Volume 05 No. 04 | September 2019 | ` 150
Pages 122 | RNI No. MAHENG/2015/64267
Parting & Grooving Miniature Master Threading
Parting & Grooving
Profiling
Parting & Grooving
Pentagonal Insert with 5 Cutting Edges for Grooving & Parting Miniature Parts Next to Shoulder
For Grooving, Parting, Turning & Threading Application
For Every Type of Material
MACHINING
Innovative
INTELLIGENTLY
Back Turning
Cost Effective Insert
Left & Right Insert Widths: 0.25 – 3.18mm (.01” - .125”)
DUSTRY 4.0
Phone: +91 77009 6370
Email: Sales@iscar.in
Website: www.iscar.in
Whatever industry sector you’re in? Aerospace, Automotive, Electronics, Medical or woodworking
ANCA Machine Tools Private Ltd 8/1 , Dr. M H Marigowda Road, Arekempanahalli , (Wilson Garden ), Bangalore - 560027, Karnataka, India T: +91 (80) 6759 2100, M: +91 96637 6991 E: indiainfo@anca.com
anca.com
linkedin.com/company/anca
CEO CORNER
Publisher & Printer Shirish Dongre
CEO Shekhar D.
Editor
Machine Tools : Making in India dream come true
Shilpa Dongre
Assistant Editor Shweta Nanda
Marketing Team Ladoji Pendurkar, Amol Powle, Bhavin Shah, Bharat Shah, Vinod Surve, Kamlesh Balkrishna, Hiren Shah
Online Marketing Kailash P.
Print & Online Division Arun P. Shinde, Nandan S. Moghe, Ganesh B. Mahale, Dinesh S. Gawade
Online Division Ganesh Mahale
Circulation Executive Satish Kadam, Amol Ranshur Branch Offices (Zonal)
NORTH (Delhi & NCR regions) Sandesh Jain : 09810837877 / 09871602777
SOUTH (Chennai & Coimbatore) Y. V. Raghu : 09566141224 Bangalore E Vikram : +91 9591488434 Vaman : +91 9686721340 Hyderabad E Vikram : +91 9591488434
EAST
WEST (Maharashtra & Gujarat) Pune Kuldeep Kshirsagar - 09689403523 Nashik Abhijit B. Joshi : 09890002333 Rajkot (Saurashtra) Swapnil Bhatia: 09227909005
Head Office : Divya Media Publications Pvt. Ltd., 3rd Floor, Harmony Tower, N.S. Road, Thane-400 602. Maharashtra Tel: +91 22-25380574/75, Telefax: +91-22-25418254 E-mail: shekhar@divyamediaonline.com Website: www.mtwmag.com Printed & Published by Shirish Dongre on behalf of DIVYA MEDIA PUBLICATIONS PVT LTD., Printed at Anitha Art Printers 29/30, Oasis, Next to Vakola Market, Santacruz(E), Mumbai-400055, published from 303/304, Harmony Tower, N.S.Road, Court Naka, Thane West, Thane-400601. Editor : Shilpa Dongre
MACHINE TOOLS WORLD
Our ability in machine tools. As a matter of fact, machine tools industry is at the core of manufacturing and the future strength and capability of the Indian manufacturing industry is closely linked to the growth of the machine tools industry. Machine tool industry is the mother industry for any manufacturing activity. By and large all manufacturing processes require machine tools directly or indirectly. Thus, the machine tool industry will play a significant role in making Make in India truly successful. The fact that both manufacturing and machine tools go hand in hand becomes evident with the fact that the world’s top manufacturing destinations are also producers of high-accuracy and sophisticated machine tools. Machine tools are a major cornerstone in the economic development of any country and are reflective of the engineering progress that it has achieved. This is confirmed by the fact that Germany and Japan are often counted among the world’s leading engineering hubs, on account of the technological sophistication achieved by their machine tool industries.
(Kolkata & Other regions) Amol Powale - 09820488541
6
Machine tools are at the core of manufacturing— without a powerful machine tools segment, manufacturing excellence cannot be achieved. Thus, India’s vision to emerge as a global manufacturing hub is closely linked to its capability in machine tools. With the government’s push on ‘Make in India’ campaign, the international spotlight is on the Indian manufacturing sector. As the manufacturing sector ramps up to close its gaps to emerge as a global manufacturing hub, there is one factor whose significance can’t be overlooked in manufacturing’s success.
SEPTEMBER 2019
So, how is Indian machine tools industry placed currently to play its role as a catalyst in realizing the country’s manufacturing vision? If we look at industry reports and findings, past few years have been encouraging for the Indian machine tools industry, which is slated for further growth in the coming years. The fact that machine tools industry is majorly dependent on the domestic market and that too automotive segment is the biggest bottleneck in its growth. To establish India as a brand globally, we need to produce high-accuracy, niche machine tools for a wide range of industries.
CEO www.mtwmag.com
Hanover, 16/09 – 21/09/2019
HALL 2 NORTH ENTRANCE
45 HIGH-TECH MACHINES
AUTOMATION DIGITAL 29 SOLUTIONS >30 INNOVATIONS
EMO.DMGMORI.COM
CONNECTIVITY COMPLETED
ADDITIVE MANUFACTURING
Contents
SEPTEMBER 2019
COVER STORY
Micro-Epsilon: Integrating precision with smart miniaturization
44
Pragnesh Mori, M.E MBA Regional Sales Manager - North Micro-Epsilon India Private Limited
BUSINESS NEWS
20
IN FOCUS
INDUSTRY SPEAK
48
52
WOMAN WELDING COMPETITION – Season 2
22
EMO 2019: Gleason to showcase latest technologies for cylindrical and bevel gears
24
Elgi subsidiary Pattons opens a new office in Los Angeles
30
Autodesk University India 2019 to showcase the potential of automation
AMT SECTION
57
32
The JUNKER Group to showcase futureoriented solutions for precise and intelligent processes at EMO Hannover
34
Renishaw to showcase its smart technologies at EMO Hannover 2019
42
Access to Success – The new access-series from GROB 8
MACHINE TOOLS WORLD
SEPTEMBER 2019
59
63
64
Improve Your Productivity with Streamlined Manufacturing
www.mtwmag.com
Contents
SEPTEMBER 2019
TECH TRENDS
68
74
Faccin technology to support the production of natural gas pipelines
Precise sensor technology for machine tools
72
88
82
90
Drake External Thread Grinders
CASE STUDY
112
114
Developing unique products to meet rail demands
Automated workpiece set-up boosts forestry equipment manufacture
PRODUCTS SHOWCASE
117
KING CUT PRO – The Large Gantry Type CNC Cutting Machine
10
MACHINE TOOLS WORLD
118
Poly / Cotton Knitted Seamless Gloves with PVC Dots
SEPTEMBER 2019
118
Steady Volt Servo Voltage Stabilizers
119
Automatically Accurate Proportioner
www.mtwmag.com
Editorial Board
Editorial Index A
KinefacÂŽ Corporation
Ador Welding
52, 117
Allied Machine
59
Autodesk
30
B
Components Mr. Arun Mahajan General Manager AMT- The Association For Manufacturing Technology
Mr. A.P. Jayanthram Ex-Managing Director, Heidenhain India
Mr. GK Pillai Managing Director & CEO Walchandnagar Industries Ltd
24
Birla Precision Technologies
80
DOLD Electric
119
Dormer Pramet
112 72
E
Mr. Arjun Prakash Managing Director Effica Automation Ltd.
Ms. Samina Khalid Marketing Manager Renishaw Metrology Systems Ltd.
Elgi Equipments
24
ExxonMobil Lubricants
48
Mr. Rupesh Paparaju Director,
F
Bettinelli Automation Components Pvt. Ltd.
FACCIN S.p.A.
68
Association of Ludhiana Machine Tool Industries
Sanjay Tools & Adhesives
Summit 2019
32
O OPEN MIND
90
R
ROLLON INDIA
34, 114 102
S Steel Plant Specialities 119
22
Suzhou Haller
GROB
42
U Unity Controls
82
J
Machine Tools Manufacturers Association - Rajkot
44, 74
N
Gleason
ISCAR India
Mr. Suhas Belapurkar Director - Sales & Marketing ( Industrial Products)
64
Superslides & Ballscrews 94
I
Mr. Sushil Kumar General Secretary
118
Mastercam
Renishaw
G
Mr. Yogin Chhaniara President
Marvel Gloves
National Productivity
D
Drake
M
Micro-Epsilon
Bettinelli Automation
63
JUNKER Group
32
88
118
W Walter Tools
100
Z
K Kemppi India
20
ZECHA Precision Tools 106
Contact : For editorial contribution E-mail: shweta@divyamediaonline.com For advertising material E-mail: advt@divyamediaonline.com
Mr. P.K. Balasubbramaniian President VBS Corporate Support
12
Mr. B.P. Poddar Vice President - Sales & Marketing FEMCO Fatty Tuna India Pvt. Ltd.
MACHINE TOOLS WORLD
SEPTEMBER 2019
Mr. Jayant Vaidyanathan VP - Sales & Application Tsugami Precision Engineering India Pvt. Ltd.
For accounts E-mail: accounts@divyamediaonline.com For online advertising E-mail: ganesh@divyamediaonline.com
www.mtwmag.com
"The most preferred Steel Plant maker up to 1 Million Ton / Annum”
®
ERF & ELdFOS
®
®
For Dephosphorization and Desuphurization
Dephosphorization up to 105 points (0.105%)
®
ENGINEERING & PROJECTS DIVISION
®
Guidance by the Advisory Board of industry stalwarts Mumbai has the Proximity to major manufacturing hubs
WHO SHOULD EXHIBIT
Filtered Audience from Southern & Western Regions of India Holistic Marketing Activities across all media targeting the right Visitor Profile Meet existing and new potential customers
Metal Forming, Presses, Press Brakes & Welding Machines
Metal Cutting Machines & Cutting Tools
Engaging demonstrations, live displays, technical seminars & workshops
Metrology and Measuring Equipment’s
FOR PARTICIPATION, PLEASE CONTACT: EDM, Laser Cutting and Waterjet
Automation & Robotics
Manufacturing Technology & Electronics Accessories
SUPPORTED BY
OFFICIAL MEDIA PARTNERS
...and many more
OFFICIAL ONLINE MEDIA PARTNERS
MEDIA PARTNERS
ONLINE MEDIA PARTNERS
SUPPORTING ASSOCIATIONS
TRAVEL PARTNER
Precision Machines.
Repeatable Results.
Precision Grinding. Repeatable Results. We are Drake Manufacturing. We are a full service, turnkey manufacturer of precision CNC machines and provider of engineered solutions. Founded in 1972, Drake is headquartered in Warren, Ohio. The premium Drake brand is known around the world for innovation and process expertise throughout the thread grinding industry. WWW.DRAKEMFG.COM Contact our Local Representative MR. ALOK NAIK, alok@empiremt.com TEL. NO. 2493 7340 / 2494 7066 / 2497 3184 | FAX NO. 2496 2380 sales@empiremt.com EMPIRE HOUSE, GROUND FLOOR 414, Senapati Bapat Marg, Lower Parel, Mumbai – 400 013 BRANCH OFFICES: Delhi, Chennai, Bangalore, Hyderabad, Kolkata, Pune, Nagpur
Hard-fine machining centre
ML 235
Higher precision, lower costs • Complete machining with reduced unit costs • Freely configurable work chamber for combined hard-fine or simultaneous machining • Integrated bore hole honing for maximum surface requirements • Optimised accessibility for simple tool changing and easy cleaning
Curious to learn more?
CONTACT US: NEMADE ENGINEERS PVT. LTD. Plot 16, Gat 605/2, Mukaiwadi Road, Pirangut, PUNE - 412115 INDIA Phone: +91-20-679-20500 Email: mail@nemade.in
Hall 17 / Booth C46
Hard-fine machining in the BUDERUS combined process
INTERNAL GRINDING
THREAD GRINDING
EXTERNAL GRINDING
SHAFT GRINDING
BORE HONING
HARD TURNING
Combination processing – a key to efficient production
Modular automation cells – compact, productive The loading options of the ML235 are modular, too. Standardised automation cells with rotary magazine, cage stacking magazine or linear automation for manual loading or process supply of up to two production cells with components. Raw parts and machined parts are always completely separated without a risk of mix-up. Traceability through consistent batch management is a matter, of course.
BUDERUS solves complex tasks such as gear wheels from passenger car gearboxes, the functional surfaces of which have to be machined to precise dimensions as quickly as possible, using the modular principle. Thus external and internal grinding can take place simultaneously. The front and rear faces are turned and, if necessary, the bore hole can also be honed in the same clamping.
Configuration examples
Find out more: www.buderus-schleiftechnik.de
BUSINESS NEWS
WOMAN WELDING COMPETITION – Season 2 It has been proven beyond doubt that women are not secondary to men in any area of work. Men dominated areas have been taken place by women considerably. Skilled trades and industry have witnessed the excellence of women involvement. As manufacturing is experiencing a renaissance it is needless to say that women in welding is on the rise. Welding is a promising industry; woman can switch into boldly in the present scenario of technological growth even though it had been labeled under non-traditional occupation to women a couple of decades ago. The complexities in handling the tools and equipment have been reduced considerably with the advent of modern technology. Technically qualified women can supplement to the demand of welding industry as it faces shortage of skilled workers. The contribution of KEMPPI in offering a privileged space to women welders is appreciable. Nowadays women are more fascinated towards skilled trades like welding, behind which the role of KEMPPI is not less. KEMPPI has opened a fascinating arena before passionate women welders. The introduction of easily operating welding 20
MACHINE TOOLS WORLD
materials by the company has replaced the old technology in welding and ensured personal protection. Women welders are most welcomed by the company to excel men to play a commendable job. Welding offers flexible hours and travel opportunities. It can be an excellent choice to women. Welding offers women an opportunity to increase their salary and job prospects in a field that is steady and growing. In terms of education, getting the necessary training to become a welder is significantly less timeconsuming as well as less expensive. Women currently make up only 10-15 % percent of the manufacturing workforce, therefore there is a good deal opportunity to take advantage of an excellent career opportunity.
SEPTEMBER 2019
With the right skills and experience, a woman can find herself in demand, with more choices than before. To stand out in the industry they should become knowledgeable as it is a critical job which should be flawless. Women can be more precise in dealing with the welding tools. Woman Welding competition 2018 was a grand success with the huge crowd support. Women Welders from different domains participated in the competition. “We had participants from Mahindra and Mahindra, GE India, Reliance Naval Engineering and many other industrial giants. The event was elevated to National attention by the media coverage done by The Hindu, The Indian Express and many
other media channels,” says Rashmi Mohapatra, Managing Director, Kemppi India. “Kemppi India and its Premium Partner NextGen Plasma are proud to announce the Woman Welding Competition 2019 beginning in the month of November 2019. This time the event is going to be held in Pune, Delhi, Kolkata and Chennai. The National final competition will be held in Kemppi India, Chennai. We look forward to the participation of young talents across the country and we want more and more women to come forward and select welding as a career,” declares Mohapatra.
www.mtwmag.com
CAMSHAFT GRINDING
Lean Selection cam The Lean Selection cam is an economical and flexible machine concept for grinding camshafts in any lot size. The wheelhead can be fitted with up to two high-capacity grinding spindles, and the swiveling B-axis allows parts to be rough and finishground in a single clamping set-up. The Lean Selection cam CBN non-cylindrical grinding machine features userfriendly controls, minimal processing times and a high rate of availability.
www.junker-group.com Erwin Junker Maschinenfabrik GmbH India Branch Office Office No. 805, Deron Heights Baner Road Pune 411045 India +91 20 27293403 info@junker.in
JUNKER PREMIUM-SERVICE: Guaranteed servicing Fast and competent 24 hours a day, 7 days a week Worldwide servicing network
BUSINESS NEWS
EMO 2019: Gleason to showcase latest technologies for cylindrical and bevel gears At this year’s EMO show, Gleason Corporation will showcase a wide array of new design, manufacturing and inspection technologies for cylindrical and bevel gears. Highlights include: world’s first Power Skiving Machine with Integrated Sharpening, new Chamfer Hobbing Technology, Hard Finishing of Gears in the Closed Loop, the new Gear Honing product line and the latest release of KISSsoft Transmission Design Software. The market leader will demonstrate the current KISSsoft® Release 2019 with numerous new highlights: Among other things, “KISSdesignTM”, an instrument that allows intuitive concept design at system level, is now available. SKF and KISSsoft have also created a new interface
22
MACHINE TOOLS WORLD
to simplify the gear development process. This interface enables engineers to perform calculations using the latest bearing data from SKF via a direct connection to the SKF cloud. The manufacturability for Power Skiving can now also be evaluated in KISSsoft. After generating a special report with workpiece and tool data, this report can be transferred to Gleason if required, which makes data exchange between the designer and the tool supplier much easier
SEPTEMBER 2019
and less error-prone. The interface between GEMS® and KISSsoft provides an exchange of gear and system information between the two software packages. This allows the user to realistically evaluate and optimize every type of spiral bevel and hypoid gear - with a Closed Loop between the design and manufacturing software. The latest edition to the Genesis® Gear Hobbing Machine family combines the state-of-the-art technology in gear hobbing with newly developed Chamfer Hobbing, which produces precise chamfers according to customer specifications, while minimizing tool cost-per-piece. Gleason will also demonstrate live the seamless integration of tool and machine workflows, reducing manual data input and minimizing input errors, tracking every aspect of tool information from supplier to machine, to crib, to sharpening, to end of tool life. It will also showcase the World’s First Power Skiving
with Integrated Tool Sharpening. The 300PS Power Skiving Machine is wellsuited for soft cutting and hard finishing of cylindrical internal and external gears. The 300PS is now available with a brand-new feature, which premieres at EMO: the integrated Tool Sharpening functionality for spur and helical cutting tools, enabling continuous gear production without frequent tool change at consistently high quality, while greatly reducing both, tool cost-perpiece and tool inventory. The 300PS is “Closed Loop ready”: it can directly interface with Gleason GMS® Metrology Systems for seamless data transfer and automatic corrections. It will also demonstrate closed Loop, high accuracy and excellent surface finish with the Genesis 260GX Threaded Wheel Grinding Machine. The GX series takes gear finishing to a new level, with features like twist-control and polish grinding as well as integrated automation and software-guided single tool setup. The machine comes “Closed Loop ready”: interfacing directly with the Gleason GRSL Gear Roll Testing System with Laser Technology for fast, reliable, automatic data transfer and corrections. Website: www.gleason.com.
www.mtwmag.com
FACCIN GROUP
MORE PRODUCTIVE METAL FORMING WITH CNC AUTOMATION WIDE RANGE & TAILORED SOLUTIONS
Industry 4.0 Compliant
The Trusted Partner in Metal Forming Machines SWEDISH DESIGN, ITALIAN ENGINEERING
BIG-CAPACITY CNC-CONTROLLED ANGLE ROLLS | R SERIES
HIGH-PRODUCTION CNC-CONTROLLED PLATE ROLLS WITH ROBOTIC ARM | HCU SERIES
Check out our latest developments at
16-21 SEP
17-21 SEP Stand
3H A230
Hall
Stand
16 D17
Hall
HIGH-PRECISION CNC-CONTROLLED DISHING PRESSES | PAO SERIES
Faccin S.p.A. is a powerful group that combines a number of leading brands – Faccin, Boldrini and Roundo - in plate rolling, profile bending and dished-heads lines. Using the synergies provided by each brand, technically and commercially, Faccin is able to offer an even wider range of options and tailored solutions in the metal forming market.
