jyoti’s exports to Europe, particularlyGermany,France and Netherland have reached 20 percent. What is the secret behind the unprecedented success?

Here we have been gained from our decision to acquire Huron. Since the acquisition we have made a lot of effort to learn, develop, and adopt the European market scene. Huron, with its experience and expertise in machine tools since 1857, has had a significant impact on footprint in the European market. In fact, we have been able to achieve manufacturing excellence through catering to the European market. Our efforts are acknowledged through an increasing demand for our products and solutions in the European countries.

We are the first one to bring contemporary trends and innovation in machine building making us a true technological leader in India.

Introducing linear motor technology and manufacturing 5-axis CNC machines in India aligned us towards manufacturing excellence.

Jyoti CNC took a big step toward offering Industry 4.0 with its Machine Shops initiative launched In 2016-17 to its customers in Europe where customers can not only order machines online, but also configure, monitor and generate reports.

Development in the field of IoT has had a wider impact and found broader applications in the making of Smart Factory. Flexibility of control makes machines more TPM aligned thus doing away with unscheduled downtime. Jyoti has developed a special software named 7th Sense as a step forward in the area of Industry 4.0.

You have termed your company as a ‘conscious corporation’, quoting your suppliers who say that working with Jyoti is an easy job. Please elaborate I would rather address them as Channel Supporters than Suppliers. In fact we are demanding in nature in a sense to do business with but the bonds that we have created with our channel supporter over a period have made our success possible.

We have always approached our suppliers as our growth partners. They have played bigger role in our success story -- be it a small regional supplier or market giants like Siemens, Fanuc, Kitagawa, Hiwin, Schaeffler and many more. Our aim is to have bi-directional growth in business integrating with our channel partners.

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Product News | BAUMER

O300 laser sensors – Top performance in object recognition in miniature format.

Picture: Baumer

Detector Of Small Things O300 miniature laser sensors for the precise detection of very small objects and gaps

T

he new O300 miniature laser sensors with IO-Link by Baumer are the specialists for the reliable detection of very small objects and gaps. Thanks to a laser beam which focuses to within 0.1 mm and the high repeat accuracy of 0.1 mm, objects can be positioned with high precision and follow-up processes controlled exactly. Thanks to the extremely short response time of less than 0.1 ms, the sensor reliably detects even closely spaced objects, thus allowing fast processes and high throughput rates. A big advantage is the exact alignment of the laser beam to the fixing holes by design (qTarget). Thanks to qTarget, detection with pinpoint accuracy can be guaranteed over the entire series.

The wear free teach-in method (qTeach) allows easy, user-friendly commissioning of the laser sensor. The weak point of the pushbutton or potentiometer is ruled out with the tamper-resistant teach-in method qTeach,

thus offering maximum reliability and system availability.

The O300 laser product portfolio impresses with its great diversity, offering tailor-made solutions for precise detection tasks. Among the five sensor principles to choose from, SmartReflect, the original light barrier without a reflector, must be highlighted. Even reflecting objects with a size of 0.5 mm can be reliably detected within a sensing distance of 250 mm. Stainless steel variants in a rugged wash-down and hygienic design extend the typical applications of the O300 laser sensors for packaging plants in the food and pharmaceutical industries.

Thanks to IO-Link integration, the O300 laser sensors are “Ready for Industry 4.0”. IO-Link allows the quick and easy configuration of sensors for all applications using standard network components. In addition, available additional data, e.g. for predictive maintenance processes, can be evaluated.

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Budget Impact | VDMA

Insights on Union Budget 2018 There are three core sectors focused in this year’s budget, says Rajesh Nath, Managing Director, VDMA. Read on to know more…

T

Rajesh Nath Managing Director VDMA

he Union Budget has managed the appropriate mix of social and economic reform. It can be termed well balanced. This year’s budget has primarily focused on 3 sectors – agriculture and the rural economy, Infrastructure and health care besides benefits for senior citizens.

The slew of measures announced in the Budget for strengthening agriculture, including fixing the minimum support price (MSP) for kharif crops at 1.5 times the cost of production, if implemented well, could possibly push up the farm incomes in the long run — in line with doubling farmers income by 2022.

The government has also proposed to double the budget allocation to the food processing ministry to Rs. 1,400 crore for 2018-19 fiscal and set up institutions to finance agro-processing projects. Under the scheme, the funds are given as grant-in-aid for setting up of mega food parks, development of infrastructure for agro-processing clusters, integrated cold chain and value addition infrastructure, creation of backward and forward linkages among others.

The various measures announced in the Budget for infrastructure are quite positive for the sector. The focus on water supply in the AMRUT programme as well as higher spending on the Watershed Development Component of the Pradhan Mantri Krishi Sinchayee Yojana will help infrastructure players.

Road developers are also set to benefit from the strong execution in projects and allocation to the Bharatmala programme. Work executed by the Border Roads Development Board and the allocation to the North East Road Sector Development Scheme will aid EPC players. The capex of Indian railways has been pegged at an increase of nearly 14 % from the previous year, thus the companies supplying equipment and technology to railways are set to gain.

The customs duty on certain components like engines, transmission, brakes and other parts has been increased to 15 % from 7.5 %, and on lithium ion batteries, used in electric and hybrid vehicles, has been raised from 10 % to 20 %, to promote Make in India. Further, the government’s move this year to cut corporate tax for companies whose turnover is Rs. 250 crore or less will help the small and mid size companies.

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Budget Impact | VDW

German Machine Tool Industry’s Orders Increase In the fourth quarter of 2017, the German machine tool industry’s order bookings increased by 24 per cent in comparison to the preceding year’s equivalent period.

Domestic orders were up by 48 per cent.

O

Dr. Wilfried Schäfer Executive Director VDW

rders from abroad rose by 13 per cent. For 2017, there is an overall plus of 8 per cent: domestic orders climbed by 10 per cent, while orders from abroad ended with a 7 per cent plus. The Eurozone nations constituted the driving forces here. “The year’s second half saw a breakthrough on the domestic market,” comments Dr. Wilfried Schäfer, Executive Director of the sectoral organisation VDW (German Machine Tool Builders’ Association) in Frankfurt am Main. “While domestic orders were still falling by double-figure rates in the year’s first half, the German industrial sector in the year’s second half threw off its caution and opted for massive investment,” he adds. In particular, following the EMO Hannover 2017 in September, orders veritably soared: plus 41 per cent in October, plus 67 per cent in November and plus 37 per cent in December.

The flood of orders is attributable not least to the good performance of the global economy. All around the planet, the economies are running superbly on broadly based foundations. Capital investment at the most important customer sectors and machine tool consumption are rising in all regions. “So, the customer sectors are confident of lucrative business and are upsizing their capacities,” explains Dr. Schäfer. “This is benefiting all technologies in the machine tool industry,” he adds. Most recently, forming technology too has been booking large-scale orders again,which had been absent in the preceding months.

Overall, the investment boom has once more boosted the machine tool industry’s results. Production output in 2017 reached another new record level, with a plus of 4 per cent and 15.7 billion euros.

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Interview | ORDERFOX

Welcome to the New Digital CNC World

O ”We recently had Genau Engineers India, a medium-sized manufacturing company with Mazak CNC TurnMill and CNC Turning Centres and Multi-Function technology based in Pune, who shared their success story with us where they have received recurring orders from a Swiss machine tool company. They first registered with us at EMO 2017.”

rderfox.com is a global online CNC industry marketplace that connects machine shops and other manufacturers with buyers seeking to place CNC manufacturing jobs. Expectedly, Orderfox is seeing a rapid growth in China, where it is helping a growing number of local machine shops find work for unused or under-utilized machines from across the world. Orderfox has also found an encouraging response in India where it has helped a number of companies bag recurring orders from international machine tools companies.

DMI met Oliver Lorenz, Head of Market Asia, ORDERFOX in Mumbai during his recent India visit, and spoke to him about his company’s vision, global response, and plans for the Indian CNC industry. Presenting his views that he shared with us in a follow-up email interview.

Please share with us a brief history of ORDERFOX.com – who are the founders of the company, when and how did the idea of ORDERFOX.com occur to the founders, and what is the market need that you seek to address?

The ORDERFOX.com platform was launched on June 1, 2017 whereas the actual preparation and development work had been going on around three years before the launch. It was exactly developed on the profile of the CNC industry.

The founders are well-respected businessmen in their own industries, so with the progressive developing work since the project kick-off in 2014, a global platform was created, which perfectly connects the actual as well as demandoriented aspects and needs of CNC manufacturer and CNC buyers.

The platform offers intelligent filter functions for both sides and thus provides accurate results.

This milestone for digital platforms is, among other things, the outcome of many years of know-how in the manufacturing industry, global market knowledge, and workshops with the CNC manufacturer and buyers.

ORDERFOX.com is extremely dynamic and will be constantly developed in the future, and therefore is considered to be the internet of the CNC industry.

Can you give us an idea of the response that ORDERFOX.com has received from the global CNC industry in terms of numbers, regions or countries, orders generated or fulfilled, and company listings?

Currently, we do have more than 2,000 active users, whereas we do have about 2,70,000 community members in our database. We have quite a number of new users who register every day that we verify to make sure, and there are only CNC-related companies registered.

Presently, China must be an important market for you where you have an active market presence. Can you share with us your experience of working with Chinese companies and their response to your offerings?

We have received great feedback [from Chinese companies] and have a large number of Chinese companies online. The difference and it is one of the reasons why ORDERFOX.com is successful in China is that we place all companies on a global network and there are no limitations on what each buyer and/or manufacturer can do on it.

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How important is India as a market to you and what has been your experience so far of working with Indian companies. Can you share with us some success stories, if any?

We recently had Genau Engineers India, a mediumsized manufacturing company with Mazak CNC Turn-Mill and CNC Turning Centres and MultiFunction technology based in Pune, who shared their success story with us where they have received recurring orders from a Swiss machine tool company. They first registered with us at EMO 2017.

ORDERFOX.com is also a knowledge platform that provides technical knowhow and industry updates to the visitors. Can you share with us the guiding vision and the purpose behind it?

Whenever a CNC manufacturer wants to increase his business by finding new clients or has an over-capacity in his workshop, he can look for a buyer on the platform who has the exact same needs that the CNC manufacturer can offer. On the other hand, the buyer can find the perfectly suitable partner for his CNC parts that he is in urgent need of. The whole process works on a local and global scale. Besides that, ORDERFOX.com has offered the Knowledge & Trends section online, as well as the Event Calendar section -- just to name a few -- so that the platform is a customized tool that everyone in the CNC industry can use for his entire workflow and all his projects. Welcome to the new digital CNC world.

Oliver Lorenz Head of Market Asia ORDERFOX

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Product News | INTERROLL

Danone Waters Optimises Handling on Loading Platforms Danone Waters has opted to make handling pallets of Evian water on platforms— before they are loaded onto trains—safer and more streamlined, using Interroll heavy-duty gravity conveyors.

A AGVs place pallets two by two on Interroll’s heavy-duty gravity conveyors Picture: Interrol

t the Publier site in the Haute-Savoie department of France’s Amphionles-Bains region, the largest natural mineral water bottling plant in the world has had a makeover! This historic Danone site spans 130,000 square meters. At the end of the line, the largest privately-owned railway station in France manages 65 per cent of production, with the rest loaded onto the many trucks lined up in front of the plant. Every day, seven million bottles are shipped on the equivalent of 7,000 pallets. It takes robust and well-oiled logistics to maintain this pace. No malfunction can be allowed to interrupt this constant flow.

