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Editorial

February 2013 - MMT 15

ational economies are complex affairs, but the reasoning behind boosting Indian SMEs’ presence on the world stage is simple—SMEs make up a majority of enterprises, so any trade that helps small businesses also helps the national economy. Small businesses must look overseas to trade their way out of the economic downturn. It is a strategy and a philosophy that will never go wrong … in good times or otherwise!

‘Exports have always exported’ is the new mantra of success for SMEs—also known as firms that are ‘born global’! These firms are viewed as engines of regional economies bringing overseas income into national and local economies. Incidentally, exports and the highly famous EXIM imbalance in the machine tool sector are the focus topics for MMT this month!!

Internationalisation or international entrepreneurial SMEs are capable of exploiting global market opportunities more rapidly and efficiently. Among them, more and more SMEs participating in international activities shortly after their inception is an international born-global phenomenon. It has been noted that internationalisation (such as outward market seeking or inward foreign resource acquisition) tends to be a successful strategy for born-global SMEs to access and exploit the vast global business opportunities that were previously capitalised almost exclusively by large, established companies. A common perception is that as SMEs grow and establish their domestic presence, they then seek to expand into overseas markets.

Clearly, many SMEs have shown that successful exporting does not necessarily require a detailed master plan. However, there is an argument that owner-managers could be missing out on valuable opportunities to do business abroad by taking a more ‘reactive’ rather than a proactive approach to exporting.

If owner-managers do not approach exporting into new markets with an extensively developed plan (i.e. they are ‘reactive’ exporters), they should ensure that they maintain a general awareness of and alertness to international opportunities. These owner-exporters must also know where to look for immediate assistance if they need it and which sources of advice they can exploit to maximise opportunities quickly.

With all this and more, this June edition of MMT is laden with lots of truly enabling business-to-business updates and analysis! As the cover shout clearly states, it’s time to demystify the EXIM divide and dilemma. It’s a perception and hence the topic of constant debate that for the machine tool sector in India, imports constitute 65%. We don’t agree simply because this figure is not all-encompassing and hence inaccurate & cannot be a reference point. Thus go the rest of the Perceptions Vs Realities—like it’s a perception that China & Taiwan are superior but the reality is that this edge is only in mass production and cannot be generalised. Or that the developed markets are out of the reach & radar of Indian companies but the reality is that there is limited thrust by Indian companies in knowing new markets!

Read on to get a Reality Check!

N

MMT Mentor

Shailesh Sheth Corporate Strategy Advisor

Archana Tiwari-Nayudu [email protected]

Born-global SMEs

iN cONVERSATiON WiTH

Contents

iNSigHTS & OuTlOOk

NExT EdiTiON HigHligHTS

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WiNdS OF cHANgE .............................. 72gROWTH mATTERS ............................... 74OPiNiONS & mORE ...............................76

iNduSTRy OuTlOOk ............................. 42myTH BuSTERS .................................... 44imPROViNg SimulATiON....................... 45TiPS & TRickS...................................... 50mulTiPHySicS ANAlySiS ..................... 52

Exim ANAlySiS ................................... 60FAcT FilES........................................... 62OPiNiONS & mORE............................... 66TiPS & TRickS...................................... 68

EdiTORiAl .................... 15SARATHi SuTRA .......... 21VANTAgE POiNT ............ 23NEWS, ViEWS & ANAlySiS ..................... 24TEcHNOlOgy & iNNOVATiON .................. 32TENdERS ....................... 84lAuNcH PAd ................. 86PROducTS .................... 92liST OF PROducTS ........ 118liST OF AdVERTiSERS .... 124

SEcTOR WATcH

SPEciAl FOcuS

SATiSH gOdBOlE

Vice President, Motion Control Systems – Drive Technologies, Siemens Ltd

EVENT REPORTHANNOVER mESSE 2013 ... 78

REPORT cARdVERTicAl ARTiculATEd ROBOT .......... 90

REgulAR SEcTiONSSpecial Focus: Metalworking FluidsInsights & Outlook: Performance Analysis of CNC Builders

60 72Exim Analysis Winds of changeiNSigHTS & OuTlOOk SEcTOR WATcH42 industry Outlook

SPEciAl FOcuS

38

TAEguTEc iNdiA P lTd ....... 56Facility Visit

June 2013 - MMT 19

Founder & editor, network 18Raghav Bahl

President & editorial director, tV 18Senthil Chengalvarayan

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Printed by Mohan Gajria and published by Lakshmi Narasimhan on behalf of Network18.Executive Editor: Archana Tiwari-NayuduPrinted at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Network18, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai - 400 028. MODERN MACHINE TOOLS is registered with the Registrar of Newspapers of India under No. MAHENG / 2008 / 24347. Network18 does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition.