BUSINESS NEWS
Elgi subsidiary Pattons opens a new office in Los Angeles Elgi Equipments (BSE: 522074 NSE: ELGIEQUIP), one of the world’s leading air-compressor manufacturers, recently announced that Pattons, its US-based subsidiary and a leading distributor announced the expansion of its services to Los Angeles, California. In addition to offering compressed air products, parts and services, the new office will also serve as ELGi’s West Coast distribution center, adding to ELGi’s ability to better serve distributors and customers across North America. The company has previously established offices in North Carolina, South Carolina, Georgia, Alabama, and Virginia. “We are excited to announce the opening of
our Los Angeles office,” said David Puck, President of ELGi North America.“Los Angeles represents one of the most significant markets in the United States and by entering it with Pattons, we will provide the local customer base with our best-in-class products and services. This new branch will help drive further brand awareness and adoption of ELGi compressed air systems in the California market.” Malcolm Lindsay, Senior Vice President of ELGi’s Industrial Division, added “In addition to serving the greater Los Angeles market, our new location will also serve as an ELGi distribution center enabling us to better address the West Coast compressed
air requirements while ensuring enhanced customer service and responsiveness levels.” Since 1945, Pattons has successfully met compressed air needs across a wide variety of industries with reliable, efficient compressed air solutions ranging from air compressors, vacuum systems, and air accessories. In 2012, ELGi Equipments Limited entered the USA market and acquired Pattons. ELGi, a global compressed air manufacturer with over 2 million installations across 100 countries, aims to become the secondlargest compressed air manufacturer in the world by 2027 and has made significant investments in
the USA. Over the past six years, ELGi has witnessed double-digit growth in the USA market, winning distributors and customers over with energy-efficient products backed by responsive service. As ELGi’s top distributor, Pattons plays a crucial role towards ELGi’s growth aspirations. With the US-Canada oillubricated market growing at approximately 2% annually, Pattons strategic expansion to the West Coast will enable them to deliver best-in-class systems and service to compressed air customers across the region.
For more information Web: www.elgi.com
Bettinelli’s High Precison Link Conveyors: A range in constant evolution Cam Driven Systems (CDS), a division of the Bettinelli S.p.A. group, has come up with the widest range of positioners, rotary tables and cam mechanisms for the automation processes. CDS Precision Link Conveyors TSL, TL and TXL provide the industry’s highest accuracy and repeatability for automated assembly and manufacturing machinery platforms combined with the highest dynamic performance available on the market. The precision link conveyor TL series has been designed to meet 24
MACHINE TOOLS WORLD
SEPTEMBER 2019
combined with excellent precision and speed, with a high degree of versatility to offer customers the most suitable solution. They are used on machines that require stability, precision, high speeds and low maintenance. They are different in terms of body width, allowing great flexibility and a more accurate choice during the designing phase.
the requirements of high productivity and reliability of modern automation,
The need of the market and customer orientation, added to the desire of CDS to expand & improve its product www.mtwmag.com
BUSINESS NEWS range has brought new innovations to the TL series: TSL 200 : In TL 200, the depth of the body has been reduced, with the same stroke, with a consequent reduction of the gearwheel diameter and a better ratio with the driver unit and a better positional accuracy. This makes the machine far more compact and it is a great advantage to the machine builder. Plastic Protections: In the TL range, the plastic protections have been studied to be applied on pallets in order to guarantee an antiintrusion covering for the components
being processed. These covers are printed in 3D. Special Links Chain: Together with the plastic protections a new links chain has been developed. The latter is equipped with special seals to reduce the accumulation of powders or abrasive material during the process and increase the protection of leads and bushes. In a nutshell, following are the salient features of these conveyors: • Versatile and compact modular-component design
• Precision machined cast iron chemical-nickel plated links • Precision chordal compensation cams • Cam Driven for fixed indexing motion or servo driven for flexible positioning The competitive price and fast lead time together with CDS quality and reliability make this series very attractive for the market, says Rupesh Paparaju, Director, Bettinelli Automation Components Pvt. Ltd., based in Pune. For more information, Website: www.bettinelli.in
Autodesk University India 2019 to showcase the potential of automation Autodesk’s annual flagship event Autodesk University India 2019 (AU India 2019) was held for the second time in Bengaluru on 5th September 2019. The sixth consecutive edition of the event in India showcased the role of automation in the Future of Making, fueled by modern technologies like generative design and building information modelling (BIM). AU India 2019 brought together product designers, engineers, architects, planners and other professionals in the ecosystem to provide them hands-on experience with the technologies shaping their industry and how they can adapt to it. “The manufacturing, construction and infrastructure sectors in 30
MACHINE TOOLS WORLD
India are going through a paradigm shift, fuelled by innovations such as generative design, robotics, BIM, additive manufacturing, VR/AR and more,” said Haresh Khoobchandani, Vice President, APAC Territory Sales at Autodesk. “AU India 2019 presents our customers, partners, and industry leaders with the opportunity to learn and experience these technologies first-hand, empowering them to grow their businesses and develop innovative responses to critical business and societal challenges of the day.” This year, AU India 2019 featured a mix of global experts from the architecture, engineering, construction,
SEPTEMBER 2019
manufacturing, media and entertainment industries, who demonstrated how they have implemented leadingedge technologies in their respective sectors. Autodesk also hosted an educator’s roundtable on “The Role of Technology in Education for NextGen Engineers” at the event. • Aether Energy showcased the use of Autodesk technology to design their flagship electric vehicle, the Aether 450. • Social Hardware demonstrated the application of Autodesk generative design technology in developing low-cost medical prosthetics. • Jendamark Techcellency expounded on the role of automation in the automotive sector and
industry stalwart TVS Motors led a discussion on how Digital Factories are shaping the Future of Manufacturing in automotive industries. • Total Environment showed how technologies like Building, Information, Modeling (BIM) can expand customer choice in real estate to build a house customized to their preferences. • Green Gold Animation showcased how they used media and entertainment software from Autodesk to create the iconic Chotta Bheem in 3D.
For more information Website: www.autodesk.com
www.mtwmag.com
Shaping the future. Together.
Two world leaders in industrial process fluids, Quaker Chemical and Houghton International, have come together as one company to keep our metalworking customers ahead in a changing world. As Quaker Houghton, we are proud to partner with metalworking industries around the world that are driving a sustainable, more prosperous future. We work with your teams to deliver expertise, service, and advanced technology related to industrial process fluids.
quakerhoughton.com ©2019 Quaker Houghton. All rights reserved.
BUSINESS NEWS
The JUNKER Group to showcase futureoriented solutions for precise and intelligent processes at EMO Hannover The JUNKER group with the JUNKER, LTA and ZEMA brands are showcasing their extensive product portfolio at the EMO 2019 in Hannover. With its 2.200 exhibitors from 44 countries, the globally leading expert trade show for metal working that attracts more than 130 000 industry experts. “Flexibility, digitalization and an increased competition for innovation are the topics that concern our customers as well as us”, states JUNKER CEO Rochus Mayer. The requirements to the JUNKER Group from the various industries are essentially the same: smaller tolerances, better surfaces, shorter production times and fast reactions to product changes. “Our experience and innovative spirit help us to realize new and viable solutions for these sectors and to deliver the grinding technology of the future!” The JUNKER Group has been well known in the grinding industry for decades. Whether cylindrical or non-cylindrical grinding, OD or ID grinding: The extensive product
JUNKER Group grinding specialist
JUNKER Group Service Network
portfolio of the technology leader offers grinding machines for each task, batch size and requirement. “Our customers from the mobility or consumer goods industries, for example, face ever new challenges: CO2 reduction, alternative drive systems and constantly increasing regulations. We are responding with innovative power, precision and experience”, said Mayer. As grinding specialists JUNKER and ZEMA develop and produce concepts and solutions for individual and complete grinding in one clamping as well as for complex production lines. All workpiece geometries and sizes can be ground on JUNKER Group machines. The proven variety of
standard machines is complemented by customized special solutions. LTA Filtration systems for suction and cleaning of coolant mist supply an efficient and sustainable air cleaning in the production plants of the metalworking industry. Dust filter, piping, fire protection systems and central suction systems complete the support by the specialist for clean air. Whereas Hall 11, booth B78 showcases the newest highlights by JUNKER and ZEMA, expert visitors have the possibility to view solutions for industrial filter systems by LTA in Hall 7, booth A16. For more information, Website: www.junker-group.de
NPS 2019 showcases innovation in manufacturing; attracts over 300 delegates The 13th edition of National Productivity Summit (NPS 2019) was held on 20 - 21 August 2019 at Bangalore International Exhibition Centre (BIEC), Bengaluru. The summit featured preevent plant visits, keynote addresses, case study pres32
MACHINE TOOLS WORLD
entations and productivity championship awards. NPS 2019 attracted over 300 delegates from 130 companies and concluded successfully on 21 August. The summit was inaugurated by Bhaskar Bhat, Managing Director, Titan
SEPTEMBER 2019
www.mtwmag.com
Make Every Second Count New Gleason P90iC and P90CD Hobbing Machines with parallel or sequential chamfering/deburring are your solutions for high-volume production of precision gears and shafts. Available with integrated automation – all from one source. www.gleason.com/everysecond
Š Gleason Corporation. All rights reserved.
BUSINESS NEWS Company Limited. Bhat in his opening address spoke on ‘Impact of Productivity on India’s Manufacturing Competitiveness’. At a special session for CEOs, T.V. Mohandas Pai, Chairman, Manipal Global Education delivered his address on ‘Winning in the Digital World’. This year’s edition featured 3 keynote speakers who delivered their keynote addresses: • ‘Adopting modern manufacturing technology to enhance productivity’ by G. Parthipan, CEO, Rane TRW Steering Systems • ‘Innovation as a powerful tool to enhance productivity’ by Dr Babu Padmanabhan, Managing Director and Chief Knowledge Officer, Steer Engineering
• ‘Thriving in the era of disruption – How organizations stay afloat’ by Sandeep Kumar Maini, Chairman, Maini Group This year, the summit received over 150 case studies from which 11 were shortlisted. Eight large companies: Godrej & Boyce Manufacturing, Carborundum Universal, Bosch, Rane TRW Steering Systems, SAAB Engineering, Bharat Heavy Electricals Limited, and Mahindra & Mahindra presented their case studies.
The summit also featured case study presentations from 3 SMEs: Gala Precision Engineering, Khutale Engineering and UCAM. At the summit, winners of the IMTMA-ACE Micromatic Productivity Championship Awards 2019 were announced, the first prize went to Mahindra & Mahindra for ‘Reduction of specific Carbon footprint by using Waste to Wealth, TPM and Industry 4.0 concept in the utility management area, second Prize went to Bosch
Limited for ‘Innovative approach using Mould flow analysis for productivity improvement in Common Rail Pump Housing’; and third prize went to Godrej & Boyce Manufacturing for ‘Use of Industry 4.0 in manufacturing for resource utilisation and reducing conversion cost’. The SME Productivity Award 2019 was won by Khutale Engineering for ‘Learn and Green approach to layout planning’. Presummit plant visits were organized to Ashok Leyland, TVS Motor Company, Honda Motorcycle & Scooter India, Volvo Trucks, Dynamatic Technologies, and Volvo Construction Equipment which provided a unique opportunity to witness some of the best productivity improvement projects being translated into action.
Renishaw to showcase its smart technologies at EMO Hannover 2019 Global precision engineering and manufacturing technologies company, Renishaw, will be showcasing its smart technologies and intelligent process control solutions across three stands at EMO Hannover 2019 in Germany, 16th–21st September 2019. These include high-speed, multi-sensor measurement systems for CMMs; highaccuracy and high-speed products for machine tool probing; flexible shop-floor gauging systems; new cali34
MACHINE TOOLS WORLD
bration and encoder innovations for machine builders; and new additive manufacturing solutions. The ‘Metrology and Quality Assurance zone’, located within Hall 6, will be home to Renishaw’s largest stand (stand D48). Here, visitors will be able to see Renishaw’s award-winning REVO® 5-axis measurement system in action and discover how it delivers high performance multi-dimensional inspection, including
SEPTEMBER 2019
surface finish analysis. Renishaw’s new OPTiMUM™ diamond styli range will be showcased, which has been specifically devel-
oped for use within metrology applications that require a hard-wearing stylus. The principal advantage of its diamond coated spheres is that they maintain their roundness and do not suffer material ‘pick up’ or premature wear when scanning abrasive materials or soft alloys. This provides multiple benefits including an increased working life and reduction in recalibration and inspection downtime. Renishaw’s latest www.mtwmag.com
BUSINESS NEWS SPRINT™ technology will also be showcased – highaccuracy machine tool probing systems for rapid part set-up and machining process control. With the unique 3D sensor technology within Renishaw’s OSP60 probe, probing systems with SPRINT technology provide exceptional, high-speed, high-accuracy scanning for CNC machine tools. Renishaw will demonstrate its range of highaccuracy machine tool probes with RENGAGE™ technology for workpiece set-up, in-process control and post-process inspection. The latest addition to Renishaw’s range of machine tool probes with RENGAGE technology is RMP400 – a new, ultra-compact and highly repeatable probe that uses radio transmission technology. Each probe in the range is tailored to suit different machine tool sizes and machining applications, combining proven silicon strain gauge technology with ultra-compact electronics to deliver world class 3D performance and sub-micron repeatability. Building on the success of its enhanced NC4 range of tool setters launched at EMO Hannover 2017, Renishaw will launch the NC4+ Blue – its latest evolution of the non-contact tool setter, delivering a step-change in tool measurement accuracy. Compared to red laser sources found in conventional non-contact tool setters, blue laser technol36
MACHINE TOOLS WORLD
ogy (patent pending) has a shorter wavelength, resulting in improved diffraction effects and optimised laser beam geometry. This enables the measurement of very small tools, whilst minimising tool-to-tool measurement errors – a critical consideration when machining with a wide range of cutting tools. Renishaw’s Equator™ shop-floor gauging systems are being used to great effect around the world to measure a vast array of manufactured parts, particularly in the aerospace and automotive industries. They enable intelligent process control of manufacturing cells and lines by delivering highly repeatable, thermally insensitive, versatile and reprogrammable shop-floor gauging. Renishaw will demonstrate the Equator gauging system in use on a range of components and assemblies, including those for electric motors. There will be demonstrations of Renishaw’s machine calibration and diagnostic technologies, designed to monitor the static and dynamic performance of machine tools, co-ordinate measuring machines
SEPTEMBER 2019
(CMMs) and other positioncritical motion systems, to ultimately establish a known and repeatable level of process capability. These will include Renishaw’s new XK10 alignment laser system which has been developed to measure geometric and rotational errors of machine tools. On its stand in Hall 6 (stand D48) Renishaw will introduce its first ever ‘Solutions Bar’. Visitors will be able to ask Renishaw’s team of experts about a variety of process control, metrology products or manufacturing queries, whilst enjoying much-needed refreshments. The Solutions Bar will allow visitors to benefit from Renishaw’s rich experience in developing manufacturing technologies for global industries and it aims to reinforce Renishaw’s role as a proven partner for innovative manufacturing. In Hall 3 (stand E36) within the ‘Precision Tools’ zone, Renishaw will focus on smart manufacturing technologies for the metal cutting sector. Using its machining demonstration cell with automated part loading, on-machine probing and
off-machine gauging, Renishaw will demonstrate how automation, measurement and feedback can deliver process control throughout all manufacturing stages. The cell demonstrates how complementary technologies can contribute, throughout the manufacturing process of a CNC machined part, to achieving high levels of productivity and manufacturing capability. Visitors will also discover Renishaw’s full range of on-machine and smartphone apps which make installing, configuring, using and maintaining probing systems even easier, saving time and maximising shopfloor efficiency through enhanced automation. Extending Renishaw’s smart manufacturing technologies further up the process chain, Renishaw’s stand in Hall 9 (stand I23) within the ‘Additive Manufacturing’ zone, will showcase its latest additive manufacturing (AM) systems and solutions.. InfiniAM Central – Renishaw’s remote process monitoring software for AM systems – will provide ready access to machine data. This Industry 4.0-ready, connected system, enables remote monitoring of AM build processes on computers and mobile devices, including near real-time insights into live AM builds and access to historic build analysis. System sensor and build information is displayed in graphic form to enable intuitive in-depth analysis. www.mtwmag.com
Circuit Identifiers Clamp Meters
Multimeters Power Analyzers
Continuity Testers
Voltage & Current Testers
Motor Rotation & 3-Phase Testers
Ground Resistance Testers
Megohmmeters
Just like the human body, electrical equipment require a complete examination to identify any glitches. Whether the process is of installation, maintenance or repair, Extech’s testers and meters are always up for the task. To ensure smooth operation of your electrical equipment, Extech offers a wide range of test instruments that help you identify a problem before it occurs. For more details call us on: +91-11-4560 3555 or write to us at flirindia@flir.com.hk FLIR Systems India Pvt. Ltd. 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034 Fax: +91-11-4721 2006 | Webiste: www.extech.com
FLIR Puzzle Find Problem & Extech AD 24x18_2019.indd 1
PROBLEMS ARE ALWAYS HIDDEN, AND WE HELP YOU FIND THEM
Problems like unplanned shutdown, overheating of electrical appliances and connections, insulation problems and harmful gas leakages can lead to a major issues and bring an entire production to a standstill. To tackle these problems and to resolve them on time, FLIR brings a wide range of preventive maintenance solutions which help you identify problems before they arise or start to worsen. Include FLIR's state-of-the-art gadgets in your regular preventive maintenance check-up and make your business operations hassle-free.