A Simple Solution to a Complex Problem At the end of the production line, automated guided vehicles (AGVs) transport pallets weighing up to 1,200 kg to the railway loading platforms.

These ultra-modern AGVs can move two pallets at once. This is where Interroll’s solution comes into play. Accurate to the nearest millimeter, the AGVs place the pallets of water bottles onto heavy-duty gravity conveyors. Sixteen lanes, holding up to 27 pallets, can easily handle the pace. The gravity lanes direct the pallets to the forklift trucks which pick these up four by four to be loaded onto waiting trains. Despite its apparent simplicity, this solution boasts advanced technologies and

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Interroll’s extensive expertise.

Firstly, to ensure the safety of the installation, operators and goods, Interroll’s MSC 80 Magnetic Speed Control rollers maintain a constant pallet speed of 0.3 meters per second. At the end of the line, and for enhanced operator safety and comfort, a mechanical separation solution enables four pallets to be picked up simultaneously for efficient loading.

Interroll’s heavy-duty gravity conveyors Picture: Interrol

A Flexible, Cost-Effective and Green Solution Preparing for this project required Interroll to operate its testing zone in La Roche-sur-Yon at full capacity. In fact, EVIAN uses no fewer than 12 different types of pallets for its global markets. The Interroll solution was technically assessed using a series of tests (e.g., the speed of the idler rollers, the number of brake rollers required, the position of the separators); Interroll’s expertise also enabled the company to work with pallet manufacturers to optimize pallet construction and design, to ensure that the pallets rolled optimally on Interroll’s heavy-duty gravity conveyor solution.

The fact that the design of the conveyor solution uses gravity means that the installation does not need to be powered. Apart from a few wear parts, it is also impressively maintenance-free.

The operating costs for EVIAN are almost zero.

Interroll’s gravity conveyors generate no carbon dioxide (CO2) emissions, which is important for a site which in 2017 became Danone’s first carbonneutral site.

Everything is Flowing Smoothly — Naturally One year after commissioning, and after a few adjustments, Interroll’s solution has already been tested by some 520,000 pallets. Danone Waters and Evian in particular now appreciate the simplicity and flexibility of Interroll’s application in a very high-tech environment subject to very demanding industrial working conditions. The gravity pallet conveyor — which may have seemed rather rustic at first glance — ultimately provided EVIAN with a cost-effective and long-term solution for the future development of the brand!

BOOK YOUR SPACE NOW...

Key Highlight: Every day, seven million bottles are shipped on the equivalent of 7,000 pallets.

It takes robust and welloiled logistics to maintain this pace. No malfunction can be allowed to interrupt this constant flow.

CONTACT:

DINESH MISHRA SENIOR VP – STRATEGY M: +91 9833076669 E: advertise@meshmixmedia.com

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Volume 2–Issue 2 M a r /Apr 2 0 1 8

Outlook | CARL ZEISS

We will continue adding talent to our India R&D centre

D

MI met the India and global leadership team of ZEISS, the optics and optoelectronics technology leader at IMTEX 2018 held during the last week of January in Bengaluru. We spoke to Dr Jochen Peter, President and CEO, Industrial Metrology Business Group, Carl Zeiss Industrielle Messtechnik GMBH, ZEISS Group of Companies; Daniel Sims, MD, Carl Zeiss India, and Wilson Thomas, COO and Director, Carl Zeiss India about visitor response at IMTEX and their India plans. Excerpts..

Key Highlight: In a global market like India where global products are available, Indian companies need to compete in the domestic market from a global level.

We displayed solutions of Industry 4.0 at our booth in IMTEX and the response was fantastic.

What are the major challenges that India is facing in order to achieve its true potential in the manufacturing sector?

Daniel Sims: I don’t see and major hurdles or obstacles in the sector. Currently, our customers (in India) are investing, developing world class manufacturing capabilities and delivering products to customers across the globe. We produce Coordinate Measuring Machines (CMMs) as well as spectacle lenses in India. The same activity is replicated in our worldwide facilities that have the same footprint, configuration, and specifications. The products are then exported from these facilities to our global customers. It doesn’t matter if you buy your glasses in Germany, Singapore, Bengaluru, Johannesburg or Dubai – we ensure that we meet the Carl Zeiss quality standard so the manufacturing location does not matter. If Indian manufacturers can ensure consistency in their manufacturing process in terms of quality, speed and cost effectiveness then there is nothing standing in the way of Indian manufacturers.

It is purely a matter of focus and strategic choice of how one is going to build their manufacturing

capability. In a global market like India where global products are available, Indian companies need to compete in the domestic market from a global level. There is a massive opportunity for Indian companies to compete in the export market.

What should be the chief objective of Mission Make in India – should it be creation of jobs or achieving global manufacturing excellence or both?

Dr Jochen Peter: I am not an India expert. Said that, I think that any Indian company should strive to be competitive from a global perspective because it is the globally successful companies that create jobs. Therefore I think if companies strive to become globally competitive, job creation is an automatic result.

In your opinion, will Industry 4.0 provide a boost to the Indian manufacturing industry?

Wilson Thomas: Absolutely, Industry 4.0 is a concept that is driven by Germany and provides a futuristic solution. I have seen many people talking about Industry 4.0; this is going to be absorbed quickly into the manufacturing sector – I am [pleasantly] surprised that even pharma companies are talking about Industry 4.0. We displayed solutions of Industry 4.0 at our booth in IMTEX and the response was fantastic.

What are the new initiatives which Carl Zeiss will be undertaking in 2018 in India as well as globally?

Dr Jochen Peter: On the global stage we are very proud of our R&D investment which we will continue doing in 2018. I think this will also be very relevant for India because, as we mentioned,

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we have our software R&D centre here. We will keep on adding people here because as we said it’s a part of our innovation network. Therefore some of these investments into R&D will also flow into India.

Presently, there is much buzz globally around electric vehicles. Since automotive is one of your major markets, what scope do you see for electric vehicles in India right now and in the coming 10 years?

Wilson Thomas: I do not see a big change in the next one-two years. It is not only that one should possess a good electric car but one also should also have the infrastructure to charge the vehicle.

Therefore I do not think that switching to electric is a brilliant idea – although it can happen in phases by means of hybrid cars. A day will come when we have to catch up with the rest of the world but I think we still have some time to go before it happens.

How will the ‘Make in India’ initiative assist in creating jobs in the Indian market?

Wilson Thomas: Any company should strive to be competitive at a global level because once they achieve the competitiveness on a global scale, they will be successful and successful companies create jobs. Therefore, if the ‘Make in India’ initiative strives to become globally

competitive, job creation will be an automatic result.

How has been the response here at IMTEX? Wilson Thomas: So far the show has been very positive. The new technologies that we have shown have been given a thumbs-up by most of the customers that we have interacted. This is a forming show; obviously we don’t expect the kind of response that we would see in a metal cutting show. But the kind of response we got for car body solution has been very good.

How do you see the future of 3D printing technology in India?

Wilson Thomas: 3D printing is catching up very fast globally as well as here. If I look at academics, I can say most engineering and polytechnic colleges have 3D printing facilities. Of course they are doing plastics, but that is a glimpse of some serious work happening in the industry with metal printing. Right now the technology itself is very nascent – it has its own issues. But the day is not far away when you will have good 3D printing components to be used for all applications – for example rotary parts going into aircraft engine and so on. The technology for non-critical parts is readily available. This is one segment that will be very fast developing in India – India has a big potential for 3D printing.

[L-R] Daniel Sims, MD, Carl Zeiss India; Wilson Thomas, COO and Director, Carl Zeiss India; Dinesh Mishra, Senior VP, DMI; Dr Jochen Peter, President and CEO, Industrial Metrology Business Group, Carl Zeiss Industrielle Messtechnik GmbH, ZEISS Group of Companies.

Picture: Carl Zeiss

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Breakthrough | KENNAMETAL

Making Turrets Terrific Still using standard lathe tooling? It’s time for a quick, but big change!

A From Bottom Left: Many styles and types are readily available at stocking locations around the world.

Center: Dual station and offset clamping units provide a great deal of flexibility when tooling up today’s multi-axis, multi-spindle, Y-axis capable CNC lathes.

Right: Turret Adaptive Clamping Units are available for the BMT turret shown here as well as Mazak VDI turrets Picture: Kennametal

s machine tools become increasingly complex and the need to produce parts in less time grows, CNC lathe owners and managers must look to the latest technologies if they are to improve shop floor efficiency. Isn’t it ironic then that one of the most productive of these solutions is far from new – in fact, it has been a champion in the war on machine tool downtime for nearly three decades. It is called KMTM Quick Change Tooling, and whether it is an old friend, a complete stranger, or an acquaintance you met briefly and discounted, it is time to take a long hard look at what it can do for your bottom line.

That’s because Kennametal is changing the rules of quick-change once again. The Latrobe, PA tooling provider launches an entirely new KMTM product line: Turret Adapted Clamping Units.

What’s more, Kennametal has partnered with global lathe tool specialist, EWS Tool Technologies,

to manufacture and support this series of KM adapters. Together, the two companies plan to redefine how shops will tool up the turrets on their DMG Mori, Okuma, Mazak, Haas, Doosan, Nakamura, Hwacheon, and Hyundai lathes, with more to come.

Embracing Change Maybe you have looked at quick-change tooling in the past and said it is not for you. Too expensive, perhaps, or not worth the hassle that comes with implementing any new technology.

That might be why an overwhelming majority of machine shops apparently choose to take the path of least resistance and use the standard turret tooling that came with their CNC lathe. “I spoke to a lot of customers at last IMTS and EMO show, and my best estimate is that 80 per cent of them do not use a quick-change tooling system,” says Michael Schuffenhauer, Manager Tooling

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Systems at Kennametal. “I was very surprised, and to me, it indicates a tremendous opportunity for these shops to become more competitive.”

Turret adapted clamping units support this opportunity by replacing the standard blockstyle turret tooling with quick-change capable adapters made specifically for your brand of CNC lathe. This is true for both VDI and BMTstyle turrets, whether they are rotating or static, and for toolholders with axial, radial, and even angular orientation. Suddenly quick-change is much easier to implement. Total tooling costs are reduced. Concerns over toolholder rigidity are eliminated. And because each clamping unit model was created by EWS to be a perfect match for prescribed machine tool builders, it is as if the machines were designed with a KM turret.

Building Bridges “Available machining time is one of the key contributors to any manufacturing company’s productivity,” notes Schuffenhauer. “Obviously, reducing setup is a big part of improving this metric, something that quick-change tooling systems excel at. But there is also the downtime that comes during tool changes, when the operator spends ten minutes looking for the screw that fell in to the chip pan, for example, or the time lost by having to touch off a drill in the middle of a job. KM eliminates this nonproductive time, and turret adapted clamping units are the bridge between the system’s quickchange capabilities and the machine tool.”

This bridge is both robust and comprehensive.

Offset and inline clamping unit models are available, as are ones for right or left-hand placement. Hydraulic chucks, ER-collet holders, shell mill adapters, ID and OD turning cutting units after close to thirty years of development, the list of KM adapters is extensive. So too is the clamping unit size range, with interfaces ranging from 32 to 63 mm (KM32 to KM63). So whether your lathe, mill-turn machine, or multitasking center produces tiny medical screws or bearing hubs large enough for a tractor trailer, turret adapted clamping units and KM have you covered.

Doing the Math But what is KM, and why is it better than the competition? For those unfamiliar with this mature and widely-accepted system, Schuffenhauer offers the following explanation.