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MMT - Febuary 201320

The machine tool industry has been playing a significant role in discrete manufacturing since years. Machine tools are referred to as mother machines that produce other machines. Therefore, any initiative for efficient manufacturing and

sustainability in the long term must have its starting point in machine tools. However, green manufacturing is not feasible, unless machine tools comply with ‘eco-friendly standards’. Over the years, the concept ‘Go Green’ has carved a prominent place for itself in the manufacturing sector. In fact, it is as important as it was 10 years ago and has gained prominence in various segments of the sector. The world of machine tools is already moving in the ‘green’ direction; take, for instance, dry machining, which is in vogue as it eliminates the need for coolants. Also, Minimum Quantity Lubrication (MQL) dramatically reduces the amount of lubricants used. However, a significant area in which the Indian machine tool industry still lags behind is pioneering initiatives with respect to recycling machine elements. For example, the concept of exchanging used equipment for new equipment has not yet been practiced as a serious marketing tool. Also, the business of reconditioning and upgrading of old equipment is at a premature level.

But the picture is not grim for India! It was recently reported that India is developing the heaviest and largest parts of Tokamak—the machine responsible for the biggest scientific collaboration on the planet—to produce unlimited supplies of cheap, clean, safe and commercially viable energy from atomic fusion. India will be one of the significant creators of Tokamak, which will weigh 23,000 tonne—the weight of three Eiffel Towers—with a plasma volume of 840 cubic metres. Beginning December 2015, the first of ITER Cryostat’s components will arrive on site from India. According to ITER, these 54 segments are among the largest and heaviest of the entire Tokamak assembly. ITER is a unique opportunity for the

Indian industry to show that fusion can be a credible and sustainable alternate energy source for human civilisation.

Who says that green initiatives are just a FAD that will FADE away with time? With the industry keen to find ways to adopt green into its manufacturing processes, the trend is here to stay. These green concepts have to

be converted into commercialised business models and the responsibility for creating them lies clearly with the Indian machine tool industry.

Merchant of DreamsBy Shailesh Sheth

Shailesh Sheth, an eminent authority, shrewd analyser of trends, brilliant strategist and considered by the industry as a ‘Guru’, to us, he manifests as ‘Sarathi’, accomplishing his timely purpose in the ever-evolving world.

“The rate of innovation and usage of materials is so high that we will need a paradigm shift in our manufacturing capacity. We have to redefine sustainability. Once we do this, our carbon footprint will be reduced and we will become smarter consumers. In my opinion, going green will be profitable for any business.” - Arun MairaMember, Planning Commission

“The major challenges for industries of all sizes have been growth and sustainability. I believe that innovation, together with sustainability, is becoming a cornerstone for many companies, especially for small and medium enterprises. Products developed nowadays are being examined from the perspective of being recyclable and reusable.”- Jamshyd N GodrejCMD, Godrej & Boyce Manufacturing Co Ltd

From Greed to Green!

June 2013 - MMT 23

TK Ramesh, the CEO of Micromatic Machine Tools Pvt Ltd, is the Marketing Guru of the `1,200-crore Ace Micromatic Group. The epitome of business analytics and a veteran in strategy dynamics, he envisions a glorious ‘Brand India’ pennant fluttering over the global machine tool arena in the near future.

Providing the right post-delivery service is one of the most important aspects of a machine tool marketing package. A

machine might encompass some of the best features and specifications, but if it fails to come with swift and efficient servicing, the product might lose its sheen and preference among its customers and the entire value of a world-class machine can crumble.

Let us look at the typical case of a Computer Numerical Control (CNC) lathe or a Vertical Machining Centre (VMC)—the physical product is the machine, and the service products comprise its installation, commissioning, training for use, making of the first part and warranty, followed by spare parts, breakdown service, post-warranty maintenance contracts, etc. Furthermore, the service delivery measures comprise response time, repair time, Mean Time Between Failures (MBTF), Mean Time To Repair (MTTR), etc.