INDUSTRIAL APPLICATIONS: Electrical & Mechanical | Building Diagnostic Automation | R&D | Gas Detection | Firefighting Test & Measurement
Images for illustrative purposes only.
FOR A COMPLETE HEALTH CHECK-UP OF YOUR ELECTRICAL EQUIPMENT
For more information, please call us at +91-11-4560 3555 or write to us at flirindia@flir.com.hk FLIR Systems India Pvt. Ltd. 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034 Fax: +91-11-4721 2006 www.flir.in /FLIR |
/FLIR |
/FLIR
18/04/19 12:50 PM
BUSINESS NEWS
Access to Success – The new access-series from GROB GROB launches its new access-series, two flexible all-rounders for the universal machining center sector: The new G350a and G550a 5-axis machining centers are a convincingly smart and economic introduction to the unique GROB technology, offering customers from demanding industries virtually limitless applications. And the utmost reliability and high productivity in the renowned GROB quality are guaranteed! The G350a and G550a machine variants offer a number of benefits already familiar to GROB customers from the conventional Gseries. Thanks to renowned GROB 5-axis technology, the new universal machining centers promise the best machining quality for single item and series production. At the same time, the basic models are designed today to meet tomorrow’s part requirements and guarantee maximum efficiency and flexibility with modularly expandable and fully customizable automation solutions. The highlight of the new access-series is its short payback time, yet another benchmark for GROB in machine tool construction. High machine availability is combined with significantly reduced costs. These universal machining centers, then, offer the ideal solution for automobile suppliers and customers from the general mechanical engineering, contract manufacture, tool construction, and also the 42
MACHINE TOOLS WORLD
pump and fitting sectors. “The access machines round out the product range of our G-modules and offer a very attractive entry version of GROB 5-axis machining centers,” explained German Wankmiller, Chairman of the Board & CEO of GROBWERKE. MORE as standard... Even in its standard version, the new G350a and G550a basic models come ideally equipped: thanks to the optimum positioning close to the operating point, a stiff spindle axis guarantees absolute accuracy and precision. Combined with the unique overhead machining technique, the machines allow excellent chip fall and reduce the thermal load in the part. The linear guidance system of the reference axis can be optionally equipped with a temperature-controlled cooling function. There are two control variants to choose from – the SIEMENS and HEIDENHAIN* control systems. The GROB engineers left
SEPTEMBER 2019
nothing to chance when it comes to machine safety either: a perfect view of the machining process through a laminated glass safety screen available even in the basic version and a wide-opening work area door allow safe access and ergonomic operations. If assistance is ever required nonetheless, the GROB Service team is remotely connected to the machine worldwide 24/7 to offer first-class support. This service is rounded out by a 24-month guarantee. Flexibly adjustable to suit every requirement To take account of the individual challenges and requirements of the various applications down to the last detail, GROB offers various option packages for its new basic models. In addition to the basic machine, which can be equipped with a decentralized work area extraction system and automatic work area door, customers can also select from various options for the tool magazine, cutting fluid
systems, software solutions and other accessories. The automation solutions offered for the G350a and G550a are also impressive: the GROB PSS-R rotary pallet storage system, for example, offers enough space for up to 15 pallets with a small footprint. The facility for a part or pallet clamping system ensures more flexibility and an optional pallet changer meets the requirements for a simple retool during the machining operation. In combination with the customized option packages, the automation solutions ensure optimal part handling and a perfect production process. With MORE know-how garnered from over 90 years experience with machine tools, the new GROB access-series delivers the ideal solution for cost-effective machining of outstanding quality in every sector.
www.mtwmag.com
COVER STORY
Micro-Epsilon: Integrating precision with smart miniaturization Pragnesh Mori, M.E MBA Regional Sales Manager - North Micro-Epsilon India Private Limited
44
MACHINE TOOLS WORLD
SEPTEMBER 2019
www.mtwmag.com
COVER STORY
Q. Tell us about the scale and geographical presence of Micro-Epsilon and the company’s India operations. Micro-Epsilon India will primarily service existing and new customers in the region. Trained in Germany, the sales engineers offer customers first-class support, establishing the presence of Micro-Epsilon in the emerging Indian market. In particular, the diverse product portfolio of the company will have a positive effect on establishing a foothold in the Indian market. Micro-Epsilon offers mechanical, electromagnetic and laser optical sensors, as well as measurement systems for displacement, position, temperature and colour, including a range of Ethernet-capable measurement systems. Q. In your view, what are the latest trends and innovations emerging in the high-precision measurement segment? Micro-Epsilon focuses on highest precision, miniaturization, smart signal processing and easy integration into machines as well
www.mtwmag.com
as data transmission via state-ofthe art interfaces. In addition to the technology, application consulting and support for the implementation of the measurement task are essential. Micro-Epsilon’s state-ofthe-art sensor technology optimizes and accelerates manufacturing processes while realizing 100% quality assurance and significantly reducing costs. In addition, further use of predictive maintenance enables to avoid repairs, reduce failures, plan maintenance cycles and save process data. Whether it is in wind power plants, the world’s largest E-ELT reflecting telescope or robotic production processes Micro-Epsilon sensors provide highprecision, reliable and process-stable measurement results. Q. Comment on how the demands of Indian customers have evolved over time. How is Micro-Epsilon meeting these requirements/ expectations to ensure customer satisfaction? Partnerships are essential in achieving such high levels of excellence. Continuous development
efforts, extensive know-how and a wide cooperation network enable the creation of innovative products. Together with our Indian customers, we develop tailor-made solutions implemented by a team of experts. Decades of experience enable us to consistently extend companyowned research and development capacities. This focus creates application competency in many different industrial sectors. It is due to this comprehensive investment in development that Micro-Epsilon is a technological leader and pioneer in this industry. Q. Tell us about your focus on R&D? Are you undertaking/have plans to undertake R&D initiatives in India? Micro-Epsilon stands for innovative and high precision measurement technology. Apart from this, we specially adapt our sensor solutions to our customer’s applications. Development, production and sales all arise from a single source. This enables us to focus on displacement, distance, position, color & temperature measurements, as well as 3D inspection of mat and shiny surfaces.
SEPTEMBER 2019
MACHINE TOOLS WORLD
45
COVER STORY
Q. Which industry segments do you cater to? Can you share some interesting case studies/application areas? In addition to the technology itself, we use our application know-how to support customers with the implementation of the measurement task. For example in predictive maintenance applications, MicroEpsilon sensors prevent repairs, reduce failures, improve maintenance planning and save process data.
46
MACHINE TOOLS WORLD
SEPTEMBER 2019
Whether for wind power plants or in robotic production processes - sensors from Micro-Epsilon provide highly precise, reliable and process-stable measurement results. Q. What would you describe as your niche? How do you stand out from the competition? The company’s main application areas are machine building and machine design, manufacturing automation and R&D. Continuous development
efforts, extensive know-how and a wide cooperation network enable the creation of innovative, high precision products. The product range of the worldwide operating sensor specialist comprises inductive, confocal chromatic and capacitive sensors, together with laser, eddy current, draw-wire and temperature sensors, including inspection and measurement systems, e.g. for modern 3D surface inspection. Q. What is your future vision and growth plans for India? Experience and flexibility in customer-oriented sensor development will be more and more in demand in times of Industry 4.0 and Predictive Maintenance. The use of intelligent sensors across complete production processes in order to record, interpret, bundle and identify trends in continuous operation, will become increasingly important. “Measuring instead of switching� and manufacturing processes, in which wear and possible faults are detected even before major damage occurs, are gaining in importance.
www.mtwmag.com
IN FOCUS
ExxonMobil™: Committed to improve customer’s competitiveness in a sustainable way Sustainability is no longer a mere choice, but it is now embedded into the very core of every activity, says Shankar Karnik, General Manager, Industrial Lubricants, ExxonMobil Pvt. Ltd. In an interview, he sheds light on the recently launched Mobil DTETM 20 Ultra series, new trends and innovations in the lubrication industry and growth plans for India market. Excerpts Q. As ExxonMobil recently launched Mobil DTETM 20 Ultra series, please elaborate on the benefits of the product. Which key industries does it cater to? The new Mobil DTE 20 Ultra Series is designed for all industries with hydraulic oil applications. The oil is designed to deliver upto 2x longer oil life and exceptional performance in harshest conditions and help industries achieve unprecedented performance goals easily. The new series lowers maintenance frequency, minimizing man-machine interaction, which makes the site safer for industrial workers. The oil also provides improved deposit control of 89.2% for longer oil life and precision operations, & delivers superior wear protection to extend component life. Q. What specific challenges faced by machine shops/manufacturing sector does Mobil DTE 20 Ultra address? Hydraulic systems across industries need maintenance due to both oil and machine factors. As the oil oxidizes with time, deposits are formed causing replacement of both oil and filter. Moreover, often times even valves, pumps and other parts of the machinery wear with age wherein the damaged components require replacement. This maintenance can be reduced
48
MACHINE TOOLS WORLD
SEPTEMBER 2019
and made effortless by using Mobil DTE 20 Ultra as it plays a major role in slowing down equipment ageing and decrease maintenance efforts. Q. According to you, which new trends and innovations will shape the future of lubrication industry and propel its growth? According to a report by Grand View Research, the global lubricants market was 36.36 million tons in 2014 and is projected to grow to 43.87 million tons by 2022, at an estimated CAGR of 2.4%. The emerging growth trends that are expected to propel the demand for lubricants both globally & in India are: High demand from automotive: Increasing demand for lightweight passenger cars and heavy-duty commercial vehicles has fostered global automotive production, which in turn is conducive to the development of lubricants for multiple application in this field. Industrialization: Rapid industrialization in countries like India, China, Brazil, and Mexico has encouraged applications in industrial machinery maintenance, thus driving the lubrication sector Burgeoning Construction sector: Lubricants are extensively utilized
Shankar Karnik, General Manager, Industrial Lubricants, ExxonMobil Lubricants Pvt Ltd
in construction and in infrastructure sectors for hydraulic oil, bearings, engine oil and wire rope applications. In addition to all this, the demand and acceptance of biobased counterparts to reduce harmful environmental effects are projected to boost global lubricants industry demand. Q. Comment on the requirements and challenges related to Indian manufacturing sector. How does ExxonMobil’s lubricants meet these requirements? Tool life and uptime are critical to the success and profitability of the Indian manufacturing industries. ExxonMobilTM invests heavily on research and development to help the sector overcome these challenges.
www.mtwmag.com
G-SERIE
ACCESS TO SUCCESS
SHORT PAYBACK PERIOD
DUE TO HIGH AVAILABILITY AT LOW COSTS
HIGHEST PRODUCTIVITY
THANKS TO MODULAR EXPANDABILITY FOR AUTOMATION SOLUTIONS
BEST MACHINING QUALITY
IN INDIVIDUAL AND SERIES PRODUCTION
SERVICE WORLDWIDE
WITH 24 / 7/360 CUSTOMER SERVICE
GROB MACHINE TOOLS INDIA Pvt., Ltd. Hyderabad, INDIA | Tel.: +91 40 4202-3336 E-mail: info@in.grobgroup.com
access_Serie_A4_India_MACHINE_TOOLS_WORLD.indd 1
www.grobgroup.com
09.09.2019 08:52:28
IN FOCUS
MobilTM lubricants are formulated with product compatibility in mind since machine and machine tool lubricants are often comingled. They are designed to work together and minimize the impact of crosscontamination. In addition to this, we also provide a range of technical services to help keep machine shops running at peak efficiency while also extending machine and oil life, reducing downtime and lowering operating costs. Q. How important is the selection of right lubricant for right applications? How does ExxonMobil assist customers in choosing the right lubricant? We have observed that incorrect lubricant usage – even over usage of lubricants - can severely hamper productivity. For instance, disregarding the manufacturer’s recommendations for any piece of equipment or component could potentially lead to failure of the equipment or affect the machine’s warranty. With usage of lubricant closely linked to varying factors like environmental conditions, speed, load and temperature, getting the usage right is imperative for manufacturers. Whenever a new machine or component is installed, one of the first things to be addressed is the type of lubricant to use. Typically, the equipment will come with a recommendation from the manufacturer, including the directives on viscosity. Base oil viscosity is one of the most important properties manufacturers consider when making a lubricant recommendation. It should take into account the speed, load and ambient temperatures. While this is a great
50
MACHINE TOOLS WORLD
SEPTEMBER 2019
start when choosing a lubricant, keep in mind that the working environment of the component or machine could be outside the manufacturer’s tested parameters. Using the appropriate grade and type of lubricant is essential for proper bearing performance. Failure to choose the right lubricant can lead to shortened bearing life. This is where professionals like Mobil Serv come in with their expertise to give the perfect lubrication solutions. Backed by more than 130 years of lubricant development and a rigorous quality management system, Mobil Serv Lubricant Analysis is trusted worldwide for the integrity and accuracy of our product test data. Mobil’s state-ofthe-art laboratories process more than one million samples every year. The data and recommendations we deliver help customers be more productive and efficient, avoiding costly unscheduled downtime while enhancing safety & environmental care.
Q. What is your future vision and growth plans for India market? We at ExxonMobil aim to develop breakthrough technologies that can benefit business and have a positive impact on society. Therefore, as a company we lay enormous emphasis on ongoing investment in research and development (R&D), working side-by-side with the world’s leading original equipment manufacturers (OEMs). Currently, we follow “India step-out study”, ExxonMobil’s
strategy for the Indian market. We have also stepped up our branding and advertising initiatives. We are growing at a high rate in terms of volume, revenue, products, sectors etc. We have launched a number of products to cater to all the four areas & soon the market will see more. Q. Elaborate on the company’s efforts in the direction of developing sustainable and eco-friendly metalworking fluids. Today sustainability is no longer a mere choice, but it is now embedded into the very core of every activity. At ExxonMobil, our ultimate goal is to improve our customers’ competitiveness through our commitment to being the technology leader with the highest level of application expertise, in a sustainable way. Our innovative products and services help deliver tangible performance benefits in the areas of safety, environmental care and productivity. In terms of safety, innovations in product formulations and services deliver long lubricant life, which can help minimize employeeequipment interaction and mitigate the potential risk of employee injury. Purely in environmental terms, ExxonMobil’s commitment to minimizing environmental impact has created technologically advanced products and services. This is achieved through optimized oil drain intervals, which can help reduce used oil volume and product packaging. Many of our advancedtechnology lubricants lower overall traction versus mineral oils, helping to reduce the amount of fuel or energy consumed while operating, and have potential to reduce energy costs and associated emissions.
www.mtwmag.com
Machine tool probe technology at your fingertips
Whether you are programming, configuring or maintaining your probing systems, Renishaw smartphone apps provide assistance in a simple and convenient format. With touch interaction and intuitive design, our range of apps provide significant benefits to machine tool probe users and integrators. Available globally in a wide range of languages, our free-of-charge apps are perfect for both new and experienced users.
For more information visit www.renishaw.com/smartphoneapps
Renishaw plc New Mills, Wotton-under-Edge, Gloucestershire, GL12 8JR United Kingdom T +44 (0)1453 524524 F +44 (0)1453 524901 E uk@renishaw.com
www.renishaw.com
INDUSTRY SPEAK
Mr. Satish Bhat, Managing Director, Ador Welding Ltd.