“KM uses a pair of hardened steel balls that sit within a tapered tool shank. As clamping force is applied, the tail end of the taper expands while the toolholder is pulled back against the locating face. Together with a small amount of interference at the gage line, this three-point contact provides extremely precise radial and axial positioning and repeatability, as well as high clamping forces. Simply put, it is the most rigid and accurate quick-change system available in this size range.”

Ready to take a look, (or maybe a second look) but still concerned about the cost? Jay Verellen, Kennametal Director of Global Product Management, Tooling Systems, points to the ROI calculator on Kennametal.com as a way to quantify improvements in machine utilization.

He notes that a potential positive return on investment (ROI) in as little as three to six months is not unusual, and that the company’s Customer Application Support (CAS) team is ready to help customers ensure they are getting the value they seek. “It is not a terribly complex calculation,” he says. “Enter a few inputs such as hourly rate and number of setups per shift and it will make sense pretty quickly. But you also need to consider the less tangible effects of KM. Setups and in-process tool changes are simpler, so having a less skilled operator is not a scary proposition. And flexibility is greatly increased. This does not refer so much to the wide variety of tools and adapters that are available (although this is certainly important) but is more about the flexibility to make your customer happy—if you can set up a machine in five minutes, it becomes much easier to meet their changing demands without losing your shirt. That is what KM and turret adapted clamping units bring to the table.”

Key Highlight: Available machining time is one of the key contributors to any manufacturing company’s productivity.

KM eliminates this nonproductive time, and turret adapted clamping units are the bridge between the system’s quick-change capabilities and the machine tool.

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Case Study | NEW GROUND

Technology Excellence In Die & Mold In the Die & Mold Excellence Center, DMG MORI has been bundling decades of experience in die and mold making with a forward-looking product portfolio and the design of individual manufacturing solutions with continuous process chains.

With the DMU 200 Gantry and DMU 340 Gantry, DMG MORI presents two world premieres for large component machining for die and mold making at the EMO 2017.

Picture: DMG MORI

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aximum demands on accuracy and efficiency mean the die & mold sector has always been a driver of technology for DMG MORI. Fiveaxis simultaneous machining for demanding geometries, HSC technology for optimal surface qualities and intelligent automation solutions for maximum productivity are just three examples with which the machine tool manufacturer has been convincing users for more than 20 years.

With consistent further development of machining technologies and innovative software solutions for a digital future, DMG MORI implements productive manufacturing concepts for the challenges associated with die and mold making in the Die & Mold Excellence Center.

The experts there work together with customers on cross-sector competitive manufacturing concepts both for small as well as large molds and dies. Highlights in the full-liner product portfolio are the powerful vertical machining centres from the DMC V and NVX series, the versatile 5-axis universal milling machines from the DMU monoBLOCK and DMU eVo linear series as well as the XXL machines including the DMU 340 Gantryas the world premiere at the upcoming EMO.Moreover, DMG MORI is setting new standards in surface structuring with the LASERTEC Shape technologies.

DMG MORI Die & Mold Excellence Center Die and mold making are among the core competences of DMG MORI. With far-reaching effects, as Markus Piber, Managing Director of DECKEL MAHO Pfronten GmbH, says: “Great importance has been placed on die and mold applications at DMG MORI for decades, which on the one hand has resulted in our enormous experience in this field and on the other has given and continues to give rise to path-breaking technologies.” The demands on precision, long-term accuracy and surface quality has transformed die and mold making into one of the most challenging manufacturing areas.

“These demands are met by high-precision and dynamic machining centres”, adds Markus Rehm, Managing Director of DECKEL MAHO Seebach GmbH. DMG MORI concentrates their experience and skill in die and mold making in the DMG MORI Die & Mold Excellence Center. The developers there implement cross-sector and unique processes – from programming through milling strategies up to the selection of holders, dies and die clamping as well as automation solutions. Markus Piber comments on the work method: “We involve our customers in the projects at a very early stage to

DMG MORI’s gantry series extends from the DMU 600 P in the XXL area to the DMU 210 P little sister machine.

Picture: DMG MORI

enable us to learn from one another and achieve optimal production solutions.”

Key Highlight: Markus Piber, Managing Director of DECKEL MAHO Pfronten GmbH comments on the work method: We involve our customers in the projects at a very early stage to enable us to learn from one another and achieve optimal production solutions.

Full-liners in die and mold making DMG MORI’s large product portfolio makes the machine tool manufacturer the right partner for every die and mold application. It starts with 3-axis machining on the powerful vertical machining centres from the DMC V series, which already set the standard with the speedMASTER® with its 20,000 rpm spindle, an innovative cooling concept and direct path measuring systems that achieves the precision demanded. The vertical machines from the NVX series expand on this with their excellent stability and damping with slideways in all axes. The speedMASTER® spindle with integrated cooling reaches a rotational speed of 15,000 rpm.

The 5-axis machining centres from DMG MORI master the most complex geometries. The range of products extends from the universal DMU monoBLOCK series with swivel rotary table, maximum automation options and up to 2,000-kg table loading capacity through the dynamic DMU eVo linear models with rapid traversing speeds of up to 80 m/min up to high-speed milling on the HSC 20 linear and their big sister machines.

Speeds of up to 60.000 rpmhere guarantee the optimal surface quality that is demanded in die and mold making.

“As a single-source provider, we provide services for the entire range of components used in the industry – from the smallest electrodes

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Case Study | NEW GROUND

The DMU P series enables productive 5-axis simultaneous machining of complex shapes and tools.

Picture: DMG MORI

Key Highlight: We have set new standards in the mold-making sector with the innovative LASERTEC Shape technology. lso here we are able to accommodate all the relevant component sizes with the LASERTEC 45 Shape to LASERTEC 210 Shape range -Markus Piber

up to XXL components”, notes Markus Piber.

This is why the successful DMU 600 G linear is primarily installed for large part machining in the area of die and mold making. With the DMU 340 Gantry, the XXL machines gain a little sister model just in time for the EMO, which effectively extends the product palette here to cover a whole range of different sizes of components.

Its work area measures 3,400 x 2,800 x 1,250 mm with expansion options of up to 6,000 mm in the X-axis and 1,500 mm in the Z-axis. Thanks to the gantry design, the DMU 340 Gantry also offers a compact footprint. With the DMU 200 Gantry, DMG MORI will round off the Gantry series at the EMO. 5-axis machining with up to 30,000 rpm and optional ULTRASONIC or LASERTEC technology integration will also enable complex components up to a weight of 10,000 kg made of aluminium or composites to be economically machined.

“Especially the ratio of the large working space of 2 x 2 m to the installation area of less than 24 m² has also impressed our customers”, explains Markus Rehm, Managing Director of DECKEL

MAHO Seebach. The XXL portfolio also includes the DMU 600 P for workpieces up to 3,000 x 6,000 mm and 40,000 kg. But also the smaller DMU 210 P and DMU 340 P, in the 3-axis as well as the 5-axis models enjoy great popularity in the car industry for the production of fittings.

DMG MORI round off their range of products for die and mold applications with the machining centres from the DMU monoBLOCK and DMU duoBLOCK series. The DMU 125 monoBLOCK with space for workpieces up to 1,600 mm long and up to 6,000 kg in weight in the 3-axis variant is thus a popular model positioned between the smaller machining centres and the large gantry models. Markus Piber comments on DMG MORI’s advanced technologies: “We have set new standards in the mold-making sector with the innovative LASERTEC Shape technology.” The laser texturing of geometrically defined surfaces is more environmentally friendly than etching and offers enormous design freedom in addition to the highest repeat accuracy. “Also here we are able to accommodate all the relevant component

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The right machine for every die and mold requirement: •

Innovative manufacturing concepts thanks to many years of experience in die and mold making

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An integrated machine portfolio for individual processing solutions in the automobile industry and the area of consumer goods

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Complete process chain for die and mold making

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Machine solutions for all component sizes

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HSC milling with up to 60,000 rpm for optimal surface quality

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Comprehensive XXL range up to 40,000 kg workpiece weight

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Maximum performance in 3-axis vertical machining

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5-axis universal vertical machining with maximum stability, precision and dynamics

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LASERTEC Shape for laser texturing of geometrically defined surfaces

With speeds of up to 60.000 rpmHSC machining guarantees the very best surface quality.

Picture: DMG MORI

sizes with the LASERTEC 45 Shape to LASERTEC 210 Shape range.”

The future of die and mold making “The highly-accurate machines are naturally a decisive factor for competing on a global scale”, understands Markus Piber. Intelligent automation solutions and innovative technology cycles are also just as important: “And the Die & Mold

The LASERTEC Shape technology makes it possible to perform laser texturing of geometrically defined surfaces.

Picture: DMG MORI

Excellence Center allows us to complement the entire integrated production process.” Pallet changers, pallet rotary storage and linear pallet pools are the bread and butter of automation.

But features to support the process are also in high demand like never before. This includes immediate tool measurement in the work area or DMG MORI technology cycles such as the Application Tuning Cycle (ATC). This adjusts the feed rate of the respective table load, reduces processing time and maximises the component quality.

DMG MORI paves the way into the digital future of die and mold making with CELOS. Aided

by CELOS APPs, the integrated user interface installed in all new high-tech machines simplifies integrated management, documentation and visualization of order, process and machine data.

In the area of die and molds, Markus Piber has a clear goal: “Our product and performance range offers the customer maximum flexibility and provides them with the capability to keep pace with the innovation speed of their customers.”

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MoU | NORD DRIVESYSTEMS

NORD Drivesystems Signs MoU with BIT The Department of Mechatronics, BIT and NORD Drivesystems signed a MoU at a function that took place on December 5, 2017 at Sathyamangalam, Erode in Tamil Nadu.

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The signatories to the MoU are PL Muthusekkar, Managing Director of NORD India and Dr AM Natarajan, the chief executive of Bannari Amman Institute of Technology.

Picture: NORD Drivesystems

he Bannari Amman Institute of Technology (BIT) has signed a Memorandum of Understanding (MoU) with NORD Drivesystems India. The signatories to the MoU are PL Muthusekkar, Managing Director of NORD India and Dr AM Natarajan, the chief executive of Bannari Amman Institute of Technology. This tie-up is for information sharing and providing training opportunities for students. The college program focuses on areas like gearboxes, industrial drives and related technologies..

NORD has sponsored an automated conveyor belt driven by a decentralised drive and a geared motor. A cut section model of the helical bevel gear motor assembly has also been presented to the college. The Industry 4.0 display models will prove beneficial for practical education of the students.

NORD also showcased its ‘Extra Mile Service Vehicle’ demo of various products for the benefit

of the students. Pradeep Magar, Senior Manager – Engineering at NORD India presented a guest lecture on the introduction and nuances of gears and its selection for industrial applications. He also elaborated on the NORD Cloud Solution.

“Our aim is to enhance the skills of the students as they step out of college,” said Muthusekkar, about the novel initiative. He continued to express that, “NORD endeavours to create a resource for students. This will help the students to be industry ready. In the future, the students have the opportunity to get direct mentors from the company.”

The Bannari Amman Institute of Technology is an autonomous engineering college located in Sathyamangalam, Erode district in Tamil Nadu, India. It is part of the Bannari Amman Group (BAG), which is one of the largest Industrial Conglomerates in South India with a wide spectrum of manufacturing, trading and service activities.

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Event Showcase | NORD DRIVESYSTEMS

NORD Drivesystems at ANUGA FOODTEC 2018 From March 20–23, NORD Drivesystems will be exhibiting its aluminium drive units for the food and beverage industry at ANUGA FOODTEC.

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he lightweight, corrosion-resistant gear units, smooth surface motors, frequency inverters and motor starters in wash-down optimised die cast aluminium housings are extremely robust and durable thanks to a special surface treatment: NORD nsd tupH surface protection.

For use in demanding environments, NORD offers the extremely effective nsd tupH anticorrosion treatment for aluminium drive units.

With this process, the material is hardened below the surface. The surface treatment creates a protective layer which is permanently bonded to the substrate material. It is based on an electrolytic process and gives aluminium

At ANUGA FOODTEC 2018, NORD will be exhibiting its drive solutions for the food and beverage industry Picture: NORD Drivesystems

corrosion resistance properties which are similar to those of stainless steel. The scratch-resistant surface is more than seven times harder than untreated aluminium alloy. The drives can easily withstand high pressure steam washing or contact with aggressive media.

Aluminium Drives in Oyster Farming Among other applications, NORD nsd tupH modules are used in the many conveyor systems which are used in oyster farming. While cast iron geared motors only remain operational for one or two years due to corrosion by the salty environment, the aluminium drive units from Northern Germany offer a durable and economical solution, which usually completely outlives the 10 year life cycle of the conveyor belts which they drive. Therefore, users save time and expense for the maintenance and repair of their systems.

An Economical Alternative with Many Variants nsd tupH drive units are a robust, durable and economical alternative to painted cast iron geared motors or stainless steel versions. The nsd tupH treatment is available for all NORD aluminium products, unlike stainless steel drives, which are only offered in a small number of versions by other manufacturers. For nsd tupH aluminium drive units, all DIN and standard components, including drive shafts, are made from stainless steel. The fan less smooth motors do not spread germs and also run very quietly. They are available as synchronous and asynchronous motors and fulfil efficiency classes IE2, IE3 (asynchronous motors) and IE4 (synchronous motors).

In addition to robust and corrosion-resistant geared motors for the food and beverage industry, NORD Drivesystems will of course also present other products from its comprehensive range of drives and drive electronics at ANUGA FOODTEC 2018 in Cologne. NORD can be found in Hall 10.1, on stand B061.

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Event | EMO REVIEW

EMO Hannover 2017 Showcased the Networked Production of Tomorrow Under the motto of ‘Connecting systems for intelligent production’, the exhibitors at EMO Hannover 2017 presented innovations designed to network the world of metalworking and progress its technological optimisation. There was a particular focus on cloud- and offline-based solutions for networking machines, tools, handling aids and production sequences, in order to achieve the intelligent production operations of tomorrow.

Author: Johann Kiesner, Institute of Production Engineering and Machine Tools, Leibniz University in Hannover Pictures: emo-hannover.de/en/news/media-library/impressions

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etworked machines, whose operating states can be acquired and statistically evaluated at any time, plus intelligent tools in conjunction with intelligent tool management systems, constitute only one aspect of tomorrow’s manufacturing operations.

Improved service structures at the customer’s facility thanks to smartglasses, comprehension-enhancing projections of complex tools using augmented reality, increase the customer benefits involved. But solutions for security-driven management of the data generated were also presented.

From a technological viewpoint, many innovations were spotlighted in the field of additive manufacturing. Besides new machines for producing additive components, numerous exhibitors showcased new process variants, and demonstrated their capabilities as exemplified by innumerable additively manufactured components.

Key Highlight: Besides new machines for producing additive components, numerous exhibitors showcased new process variants, and demonstrated their capabilities as exemplified by innumerable additively manufactured components.

The use of innovative materials, such as CFRPs for machine tool spindles, renders processes faster and more productive. Responsively customised tool dimensioning and more efficient machine tools additionally enable significant gains in productivity to be achieved in conventional chip-cutting production of high-precision components.

The descriptions below exemplify what trends and issues are the major focuses of production technology today.

Additive Manufacturing The proportion of additive manufacturing in the industrial environment continues to increase.

This trend was discernible almost everywhere at the EMO Hannover, due not least to the numerous impressive additively manufactured application examples at various stands, with which the exhibitors showcased their hardware and software

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Event | EMO REVIEW

Key Highlight: The experimental machine showcased at EMO Hannover offers additive deposition a work space of about 800 mm x 300 mm x 150 mm.

solutions. Additively manufactured products can not only be manufactured for optimum loadbearing capacity and weight by generatively building up bionic structures, but also permit the integration of additional functions, such as selective internal heat dissipation through integrated cooling channels. For metal printing, two processes currently predominate: the powder-bed process and laser deposition welding. Criteria for creating structures from the powder bed are primarily the high degree of design freedom, and fine resolution with 30 micrometres.

On its stand, EOS from Krailling exhibited an additively manufactured injection head for a rocket engine from the Ariane Group. By using powderbed-based technology, the construction time could be reduced from three months to 36 hours, the costs halved, and the number of individual parts reduced from 248 to a single component. One issue gaining steadily in perceived importance is quality assurance in generative manufacturing, particularly when it comes to safety-relevant components for aircraft construction. In conjunction with MTU Aero Engines AG, EOS creates solutions that monitor the system’s general status by means of numerous sensors. Optimum layer quality is additionally assured by camera-based surveillance of the exposure process and the melting behaviour of the material.

Besides the powder-bed process, the technology firm Trumpf from Ditzingen showcased at its stand the process of laser deposition welding, which enables build-up rates to be achieved that are ten times higher than the ones obtained in the powder-bed process. Here, the laser creates a melt pool on the component’s surface, into which metallic powder is inserted via a nozzle.

This production process is used for applying wearprotection layers, repairing components, and for creating new structures. The Trumpf lasers could be viewed in operation on the multi-tasking machines of the Laser EX series, which the Japanese machine tool manufacturer Okuma was premiering in Europe on the opposite stand.

Consistently harmonised solutions from a single source, from the CAD/CAM software to combined machining of the finished part, were presented by the machine tool manufacturer DMG Mori, Bielefeld. With the new Lasertec SLM, components up to a maximum size of 300 mm x 300 mm x 300 mm can be created from the powder bed. The premiered Lasertec 65 3D even produces components with a diameter of 650 mm and a maximum height of 560 mm in an additive process. This machine, designed purely for additive manufacturing with the powder nozzle, requires 45 per cent less footprint as compared to the hybrid

model, and offers not only a 40 per cent larger work space but also technological innovations like different track widths, higher laser ratings of up to 4 kW, and manufacture featuring reactive materials like aluminium and titanium.

Functional layers and component structures are created entirely without lasers using additive 3D coating technology from the machine tool manufacturer JG Weisser Söhne in the Black Forest. Using a patented process, simple semifinished material is rotationally imprinted onto a component’s surface, melted by the friction this generates, thus converting the semi-finished material into a component. The experimental machine showcased at EMO Hannover offers additive deposition a work space of about 800 mm x 300 mm x 150 mm. However, there would be a potential for utilising the technology on machines with different work spaces, and besides additive deposition combining it with further machining units for mechanical reworking. According to this company, the advantages compared to the laserbased additive manufacturing process featuring a powder bed are that the semi-finished materials are 10 to 30 times more affordable, that the deposition rates of two litres per hour are 20 times higher for aluminium and even up to 100 times higher for steel. One significant disadvantage, however, is that currently no complex structures can be created.

The metal-powder deposition process of Hermle Maschinenbau from Ottobrunn does not require any lasers either. In this thermal injection process, metal powder is accelerated to very high velocities with the aid of a carrier gas and applied

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layer by layer via a nozzle onto the component’s surface. The advantages of this process are that there are hardly any restrictions on the choice of material, provided that it is available in powdered form, and that it is possible to apply up to seven different materials in any desired mixing ratio on free-form surfaces. Other advantages are the low temperatures of 200°C to 300°C and the good amenability to a combination with subtractive mechanical machining processes, such as milling or turning, in a machining centre.

With the 3DXpert holistic software package, the American company 3D Systems from Rock Hill, South Carolina, offers a complete software package for additive metal manufacturing. This manufacturer, which itself also produces machines in the field of additive manufacturing, thus presented a solution constituting a producer-/process-independent variant for creating additive components. After the data has been imported and the component has been positioned, it is easy to subsequently create and optimise its structures and support geometries for the production operation. Then both the printing strategy for individual segments of the component is defined, and the scanning tracks are calculated. Since after additive manufacturing it will be necessary to rework individual surface areas and remove support geometries, the software also offers a part-step for this step in the process as well.

The VDW’s Sectoral Initiative for Networked Production The VDW (German Machine Tool Builders’ Association) has launched a sectoral initiative for

networked production. Its aims are development and software-based implementation of a standard for linking a whole array of highly disparate machine control systems at a shared interface. The initial phase of the project involves a core team comprising not only the VDW, but also prestigious companies like DMG Mori, Emag, Grob, Heller, Liebherr-Verzahntechnik, United Grinding and Trumpf. With this collaboration, unique in its form, between firms from the machine tool industry and the VDW, machine tools are to be prepared for the digital future, and an urgently necessary foundation for ‘Industry 4.0’ created. The planned standard is tasked with making it possible to interchange data between machines with different control systems of many generations and forward them to manufacturing execution systems and/ or to the cloud, in order to evaluate the data and utilise them for optimisation tasks. The goal of the initiative thus lies in harmonised networking of the production operation based on secure interfacing with EDP systems and clouds. Initial results are already expected for early 2018.

Key Highlight: The Swedish tool manufacturer Sandvik Coromant from Sandviken exhibited a series of tools as part of its Industry 4.0 initiative. Here, under the roof of Coroplus, integrated sensor technology in tools and tool-holders during machining was spotlighted.

Intelligent Tools Thanks to Integrated Sensor Technology The Swedish tool manufacturer Sandvik Coromant from Sandviken exhibited a series of tools as part of its Industry 4.0 initiative. Here, under the roof of Coroplus, integrated sensor technology in tools and tool-holders during machining was spotlighted. For vibration-damped drilling rods, the silent tools, the final machining steps in elaborate components can be monitored using app-based systems. The customer can see whether the tool has engaged and what the thermal stress in the drilling rod is like. The manufacturing process for expensive and complex components is thus monitored. In addition, intelligent tool-holders forward data on running time, loading and battery status to an app and thus incorporate the idea of predictive maintenance. Fine-drilling heads can be precisely adjusted by means of an app for manufacturing accurate borehole diameters. A comparable solution is also offered by BIG Kaiser from the Swiss town of Rümlang. This means the tool does not have to be manually adjusted in the tool presetting device, but can, for example, be extended and retracted for different diameters directly in the machine using an app on the tablet. This shortens process chains and reduces non-productive times during tool adjustment.

Intelligent Countersink Tools for Interior Component Machining The high-precision-tool manufacturer Hermann Bilz from the Swabian town of Esslingen has for

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Event | EMO REVIEW many years now been producing countersink tools.

These are used where the surface to be machined can be reached only through a borehole, e.g. in closed housings. A reversal of the sense of rotation causes the tool’s blade to be extended. In order to remove the tool from the borehole after machining, it is essential to retract the blade. Under the aegis of a joint project with O. Bilz and EWS, the Hermann Bilz company has developed a countersink tool that monitors retraction of the tool blade. The data are transferred to the machine’s control system using a communication protocol developed specifically for this purpose, and prevent a tool crash with the component if the blade is retracted incorrectly.

Key Highlight: At EMO Hannover, in the context of Industry 4.0, holistic tool management systems were a major focus.