Smart Manufacturing Ador’s Perspective “Technology or the access to it is not difficult. However, for our country the priority is to provide employment to the masses. Hence the onus should be on improving specialised skills needed to complement the introduction of smart technologies, and also develop need-based solutions using IOT and other tools. Our approach should be to keep on improving quality while maintaining cost-competitiveness.” Q. What’s your standing and niche in the manufacturing sector? Since its inception (1951), Ador Welding Ltd. (AWL) has played a significant role in the country’s Industrialization and infrastructure development. AWL is a complete welding solutions provider with
52
MACHINE TOOLS WORLD
SEPTEMBER 2019
manufacturing plants located across the country, equipped with latest technologies and efficient processes, to manufacture quality products. Ador Welding (formerly Advani-Oerlikon Limited) is a name synonymous with the welding industry in India for over six and a half decades now. We are widely
www.mtwmag.com
INDUSTRY SPEAK
respected as a pioneer and leader in the welding industry providing the finest Welding Consumables & Equipment, Welding Automation solutions, CNC cutting systems, PPE & Gas cutting products and accessories. The Project Engineering Business (PEB) of AWL is a forward integration of its welding capabilities. PEB manufactures Gas flares for refineries and steel plants, Process Equipment for Petrochemical Industries, Fertilizer and Chemical plants, Heat Exchangers and Pressures vessels, Furnaces for Cremators and Incinerators and has most recently forayed into EPC contracts in India and abroad. AWL, best known as ‘Welders to the Nation’, provides its comprehensive range of products to industries like Automobile, Wind Energy, Thermal & Nuclear Power, Heavy Engineering, Mining, Chemical and Fertilizer, Oil & Gas, PEB, Railways, Defence, Infrastructure and others ensuring the highest level of welding & fabrication excellence. The Skill development Institute, AWA: We also have separate skill development institute “Ador Welding Academy” to enhance skill set of Students, Professionals and trainers. Through AWA, Ador Welding has progressively extended its knowledge and expertise to cover specializations by catering to the most stringent and sophisticated demands of the industry. AWL has evolved with the growing demands of the industry and is India’s largest manufacturer of welding consumables catering to the Domestic market and an International clientele spanning more than forty countries!
54
MACHINE TOOLS WORLD
SEPTEMBER 2019
Q. What’s your definition for Smart Manufacturing? Technologies and solutions which help in optimizing the entire manufacturing process and thus increase overall profits in a manufacturing ecosystem is termed as Smart Manufacturing.
equipment which facilitate predictive maintenance using innovative means, etc. These initiatives have enabled us to increase productivity efficiently while improving quality and lowering downtime. Our competitiveness in the industry is the result of these practices.
Some of the technologies and solutions in the current market scenario include: • Artificial Intelligence • Supply chain management and optimisation • Industrial Internet of Things • Robotics • Predictive maintenance / analytics • Cyber Security
Q. Today everyone is conscious of productivity and operational efficiency while maintaining quality and cost-effectiveness. How do you achieve this in your manufacturing? Smart factories increase output, quality, and consistency using Smart Manufacturing. Additional benefits include,
At Ador Welding Limited, we are constantly investing and exploring how to obtain benefits through the implementation of technologies and solutions which either generate data, accept data, or both. Data analysis helps in making the production process efficient, transparent and flexible. Q. How do you implement Smart Manufacturing in your production set-up? We are perhaps the most digitally advanced company in our segment in the industry. We have smart manufacturing line viz; clean room for manufacturing of welding inverters which gives not only the faster outputs but far better quality as compared to international competition which enables us to offer 3-year warranties on our welding equipment. Manufacturing processes in our consumables plants have also been upgraded with smart layouts, automation in material handling and on production lines, smart process
Streamlined and automated data: Smart technologies automate data collection and provide advanced production analytics, so managers can make more informed decisions. In a smart operating environment, manufacturers can tie their operations technology with business systems to measure their key performance indicators against business goals. Predictive maintenance: With better visibility, manufacturers can predict and resolve maintenance issues before they lead to downtime or product-quality issues. For example, sensors affixed to machines or devices may send conditionmonitoring or repair data in real time, so manufacturers can identify problems more efficiently. Significant cost reductions: Manufacturers can identify waste and increase forecast accuracy when their operations and enterprise systems are connected. They have better insight into supply chain issues, such as inventory levels and
www.mtwmag.com
INDUSTRY SPEAK delivery status, as well as demand cycles. With this information, they can reduce costs related to excessive inventory or unexpected production volume.
greasing arrangement interlinked through PLCs and many more projects have been implemented and at our plants and many more are in progress.
Reduce workforce challenges: Automation helps manufacturers launch and complete projects with fewer workers. Having real-time access to data across multiple platforms frees workers to focus on their core responsibilities. This allows manufacturers to innovate faster without investing in additional resources. Enhanced productivity: Smart, connected systems help factories improve throughput. In a connected enterprise, manufacturers have seamless visibility into bottlenecks, machine performance, and other operational inefficiencies. With this data, manufacturers can adjust, increase yields, improve quality, and reduce waste.
Q. What are the benefits your customers can derive from your Smart Manufacturing, making best use of tools like digitalization, robotics, AI, IoT, etc.? One major benefit of a smart factory is higher levels of customer satisfaction. Smart manufacturing relies upon data. That data comes from a variety of sources: customers, internal data, data generated by connected products, etc. With that information, one can predict demand for the products. One can see if an item is selling well and ramp up production in real time. By the same token, one can scale back production (again, in real-time) of an item that isn’t selling well. One can also ensure flexibility by creating an agile configuration of equipment. It can be easily adapted to manufacture different products. When the configuration is agile, one saves time and money because adapting to new production schedules is less disruptive. Yet another benefit of smart manufacturing is gaining a competitive advantage in a crowded marketplace. When you can work faster, smarter, and more costeffectively than your competitors, you will gain more customers. Automating your factory, as mentioned earlier, allows you to be more efficient. Greater efficiency means you can produce more of a product with fewer resources, making what you produce more desirable to customers. Because you can manufacture products efficiently, you can better satisfy customers. That
Q. What are the initiatives you have taken in your march towards Industry 4.0? Ador Welding has automated several of its manufacturing processes; our clean room with a fully automated assembly line for the assembly of inverter welding equipment; the only such clean room in the country, fully automated ready dry mix flux units that dispense through a fully automated setup very accurately the exact quantities of minerals and alloys of varying densities giving our products unmatched quality, automated spool dispensers, conveyor lines for subassemblies, automated wet drawing lines, QR codes for equipment as we move towards industry 4.O implementation, Automated edge winding equipment, Multipoint auto
56
MACHINE TOOLS WORLD
SEPTEMBER 2019
makes you a valuable commodity in a crowded marketplace. Your competitive advantage allows you to stand out while others struggle to produce items on-time and without cost overruns. Q. What are the global trends in technology in the area of Smart Manufacturing and how do we keep in step with them? Dark factory is a concept that people are looking at today. Companies are going in for totally automatedfactories that will have a 24x 7 hour operations with robots replacing humans completely. Lights will be off and so will the airconditioning or heating. This is being called industry 4.O as in the 4th industrial revolution. IOT will come to the fore in a big way. On the R&D front, AI will help ways in which a better product is designed. Planning and Sourcing will have blockchain projects integrating suppliers, 3D printing, Augmented reality tools usage in manufacturing, 3D printers in manufacturing, Automated vehicles in transportation and logistics, etc. As the western world grapples with lack of skilled manpower and the cost associated with it, automation continues to be the way to go for them. Technology or the access to it is not difficult in today’s day and age. However, for our country while the priority is to provide employment to the masses the onus should be on improving specialised skills needed to complement the introduction of these technologies as also develop need based solutions using IOT and not just keep up but look to be innovative with a ‘horses for courses’ and a strictly need-based approach to keep on improving in both cost and quality.
www.mtwmag.com
AMT SECTION
TECH TRENDS
AMT SECTION LEARN MORE ABOUT AMT’S CHENNAI TECHNOLOGY CENTRE AMT’s Chennai Tech Centre (CTC) is located in the MEPZ duty free zone just 7 km from the Chennai airport. It encompasses an area of 1,500 sq.m., including a 650 sq.m. technology demonstration area. Operational since May 2011, CTC has successfully served as a bridge between the Indian manufacturing sector and American advanced manufacturing technology. To learn more, please contact or visit CTC: AMT - Chennai Technology & Service Centre A 44 - Phase 1, MEPZ, SEZ Unit Tambaran, NH 45, Chennai - 600 045 Tamilnadu, India Phone: (+91) 44-22622690-92 Fax: (+91) 44-22622693 Arun Mahajan General Manager AMahajan@amtonline.org Cell Phone: (+91) 9790887032
WWW.AMTINDIA.ORG
www.mtwmag.com
SEPTEMBER 2019
MACHINE TOOLS WORLD
57
Boring different hole sizes daily?
AMT SECTION
TECH TRENDS
WE HAVE A KIT FOR THAT. Wohlhaupter™ VarioBore, DigiBore, and PrimeBore kits provide versatility for different boring jobs throughout the day. Be prepared for the work tomorrow will bring.
Find your solution. Give us a call today. SOLUTION HUB APP All of Allied All the time. DOWNLOAD NOW
DRILLING BORING
58
REAMING
BURNISHING
THREADING SPECIALS
Email: info.in@wohlhaupter.com | Phone: +91 11 41827044 Holemaking Solutions for Today’s Manufacturing MACHINE TOOLS WORLD SEPTEMBER 2019 www.mtwmag.com www.wohlhaupterindia.in
AMT SECTION
TECH TRENDS
Allied Machine and Wohlhaupter India Launch Newest App – Machinist Tool Smart manufacturing and modern machinists demand quick access to vital information. Allied Machine and Wohlhaupter deliver with a customized app for machining holes. Written by Deborah A. Froelich
W
ohlhaupter India Pvt. Ltd. provides engineering, technical support, and onsite application services within India for Wohlhaupter GmbH and Allied Machine and Engineering Corp., leading manufacturers of holemaking and finishing tooling systems. Together, they announce the release of their most recent mobile app, Machinist Tool, available for download now at both the Apple Store and Google Play. This app is designed for machinists, tooling distributors, and manufacturing engineers working with their tools. Machinist Tool offers easyto-navigate utilities and streamlines operations on the shop floor by mobilizing resources for drilling, boring, threading, reaming, and roller burnishing. Ben Morrett, a senior product manager at Allied Machine, says, “No need to fumble through multiple apps. We created the Machinist Tool app as a one-stop shop to be used in conjunction with all our product lines.” Machinist Tool includes speed
www.mtwmag.com
and feed, as well as trig functional, calculators, G & M machine code definitions, and seven different tap drill charts including the ACME general purpose (full profile), the Unified National, and the ISO Metric – J Series. The app offers hot links to call Allied’s engineers or to find a local Allied tooling distributor if users need technical support. Machinist Tool also includes quick access to GD & T definitions as well as the Boring Insert Selector, a utility that helps machine operators choose the correct insert for each boring application they might encounter. The mobile app compiles a quick reference library their valuable holemaking and finishing resources such as technical guides and operation manuals. Accessible tech guides
include an illustrated pocket reference for threading as well as recommended cutting data for ISO material types like hardened steel, stainless steel, and titanium. Machinist Tool is available for download on both iPhone and Android devices and is available in Chinese, English, French, German, Korean, Mexican Spanish, & Russian.
For more information Email: info.india@alliedmachine.com, info.in@wohlhaupter.com Website: www.wohlhaupterindia.in
SEPTEMBER 2019
MACHINE TOOLS WORLD
59
AMT SECTION
TECH TRENDS
Kinefac® Corporation : The legacy of five decade
K
inefac® Corporation, founded in 1962 to develop cylindrical die rolling equipment, is recognized as a world leader in the development and manufacture of specialized precision metal forming machinery and processing technology to meet the demands of the global aerospace, automotive, energy, medical, power generation and precision fastener industries. The company operates under six separate corporate divisions offering the most advanced CNC metal forming and metal cutting systems with interactive HMI user experience, process control and monitoring features, and fully integrated automatic parts handling systems including robotic and servo-mechanical control. All Kinefac products are designed and manufactured in the United States with high quality parts and workmanship at the 55,000 SQ-FT Kinefac World Headquarters in Worcester, Massachusetts. Kinefac is an ISO 9001:2015 registered company. Kinefac offers a wide range of machinery including CNC and conventional Two-Cylindrical Die and ThreeCylindrical Die High-Precision Rolling Systems under the KINEROLLER™ product to produce precision threads, worms, knurls, splines, and other helical and annular forms at high speed. The KINEFORM™ division provides high-precision cylindrical rolling dies for all makes and models. Additional Kinefac product lines and technology include KINETURN™ CNC CenterDrive Double-End Lathes allowing simultaneous turning operations on both ends of a shaft; KINEXTRUDE™ CNC Double-End and Single-End Extrusion Systems for high-speed forming of solid and hollow precision shaft forms; KINESPIN™ Centrifugal Machinery allowing fluid recovery, chip cleaning,
www.mtwmag.com
and parts cleaning; KINECOIL™ Helical Spring Forming Machinery on the Nano and Macro scale for the medical device and industrial spring industries, and KINEPOWER™ Fluid Power Motion for hydraulic, pneumatic, and other mechanical linear motion devices. The KINEPRO™ prototyping and production services division meets the needs of those customers who desire an outside source for unusual or difficult rolling, coiling, and extrusion operations. Throughout its 56-year history, the continued success of Kinefac has been built on a cohesive team of engineers, designers, assemblers, and supporting staff who are all committed to establishing worldwide leadership in the company’s various niche markets. Kinefac machines can be found operating on all seven continents of the globe thanks to its internationally expanded footprint. The company has sales and service offices in Shanghai-China, Chennai-India, and Monterrey-Mexico through the Association for Manufacturing Technology (AMT) where it has achieved considerable success servicing our global partners. The achievements of Kinefac and its employees have been recognized
by several organizations including the U.S. Small Business Association from which it received the Exporter of the Year Award, and the Massachusetts Manufacturing Extension Partnership which named Kinefac as Small Manufacturer of the Year. Kinefac was recognized by Fastener Technology International with a Technical Achievement Award for innovations in thread rolling. Kinefac received a Certificate of Machine Performance in End User in China. The company is a member of AMT, NCMS, NAM, AIM, PMPA, CASMI and MASS MEDIC Associations. Kinefac Corporation is committed to total excellence and customer service. Please contact us for your precision metal forming and metal cutting needs!
For more information, Kinefac Corporation Phone: 011-91-900-307-5035 kinefac@amtindia.org www.kinefac.com
SEPTEMBER 2019
MACHINE TOOLS WORLD
63
AMT SECTION
TECH TRENDS
Improve Your Productivity with Streamlined Manufacturing
•
D
evelopments in Mastercam Mill target a streamlined manufacturing process. Mastercam® 2020 Mill offers expanded machining flexibility and an increased emphasis on speed and automation. 2D high speed toolpaths, 3D enhancements, and Multiaxis features combine with dozens of additional new enhancements in a software package designed to improve shop floor productivity. Significant highlights and new functionality include: General Enhancements Mastercam’s signature Dynamic Motion™ toolpath has been updated to streamline performance and increase programming speed. Accelerated Finishing™ receives new support for oval form and lens barrel form tools, delivering faster, smoother finishes on select surfaces. Toolpath Hole Definition has been improved, and the Features list displays more information about the selected points, in addition to the type of selection you have made and the diameter of the selected point. 3D Enhancements Mastercam’s Equal Scallop toolpath delivers finish across sloped, curved, and flat surfaces. Now tool tip containment and “Closed” or “Trimmed” toolpath offsets deliver optimal finishes for different types of complex shapes.
64
MACHINE TOOLS WORLD
SEPTEMBER 2019
A new toolpath, Blend, has been added to the 3D High Speed suite of toolpaths. Blend is based on the Surface Finish Blend toolpath but is faster and has a superior quality and includes the use of stock and holder checking. Multiaxis Improvements Deburr can use ball end mills or lollipop undercut tools to break edges for 3- to 5-axis, and to remove burrs. You now have the benefit of fast, automated part deburring using climb or conventional cutting, with more controls for selecting which area of your part to deburr. Hole making is now easier with Toolpath Hole Definition supporting the selection of solid features and lines, in addition to arcs, points, and AutoCursor positions. You can also pick all or some matching diameters and vectors. Port Expert is fast and easy-touse add-on software for creating Multiaxis toolpaths within cylinder head ports, complex tubes, or deep pockets. It is now material-aware, allowing automated programming of remaining stock.
•
•
•
chains, instead of only one per machining region for Dynamic Mill and Area Mill toolpaths, defining different safe regions in which the tool can travel. When dragging geometry from one 3D HST operation to another, the pop-up menu now displays more options for copied geometry. In Swarf Milling, a new dropdown is available for cases where you need to realign the operations orientation from world Z to the WCS, Tool Plane, or Construction Plane. Spring passes and Overlap now work together for Contour, Pocket, Model Chamfer, and Dynamic Contour toolpaths. Overlap is applied to the final spring pass. When creating a tool, you can view a more extensive list of size properties.
Learn more about these and other
Additional improvements that benefit efficiency include: • Advanced Toolpath Display supports multiple wireframe toolpaths such as Ruled and Revolved. • You can have multiple air region
enhancements to Mastercam Mill at whatsnew.mastercam.com. To purchase Mastercam Mill or learn how the world’s leading CAM software can improve your productivity, info@mastercamapac.com. www.Mastercam.com
www.mtwmag.com
TECH TRENDS
Faccin technology to support the production of natural gas pipelines Written by: Mr Javier Lanfranchi - Senior Sales Area Manager
A
s per several studies, the onshore oil and gas pipeline market is expected to grow between five and 6 per cent during the next five years, a safe and efficient solution for the transportation of crude oil and natural gas in either a liquid or gas form, from the production points to refineries and distribution centres. Amongst the hydrocarbon products, the consumption of natural gas is expected to have the fastest growth, particularly in the AsiaPacific region due to the lower cost compared to other fuels, the use of natural gas as raw material in fertilizers production, environmental
68
MACHINE TOOLS WORLD
SEPTEMBER 2019
benefits and energy security, with the consequent growth of the natural gas pipeline. China is expected to strengthen its gas pipeline network to improve its energy mix and control over the transmission fees and India will invest in the extraction of its natural gas resources, thus significantly increasing the market demand in the APAC region. Pipeline and energy infrastructure companies face huge operational challenges. Pipes production is an area of such difficulty that only companies with many years of experience and high technology background can be trusted to
reliably design and provide pipesmanufacturing machines suitable for the most challenging projects. Faccin S.p.A. has been a reference point throughout the years for its expertise in designing and manufacturing special machines, standard and customized, for the production of pipes. In order to meet specific production requirements in the industry, the company offers the HAV-2P, a series of NC-controlled high-performance pipe mill bending rolls able to support the production of pipes delivering productivity, repeatability and automation of the entire manufacturing process. These
www.mtwmag.com
DER ANTRIEB Reliable. Versatile. Global.