WGP Symposium on Production for Tomorrow At the Production for Tomorrow Symposium hosted by the WGP (German Academic Society for Production Engineering), members provided insights into the challenges and opportunities of tomorrow’s production operations. The speakers, all of them themselves academics at universities and institutes, illuminated with their presentations how production technology in Germany is and will be addressing the sectoral trends involved.

In his keynote address, Prof. Eberhard Abele, the then President of the WGP and Director of the Institute for Production Management, Technology and Machine Tools (PTW) at Darmstadt University of Applied Science, dealt with the intermeshing trends featuring mechatronics, digitalisation, energy transformation, new production technologies and learning factories. For this purpose, he adduced impressive examples from specialisms of his colleagues at the WGP: intelligent sensor technologies for measuring and visualising machine loadings, simulation and optimisation of complex manufacturing processes, CAM systems in the cloud, consequences of the digital transformation and options provided by additive manufacturing. Prof. Hans-Christian Möhring from the Institute for Machine Tools (IfW) at Stuttgart University spotlighted in his presentation the possibilities opened up by intelligent machine components. For example, intelligent solutions for component clamping, designed to prevent component warping, and an adaptive process control capability for avoiding surface damage when milling complex parts, constitute the foundation for self-optimising production systems.

Prof. Berend Denkena, the then Vice-President and current President of the WGP and Director of the Institute of Production Engineering and Machine Tools (IFW) at Hanover University, also addressed this issue, and presented solutions for extending the dynamic behaviour of machine tools and thus

shifting the previous boundaries applying in the manufacturing process. Prof. Jan C. Aurich, who heads the Institute for Manufacturing Technology and Production Systems (FBK) at Kaiserslautern reported on performance-enhancing drilling tools featuring customised discharge openings and positions for cooling lubricants. Using modernday methods for flow simulation (ComputationalFluid-Dynamics (CFD) Analysis), these discharge openings and positions can first be optimised by simulations and then validated in actual trials.

New Interface between Machine Tool and Cyber-Physical Add-On Modules In particular, the Industry 4.0 Special Show offered exciting insights into tomorrow’s networked future for production technology. The academic community was represented at this special show by a large number of universities. One highlight was indubitably the government-subsidised BazMod research project, aimed at developing a manufacturer-independent standardised interface for exchanging media, data and energy between the machine tool and cyber-physical add-on modules. This enables an innovative functional expansion of machine tools to be achieved using sensor/actuator-based cyber-physical systems (CPSs), which had previously been integrated into the machine tool, depending on the manufacturer involved. Standardised contacts at the face expand the established hollow-shaft-cone holder and thus make possible an intelligent interface for supplying data and energy to intelligent tools. The signal transmission feature integrated into the spindle provides a link to the machine, thus rendering superfluous complex signal receivers that had hitherto been installed in the machining space at the tool-holder, and expanding the technical duty options for actuator-based tools.

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showcased: these included the even sturdier NHX 6300 horizontal machining centre for titanium machining, the high-dynamic-response DMU 200/340 gantry for machining large components, and the Multisprint 25/36 multi-spindle automatic lathes, which promise more productivity when machining long turned parts.

Holistic Tool Management Systems At EMO Hannover, in the context of Industry 4.0, holistic tool management systems were a major focus. Many manufacturers of high-precision tools such as the Iscar, Gühring and Sandvik companies as well as metrological specialists like Zoller from Pleidelsheim, supplied intelligent storage solutions for tools, components and accessories. Systems of this kind offer far more than merely an orderly and tidy tool management concept. The customer can precisely determine the tool costs per component, arrange for tools to be made available quickly and promptly, and avoid incorrect tool selection. In addition, intelligent systems feature a link to the machine tool, and receive information on a tool fracture, trigger a new purchase order at the tool vendor, and provide the machine’s operator with a constructionally identical tool. Systems of this kind render tool flows within the manufacturing operation and are clearer and more transparent.

With Digitalisation Initiatives to the Digital Factory The machine tool manufacturer DMG Mori showcased numerous innovations at EMO Hannover 2017. One highlight announced was the open IIoT platform (Industrial Internet of Things) Adamos, which began operation on October 1, 2017 with 200 experts. It originated from the alliance between DMG Mori, Dürr, Software and Zeiss ASM PT, and is tasked with offering solutions for digitally networked production. In addition, DMG Mori uses Open Connectivity for access to its Celos-Ecosystem, so as to make possible a consistently harmonised digital data flow even with third-party makes or manual workplaces, thus taking one step further towards its vision of a digital factory. Besides innovative software solutions for networking, several new machine models were

Key Highlight: MindSphere was demonstrated for the first time at EMO Hannover 2017. The application concerned involves digitalisation of the entire value added chain, as exemplified by an injectionmoulded component for a drone.

First Collection, Then Networking Systems can be networked on different levels.

The question here arises for machine tool users of whether all data must be sent to the cloud immediately. The answer to this is no, as far as Bosch Rexroth from Lohr am Main is concerned.

The present-day net would certainly not be able to provide the capacity that would be necessary in order to transfer to the cloud the huge quantities of sensor information that machine tools are nowadays already able to make available. For this reason, Bosch Rexroth premiered at the EMO Hannover the Data Analytics Server on a machine from the machine tool manufacturer Pfiffner. What’s involved here is additional local computing power installed in the machine tool’s control cabinet, enabling machine and process data to be collected, stored and analysed. The aim is to process data beforehand, so as to admit to the cloud only the really essential compressed quantity of data, and in this way avoid overloading the data lines. It remains to be seen, though, what data it is expedient to send. They can, however, be determined by the users themselves using appropriate analytical tools and configuration programs that can be operated with minimal previous knowledge.

To enable machine tools to begin machining more quickly, Bosch Rexroth integrates measuring sensors and evaluation electronics into its linear guides, so that absolute position actual values can be acquired in real time and without a reference run. Positioning accuracy is further enhanced by means of another innovation premiered at the fair – an actively temperature-controllable guide rail.

This newly developed feature is designed to avoid inaccuracies resulting from thermal expansion of the guide system.

Connected Machining – Networking Without the Cloud Dr. Johannes Heidenhain from Traunreut demonstrated at EMO Hannover its Connected Machining function package, enabling consistently digitalised job management to be provided: transparent processes, time-saving work sequences and facilitated use of the data involved. The Remote Desktop Manager from Heidenhain premiered at the fair, for example, enables the customer to access the PCs located in the network and the software

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Event | EMO REVIEW

installed on them directly in the control system at the touch of a button. In the demonstration, Heidenhain did not restrict themselves to their own stand, but networked no fewer than 22 machines, which were distributed over the entire grounds of the fair. In order to check the status of the machines, there was no need to take a long walk over the huge exhibition grounds, since with the aid of the new StateMonitor software package a glance at the screen sufficed in order to find out the machine’s current state using RAG status displays. Further functions, such as displaying the current machining program or using filters so as to display only machines in a particular operating state, simplify the work of machine operators. Heidenhain wants to deploy the Connected Machining solutions in small and mid-tier companies with 10 to 15 machines. For this reason, they deliberately rejected the idea of a cloud solution and the concomitant risks, in regard to data security, for example. Instead, networking takes place on local servers.

Key Highlight: Besides networking solutions, Siemens also exhibited new software tools, such as Analyze MyWorkpiece. This easyto-operate graphical tool enables the path of the tool’s tip to be visualised and analysed, so that different traversing speeds and tool orientations can be clearly edited and displayed.

Digitalisation of Value Added Chain as Exemplified by a Drone Component Siemens had already presented its concept for its Internet of Things (IoT) Ecosystem MindSphere as a digitalisation platform for all industrial sectors at the AMB 2016. MindSphere was demonstrated for the first time at EMO Hannover 2017. The application concerned involves digitalisation of the entire value added chain, as exemplified by an injection-moulded component for a drone.

Machine tool manufacturers and operators were able, with the aid of such specific practical examples, to bring themselves up to speed on the advantages that the merging of the real and virtual worlds offers them. For this purpose, Siemens for EMO connected up more than 200 machines to MindSphere via the Manage MyMachine app. This

enabled visitors to retrieve from a computer live information on the machining code being executed and the current operating state of machines from all over the world. Openness of this kind, of course, necessitates appropriate solutions with a view to data security. Identify3D is a security solution of this nature, which assures the traceability of digital manufacturing processes for protecting intellectual property while enabling the design and production data available to be used for components with technically precise specifications only for a limited quantity.

Besides networking solutions, Siemens also exhibited new software tools, such as Analyze MyWorkpiece. This easy-to-operate graphical tool enables the path of the tool’s tip to be visualised and analysed, so that different traversing speeds and tool orientations can be clearly edited and displayed. Only on this basis is it possible to detect errors and effect optimisations. The program operates irrespective of whether the machining code was created with the aid of any desired CAM software package or was programmed by hand.

On its stand at the fair, Siemens presented not only new software, but new hardware as well.

Multi-touch displays have gained wide acceptance as an operator control concept, since the screens themselves work sturdily and dependably even in oily, dirty and harsh environments. For this reason, Siemens presented its new control panels in the 16:9 format and with multi-touch operator control.

It can be safely assumed that panels of this kind will in future replace the old control consoles.

Vibrations at machine structures created during mechanical metalworking reduce the productivity of machine tools. In order to avoid this disadvantage, Siemens has developed an active damper. The designation of Active Vibration Absorber denotes a mechatronic system for machine tools that reduces vibrations at structures susceptible to them. This system, the size of a shoebox with a total mass of about 20 kg, is able to measure accelerations, and in variable-speed operation at frequencies of up to 200 Hz actively counter an oscillating mass of 10 kg.

Industry 4.0 Platform for Gear-Cutting At EMO Hannover, the family firm Klingelnberg presented its Industry 4.0 solutional approach tailored to the gear-cutting industry, which is based on an IT platform. The key idea here is rigorous networking and holistic provision of process information along the entire process chain involved in gearwheel production. With this approach, the Hückeswagen-based company embraced the leitmotif of EMO Hannover 2017: Connecting systems for intelligent production. The resultant GearEngine IT platform constitutes the backbone

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of the cyber-physical Closed Loop production system. As a central link between the machine tools and other services (like the firm’s own SmartTooling tool identification system), it manages toothing data, production equipment, and the part history in three databases. For this purpose, the machines involved report to the platform individual data, e.g. about the tools and clamping devices used in machining the current gearwheel. This enables the entire production process for an individual gearwheel to be reconstructed. In addition, it is possible to intervene directly in the production operation, e.g. by improving the machining parameters between machining two gearwheels.

Expanded Service with Smartglasses within the Framework of Industry 4.0 Index-Werke and Hahn & Tessky from the Swabian town of Esslingen showcased various innovative solutions for the digital era within the context of its iX4.0 initiative. Besides a cloud-based IoT platform for receiving and editing machine and process data, the new service structure with smartglasses is particularly noteworthy. By using smartglasses with a real-time capability, the customer can repair his machine himself in the event of failures. A service technician from Esslingen offers visual support for this. The information and instructions are transmitted to the customer via the glasses onto his machine.

This saves time and reduces standstills.

Integrated Sensor Technology for Avoiding Rejects The Renishaw company from New Mills, UK, as a globally operating player in the field of highprecision technology, showcased its portfolio of systems for metrological applications and generative manufacturing. In the context of connectivity, Renishaw showcased an integrated metrological capability. In the shape of the Equator flexible test instrument, the firm offers an intelligent process control system that enables tool corrections in the CNC production process to be updated fully automatically. Thanks to direct embedding in the production operation, correction data are transferred from the measuring instrument to the machine, and taken into due account when manufacturing subsequent components. Waste can thus be simply avoided by continual readjustment.

Start-Ups in the Technological Environment To enable large components to be flexibly and cost-efficiently machined irrespective of the component’s dimensions, the start-up Picum MT, created by the Institute of Production Engineering and Machine Tools (IFW) at Leibniz University in

Hanover, is adopting fresh approaches. Instead of bringing the component to the machine tool, the Picum One, an intelligent tool robot weighing about a mere 100 kg with its own single-software solution and innovative metrology, is brought to the component. According to the start-up, procurement and operating costs are thus avoided, as are inaccuracies increasing with the machine’s size. The Picum system docks with any desired component, and automatically determines its position in the space to an accuracy of 15 µm.

The prototype is fitted with five-axis kinematics and a 7.5-kW milling spindle, and handles tasks like drilling, milling and grinding. In future stages of development, expansions to the system will be able to perform additional jobs like measuring, laser-cutting, and 3D printing.

An innovation in the field of spindle manufacturing was showcased by CarbonDrive from Darmstadt. The start-up venture from Darmstadt University of Applied Science is the world’s first manufacturer of full-carbon motor spindles for machine tool construction. High levels of specific rigidity and thermostability open up a multiplicity of advantages in the application concerned. Thanks to the reduced mass of the material used, the spindle is 50 per cent faster in all acceleration and deceleration functions, thus reducing energy consumption, non-productive times and costs. In particular, locally adaptable material properties are ideally suited for integrating metrological equipment to provide real-time monitoring of the metal-cutting process.

Summary EMO Hannover 2017 showed that the radical shift towards digitalisation is being well received in the metalworking industry. Numerous IoT platforms like Adamos, Grob-Net 4 Industry or MindSphere were presented, which are progressing the advance of digitalisation. In line with this trend, manufacturers showcased numerous tools and other equipment that – fitted with sensors and digital communication interfaces – serve as suppliers of data to the digitally networked production systems. The up-to-the-future technologies nonetheless pursue traditional goals, such as trackable production processes, optimised resource utilisation, higher flexibility and increased productivity. The numerous new technological developments in machines, tools and machine components exhibited at EMO Hannover 2017, however, also contribute towards achieving these goals. In the field of additive manufacturing, particularly, there were many innovations on show – a fact that will indubitably favour a more costefficient deployment of the young technology.

Key Highlight: Besides a cloud-based IoT platform for receiving and editing machine and process data, the new service structure with smartglasses is particularly noteworthy.

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Special Feature | SCHULER

100 Hot Stamping Line Sold th

Order from Chinese automotive supplier confirms continuing trend towards lightweight technology advanced by Schuler.

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n 1993, Schuler delivered the first three hot stamping lines to automobile manufacturer Ford in the USA. What was a brand-new method at the time has since established itself on the market as a global forming technology for automotive lightweight construction – and the trend continues unabated: Schuler has now sold what is the 100th hot stamping line to a Chinese automotive supplier.

“Compared with forming aluminum, carbon fiber-reinforced plastics and dual phase steels, this technology is an inexpensive alternative

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for lightweight automobile construction,” as Daniel Huber explained, the head of Division Hydraulic at Schuler. Oemer Akyazici, the CEO of Schuler China, added: “Chinese automobile manufacturers and automotive suppliers, such as Shanghai Superior Die Technology Co. (SSDT) or Baowei are increasingly turning to hot stamping.”

The method, which involves heating sheet steel blanks to 930 degrees and cooling them during forming, was first introduced in the early 1990s – initially to improve passenger safety in vehicles – for example,

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"Chinese automobile manufacturers and automotive suppliers, such as Shanghai Superior Die Technology Co. (SSDT) or Baowei are increasingly turning to hot stamping."

Oemer Akyazici, CEO, Schuler China

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to reinforce the doors in the Saab 9000, thus helping it to pass the stricter crash tests in the USA. The technology was first introduced to large series production of the Ford Sierra in Europe and the Ford Mercury in the USA. The side impact beams and bumpers were created on Schuler systems at the time. After the turn of the millennium, the industry increasingly saw this method’s potential for reducing vehicle weight while keeping pace with increasing safety requirements. Because press hardened components have a greater tensile strength than cold-formed high-strength steels, the use of material can be reduced, thus making the components lighter.

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In 2006, the body of the Volkswagen Passat was the first to use twelve press hardened components. To allow this to happen, Schuler had built six hot stamping lines within the shortest possible time, and installed these at the Kassel plant. “This laid the foundation for growth that is still continuing,” said Daniel Huber, general manager of the Schuler site in Waghäusel, Germany.

Currently, some 500 million hot stamped parts are produced annually on more than 400 systems worldwide. And, according to Huber, experts anticipate further growth: “Schuler identified this development at an early stage, and set up a Competence Center for press hardening at our Waghäusel site in the year 2006”. This was followed in 2016 by the Hot Stamping TechCenter in Göppingen, a research and demonstration facility at the company’s headquarters.

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1,2: Hot Stamping has established itself on the market as an economical technology for lightweight automobile construction.

3: In 2016, Schuler opened the Hot Stamping TechCenter in Göppingen, a research and demonstration facility at the company's headquarters.

4: The method involves heating sheet steel blanks to 930 degrees and cooling them during forming.

The effect: excellent tensile strength.

Picture: SCHULER

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Breakthrough | RENISHAW

Additive manufacturing for smart body implants Matt Parkes, Senior Medical Development Engineer at Renishaw and currently working on a collaborative project with Western University in Ontario, Canada, discusses how smart implants are changing the way bone diseases and injuries are treated.

S Sensors can be incorporated into bone reinforcement implants, which are used to help fractures heal Picture: Renishaw

ince the early 1900s, surgeons have been using metal implants in healthcare, typically to treat bone diseases including osteoarthritis and inflammatory rheumatoid arthritis, as well as in reconstruction therapy. Though a long-established technology, traditional implants often cause challenges for patients and surgeons. One area currently being developed is smart implants, which improve patient outcomes, bringing the technology into the modern age.

Implants can be smart in two ways, either by being additively manufactured to produce patient specific implants (PSIs) from computed tomography (CT) data, or by incorporating sensors. Still in the early phases of development, inbuilt sensors could collect patient-specific data, enabling surgeons and other healthcare professionals to tailor treatment to the needs of individual patients.

The Challenges with Traditional Implants One of the key challenges that traditional implants present is loosening. Particularly common following joint replacement procedures, loosening can be a result of poor osseointegration — the structural and functional connection of the implant with the patient’s bone. This can occur due to wearing over time and is exacerbated by factors including infection and poor compliance with advised physiotherapy regimes.

Another limitation of traditional metal implants is that they are only manufactured in a discrete number of shapes and sizes. Therefore, it is unlikely patients will receive an implant that fits them accurately. This can cause poor physical function and contribute to loosening.

Poor physical function can also occur because of stress shielding — the process whereby metal implants remove stress from the patient’s bone.

The bone responds by reducing in density and

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therefore becomes weaker.

The increasing incidence of obesity is one reason joint replacements are becoming more common in young people. This poses longevity issues as implants can reach their maximum lifespan and need replacing several times during the patient’s lifetime.

To combat these issues, researchers and engineers have been developing implants in new ways, using techniques such as additive manufacturing (AM). The technology aims to improve the form, fit and function of implants.

Additive Manufacturing AM has been used as a manufacturing method in the medical field for over ten years, but the technology is yet to reach its full potential in this industry. Because AM builds an implant layer by layer, it is possible to produce PSIs that are a more accurate fit for the patient.

The manufacturing method also has fewer geometric constraints than subtractive manufacturing. PSIs designed and manufactured according to a patient’s CT scan encourages the implant to integrate with the patient’s bone, reducing the risk of loosening. As a result, patients are less likely to suffer pain or require revision surgeries.

As well as being able to manufacture an exact shape, AM enables surgeons to control additional properties of the material. They can design implants that mimic the patient’s bone stiffness, density and trabecular structure, which can reduce stress shielding and improve osseointegration and physical function further.

Sensors Implants can also be made smarter by adding sensors. This allows clinicians to accurately measure patient data — the key to evidencebased medicine. One parameter a sensor could measure is temperature, as a raised temperature can indicate an infection before symptoms appear.

This could benefit both patients and doctors by enabling treatment before the infection becomes complicated and expensive to treat.

Sensors can also be incorporated into bone reinforcement implants, which are used to help fractures heal. In this example, sensors can measure the strain exerted on the implant, which indicates the extent the fracture has healed.

From this information, surgeons can determine the best time to progress the patient to the next stage of therapy and could identify healing problems earlier than currently possible.

As implant loosening can be affected by non-compliance with physiotherapy, technology

has been developed to overcome this issue.

Incorporating accelerometers to monitor the movement of patients would allow healthcare professionals to remotely obtain data. These could be used to determine whether a patient is complying with their prescribed physiotherapy and rest regime.

One institute developing technology in this field is a collaboration between Renishaw and Western University in Ontario, Canada, who have set up the Additive Design in Surgical Solutions (ADEISS) Centre to bring together clinicians and academics to generate novel 3D printed medical devices. ADEISS recently showcased the smart hip concept, which uses temperature sensors and accelerometers to collect patient data that can be communicated to a remote device.

By making use of advanced sensor technology, there is now potential for the development of implants that can detect an infection and subsequently secrete the appropriate dose of antibiotic to treat it before it becomes symptomatic. This could reduce the number of patients admitted to the hospital.

Changing the Face of Medicine The ultimate driving force for developing smart implants is the potential to considerably improve patient outcomes. AM offers several benefits, one major advantage being that the fit time schedule is reduced — a benefit to patients and surgeons. The benefits that smart implants have over traditional metal implants could mean that patients will suffer less pain and discomfort, will be less likely to become seriously ill due to infection and could be at lower risk of needing revision surgeries, critical for younger patients.

However, for widespread clinical adoption of smart implants, there are still challenges to overcome. Clinicians must run clinical studies to collect data on the safety and performance the implants offer to patients. This must all be done in line with regulations such as the EU Regulations on Medical Devices. A further key consideration is the processing of personal data in smart implants and how that data is used by the industry and clinicians.

The treatment of bone diseases and injuries has come a long way since the days of bone setters and blacksmiths. Patients can now receive metal implants specifically designed to their individual requirements. Pioneering research institutes are overcoming the hurdles and improving the technology, so the uptake of additively manufactured and data-driven implants is set to rise, improving outcomes for patients and hospitals.

Key Highlight: Renishaw and Western University in Ontario, Canada, who have set up the Additive Design in Surgical Solutions (ADEISS) Centre to bring together clinicians and academics to generate novel 3D printed medical devices.

Patients can now receive metal implants specifically designed to their individual requirements.

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Vision Make In India | MAGAL - INGYU

Empower SMEs.

Empower Mission Make In India

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MI met with the leadership team of Magal Engineering and Ingyu on the sidelines of IMTEX 2018 where Magal Engineering showcased Ingyu’s high-precision press technoligies. We spoke with M. K. Narasinga Rao, MD, Magal Engineering, Peter Dias, CEO, Unitech Metalforming Technologies Taiwan; Brenda Tung, Sales Manager, Ingyu about their product focus, future plans, India-Taiwan trade ties, views on India’s SMEs and their role in the furthering of mission Make in India. Edited excerpts.

Key Highlight: India must start working in this direction because our Prime Minister has already conveyed that by 2030 there will be no internal combustion engines anymore. We hope that from Taiwan, we are in a position to pass on the bulk of this technology to the Indian manufacturer.

What are the major products you are exhibiting here?