NORD
4.0 READY!
THE GEAR UNIT
THE MOTOR
THE DRIVE ELECTRONIC
n Strong bearings n Quiet running
n High efficiency n Global standards
n Compact design n Easy commissioning
NORD DRIVESYSTEMS PVT. Ltd. | Toll Free No. 1800 200 2042 | india@nord.com
nord.com
TECH TRENDS pipe production-bending rolls are constructed with an extremely sturdy electro-welded structure and are fitted with three rolls in thermally treated steel alloys. HAV-2P long bending rolls are designed for rolling plates up to 45 mm thick, ideal for producing pipes up to over 18 m long, complying with the customer’s specific technical and roundness tolerances and offering a high-quality finished product that meets the high API standards. The rolls of the special HAV2P bending rolls are moved independently – the top roll moves vertically, the lower rolls move horizontally – which allow the power of the machine to be fully exploited, depending on the various thicknesses to be rolled. To offer high performance in the production
70
MACHINE TOOLS WORLD
SEPTEMBER 2019
of long pipes with relatively small diameters the lower rolls of the HAV2P bending rolls are supported by backups for their entire length. The top roll is preloaded to compensate for the flexion during plate bending and may be replaced quickly to extend the range of diameters and thicknesses that can be obtained by rolling. To further increase the production speed and automation, the company proposes along with the HAV-2P pipe mill bending roll, an accurate post-bending machine that prepares the pipe for welding and a series of outboard motorized guide rollers that control the movement of the pipe from the HAV-2P to the post-bending machine and successive working stations achieving a fully automated manufacturing process.
The Company More than 200 years combined experience, forming today’s future. Faccin S.p.A. is a very powerful group which combines the best brands – Faccin, Boldrini and Roundo – in plate rolling, profile bending and dished-heads manufacturing, all united under one roof and offering the widest range of high-quality options available in the metal forming market.
For more information, Website: www.faccin.com
www.mtwmag.com
An ISO 9001:2015
An ISO 9001:2015
TECH TRENDS
Drake External Thread Grinders
G
rind a full range of threads, worms, ball screws, gages, and other parts up to 4 meters long on Drake’s GS:TE External Thread Grinders. All GS:TE models are fully programmed and delivered with a grinding process optimized to run customers’ parts. Equipped with a power helix and Drake PartSmart™ menu-driven screens, these machines are easy to operate and deliver repeatable, accurate results. Drake grinders are built using premium materials, ensuring dependability and longevity regardless of your production schedule. Drake machines are designed for accuracy, consistency, and reliability. These external thread grinders are built on high mass, cast polymer bases for vibration damping and thermal stability. The use of linear motors and linear roller ways allows for maximum acceleration and contouring. Dressing software is available for contour dressing of ISO, 60°, Whitworth, Acme, Buttress, Worm (ZA, ZN, ZK, ZI), full radius, Gothic arch, and other thread forms. Other standard features of Drake external grinders include a high precision workhead and motorized wheel spindle. Additional upgrades, including automation, are also available. After assembly and verification is completed, Drake offers hands-on training. Working with the Drake team ensures that all your thread grinding requirements are met. Drake’s line of precision machines also includes: • Internal Thread Grinders: grind
72
MACHINE TOOLS WORLD
SEPTEMBER 2019
internal threads up to 220mm • Dual Spindle Grinders: grind multiple operations in one fixture setup • Crown Grinders: grind drums for tapered roller bearings • Vertical Thread Mills: rough mill parts for finish grinding • Rack Mills: high speed rack milling
throughout the thread grinding industry. For more information, WWW.DRAKEMFG.COM For additional information, contact our local representative. EMPIRE MACHINE TOOLS Mr. Alok Naik, alok@empiremt.com
DISCOVER DRAKE We are Drake Manufacturing. We are a full service, turnkey manufacturer of precision CNC machines and provider of engineered solutions. Founded in 1972, Drake is headquartered in Warren, Ohio. The premium Drake brand is known around the world for innovation and process expertise
2493 7340 / 2494 7066 / 2497 3184 sales@empiremt.com
www.mtwmag.com
TECH TRENDS
Today machine tools can produce accuracies down to the micrometer range. Modern sensors from Micro-Epsilon make this possible.
Precise sensor technology for machine tools Faster, more precise, higher productivity - these are the key requirements when developing new machine tools. In many cases, improvements can only be achieved using sophisticated sensor technologies. Machine tool manufacturers and their suppliers benefit from easy sensor integration. Micro-Epsilon demonstrates this with a wide range of sensors that are ideally suited to the machine tool industry.
I
n machine building and machine design, sensors are the eyes and ears of machines. Therefore, the control system is able to process the information provided by the sensors and to correspondingly control the actuators. Of course, the machine can only work as precisely as the sensors measure. High precision production The industry for high precision
74
MACHINE TOOLS WORLD
SEPTEMBER 2019
machine tools has been experiencing a genuine boom in the last few years. These tools produce workpieces whose accuracy is often in the micrometer range. Achieving these accuracies requires the optimization of machine tool designs in many areas. One of the most critical components is the spindle. High speeds and the friction between the tool and the workpiece can lead to heating up of the spindle and a
change in its length. Liquid spindle cooling can limit this effect but cannot entirely compensate for it. In addition to the temperature effect, the length can change due to high centrifugal forces that occur with rapidly rotating spindles. In order to achieve very high accuracies during finishing of the workpiece, the change in length of the spindle must be detected by a sensor. The CNC control system
www.mtwmag.com
TECH TRENDS can then adjust the position of the tool based on the measured values. For this application, Micro-Epsilon offers the SGS 4701 (Spindle Growth System) measuring system, which the company developed specifically for use in high-frequency spindles. The system is based on eddy current inductive sensors of the eddyNCDT series, which measure on a non-contact, wear-free basis. This measuring method, which can be adapted to ferromagnetic and nonferromagnetic materials, is insensitive to heat, dust and oil. The system design including the miniature sensor, sensor cable and compact controller, allows the designer to integrate all components into the spindle. The sensor is installed in the spindle in most applications so that it can measure the change in length of the labyrinth ring of the spindle. The controller can either be mounted on the spindle housing via a flange or integrated directly into the spindle. The sensor system measures the temperature and the length expansion and outputs these values to the controller. The resolution of the length measurement is 0.5 Îźm, which enables high precision manufacturing. Protection against collisions Another critical component of a machine tool is the tool clamping system. Modern machining
The measuring system for linear expansion of the spindle based on eddyNCDT eddy current sensors from Micro-Epsilon can be perfectly integrated due to its miniature design.
centers can normally change tools automatically and thus ensure high productivity levels that are required in many manufacturing environments. In a magazine, various tools are each mounted in a tool holder. When changing the tools, the machine automatically removes the appropriate tool holder and places it on the spindle whose clamping system locks the tool holder in position. The perfect function of the clamping system on the spindle is extremely important. If the tool is incorrectly positioned, this can lead to faulty processing that incurs high costs. If the tool is tilted, the worst case scenario is that it can loosen due to the high speeds and the associated forces, resulting in high damage
induSENSOR LVP sensors determine the position of the drawbar in the tool clamping system while inspecting the correct tool position.
76
MACHINE TOOLS WORLD
SEPTEMBER 2019
caused by collisions with other machine tool components. Often, initiators and switching rings are used to monitor the clamping position. However, these are difficult to adjust. The analog induSENSOR LVP sensors from Micro-Epsilon offer a much simpler constructive solution. The cylindrical sensor can be easily integrated into the release device of the clamping system. A ring, which serves as a target for the sensor, is simply glued onto the drawbar. The measuring principle of the sensor is non-contact and so is not subject to wear. Since the sensor provides an analogue signal that is proportional to the stroke of the drawbar, this solution enables continuous monitoring. The tedious setting of the switching point, which is necessary in other solutions, is completely eliminated here. Even with this sensor, the sensor electronics are very small and can therefore be integrated directly on site. Low cost and easy integration Another common measurement task in machine tools is determining the position of the tailstock. Although
www.mtwmag.com
TECH TRENDS
As the measuring wire can be deflected easily, the draw-wire sensors perfectly fit into the machine.
this measurement has no direct impact on the precision or safety of the machine, it poses many challenges for designers. Thus, the position of the center point of the tailstock often has to be determined over a very large area up to a few meters. To make matters worse, the space for the corresponding measuring system is limited. An ideal and also cost effective solution is offered by MicroEpsilon with its wireSENSOR drawwire sensors. Due to their compact design, these sensors can be easily mounted even in confined spaces. The sensor does not have to be installed directly in the vicinity of the tailstock, as the measuring rope can be guided very flexibly over different pulleys. Typical sensor models for machine tools offer measuring ranges
78
MACHINE TOOLS WORLD
SEPTEMBER 2019
from 300 mm to 2,100 mm, although larger ranges are also available. The sensors are extremely robust and very durable even under difficult environmental conditions, such as those that prevail in a machine tool. Solutions for different measurement tasks from a single source With Micro-Epsilon sensors, the machine builder has the opportunity to implement all measurement tasks with solutions from a single source. In addition to the tasks described above, other measurement tasks can also be solved using products from the sensor specialist. For example, the optoNCDT laser sensor can precisely check the position of the tool holders in the magazine. Fast and precise position determination is
often required during the set up of the machine tool. Micro-Epsilon sensors have common interfaces that allow them to be easily connected with the CNC controller. They are of very high quality, so that the reliability of the machine tool and thus their productivity are ensured. The miniature design of most sensors allows them to be optimally integrated into the machine without the need for any costly design changes. Author: Dipl.-Ing.(FH) Christian Niederhofer Product Manager MICRO-EPSILON MESSTECHNIK GmbH & Co. KG www.micro-epsilon.com
www.mtwmag.com
TECH TRENDS
Enhance efficiency and accuracy by 25% precision Work Holding solution
B
PT is the first standard and custom-build Work Holding devices manufacturer in Asia – Pacific in addition to AT3 class Rotating Tool Holder since more than 3 decades. Erstwhile ‘Birla Kennametal’, Joint Venture with Kennametal, a USD 4 billion company, giving world class Work Holding devices and Tool Holding devices at one third of the cost of which is being supplied globally. With the help of BPT Work Holding devices there is a reduction in setup time, manpower cost, machine hours as well as rejection percentage; all together around 10 to 25% saving on non value added activity is the additional benefit to the customer. Whether it’s a small or large manufacturing shop, one thing they are constantly seeking is solutions to enhance productivity while keeping constant the quality requirements. After all, more efficiency & productivity with quality guarantees them not only better profit margins but also gives them an edge over the competiton. The constant need for increased efficiency calls for a special chucking system. One such solution that is designed specifically to meet the twin goals of productivity with quality is Birla Precision’s Outer Diameter Clamping Chucks (ODCC). The unique solution has primary application in CNC Turning and CNC Grinding machines, as well as boring, milling, measuring and inspection. BPT’s Collets in ODCC are designed and tested to get better gripping actions, higher concentricity and minimum distortion. Special Collets can be designed based on configuration of the customer component and can be customized as per customer requirement.
80
MACHINE TOOLS WORLD
SEPTEMBER 2019
BPT’s ODCC are a perfect fit for clamping OD Round, as well as profile any uneven OD for any secondary operations, including grinding, facing and boring where high degree of concentricity control is required with respect to OD and profile. The solution also helps to save NVA set ups of jaw borings & reduces the internal NVA cost. BPT’s ODCC have simple loading and unloading mechanism and require no indicating or adjusting. They have automatic self-centering capabilities and offer uniform, adjustable holding pressure. To meet the customer requirements, they are designed to support both automatic or manual operation. ODCC are completely sealed from harsh environments. BPT’s ODCC are highly reliable as they come with flexible Collets for extremely long life. They are counterbalanced to operate at high speeds and come with built-in, self-contained air cylinder. Further, they are packed with built-in safety features. They are also easy to maintain as no lubrication is required. BPT’s ODCC’s CONSTRUCTION BPT is a leading provider of precision Work Holding solutions. Its solutions promise accuracy, reliability, repeat-
ability, concentricity and productivity. It guarantees a competitive price for a complete Work Holding solution, which are engineered and manufactured to adhere to the customer’s work piece tolerance. BPT standard Work Holding that is OD Collet Chuck models are available as under, according to bore diameter, DA100/ DA 200/ DA 400/ DA600/ DA 800.Standard chucks are adaptable to CNC’s various spindle nose sizes i.e. A2-5”//A2-6”// A2-8”// A2-10”// & A2-12. The specialty of the BPT OD Collet Chuck is they have a built in facility to set the accuracy of the bore to perfect zero run out, to nullify the run out on machine spindle assembly within a fraction of second, it means tremendous reduction in setup time. Special ODCC are available with up to flange outer diameter of 450 mm. Its top tooling is custom designed with special profile collets and back stops. Unique advantages of the Double Angle system are:• A stronger uniform body. • Uniform DA Collet wall section for even expansion. • Self releasing Actuating Angles. • Wear to continuous gauge fit. • Full 360 degree contact. • Self releasing for fast load and unload. • Parallel expansion supports work piece for entire length. • Accuracy 0.008 mm TIR on nose of master gauge piece, maximum collapse 0.80 mm to 1.6 mm standard based on clamping diameter. For more information Birla Precision Technologies Limited santosh.tipale@birlaprecision.com
www.mtwmag.com
More Precision Inductive sensors (eddy current) for displacement, distance & position
eddyNCDT High precision inductive sensors (eddy current) for non-contact displacement, distance and position measurements Robust and industrial-grade sensors for harsh, industrial environments: dirt, vibrations, pressure, temperature High resolution and temperature stability High frequency response for high-speed measurements Customer-specific sensors and controllers Extensive product range for versatile application possibilities
+91 20 2674 1009 | info@micro-epsilon.in | www.micro-epsilon.in
TECH TRENDS
High Speed Accurate Machining High cutting speed is a natural attribute of high speed machining. Understandably, a tool should be also precise; it is required not only by machining accuracy but also by the mechanics of a fast-rotating body. However, in the last years the issue of tool accuracy has become an additional point to consider. What is the reason? Why is high speed machining penetrating more and more into rough processing? How do cutting tool producers formulate their solutions to meet these new industrial demands?
T
he metalworking industry adopted high speed machining (HSM) in the 1990s. This method was engrained in various industrial branches and caused serious changes in technology and machine tool engineering. The wellknown advantages of high speed machining are repeatedly cited in various books, guides, magazines and other sources of information. Recently, there has been a significant interest in accurate high speed machining and, more specifically, in precision and other characteristics of cutting tools and toolholding devices intended for this purpose. Accurate (or precise) machining means maintaining repeatable strict tolerances during cutting operations. The level of such a “strictness” depends on the machining method, for example: milling, turning, or drilling, and the type of operation: rough, semi-finish or finish. Technological advances, especially in producing workpieces that are preformed half-finished products, place special emphasis on accurate high speed machining. Precise casting, metal injection molding and 3D printing ensure that the production of workpieces is very close to the final shape of a part. As a result, the need to remove a high volume of material by means of rough cutting decreases. In die and mold making, utilizing high speed machining as a means of reducing production time has brought a real alternative to traditional
82
MACHINE TOOLS WORLD
SEPTEMBER 2019
methods. In the aerospace industry, machining difficult-to-cut heatresisting superalloys by ceramic tools at extremely high cutting speeds, in combination with a small stock to be removed, is now common. As for manufacturing aluminum components, here HSM has simply become a daily reality.
Machining operations with low stocks per pass have distinct advantages such as lower power consumption, less heat generation, and better surface finish. Accurate high speed machining, which features low stock removal, is a logical extension of producing workpieces by precise modern methods. Usually, HSM relates to cutting by rotating tools - mainly milling cutters. In many cases, when a part featuring complex profiles and slots is produced from a solid material, HSM provides productive low-loaded roughing by trochoidal milling. According to this technique, a rapidly rotating milling cutter moves along a complicated trajectory and slices thin but wide layers of the material. This results in pre-shaping the part very close to a final form. The remaining small allowance is removed in the next stage: high speed finish milling. Producing blisks (bladed discs) and
impellers is a typical example of the mentioned process that may be defined by the rather oxymoronic term: “accurate roughing”. Successful high speed machining relies on a key element chain comprising a machine tool, an effective machining strategy, proper toolholding, and a cutting tool. The low-power multi-axis machine tools designed especially for HSM feature high-torque characteristics, highvelocity drives, effective controllers and intelligent software. They are capable of realizing various machining strategies which were developed for ensuring maximum efficiency. Today, metalworking has in its arsenal highly reliable tool holders designed for secure tool mounting in an expanded range of rotational speeds. Under such conditions the cutting tool - the element that directly contacts a machined part during a cutting operation – can be a limiting factor in maximizing the potential of advanced machine tools . This element is much smaller and less complicated compared to machine tools and holders. Each improvement in the last chain element – the cutting tool - may be crucial. The cutting tool industry is far from stagnation; the branch is on the constant move in developing new solutions to meet the demands of changing metalworking technologies. Time has not radically changed principal tool requirements: it is expected to be more durable and
www.mtwmag.com
TECH TRENDS more efficient when cutting at considerably increased cutting speeds and feed rates. Lowering machining allowances leads to additional tightening tool accuracy parameters. An ideal product is a precise and high-balanced tool that ensures high performance in combination with excellent tool life when cutting at high rotational speeds. ISCAR, staying true to its motto “Where innovation never stops!”, has developed a range of solutions that give new momentum to high speed machining concepts, and many proposed designs relate to the field of solid carbide tools. More flutes, less vibrations Multi-flute solid carbide endmills from ISCAR’s “CHATTERFREE” line were developed especially for vibration-free high speed machining operations. Their design features a varying helix angle, variable tooth pitch and a specially shaped chip gullet, intended for applications such as semi-finish and finish high speed milling, as well as roughing by trochoidal technique. The CHATTERFREE range comprises several endmill families for different applications. 7 flute endmills, produced from an ultra-fine carbide grade, are designed for machining hard materials and finish operations. General-purpose multi-flute endmills incorporate an interesting concept, according to which the number of teeth is equal to a nominal diameter in mm. 7- and 9 flute endmills were designed originally for trochoidal milling complex parts from titanium and today they form the Ti-TURBO family – this name reflects a real “turbo” metal removal rate when milling titanium. The latest step of the line development integrates chip-splitting grooves (Fig.1) in the endmill design.