M. K. Narasinga Rao [MKNR]: We are focusing on Ingyu. Peter Dias, CEO, Unitech Metalforming Technologies is our Taiwanese partner and we work together in India.

Peter Dias [PD]: We manufacture high precision metal stamping press lines. We integrate these press lines into total solutions for the Indian market.

How is the show IMTEX 2018 panning out for you as of now?

PD: I see a lot of optimism this year. We hope that this optimism is translated into real investments into the future.

What is your view on Mission Make in India?

Should the objective be to create jobs or to make India on a global manufacturing hub or both?

PD: If you focus on making jobs, you do not necessarily become global. You have to become a globally competitive manufacture first, only then will the jobs come.

MKNR: If you don’t invest in the right technologies then they we [as a country] we will miss the future.

What are the major challenges that are stopping India from becoming a global manufacturing hub?

PD: Challenges are more to do with the attitude of customers. There is a lack of long-term commitment on part of the government and the large buyers that.

Nobody can see the future very clearly.

Therefore they can’t make big investments or even for the short term of, say, five years. So finally who are the people who are making parts? It is small medium enterprises; not the Birlas and the Tatas. Indian is leaning on the SMEs. Most SMEs are families or individual entrepreneurs, who must be given the confidence and the capital to make the right investments and be sure that their investments are guaranteed for sure and reasonable period.

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What are the major industries you are focusing on with Ingyu?

PD: Automotive is number one. We are looking at the high-tech industries, motor manufacturing specially the new electric vehicle motors. India must start working in this direction because our Prime Minister has already conveyed that by 2030 there will be no internal combustion engines anymore. We hope that from Taiwan, we are in a position to pass on the bulk of this technology to the Indian manufacturers. The motor stamping industry has level up into high-efficiency industrial motors and electric vehicles motors.

How do you see the trade partnership between India and Taiwan?

Brenda Tung [BT]: Taiwan is the only country that can actually pass on technology to India. We are very happy that the Narendra Modi government looks beyond the One China Policy (OCP) and believes in strengthening trade ties with Taiwan.

[L-R] Peter Dias, CEO, Unitech Metalforming Technologies Taiwan; Brenda Tung, Sales Manager, Ingyu; M. K. Narasinga Rao, MD, Magal Engineering.

Picture: Magal Engineering

Key Highlight: We are very happy that the Narendra Modi government looks beyond the One China Policy (OCP) and believes in strengthening trade ties with Taiwan. We want the ties to go one step further and see a free trade agreement between India and Taiwan.

We want the ties to go one step further and see a free trade agreement between India and Taiwan. Because right now people in India who want Taiwanese technology are deterred by high custom duties, so the government must make it easier for Indian SMEs to get technologies from Taiwan.

PD: China is our [India’s] competitor; Taiwan is our partner. Taiwan can pass on technologies from manufacturing where they are much ahead of the curve. Taiwan has no [ulterior] aspiration; you can see there are no Taiwan joint venture companies, because we give the technology to the Indian manufacturer. We don’t want to stay here or run the company. So Taiwan has become an excellent technology partner for the Indian SMEs. But SMEs are now are being hindered by a wrong taxation policy which is a remnant of of the One China Policy years. This government will need to make an environment in which the Taiwanese technologies can flourish in India.

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Vision Make In India | MAGAL - INGYU How is Magal helping Ingyu to market in India?

MKNR: We have a service sector where people are going to be trained in Ingyu for support. We are starting by selling spare parts and are going forward in the positive direction.

PD: We are also offering technologies and understanding the needs of the SMEs in the industry. Our local partners are very crucial as we are trying to tailor-make our technologies and machines according to the requirements of the Indian SMEs. Visiting small industries, interacting with them when they visit the shows, seeing their aspirations, valuating their technology challenges and then suggesting a solution for them; all of this is very crucial. Our local partner does a lot of work in this regard.

In your opinion, how will Industry 4.0 provide a boost to the Indian manufacturing industry?

MKNR: Industry 4.0 is catching up in the European market but the penetration into the South East Asian markets is not that much.

PD: India has other priorities, information integration is a part of a globalised world but it is not our priority right now. Our priority is to develop our base industry, provide jobs, offer every single engineer who wants to become an entrepreneur with capital and technology in order to become a manufacturer. We need to go in the right directions.

Everything has to be a networked and smart industry. Hence, Industry 4.0 is a norm and not a preference but at the moment it is not our priority.

Key Highlight: Industry 4.0 is a norm and not a preference but at the moment it is not our priority.

latest tech to India. For example it’s a known fact that Taiwan is the 4th largest producer of machine tools in the world. The government of India must give tax sops for people to buy technologies from Taiwan rather than going to China or Malaysia.

Every rupee invested in machine tool technology adds to the nation’s manufacturing potential.

MKNR: SMEs will have to, for a change, focus more on technology than the price.

PD: We [India] will have to learn from China that subsidised investment into new technology in the initial years. We had also incentivised investment in our country for so many years but the government took it away. So the small fellow investing here has got no tax benefit; in addition he has got to pay high interest rates and on top of it he does not have the money to make investments. This is not a viable model. We must understand how vital the SMEs are to the Indian economy.

Taiwan offers the most cost effective technologies.

Our government must make it easier for Indian SMEs to collaborate with Taiwan’s industry. The window of opportunity is very small, the world is moving ahead. We don’t have ten years to achieve this. It is for us now increase and seize this chance and take the opportunity to become the global leader of manufacturing.

How do you see companies like Mahindra and Mahindra using your technology to build their electric vehicle?

PD: Well everything in India in the automotive supply chain starts off with local SMEs who supply components. India’s Prime Minister has shared his vision of 2030 regarding the ubiquity of electric vehicles in India. It means that by 2020 we must start manufacturing components, and that is where the Taiwanese companies could work as enablers.

You think that India has the potential to become the global manufacturing hub?

MKNR: Indians are among the smartest people with sound engineering skills and are very fast to grasp technology. Even if you give the guys from the villages and train them as technicians, they pick up very fast in one-two years. They only need to be given a proper platform and the right direction.

PD: We see in this exhibition the curiosity of the young people looking at this technology with curiosity and aspiration. Very few countries can boast of this demographic – we have this large young talent pool of energetic, ambitious people which is our strength. They will leave and go to USA or go somewhere else if we don’t give them a chance to become a part of the growth story of this country.

So the Indian SMEs or MSME has to be educated with this kind of technology are there.

PD: Indians are very well aware of all the technological advancements. They frequent travel the world, but when they come back to India, they, especially the SMEs face the [bureaucratic] roadblock that discourages them from bring the

Anything specific you want to say about Ingyu to our readers?

PD: We have been present here in India for about 30 years. We have seen a time when the investment cost was very high. We have a longstanding commitment to this country and we will continue to drive the technology and innovations to contribute to mission Make in India.

India’s Prime Minister has shared his vision of 2030 regarding the ubiquity of electric vehicles in India.

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Primer

High Precision:

A World On Its Own To Be Respected The write-up analyses the subject of accuracy of precision machines in light of today’s production environment and increased demands made by their users.

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here is a growing demand for superior precision in production for obtaining high-surface finish and close dimensional tolerances eliminating any further machining requirements.

Examples of production processes that require superior precision:  Hard Turning substituting Grinding  Die-mould applications eliminating further finishing or polishing operations

Key Highlight: Undesirable heat originates from the axis drive motors that have replaced handwheels.

The selection of materials required in manufacturing, inspection and assembly is based on their properties: strength, weight, thermal expansion – which contribute to precision.

A Longstanding Problem The journey towards precision in machining started in 1775 with John Wilkinson, an English industrialist who invented a precision boring machine of diameter 1800 mm with an accuracy of 1 mm. The dimensional unit for precision has changed gradually from millimeter through Microns* to Sub-microns, Nanometer and Angstrom units.

If we go back a hundred years, when Jig Boring Machines were first designed and developed, we would see that precision engineering was being applied to its limits, as they existed back then.

The watch-making industry required machines to manufacture small components to

produce accurate center distances for miniature watch movements. Positioning errors were also found to be caused by heat which is why handwheels were moulded in clay to eliminate heat transfer between hand and the lead screw.

Today, undesirable heat originates from the axis drive motors that have replaced handwheels. The fact is that even most remarkable technical advances still run-up against the laws of nature, and these laws must be studied and mastered by appropriate means.

The Concept Of Precision Machines Across the industrial world, high-precision manufacturing is increasingly seen as a set of technologies which are key to global competitiveness. Many advanced technological products necessitate manufacturing processes and machines operating in the regimes of:   

Precision Engineering Micro Engineering Nano-technology

Worldwide trend in industry reveals that two major thrust areas of manufacturing technology are:

Vo l u m e 2 – Is s u e 2 M a r /Apr 2 0 1 8

Mr B P Poddar is the Vice President of Sales and Marketing at Fatty Tuna India Pvt Ltd. He has 30 Years of experience in Metal Cutting Machine Tools and Auto Component Manufacturing industry and has worked with several German and Swiss machine tool makers in various technical & management positions.

He delivers keynote speeches at prominent industry events, and writes articles for leading industry magazines and portals.

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Automation in manufacturing [CAD/CAM/ FMS/CIM] High-precision manufacturing [Precision Engineering / Micro Engineering / NanoTechnology].

To meet requirements of high-precision machines, considerable efforts have been put in the design of machine tools and their elements. The selection of materials required in manufacturing, inspection and assembly is based on their properties: strength, weight, thermal expansion – which contribute to precision.

Dimensional changes caused by thermal fluctuation and gradients are very important factors. The compensation and elimination of these effects are some of the design strategies.

The effects of change in temperature and heat sources cause changes in size and shape and lead to non-equilibrium conditions.

The desirable properties of the machine tool material are:  Low distortion under thermal load  Re-stabilization in rapidly changing thermal loads  High-resonance frequencies.

A host of conditions must be met, if workpiece accuracies are to be reached, of which the the following are particularly important:  Substantial and symmetrical structure of main machine components  Protection of machine components against heat radiation  Careful scraping of slide-ways in accordance with specific compensation curves to ensure inherent flatness and straightness of slideways and their perpendicularity with respect to another axes. There is still no substitute for fine hand-scraping.  Z-axis parallel to spindle.  Perpendicularity of spindle with traverses of other axes.

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Other conditions have to be met, such as: Optimum layout of machine components and guides to ensure an even load distribution i.e. position of Z-axis screw in the same plane as the spindle axis, thus avoiding leverage.

The cooling of spindle bearings and associated mechanical components which also have to be kept at constant temperature under extremely varied dynamic conditions.

The cooling of cutting oil which progressively

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Primer

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charged with calories and transfer heat to work-piece.

Ideal location of measuring systems with regard to the slide-ways and feed screws to reduce positioning errors resulting from reversal of forces exerted into slides.

These and the other sources of instability can lead to significant work-piece inaccuracies and loss of overall machining quality.

The Micron: A Dream or Reality Not very long ago, only the manufacturers of measuring instruments, jig borers and metrology equipment talked in terms of a thousandth of millimeter and could claim to have some degree of control over how they were used.

Infographic 1: Errors and Influences.

Today, nearly all manufacturers and users of machine tools claim to be familiar with this microscopic unit of measurement and even specify its use in such a way they exceed the capability of their own manufacturing and inspection facilities!

The micron must be treated with good deal of consideration and respected.