84
MACHINE TOOLS WORLD
SEPTEMBER 2019
Fig 1 Solid carbide endmill with chip splitting grooves
seeking ways to increase productivity when manufacturing parts from HTSA; and low cutting speed is one of the existing barriers to this goal. A solution may be found in applying cutting ceramics as a tool material for high speed machining. ISCAR has developed solid ceramic endmills that enable a dramatic increase in cutting speeds of up to 1000 m/min (3280 sfm) when compared to tools made from cemented carbide. The new endmills have a diameter range of 6-20 mm (0.236-0.787 in) and are designed with 3 or 7 flutes. (Fig. 2). Introducing the ceramic endmills in rough milling operations has proved to decrease machining time drastically and to enable fast preshaping of a part for further finish operations.
The new geometry has an unusual appearance because HSM forms thin chips that do not appear to need an additional chip-splitting action. However, the grooves increase vibration resistance and reduce cutting forces, significantly improving trochoidal milling and machining performance at high overhangs. In trochoidal milling, the produced chips are thin but wide. Splitting the chips into narrower segments contributes to better chip evacuation and surface finish, which increases accuracy and effectiveness in rough high speed machining.
Fig 2 Ceramic endmill
Ceramics that cut fast Milling difficult-to-cut high temperature superalloys (HTSA) by carbide tools necessitates low cutting speeds, normally 20-40 m/min (65130 sfm). High speed machining with a small radial engagement, when the width of cut is up to 10% of a mill diameter, usually features cutting speeds of 70-80 m/min (230-265 sfm). The metalworking industry is always
High speed master Long-reach high speed milling operations require tools with long overall length. A solid tool concept is not an economically attractive option. An assembled cutter comprising a body carrying a carbide cutting head is a solution that makes economic sense. Such an approach is at the core of ISCAR MULTIMASTER – a family of tools with
www.mtwmag.com
TECH TRENDS
exchangeable heads. A rich variety of tool bodies, heads, extensions and reducers ensures various tool configurations and fundamentally reduces a need for special tools. An important advantage of the MULTIMASTER line is its no setup time principle, whereby replacing a worn head does not require additional tool measuring or appropriate CNC program adjustment - the insert can be replaced without withdrawing the tool from a machine spindle. High assembly rigidity, a balanced structure and high geometrical accuracy make MULTI-MASTER suitable for high speed machining. A typical example of this application
Fig 3. MM HBR head
86
MACHINE TOOLS WORLD
SEPTEMBER 2019
is finish milling 3D surfaces of parts produced from hard materials. ISCAR’s “MM HBR” bulb-shape head (Fig. 3), featuring a 240°-spherical cutting edge, center cutting ability and strict ISO h7 grade tolerance limits for the head diameter, was developed for this type of operation. Reliable toolholding High speed machining is impossible to perform without the use of reliable, high-grade balanced and accurate tool holders. Thermal shrink chucks are one of the most popular types of tool holder. ISCAR’s line of SHRINKIN chucks includes the X-STREAM family of thermal chucks, featuring coolant jet channels along the shank bore. The new design provides coolant flow directed to the tool’s cutting edges. In the high speed milling of aerospace components (the aforementioned blisks, for example), a well-directed coolant significantly enhances performance. For deep pockets and cavities, the new chucks with pin-pointed coolant flow have resulted in preventing re-cutting, thereby improving chip evacuation and increasing tool life. A wet coolant may be a means for upgrading machine tools from low-velocity to high-speed. SPINJET, a family of compact coolant-driven
Fig 4. SPINJET high speed spindle
high-speed spindles (Fig. 4), is capable of maintaining rotational velocity up to 55000 rpm and facilitate high speed machining even on the low-speed machines that are still so common in the shop floor. Changing technologies require new machining concepts: more productive, more economical, more sustainable. High speed machining has already proved itself as a method that meets today’s industrial needs. The progress in producing workpieces by non-machining processes brings in focus low-power high speed roughing. Accordingly, cutting tool manufacturers already feel the growing demands for appropriate products. It is a definite trend, which, no doubt, should be considered.
www.mtwmag.com
TECH TRENDS
HALLER-M1•Linear: German Design, European Quality, Built in China
S
uzhou Haller is a company specialized in the production and development of 5-axis CNC grinding machines since year 2014. Starting by building original German machines in China, we have successfully absorbed the German technology, transferred the assembly line and maintained high quality European supply chain and strict production control till now. We are committed to providing complete solutions of tool grinding upon customized requests. To realize this target, we combine the basic technology from Germany with more than ten years’ tool machining experience in China. Strong application ability, professional application training and fast response of after-sales service and technical
supports are all our advantages, which perfectly present German Design, European Quality and Built in China. To maximum satisfy customers’ demands, we continuously upgrade the existing PG series grinding machines and also concentrate on innovating and developing new machines. During 2019 CIMT international show in April at Beijing, Suzhou Haller launched our first new machine named HALLERM1. It is a high precision 5-axis CNC tool grinding machine designed through market research, instructed by German Design Company and finished by Suzhou Haller technical team. It is beautiful and space-saving. Natural granite body has good shock absorption and heat resistance ability. The unique structure design is in short travel for high processing efficiency. X, Y axis high precision linear motors equipped with full closed-loop glass scale, durably stable. Double-ended grinding spindle, simply realize fast processing. A, C axis are equipped with separate oil cooling system to ensure the precision reliability. Automatic full-directionally internal measuring system for both work piece and grinding wheel are efficient and accurate, ensuring the tool machining stability. UM control system has the electrical cabinet with optimal
N
88
MACHINE TOOLS WORLD
SEPTEMBER 2019
arrangement and accessibility for easy servicing. NUMROTO grinding software is easy to learn; ordinary workers can quickly acquire grinding skills and be able to operate proficiently in a short time, greatly reducing the difficulty and cost of workers’ training. Individualized control panel is visually simple to use. HALLER-M1 is widely applied in manufacturing and regrinding of standard cutting tools, high precision complex woodworking tools, medical dental and bone tools, such as drills, step drills, end mills, ball nose, corner radius cutters, form cutters. For more information: Suzhou Haller CNC Grinding Machines Co., Ltd. E-mail: info@hawema-haller.com Web: www.hawema-haller.com
www.mtwmag.com
TECH TRENDS
OPEN MIND expands functions in highperformance cutting module Adds two key enhancements to the hyperMILL® MAXX Machining performance package
O
PEN MIND Technologies produces the hyperMILL® MAXX Machining performance package, a powerful tool for high-performance drilling, roughing, and finishing. These modules within hyperMILL® feature special machining strategies that allow users to gain maximum benefit from their machining center and cutters. Two key enhancements have been added to the performance package: Perfect pocketing technology ensures more efficient pocket machining with high-feed cutters. High-performance finishing and roughing strategies are also available for turning. OPEN MIND has implemented a new high-performance mode for turning/roughing. This was made possible by applying the proven concept of trochoidal milling to turning. Optimized connecting paths and fluent machine movements
Trochoidal toolpaths for highly efficient turning
90
MACHINE TOOLS WORLD
SEPTEMBER 2019
For fillets: Mill high-quality transitions between two surfaces
ensure high-performance machining. The user benefits from the special plunge behavior of the insert in the material, which increases process reliability while reducing the manufacturing time. Meanwhile, when it comes to finishing, OPEN MIND offers an innovative strategy to make optimal use of the special rollFEED inserts. The inserts’ large radii enable enormous time savings for finish turning. Expanded range of functions for barrel cutters Another new feature is the “5axis Prismatic Fillet Finishing” strategy, which supplements the innovative strategies for the highly efficient machining of planes and continuous surfaces. This strategy makes it possible to use barrel cutters
according to the principle of highfeed cutters with plunging and pulling machining. The calculation of the optimal inclination of the barrel cutter is fully automated. This allows, among other things, highquality transitions between different wall areas. This strategy perfectly complements the machining of deep pockets with barrel cutters. Multi-surface machining Multi-surface 5axis machining with conical barrel cutters makes it possible to produce entire surface formations in a single job. The toolpaths are generated fully automatically using a surface selection; this eliminates the timeconsuming step of creating cutting contours in the CAD beforehand. As a result, high-quality surfaces can be easily programmed and quickly
www.mtwmag.com
TECH TRENDS
Multi-surface machining of several free-form surfaces – simple selection, quick programming: time-consuming creation of cutting contours in the CAD system is no longer necessary.
produced for both free-form surfaces and planes. Mill pockets more quickly To ensure maximum speed and efficiency, hyperMILL® MAXX Machining also features perfect pocketing technology for roughing. An intelligent algorithm fits the largest possible pocket into the area to be roughed and automatically generates linear toolpaths for high feed milling. Linear and contourparallel toolpaths are optimally linked to guarantee rapid production. Special retract movements reduce rest material in the corners. Multifaceted applications for barrel cutters hyperMILL® offers a broad range of applications by supporting various barrel cutters. For example, a great deal of time can be saved by using barrel cutters during impeller or blisk production. If the taper angle of the milling tool corresponds to the wall inclination, the barrel cutters can also be efficiently used for 3axis machining. All machining is always carried out in an efficient, collision-free way at the highest level of quality.
92
MACHINE TOOLS WORLD
SEPTEMBER 2019
Perfect pocket technology fits pockets perfectly into the area to be machined and optimizes toolpaths for high feed milling.
About OPEN MIND Technologies AG OPEN MIND is one of the world’s most sought-after developers of powerful CAM solutions for machine and controller-independent programming. OPEN MIND develops optimized CAM solutions that include a high number of innovative features not available elsewhere to deliver significantly higher performance in both programming and machining. Strategies such as 2.5D, 3D as well as 5-axis milling/mill turning, and machining operations like HSC and HPC are efficiently built into the hyperMILL® CAM system. hyperMILL® provides the maximum possible benefits to customers thanks to its full compatibility with all current CAD solutions and extensive programming automation. OPEN MIND strives to be the best and most innovative CAD/ CAM manufacturer in the world, helping it become one of the top five in the CAM industry according to the “NC Market Analysis Report 2019” compiled by CIMdata. The CAD/ CAM solutions of OPEN MIND fulfil the highest demands in the automotive, tool and mold manufacturing, production
Efficiently machine inclined walls with barrel cutters on 3axis machines.
machining, medical, job shops, energy and aerospace industries. OPEN MIND is represented in all key markets in Asia, Europe and America, and is a Mensch und Maschine company.
For more information, Website: www.openmind-tech.com
www.mtwmag.com
Far from the ordinary
And you know.
www.kemppi.com Kemppi India Pvt. Ltd.
Lakshmi Towers, 2/770, Kazura Garden, First Street, Neelankarai, Chennai, Tamilnadu-600041
Kemppi India Pvt. Ltd.
Robotic Welding Application Center, Plot No P-84, D II Block, MIDC, Chinchwad, Pune, Maharashtra-411019
Tel : +91 44 45671200, Email : sales.india@kemppi.com Kemppi-MasterTig-A4.indd 2
10.6.2019 15:15:45
TECH TRENDS
Ball Chain Type Actuator PMI SKM Series Designed to achieve high rigidity and high accuracy in the minimal space, especially in saving time of installation
P
MI’s SKM series consists of linear guideway unit and ballscrew unit. For saving space, PMI has combined the carriage of linear guideway and nut of ballscrew to an integral Carriage-Nut. The carriage-nut cooperate with the U rail designed to achieve the high rigidity and high accuracy in the minimal space, especially in saving time of installation. Moreover, the design of two rows with Gothic-arch groove and contact angle of 45°can bear four directional loading. Application IC / LSI Manufacturing Machine, Hard Disc Drive, Slide Unit of OA Equipment, Wafer Transfer Equipment
The U rail and carriage-nut circulating system with the ball chain design which use the strengthened synthetic resin of accessories and avoid interference between balls to make it more stable during passing the load district. Besides, the ball chain can keep the ball move in line and improve the movement. Low Noise The retaining pieces of the carriage-nut can avoid collision between balls then decrease the noise. Also, non-mutual friction can decrease heat generation and keep the accuracy in the range.
Features Ball Chain Design, Smooth Movement
High Dustproof, Extend the maintenance intervals The carriage-nut with the wiper at both ends can reduce grease leakage. Besides, the wiper with a special lips structure can matches the threads that ensures the removal of scraps as well as insulation dust.
94
MACHINE TOOLS WORLD
SEPTEMBER 2019
www.mtwmag.com
C A T E R I N G
A
C
R
O
S
S
T
H
H U M B L Y
E
G
L
O
B
E
EXHIBITING MX 9
K3X8 Five nvu
U Mill 6
5-Axis Bridge Type Machining
DX 200 5A nvu
AX 200 MY
VMC 850 nvu
Turning Center
High Precision Turn-Mill Center with Y-Axis
High Performance Vertical Machining Center
High Performance Vertical Machining Center
Tachyon 5
Tachyon 7
K Mill 10
KX 50 L
High Speed Drill Tap Center
High Speed Drill Tap Center
Bridge type Vertical Machining Center
VMC 1260 nvu
5-Axis Bridge type Double Column Machining Center
TECH TRENDS Saving Space Combine the carriage of linear guideway and nut of ballscrew to a carriage-nut, SKM series can achieve the best use of space.
Four Directional Equal Load SKM series are applied two rows with Gothic-arch groove and designed to contact angle of 45° which enables it to carry an equal load in radial, reversed radial and lateral directions to suit to any mounting orientation.
High Rigidity Based on the optimal analysis of FEM for the shape of U rail, it has the balance between light weight and high rigidity.
High Accuracy The design of two rows with Gothic-arch groove and stable manufacturing technology can control the variation by load at the minimum. It can provide the smooth feed with high accuracy.
96
MACHINE TOOLS WORLD
SEPTEMBER 2019
www.mtwmag.com
TECH TRENDS
Threading tools for hard machining Walter has come out with a full product range for producing threads in hardened steels with an additional thread milling cutter
P
roducing threads in hardened steel is costly. This applies to blind hole machining in particular because reversing the tap during this process can cause torque peaks when the root of the chip is sheared off, resulting in fractures. Walter is solving this problem with two new taps – offering its customers a full product range for producing threads in hardened steels with an additional thread milling cutter: The TC388 Supreme (50–58 HRC) or TC389 Supreme (55–65 HRC) and the TC685 Supreme (> 44 HRC). The TC388 and TC389 Supreme solid carbide taps boast special cutting geometries. These fully shear off
100
MACHINE TOOLS WORLD
SEPTEMBER 2019
the root of the chip when reversing; torque peaks are minimized. This prevents fractures, prolongs the tool life and increases process reliability. Lubrication with oil, which was often necessary until now, is no longer required. Instead, emulsion can be used, which optimizes handling and saves additional machining time. Both taps are characterized by a short machining time. The TC685 Supreme orbital drill thread milling cutter enables maximum process reliability and the highest possible tool life quantity. The core hole and thread (chamfer if required) are produced in a single operation, thereby saving tool spaces.
The milling geometry on the face produces stabilizing forces in the axial direction. This improves the stability when milling and reduces the deflection. Advantages for the user: Fewer radius corrections and reduced wear, with a high tool life quantity and minimal costs per thread. The 15° helix angle and internal coolant from M6 guarantee reliable chip evacuation. This allows even tougher steels and deep threads to be machined reliably. Common applications for all the tools mentioned include mould and die making, for example. For more information, Website: www.walter-tools.com
www.mtwmag.com
Taming power quality is now child's play
When you use DigiVolt Stabilizers, Tranquil Ultra Isolation Transformers and Powercon Power Conditioners from Unity Controls, power quality is under total control and would no more hamper your production and product quality. These silent sentinels protect your sophisticated, high precision production equipment from the ill-effects of voltage, spikes, surges, transients, sags, noise and harmonics affecting AC power lines. Thus ensuring continuous uptime and enhanced productivity and consistent quality.
Intelligent Microprocessor-based, High Efficiency, Energy Savers specially designed for CNC machines
Our equipment are approved by major OEMs and exported (up to 2000 KVA) to countries in Europe, Middle East, Africa
Our Allied Products: n
Active Harmonic Filters K-Rated Transformers Light Energy Management Systems
n
KVAR MAX - Real Time Power Factor System
n n
and Asia Pacific. So leave power quality and energy management to the experts – Unity Controls. With our nationwide network we are only a phone call away!
Contact us for Power Quality & Harmonic Audits to Conserve Energy and Save Costs.
The power quality & energy experts
D-137, TTC MIDC Industrial Area, Nerul, 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E),400 Mumbai 400 077, India Navi Mumbai 706, INDIA +91-22-2501 3832 +91-22-2761 1872/ 33 / 4612 sales@unitycontrols.in www.unitycontrols.in
Ahmedabad l Bangalore l Chennai l Delhi l Gurgaon l Hardwar Indore l Jalandhar l Jamshedpur l Kolkata l Kanpur l Mumbai l Pune l Rajkot
l l
vijayshreyaarts@gmail.com
UNITY CONTROLS PVT. LTD
TECH TRENDS
Achieving corrosion resistance through specific solution for every application Several treatments for high resistance to corrosion and solutions in stainless steel define the range of linear and telescopic rails and actuators from Rollon Group
A selection of Rollon linear guides. Different anti-corrosion treatments are available, and in some cases, there are also versions in AISI 360L stainless steel.
C
A version of Rollon’s DSS telescopic rail, treated with Rollon Alloy and used in underfloor applications on trains, can withstand 720 hours in a saline mist test.
102
MACHINE TOOLS WORLD
SEPTEMBER 2019
orrosion is an irreversible process that alters the nature of any steel component after exposure to humidity or substances with acidic or basic pH. The technical characteristics of the material change, rust appears and the metal starts to break down. For linear or telescopic rails, or, more generally, components of linear motion systems, corrosion causes fast and inevitable deterioration of sliding quality and weakens the structure of the component in question, with dangerous consequences for the efficiency of any system. For this reason, it is crucial that every solution be designed and built to accommodate the characteristics of
the environment where it is installed: an excellent rail, even if it’s precisely sized and performs correctly, will ruin quickly in a strongly corrosive environment if it has not been treated suitably. Its shortened life span would be an inevitable disaster. This is why Rollon offers a wide range of different materials and anticorrosion treatments for its products. The goal is to offer the best solution for any specific application, which increases reliability and system efficiency. For the most demanding applications in railway systems, for example, the required corrosion resistance standard for components is 500 hours in saline mist, according to
www.mtwmag.com
Linear solutions global provider.
Linear Line
Actuator Line
Telescopic Line
Actuator System Line
ROLLON India Pvt. Ltd. - INDIA 1st oor Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA www.rollonindia.in - info@rollonindia.in
Rollon is a global provider of linear motion solutions for several industrial sectors, such as: industrial machines, railway, automation, packaging and logistics, aerospace.
TECH TRENDS
Rollon’s ELM actuator is available in a corrosion resistant version with Anticorodal aluminum profile and bearings, linear rails, nuts and bolts and components in stainless steel.
ISO 9227 specifications that determine the Salt Spray Test (see the sidebar). The Rollon Aloy treatment that Rollon offers for these applications exceeds the standard by 44% with 720 hours of resistance in saline mist. Now, let’s look at Rollon’s solutions for fighting corrosion: • Rollon Aloy: This galvanizing process involves high resistance passivation. It offers very high resistance to corrosion and is indicated for rails used in the railway sector, for special vehicles and in the transport sector in general, therefore in outdoor applications. The treatment has a thickness of 15 µm and a resistance to corrosion in saline mist up to 720 hours: a level of effectiveness that makes it the ideal solution for all underfloor applications in trains. • Chemical nickel plating: The process offers high resistance to corrosion caused by chemicals, acids or bases. It is the perfect solution in applications related to the food industry where direct contact with food is not involved (which require the use of stainless steel). It is also perfect for the medical sector. Chemical nickel plating has a thickness of 10 µm. • Rollon e-coating: This is a cataphoresis treatment. Rollon e-coating can be paired with a color for the rails, normally black, and is used in contexts where
104
MACHINE TOOLS WORLD
SEPTEMBER 2019
product aesthetics are important. Appearance is, in this case, on the same level as efficiency: the treatment has a maximum thickness of 30 µm and makes it possible to achieve a level of corrosion resistance that permits 700 hours in saline mist. • Electro-galvanization: Applied in compliance with the ISO 2081 standard, Rollon uses this treatment as its standard for all of its rails. This is the best for products that operate indoors, such as industrial machinery, packaging machinery, and intralogistics systems. Electro-galvanization has a thickness of 8 µm and offers a level of corrosion resistant that permits up to 120 hours in saline mist. If the anti-corrosion treatments are not sufficient or suitable for the work environment, Rollon also offers a wide range of linear and telescopic rails in stainless steel AISI 316L, which can guarantee maximum resistance to corrosion. The line of linear actuators from Rollon is available with different
SALT SPRAY TEST The Salt Spray Test is the reference standard for measuring resistance to corrosion, defined as a number of hours of permanence in an environment with saline mist. In compliance with ISO 9227, the rails are put inside a test room and a solution of 5% sodium chloride (NaCl) with a pH of 6.5 is poured over them. The NaCl solution is administered with a continuous misting process at 35° for the entire duration of the test. Assessments of the quality of the surface protection are made at intervals set for the different samples.
drives and linear motion systems. It comes entirely made of anodized extruded aluminum profiles. For the most demanding applications, specific versions of the axes are available made in Anticorodal aluminum 6060 and 6082 for the extruded pieces and stainless steel for the bearings, linear rails, nuts and bolts and other components. Rollon’s commitment in the fight against corrosion also contemplates the future: the Italian Group’s research and development department is working on designing new treatments against corrosion to offer products that perform better than ever.
For more information: ROLLON INDIA Pvt. Ltd. 1st floor, Regus Gem Business Centre 26/1 Hosur road, Bommanahalli Bangalore 560068, INDIA Tel: +91 80 67027066 Fax: +91 80 67027004 Email: info@rollonindia.in Website: www.rollonindia.in
The test chamber to measure resistance to saline mist in compliance with ISO 9227.
www.mtwmag.com
TECH TRENDS
Impressive results even under the hardest conditions. Homogenous surface quality even after hours of use and this at the highest performance levels - anything demonstrating these features in the hard milling environment is already playing in the champion’s league of processing. The PEACOCK mill cutters from ZECHA just keep on going even at 67HRC.
Homogenous surface quality even after hours of use and this at the highest performance levels.
Optimised tool design for materials up to 67 HRC Other rules apply when it comes to hard machining in comparison with the processing of “normal” materials: Interventions in steels up to 67 HRC generate wear and friction above the norm and call for tools of uncompromising quality. “But never fear, we have the right answer even for such demanding applications: The PEACOCK series provides the tool and mould maker with a high-tech mill cutter that can
106
MACHINE TOOLS WORLD
SEPTEMBER 2019
create even complicated structures in the hardest of materials without constant tool changeover or flagging machining quality impairing economic efficiency!”, stresses Martin Ruck, Head of Research and Development at ZECHA HartmetallWerkzeugfabrikation GmbH in Königsbach-Stein. Dazzling name - cool(ing) design The two-flute ball and torus mill cutters in the PEACOCK series demonstrate unrivalled eagerness
to tackle hard and powder metallurgical steels, always confident of having the better arguments in the encounter. “And some of them can be found on the cutting edge,” adds Mangesh Awate, Sales Manager, Zecha Precision Tools Limited, India. “From the substrate to point and micro geometry, the PEACOCK mill cutters have been configured for the highest level of resilience. Our engineers’ attention to detail in producing the series means
www.mtwmag.com
TECH TRENDS
nothing has been left to chance and our customer requirements have thus been implemented in full.” These include the diameter coordination relevant in manufacturing. On the PEACOCK ball mill cutters in the 581P series they range from 0.2 – 12.0 mm and the PEACOCK torus mill cutters in the 583P series are available from 0.2 - 6.0 mm. Common to all is the new point geometry, which ensures faster removal of the hot chips from the treatment zone - a vital measure for hard mill cutters. The groove design stabilises the entire geometry, which in turn is supported by the soft radius transitions in the shaft.
The smallest 3D contours are milled into high-alloy steels with up to 70 HRC.
108
MACHINE TOOLS WORLD
SEPTEMBER 2019
left-hand processed with conventional milling cutter (100-x magnification) and on the right-hand side processed with PEACOCK (100-x magnification)
Smooth coating for long tool life The mill cutter design is rounded off by the latest coating technology. It is characterised by minimised friction, very smooth and homogeneous coating surfaces in combination with great stability and strength including excellent coating adherence. “In comparison with conventional solutions our WAD coating helps to more than double tool life. And the user will notice this in the longer tool changeover intervals and resulting shorter transition times,” says Mangesh Awate. This means that as far as efficiency is concerned, the mill cutters have it in them to come top of the class in high speed machining for tool and mould making. Just to top it off, the PEACOCK mill cutters are exceedingly flexible in their deployment. Even highly alloyed, somewhat soft materials can be roughened with cooling lubricant, semi-finished and even finely
finished with the highest degree of component precision. Reproducible quality creates safety “Life is not becoming easier for tool, mould and machine makers: price pressure, extreme quality demands and also unforgiving materials as the measure of all things, set a very high bar. Yet with our PEACOCK hard mill cutters, we have provided a good balance of performance, highest reproducibility and safety in application. This is why the series is really a feather in our cap!” summarises Martin Ruck.
For more details please contact ZECHA Precision Tools Limited Mr. Mangesh Awate DGM- Business Development Email: mangesh.awate@zecha.in WEB: www.zecha.in
www.mtwmag.com
HIGH QUALITY FOR YOUR HIGH QUALITY FOR YOUR MACHINERY MACHINERY
MGM brake motor main features • TEFC 3-ph asynchronous brake motor (0.09kW-130kW)
MGM motor main orfeatures • ACbrake 3-ph brake (no rectifier) DC brake on request
• TEFC 3-ph asynchronous brake motor (0.09kW-130kW) • Oversized brake disc for higher brake torque, longer life and • AC reduced 3-ph brake (no rectifier) or DC brake on request maintenance • Oversized brake fortorque higher adjustment brake torque, life and • Fine and easydisc brake (aslonger standard) reduced maintenance • Very quick brake reaction time • Fine and easySTART/STOP brake torquecycle adjustment (as standard) • Frequent applications • Very quick brake timestandard) • Manual brake reaction release (as • Frequent START/STOP cycle applications • Hexagonal hole on non drive end of the shaft for manual rotation • Manual brake release (asspeeds standard) • Single speed or two motors • Hexagonal holedesigned on non drive end of the shaft for manual rotation • All motors for inverter duty • Single speed or two speeds motors • All motors designed for inverter duty
VARVEL production lines • RS-RT worm gearboxes: 28 to 150 mm centres.
VARVEL production lines and double worm. One stage worm, helical/worm
• RS-RT mmNm. centres. • RD worm helicalgearboxes: gearboxes:2850toto150 2300 Two and three stages. One stage worm, and double • RN parallel shafthelical/worm gearboxes: 180 to 3300 Nm.worm. Two and three stages. • RD helical gearboxes: to 2300 Nm. andNm. three stages. • RO-RV bevel/helical50 gearboxes: 180 Two to 3300 Three stages. • RN shaft gearboxes: to 3300 Nm. and three • parallel RG precision planetary180 gearboxes: 10Two to 230 Nm. stages. • RO-RV gearboxes: 180 to 3300 Nm. Three stages. Onebevel/helical and two stages. • RG precision planetary 10 to 230 Nm. • VR dry friction speedgearboxes: variators: IEC63 to IEC90 One1and stages. to 5two stepless speed range, 300 to 1500 rpm. • VR• dry friction speed variators: IEC63 to to IEC90 VS planetary speed variators: IEC71 IEC112 1 to15tostepless speed range, 300200 to 1500 rpm.rpm. 5 stepless speed range, to 1000 • VS planetary speed variators: IEC71 to IEC112 1 to 5 stepless speed range, 200 to 1000 rpm.
agency.com
agency.com
A new generation of electric motors and gearboxes for power transmission quality from the alliance of two dynamic italian companies. A new of electric motors and gearboxes for power transmission For generation those who want quality. quality from the alliance of two dynamic italian companies. For those who want quality.
MGM-VARVEL Power Transmission Pvt Ltd Ware House No.No. G3 G3 and and G4 •G4 Ground Floor •Floor Indus •Valley’s • Unit 3Park • Mel Ayanambakkam • Vellala Street •Chennai - 600 095 Ware House •Transmission Ground Indus Valley'sPark Logistic • Unit 3 • Mel Ayanambakkam • Vellala Street MGM-VARVEL Power Pvt Logistic Ltd • Tamil Nadu, Phone: +91 INDIA 44 26533665 / 9629691777 • info@mgmvarvelindia.com • www.mgmvarvelindia.com Chennai - 600INDIA 095 ••Tamil Nadu, • Phone: +91 44 64627008 • info@mgmvarvelindia.com • www.mgmvarvelindia.com Ware House No. G3 and G4 • Ground Floor • Indus Valley's Logistic Park • Unit 3 • Mel Ayanambakkam • Vellala Street th REGIONAL KOHLI TOWERS • 4+91 Floor, Dapodi •• info@mgmvarvelindia.com Near Bharat Petrol Pump ••Pune - 411012 Chennai - 600 095OFFICE: • Tamil Nadu, INDIA • Phone: 44 64627008 www.mgmvarvelindia.com th
110
MACHINE TOOLS WORLD
SEPTEMBER 2019
www.mtwmag.com
Scan to Exhibit
Scan to Visit
CASE STUDY
Developing unique products to meet rail demands
Global cutting tool manufacturer Dormer Pramet is working in partnership with several high-speed milling machine manufacturers to deliver key rail projects around the world
W
hen renovating railway lines there are generally two preferred options; grinding or dynamic milling. Compared to grinding, the high-speed re-profiling of a line represents significant time and financial savings. Specially designed trains, operating at a constant speed of 700 meters per hour, machine the existing track profile. By removing millimetres of metal from the damaged surface, the track is restored to its original condition. With each application, the first cutter roughens the surface, the second one finishes it, and the two units act on both rails simultaneously. The operation provides a high-quality surface finish, while metal chips produced during the milling stage are transferred to a nearby container, ensuring no debris is left on the track. This ‘on the-move’ application
112
MACHINE TOOLS WORLD
SEPTEMBER 2019
requires specialized equipment to achieve optimum results, such as ‘train machine tools’ designed to carry dynamic rail milling cutters and inserts. An increasing number of these are being produced by leading global manufacturers as demand from railway organizations and government bodies for track maintenance increases. Global cutting tool manufacturer Dormer Pramet works in partnership with several high-speed milling machine manufacturers to delivery key projects around the world. One of these projects included the milling of three different rail profiles for a customer in the Netherlands. Dormer Pramet’s 600mm diameter dynamic rail milling cutter was able to machine the combined profile (60E1, 54E1, 46E3 1:40) and another profile 54E5 1:40, without having to change the inserts. Using the same cutting
tools across several profiles is hugely beneficial as it saves both time and costs, reducing the number of tool change-overs. Tomas Hantek, application manager for railway at Dormer Pramet, said, “As with all railway projects, each application is different from the next, so we regularly tailor our products to meet the need of the customer. “It is very important we work closely with the machine tool manufacturer and rail organization to identify where adaptions need to be made to achieve the desired results.” The development of new rail technology is constantly taking place and modifications are needed on both sides to optimize the match between the machine and cutting tool. Dormer Pramet has adapted its popular dynamic milling cutter in various sizes, from 300mm to 900mm, with plans to
www.mtwmag.com
CASE STUDY develop a 1,400mm diameter version in the future. Tomas added, “We recently delivered a 300mm diameter dynamic rail milling cutter to a customer for testing. This has been custom made to specifically fit their new machine. In the first trial, they discovered that the cutter profile was as they required. However, they realized their new machine was not strong or rigid enough to cope with the demands of the application. We are now working with them to make some changes and help move the project forward.� At present, Dormer Pramet has more than 50 dynamic rail milling cutters out in the market, including in the Netherlands, Germany and Poland. This is an indication of the international nature of the railway segment, with tool suppliers, machine tool builders and customers from different parts of the world, working together on applications which often take place in different countries. This not only requires precise logistical management, but an understanding of different standards and accreditations between countries. Many projects involve large international organizations, as well as support from government agencies and administrations, along with affiliated transport associations.
www.mtwmag.com
Wheel returning Another example where Dormer Pramet provides support to the railway segment is in wheel returning. This too can see standard tools being modified to become custom-made specials, unique to the requirement of the application. Its assortment of rectangular LNMT and round ROEX inserts, for example, have proven a big hit with customers in North America, with the range available from its distribution center in Hebron, Kentucky. A customer in Philadelphia was having issues with its previous LNMT inserts as they were not able to break chips during a wheel turning operation. The resultant long, continuous swarf congested the area around the workpiece. The process to clear the chips is not only time consuming but can also be hazardous. Dormer Pramet put forward its standard LNMT inserts, but during tests, found these too did not break the chips as required. Following further feedback and discussions with the customer, the company was able to make two key changes to its insert. First it added a corner radius chip breaker to relieve some of the pressure on the tool. It then tailored the geometry and design of the insert to prevent nesting at high depths of cut. The end user wanted to make one
pass, so the LNMT insert needed to be able to achieve a staggering .700� (18mm) depth of cut at the first attempt. Following the changes, the insert was put in for further testing. Not only did this new design fix the chip control problem, but it consistently outperformed all other inserts tested. The customer now orders from Dormer Pramet. In addition, the company has started to use their RCMX, RCMT and TNMG inserts on a variety of operations, such as the turning down of axles. This has allowed them to reduce cycle time by an average of 30%, saving more than $30,000 in the first year, with greater operational efficiency and improved performance. Railway wheel turning is an area Dormer Pramet is looking to expand its assortment further. Where the LNMT can support large depths of cut, the company is now working on a new insert for delivering small depths of cut, around 1mm. A popular trend with customers when machining railway wheels is to perform the operation with a low depth of cut. This is still completed in one pass, but the reconditioning will be required more often between uses. This new product will support those applications. It is currently in the testing phase, with the aim to launch the insert in 2020.