Do you know, for example:  Steel enlarges by 0.011 mm/1000 mm/degree Celsius. The slightest change in temperature causes variations of a few microns.  If a 500mm-long aluminium component is only 2 degrees warmer than an assumed temperature of 22 degrees of measurement machine, the longitudinal measurement error will be nearly 0.030 to 0.040 mm.  The thermal effect on any object is significant not only in linear dimension but also in shape.  A change in temperature has different effects on various elements of machine and measuring equipment which take different time spans to attain equilibrium.  Any slightest heat radiation effecting a machine causes bending or deformation of work-piece or the machine component.  Along with temperature; dust, humidity, vibration, air turbulence, and noise can effect measurement and machining.  The foundation on which machine rests is subject to the same physical laws as the machine. Therefore the foundation cannot be subjected to changes in temperature without exerting an effect on machine.

Many machine-tool makers who state accuracies in their brochures imply different meanings as per different standards. Standards and their meanings must be properly understood before getting carried away by numerical values or numbers.

There is no doubt that numerical control has impressively improved accuracy as far as the axis positioning is concerned. The basic structure of machine, its design and dynamic performance are key factors determining stability and accuracy.

What High Precision Means Association between the accuracy required on a drawing and the indicated accuracy of machine tool provides confirmation that machine needs sufficient accuracy in reserve to allow for the inevitable geometrical variations that occur, without upsetting the range of tolerance.

Otherwise this will lead to the non-acceptance of work-pieces.

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This involves not just geometrical errors in positioning or on machine itself, but an accrual of all the minor faults connected in one way or the other with machining and work-piece measurement.

What Are These Influences What are these influences and to what extent do they affect the machine’s basic accuracy?

If, say, the mean accuracy of 0.020 mm must be obtained for work-piece on machining center on a 1000 mm cube, the sum of errors can be imagined is as shown in the infographic 1.

Infographic 1: Errors and Influences It is inconceivable technically, but today the reality is that customers require performances from a typical machine tool that its basic design is not able to give. As a consequence, it will be present many production problems which will need to be solved.

Many times the customers choose machines those are foremost economical but at the same time the customers demand unrealistic specifications, such as:

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Spindle speeds of 20,000 rpm and more are demanded Spindle power 20 kW and more Rapid feed rates 30 mtr/min and more Positioning accuracy of 0.005 mm with repeating accuracy 0.002 mm

Therefore we must ask:  How to dissipate all excess heat that is unnecessarily generated?  How do we control acceleration and deceleration?  How do we control moments of inertia?  Will the high-speed spindles and their bearings deliver high accuracy under heavy duty conditions?

Machines cannot be used for every conceivable job without certain limitations.

There will always be some constraints that need to be taken into account. * MICRON -The thousandth of a millimeter is becoming more and more a ‘must’. This requires complete adherence to the basic rules of Physics and Metrology.

Key Highlight: Nearly all manufacturers and users of machine tools claim to be familiar with this microscopic unit of measurement and even specify its use in such a way they exceed the capability of their own manufacturing and inspection facilities!

Product News | SECO TOOLS

New Seco Jetstream Tooling Delivers HighPressure Coolant During Thread Turning

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eco Tools has introduced Jetstream Tooling high-pressure coolant technology for threading shank holders. The new range includes square shank holders for external applications, boring bars for internal applications and GL-heads for use with Steadyline bars.

The Jetstream Tooling threading turning holders deliver a concentrated high-pressure jet of coolant – up to 150 bar/2,175 psi or hose connections for up to 275 bar/3,988 psi coolant inlets – to the optimum position close to the cutting edge making it possible to guide or steer chips a certain direction away from the cut. The toolholders are available in 22 external, 28 internal and 14 GLheads types in insert pocket sizes 16, 22 and 27.

For parts made from titanium or similar materials, Jetstream Tooling technology is capable of breaking the tough threading chips to increase tool life. When threading steel and stainless steel, the improved chip control of the new thread turning tools allow for potentially 30 percent to 60 percent higher cutting speeds without compromising thread surface quality.

The square shank holders also include the JETI and Duojet features. JETI delivers coolant through holders without using a hose connection, and DuoJet applies one or more additional coolant jets from a second direction.

Incorporation of these features brings optimized heat removal, effective chip elimination, longer and more predictable tool life and enhanced thread surface

quality to thread turning operations.

The use of the JETI feature with square shank holders requires the use of adapters. The new range includes both face mount and star mount adapters for Seco-Capto C5, C6 and C8 turrets and star mount adapters for HSK-T 63 multi-tasking machine spindle interfaces. The adapters accommodate square shank sizes 20 mm and 25 mm.

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Product News | HAIMER

Safe as well as efficient T MTU Aero Engines manages challenging roughing applications for the military turboprop engine TP400-D6 with Haimer Safe-Lock. MTU is responsible for the TP400D6´s intermediate-pressure compressor, intermediatepressure turbine and intermediate-pressure shaft and has a stake in the engine control unit. Furthermore, final assembly of all TP400-D6 production engines takes place at MTU Aero Engines in Munich.

Picture: MTU Aero Engines

he HAIMER Safe-Lock pull out protection system ensures safe cutting tool clamping. Special drive keys in the tool holder perfectly match the spiral shaped grooves on the cutting tool shank, thus creating frictional clamping forces and a positive locking form-fit. This effectively prevents the cutting tool from pulling out of the tool holder.

Furthermore, it increases the productivity through faster permissible speeds and increased tool life.

By now Safe-Lock has become a de-facto standard in the area of tool holding for milling operations. Within the last ten years, since the introduction of the Safe-Lock system, it has been confirmed over and over that this method of clamping the tool is often clearly superior to conventional Milling Chucks and Weldon shanked tool holders. This is proven by a large number of

license partners, some of which rank amongst the world´s leading cutting tool and tool holder manufactures - for example Walter, Widia, Sandvik Coromant, Seco Tools, Sumitomo, Kennametal, Helical, Emuge Franken, Data Flute, Niagara, OSG and Mapal. In 2017, Iscar and Ingersoll also decided to offer tools with the Safe-Lock shank.

Furthermore, the shrink, collet and hydraulic chuck Safe-Lock tool holder portfolio has become much larger within the last few years.

In addition to the Safe-Lock hydraulic chucks from Kennametal, Mapal is already working to introduce its hydraulic chuck offering with SafeLock to the market.

Andreas Haimer, Managing Director of HAIMER GmbH, explains: “We are proud that our Safe-Lock pull out protection system has established itself as the new standard in the

Trochoidal milling makes the milling operation three times faster and deeper, even in hard materials like stainless steel or titanium. Ideal tools for machining are the HAIMER Power Mill end mills with Safe-Lock™-chuck.

Picture: Haimer

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heavy duty and rough milling industry and is also becoming more and more important in other areas such as trochoidal milling. We are also very happy about our new license partners, who help expand the Safe-Lock portfolio and also make it available for more end-users.”

Successful in the Aerospace Industry Safe-Lock has emerged from the requirements of heavy-duty machining, which is a daily challenge in the aerospace and energy producing industries. Innovative materials such as various titanium alloys are not only light, but also very rigid, corrosion resistant and difficult to machine. This doesn´t only affect the machine concepts and processes, but also the cutting tools and tool holders that are being used.

Many workpieces are made from a solid block - during this milling process up to 90% of the material is being removed. In order to optimize the process economically as well as qualitatively and in order to achieve a high metal removal rate, high torques and feed rates with low RPMs are chosen. But during this High Performance Cutting operation (HPC), high pulling forces occur. In combination with high cutting forces and aggressive feed rates, a flexing movement of the tool in the tool holder is created which in the end increases the risk of tool pull out.

This especially affects all the tool holder designs which provide accurate clamping and a high runout accuracy, like for example shrink, hydraulic or milling chucks.

As a consequence Safe-Lock is now widespread within the aerospace industry. Alexander Steurer, Senior Manager NC - Programming Stator Components at MTU Aero Engines in Munich, explains the decision to use the HAIMER system: “Through the introduction of Safe-Lock and

the shrinking technology from HAIMER, we can guarantee process reliability even with milling challenging high temperature materials. This is a prerequisite to guaranteeing smooth processing during manufacturing of frames and castings, given our high degree of automation.” The combination of pull-out protection and highest concentricity of the Safe-Lock system leads to low vibration and as a result, a very stable machining process. Due to the increased cutting depths and feeds, the metal removal rate can be increased significantly. And thanks to the improved run-out accuracy of HAIMER shrink fit chucks, tool life is improved by up to 50%.

The benefits of less than 3 µm runout, that the symmetrical Safe-Lock design provides, coupled with optimum balance and the possibility for easy length presetting were substantial reasons for MTU to switch to the HAIMER system instead of continuing to use Whistle Notch or Weldon tooling systems. While these other systems do in fact prevent tool pull out, both are unsymmetrical by design, hence providing insufficient runout and balance accuracy.

Higher Productivity with Safe-Lock However, Safe-Lock has not only found enthusiastic followers in the aerospace industry.

Working at Glätzer, Daniel Rautenbach knows how fiercely competitive and thorough the automotive industry can be. The Managing Director of the CNC-Machining Specialists located in Solingen explains: “Perfect quality and delivery reliability are the basic requirements in order to quote in our industry. Pricing is highly competitive.” Therefore, in his business, the difference between profit and loss comes down to process efficiency. Hence quality without compromise is a must.

Safe and Efficient Tool Clamping

The Safe-Lock principle can be explained as follows: spiral-shaped grooves are ground into the cutting tool shank, which have the same angle like that in the tool. In combination with special EDM form closed drive keys in the tool holder (shrink fit chucks, collet chucks or also hydraulic chucks) the grooves prevent the cutting tool from twisting or being pulled out of the chuck during extreme machining, which causes very high costs when producing expensive work pieces.

The combination of pull out protection and high runout accuracy leads to less vibrations and very efficient metal removal rates. With this it is possible to increase the metal removal rates significantly by increasing the cutting depth and the feeds. In addition tool wear will be reduced.

Glätzer CEO Daniel Rautenbach (on the right) and Manager Ingo Schulten are continuously extending the use of HAIMER shrinking technology, with and without Safe- Lock™: »To us the switch to Safe-Lock™ seemed obvious, like using an electric starter instead of a crank to start a car.

Picture: Haimer

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IMPRINT

COMPANY INDEX Ace Micromatic

24

Aerotech 12 Anuga Foodtech 2018

47

Balluff 13 Baumer 31 BIT 46 Bosch 25 Carl Zeiss

38-39

Celos 45 Danone Waters De Dietrich Deckel Maho DMG Mori

37 14-16 43 42-45

Elesa + Ganter

18

Emo Hannover 2017

33

EMO 48-55 Evian 37 eWon Business Unit

17

EWS 41 Genau 34-35 Haimer

68

HMS Industrial

17

Huron 29-30 Ingyu 60-62 Interroll 36-37 Jyoti CNC

28-30

Kennametal 40-41 Magal 60-62 Maini Materials Movement Maini Precision Products Marshall Aerospace

26 20-27 20

Nord 46-47 Oderfox 34-35 Poddar 64-67 Renishaw 58 Safran Aircraft Engine

20-21

Schuler 56-57 Seco Tools

67

Tachyo 30 Unitech Metal Forming

60

VDMA 32 VDW Volkswagen Passat

33, 51 57

Zeiss 24

ADVERTISERS INDEX C G Tech DMG MORI Dynamic Manufacturing India Machine Insider Magal Engineering Co India

7 72 9

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Contact: +91 9324240965 CIN No: U74999MH2016PTC287532 Volume 2–Issue 2 Printed by Meshmix Media Private Limited, India Disclaimer: All the content and views expressed in this magazine are those of contributors and appointed agencies from various organizations and brands and is the sole property of the publisher.

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