SEPTEMBER 2019
MACHINE TOOLS WORLD
113
CASE STUDY
Automated workpiece set-up boosts forestry equipment manufacture To meet the rising demand for its market-leading range of forestry equipment, Tigercat Industries aimed to boost production efficiency and output at its manufacturing facility in Ontario, Canada. In line with this objective, the company automated workpiece set-up using Renishaw machine tool probing systems and software. The solution has enabled Tigercat Industries to achieve 40% increase in weekly production figures and 75% reduction in set-up times.
A
manufacturer of premium quality forestry equipment, Tigercat prides itself on providing the lowest cost per tonne timber harvesting solutions. From its base in Ontario, Canada, the company exports its products to busy logging operations throughout the world. With a strong engineering culture, Tigercat thrives on the design and
114
MACHINE TOOLS WORLD
SEPTEMBER 2019
continuous improvement of all kinds of forestry machinery. Its broad product range features both treelength and cut-to-length machines and includes feller bunchers, skidders, loaders, harvesters and fellers. They are big, strong, robust machines, typically weighing in at 25 tonnes. Since logging crews often need to rely for example on a single drive-
to-tree feller buncher for continuous operation, machine reliability is always a paramount concern. Just one machine down can cause a whole felling operation to stop. For Tigercat this means that robust construction, high uptime and a long useful lifespan are key product design requirements. At its Southern Ontario, Cambridge site, Tigercat manufactures the larger
www.mtwmag.com
CASE STUDY
steel components for its wheel-based forestry equipment, most notably its feller bunchers, a gold standard in the logging sector since 1992. Busy production line operations include laser cutting, machining, manual and robotic welding and assembly. Challenge In the face of increasing global demand, Tigercat set itself the task of increasing production efficiency and throughput through greater use of automation. A wide-ranging review of existing production processes identified workpiece set-up as a particular area for improvement.
www.mtwmag.com
Plant-wide standardization on a new automated workpiece probing solution would need to accommodate the very large scale and diversity of Tigercat’s thick gauge steel high-tolerance parts, as well as the range of different production line operations. Probes would need to be capable of accurately inspecting critical, hard-to-reach features and be robust enough to operate in close proximity to new automated welding cells. At the same time, the company also wanted to utilise the MazaCheck health check diagnostic capabilities of its Mazak Versatech V100N, a production-critical 5-axis doublecolumn machining centre for very large parts. Solution A review of a wide range of machine tool probe technologies led to the selection of Renishaw’s highaccuracy touch probes with radio transmission and, PC-based probing software. David Hodder, Machine Shop Supervisor, Tigercat said, “We were actually looking at several different companies for the provision of the machine probing systems we needed. We settled with just one company that we felt comfortable
with and that fits perfectly with our engineering culture. That company was Renishaw. They provide good technical support, their on-site technicians are very knowledgeable, and I’d describe their equipment as top-notch.” Designed to aid workpiece setup and inspection on multi-tasking machines and machining centres, the flexible RMP60M spindlemounted radio transmission probe was deployed by Tigercat throughout its Cambridge production line. Drawing on Renishaw’s wide range of compatible ceramic stem and ruby ball styli, the company was able to develop automated set-up solutions, customised to meet the specific demands of Tigercat’s many large and varied workpieces. The RMP60M’s proven kinematic resistive probe mechanism, combined with its unique frequency hopping spread spectrum (FHSS) radio transmission provided Tigercat with a robust solution capable of tolerating any signal interference effects from welding processes and overcoming any line-of-sight challenges. Operating in the 2.4GHz waveband, the RMP60M machine probe is compliant with radio regulations in all major industrial markets. It
SEPTEMBER 2019
MACHINE TOOLS WORLD
115
CASE STUDY offers a variety of activation options, an adjustable trigger force and measurement repeatability of ±1 µm 2σ. Renishaw RMI-Q combined radio transceiver and machine interfaces were employed throughout the plant, converting signals from the RMP spindle probes into voltage-free solid state relay outputs for the machine controllers. For Tigercat’s Mazak Versatech V100N 5-axis machine, an RMP600 probe was specified. A compact, high accuracy touch probe equipped with the same FHSS radio communication capability as the RMP60M, it provided Tigercat with all the benefits of automated workpiece setup along with the ability to measure complex 3D part geometries to unrivalled sub-micron levels. The probe uses Renishaw’s RENGAGE™ technology (a combination of proven silicon strain gauges and ultra-compact electronics) and delivers highaccuracy measurement even when using long and custom styli – ideal for Tigercat’s applications which often require measurement of
116
MACHINE TOOLS WORLD
SEPTEMBER 2019
features in hard-to-reach locations. Finally, Renishaw’s simple-to-use Productivity+™, PC-based software was used to seamlessly program and integrate inspection routines within the V100N machining cycles. Results The integration of Renishaw’s highaccuracy radio transmission probes into Tigercat’s production processes has seen workpiece set-up times reduce by 75%. Manual set-ups that once took an hour have been replaced by automated set-ups that take 10-15 minutes. The new machine probing systems log and record every part they touch. If a part cannot be aligned correctly or does not conform to specification, the operator is immediately notified. Data can be collected to track machine and process performance over time. Since Tigercat partnered with Renishaw on automated machine probing the company has achieved a 40% increase in weekly production figures, and expects further improvements to be made going forward.
There is also now a greater consistency in day-to-day part production and a new-found freedom to be able to move machine operators across machining centres when production demands dictate. The risk of human error has been virtually eradicated and operator safety has been improved by eliminating manual operator interventions. Over time, Tigercat has evolved its use of probing from basic part set-up (pre-machining) to fully integrated, in-process control and part verification, all before the part leaves the machine bed. It has led to improvements across the board, in terms of machine cycle times, part quality and operator safety. It is also being used for machine health checks, giving Tigercat even greater confidence that all of its production processes are perfectly up to specification
For more information www.renishaw.com/tigercat
www.mtwmag.com
PRODUCT SHOWCASE
PRODUCTS SHOWCASE
KING CUT PRO – The Large Gantry Type CNC Cutting Machine Ador’s KING CUT PRO is a CNC portal cutting machine which is very precise and reliable. The machine has one head for plasma sheet metal cutting & one head for flame cutting of sheet metal with a dual side longitudinal drive with AC motors. The standard equipment comes with a basic machine package with CNC controller, one torch, central gas diffusion with manometers and a remote flame ignition. The following equipment are supplied as required by the customer: Additional Equipment: • Plasma power source KJELBERG with machine torch • Programming software MOST 2D • Support table for sheet metal with segment extraction system • Extraction-filter system • Laser position indicator for determining the cutting point Optional : • Extension of the longitudinal rail • Additional cutting head
For Product Enquiry Contact Ador Welding Limited Akurdi Chowk, Chinchwad, Pune 411 019 Tel.: 020- 4070 6000 Email: cmo@adorians.com Web: www.adorwelding.com
www.mtwmag.com
The CNC Controller – Phantom: The Phantom brings you the performance of a cutting edge CNC that is built on more than 40 years of experience in the motion control and cutting industries. This controller is designed for multiple axis cutting machines and features the latest advances in CNC technology on a proven platform engineered to increase productivity, reduce costs and enhance profitability. The software provides flexibility, ease of operation and technologies that put Ador’s experience and expertise in your operator’s hands, resulting in extremely good cut quality and high productivity. The Phantom can operate any cutting machine and interface with virtually all plasma systems. Following are its standard features: Bright touch screen interface, Touch screen interactive display, Expandable shape library, True multi-tasking environment, Fast Dxt file conversion, Go to(Job interrupt), Quick plate alignment, and Monitor & track consumables. Advanced Plasma Process Control (Plasma Process Wizard) is available as optional extra. Ador offers costsaving height control unit for simple plasma cutting applications. The KHC1 system provides all the essential functions that are needed for good cuts and optimum utilization of work-piece.
SEPTEMBER 2019
MACHINE TOOLS WORLD
117
PRODUCTS SHOWCASE
Poly / Cotton Knitted Seamless Gloves with PVC Dots Features & Benefits These gloves are made from blended fibers like Cotton, natural fiber for comfort, while Polyester, a synthetic fiber to increase the strength and to some extent basic abrasion resistant & increased durability. These gloves are generally available in 10 & 7 Gauge in various thickness, colors & weights. These Poly/Cotton Dots are offered in Blue colour as standard model. But the dots colour can be offered in Black, yellow, Red, Green or as per the customers requirement. These gloves are offered at more economical priced. There is an option of different weights, sizes, dots pattern & also both sides dots for some of the models.
For Product Enquiry Contact Marvel Gloves Industries Manufacturers, Exporters & Importers of Gloves & PPEs 187/188, 2nd Floor, Ashoka Shopping Centre, G.T. Hospital Complex, L. T. Marg, Mumbai 400 001 INDIA Phone : +91 22 2262 6546 / 2262 6876 Email : marvelgloves@gmail.com www.marvelgloves.com
Application • General maintenance • Shipping & receiving • Food processing • Light fabrication • Shipping & Port Handling • Drilling Rigs & Offshore companies • Packaging • Automobile Industries • Material Handling
Steady Volt Servo Voltage Stabilizers Frequent voltage variations are a menace that can damage electronic components like power supplies, drives, PLCs, controllers, etc. Their effects are widely felt in CNC, printing and textile machines as well as laboratory, data processing, medical & telecommunication equipment. Frequent breakdowns of such machines are costly to repair. This apart, the downtime and frequent interruptions in operation brings substantial loss of revenue. Steady Volt from Unity Controls is a state-of-the-art Voltage Stabilizer designed to protect such equipment from voltage variations and its ill-effects.
For Product Enquiry Contact Unity Controls Pvt. Ltd 405, Sapphire Arcade, 42 M.G. Road, Ghatkopar (E), Mumbai 400 077 Phone: 022- 2501 3832 / 33 E-mail: sales@unitycontrols.in Web: www.unitycontrols.in
118
MACHINE TOOLS WORLD
SEPTEMBER 2019
Following are some of its unique features: • Intelligent microprocessor-based system(available in new digital models) • Digital interface with large LCD display and keypad • Auto re-start, adjustable output voltage, trip bypass, fault list • No hunting, oscillation and noise generation • Innovative transformer design to minimize power loss • Constant output voltage across a wide input voltage range • Single phasing prevention, surge suppressor and EMI / RFI filter With the best-in-class response time and correction rates, Steady Volt offers improved power quality and greater energy efficiency, thereby saving the cost of breakdowns and energy utilization. Apart from protecting your equipment from damage, Steady Volt also saves energy during continuous operations.
www.mtwmag.com
PRODUCTS SHOWCASE
Automatic Accurate Proportioner Reducing cost of coolants, lubricants and quenchants by automatic proportioning with water Huge losses due to improper mixing of coolants / quenchants / lubricants with water are experienced throughout industries. These include coolant spillage losses of up to 5%, high evaporation losses of coolants from sump, failure of heat treated parts due to improper quenchant mixing, low die life or excessive lubricant consumption in die casting, hot forging operations and low tool life in CNC/ VMC operations due to improper coolant mixing with water. Manual mixing methods followed in the industry are always subjected to human error. Maintaining consistent, correct dilution ratio of concentrates with water is a challenge faced by metal-forming industry. Steel Plant Specialities LLP, Mumbai, offers Accurate Proportioner for correct mixing of coolants / lubricants / quenchants with water, consistently and automatically. Mixing in correct dilution ratios with water enables a number of benefits in important operations like: • CNC / VMC operations: Correct mix of CNC coolant with water enables reduced evaporation losses, increased sump life of coolant, preventing bad odour from sump and increased tool life due to better lubricity • Polymer quenching: Correct mix of polymer quenchant with water enables uniform heat treatment of parts at all locations of quenching tank and desired heat treatment characteristics of induction hardened parts • Die casting and hot forging lubrication: Correct mix of die lubricants with water enable optimal die life and ease of operations, without job sticking
For Product Enquiry Contact STEEL PLANT SPECIALITIES LLP 211, Raikar Chambers, Govandi East, Mumbai - 400 088, India Tel.: 022-67978060 / 022-25552459 Cell: +91-9820493373 Email: info@steelplantspecialities.com www.steelplantspecialities.com
Accurate Proportioner automatically sucks pre-set quantity of coolant directly from coolant drum. It emulsifies (mixes) the coolant with water and delivers the diluted solution through the outlet. The Accurate Proportioner operates only on water connection. No electricity connection and no complex softwares or settings are required. As it works on water pressure, the proportion will always be accurate, as per the inlet of water quantity. Difference in water inlet water pressure will not affect accuracy of proportioner. Capacity of Accurate Proportioner is up to 350 litres per hour (concentrate + water)Successful case studies and certificates of appreciation from reputed Organisations are available on request. Complete support in installation of equipment and training is offered by Steel Plant Specialities LLP.
Looking for industrial Products for your plant/workshop ??? Connect to right manufacturers & suppliers http://www.mtwmag.com/category/products/ www.mtwmag.com
SEPTEMBER 2019
MACHINE TOOLS WORLD
119
ADVERTISERS INDEX COMPANY NAME
PG. NO.
A ACCUSHARP CUTTING TOOLS PVT. LTD.
71
ACE MANUFACTURING SYSTEMS LTD.
BACK PAGE
ADOR WELDING LIMITED
87
ANCA MACHINE TOOLS PRIVATE LTD
5
APEX PRECISION MECHATRONIX PVT. LTD.
97
B
COMPANY NAME
PG. NO.
COMPANY NAME
PG. NO.
GLOBE-TECH ENGINEERING EXPO - 2020
107
NORD DRIVESYSTEMS PVT. LTD.
69
GP PETROLEUMS LTD.
73
P
GROB MACHINE TOOLS INDIA PVT. LTD.
49
PARAGON MACHINERY CO. LTD.
29
PRECISION MOTION INDUSTRIES, INC. ( PMI )
79
H HANGSTERFER'S
60
Q
HURCO INDIA PVT. LTD.
61
QUAKER HOUGHTON
I
BEARING EXPO & CONFERENCE - 2019
39
BETTINELLI AUTOMATION COMPONENTS PVT. LTD.
85
BIRLA PRECISION TECHNOLOGIES LIMITED
75
ISCAR INDIA LIMITED
31
R INNER INSIDE FRONT COVER
J
RENISHAW PLC
51
RENMAKCH INDIA PVT. LTD.
43
JAYASHREE ELECTRON
91
ROCKLIN MANUFACTURING CO.
65
JERGENS INDIA PVT. LTD.
62
ROLLON INDIA PVT. LTD. - INDIA
103
JYOTI CNC AUTOMATION LTD.
95
RR KABEL LIMITED
27
D DMG MORI INDIA
7
DOWEL ENGINEERING WORKS
77
DRAKE
17
DVS TECHNOLOGY GROUP
18 - 19
E ELECTROTHERM (INDIA) LTD. ELGI EQUIPMENTS LTD.
13 25
K KEMPPI INDIA PVT. LTD.
S 93
L LAKSHMI ELECTRO CONTROLS & AUTOMATION
35
LASER WORLD OF PHOTONICS INDIA - 2019
47
M ENGIMACH - 2019
111
EPPINGER TOOLING ASIA PVT. LTD.
98 - 99
ERWIN JUNKER MASCHINENFABRIK GMBH
21
F
120
91
STEEL PLANT SPECIALITIES LLP
55
SUGINO MACHINE INDIA PVT. LTD.
37
T THE ASSOCIATION FOR MANUFACTURING TECHNOLOGY
57
FALSE COVER
MACHINE TOOLS, MANUFACTURING & TECHNOLOGY EXPO
15
TRUCUT PRECISION TOOLS PVT. LTD.
MARVEL GLOVES INDUSTRIES
105
U
MASTERCAM INDIA
INSIDE BACK COVER
UNITY CONTROLS PVT. LTD. V
FACCIN S. P. A.
23
MGM-VARVEL POWER TRANSMISSION PVT LTD
109
FIBRO INDIA PRECISION PRODUCTS PVT. LTD.
53
MICRO-EPSILON INDIA PRIVATE LIMITED
81
FLIR SYSTEMS INDIA PVT. LTD.
41
MILLENIA TECHNOLOGIES (I) LLP
66 - 67
MMC HARDMETAL INDIA PVT. LTD.
INSIDE FRONT COVER
G
SEW-EURODRIVE INDIA PVT. LTD.
GEDEE WEILER PRIVATE LIMITED
9
N
GLEASON WORKS (I) PVT. LTD.
33
N. GANDHI & CO.
MACHINE TOOLS WORLD SEPTEMBER 2019
V M TRADERS
101
89
W WOHLHAUPTER / ALLIED MACHINE & ENGINEERING COMPANY
58
Z 83
ZECHA PRECISION TOOLS LIMITED
11
Mastercam X8 is retiring.
UPDATE NOW. TIME IS RUNNING OUT! With the upcoming release of Mastercam 2020, you will no longer be able to update or receive support for your copy of Mastercam X8. If you update now, you have the opportunity for dramatic savings and revolutionary, industry-changing new technologies! Mastercam X8 was released nearly seven years ago. Although it still gets the job done, you are missing out on dramatic advances across the entire Mastercam family, including our breakthrough Dynamic Motion and Accelerated FinishingTechnologies:
!
Efficient Motion
!
!
Save Time & Money
Extend Tool Life
!
Increase Output
Thousands of existing users have already taken advantage of the new technology introduced in Mastercam since X8 was released. ACT NOW! Help Shape the Future of Manufacturing by updating today!
Email us at : Call us at :
marketing@mastercamapac.com +91 7378 55 2000
Mastercam India | 303 - Tower 1 | World Trade Centre | Kharadi | Pune - 411014
RNI No. MAHENG/2015/64267 Postal Reg. No. THC/173/2018-2020. Posted at Mumbai Patrika Channel Sorting Office G.P.O. Mumbai 400 001 on 15th of every month and Published on 10th of every month
122