Intricacies of Service Theoretically, service has two dimensions: (1) procedural dimension or the ‘what’ of service, which, in case of machines, is installation, commissioning, training, breakdowns, etc. and (2) personal dimension or the ‘how’ of service, which is people, their attitudes, behaviour, communication, etc. The combination of what & how determines the satisfaction levels and this combination is not a simple arithmetic sum of these two dimensions. So, what then leads to customer satisfaction or dissatisfaction? The gap between what

customers expect and what they ‘think’ they get decides the extent of their satisfaction or dissatisfaction. Customers’ expectations are greatly influenced by their needs, options available, past experiences and inferences from the marketplace. Understanding their needs is the only way to gauge their expectations while their perceptions are managed through

effective communication.National capital

equipment surveys have shown that over 60% of the customers who complain come back for repeat business if their complaints are resolved, while at the same time, about 50% of the customers who don’t complain never repeat their business.

Thus, it is of strategic importance to have a robust complaint management & resolution system in place, which should be seen as a defensive marketing strategy that involves not only retaining existing customers but also engagin in positive

word-of-mouth publicity to attract new customers. Hence, it is essential to relay the message ‘We Care’ to your customers. Despite best efforts, there will be situations where customers will be unhappy. But complaints need to be seen as opportunities to retain customers and improve business.

Service: A USP in Marketing Machines

Despite best efforts,

there will be situations

where customers will be

unhappy. But complaints

need to be seen as

opportunities to retain

customers and improve

business.

Our Management

Guru is eager to hear

your views. Please send

them in at

[email protected]

By TKR

Solve NowPrioritise & Improve:Will Add Value Overall

Consider Improvements: Can Significantly Impact Some Segments

Ignore

Complaint Management MatrixHigh

Freq

uenc

y

HighLow Impact

MMT - June 201324

News, Views & Analysis

Seco Tools to strengthen its operations in India

Sandvik envisions India as its specialised centre of excellence by 2016

Seco Tools India Pvt Ltd, a wholly owned subsidiary of Seco Tools AB, Sweden—a leading

manufacturer of high-performance metal cutting tools, is in the advanced stages of strengthening its operations in India. The company, in sync with its expansion plans for India, has acquired around 25,000 sqmt of land to add to its production capacities adjoining its existing production facility at Nagar Road, Pune.

Within the Seco Tools Group, the Indian production facility is the 3rd largest unit and with ambitious expansion plans for India, the company is now gearing up to expand its manufacturing base in India with the intention of not only catering to the growing needs of Indian

markets but also to those of international markets. Seco’s expansion plans in India were announced by Lars Bergstrom, President & CEO, Seco Tools. Andreas Fritz, Vice President - Asia Pacific, Seco Tools, and Anders Fager, MD, Seco Tools India Pvt Ltd, were also present at the occasion.

Talking at the occasion, Bergstrom said, “India holds many advantages such as upcoming infrastructure, workforce, language and strong patent security. The company sees a lot of potential in India for further growth in production and continuous expansion of R&D activities. He added, “The country has many emerging sectors such as agriculture, biomedical and general engineering apart from the

traditional sectors. India being one of the important countries in terms of growth, Seco Tools has shifted its Asia Pacific headquarters to India.

Speaking about product innovations at Seco, Fritz said, “Product innovation continues to be one of the key strategies for growth at Seco Tools. As a biannual introduction of products developed in response to specific customer needs, Seco News—the new definition of product innovation & launching—offers new solutions pertaining to all application areas and industry segments. The upcoming Seco News launch will have a wide range of all-new products for a diverse range of applications catering to emerging sectors such as composite machining, biomedical, etc.”

Sandvik is planning to redefine its growth strategy in India to increase its market penetration

and share in the country. The company announced the acquisition of 50 acres of new land for Sandvik Asia Pvt Ltd and has projected significant investments, including R&D, by 2016. Sandvik continues to successfully add new products to its portfolio for Sandvik Mining, Sandvik Machining Solutions, Sandvik Materials Technology and Sandvik Construction.

The company has recently launched 160 D Surface Rock Drill, which is locally designed, sourced and manufactured for the Indian market, mainly for medium-sized industries. This is one of the first developments from the engineering and design centre in mining and construction, which will now be expanded to include about 15 designers in the first phase in Pune. Besides, the R&D team and Patancheru (Hyderabad) will continue to grow in line with the global requirement of specific types of rock excavation tools.

Sandvik’s cemented carbide recycling plant at Chiplun, Maharashtra, has

been a success story in terms of global and local R&D. The plant recycles all expensive components in cemented carbide using a physical process. Over the last few years, tonnes of carbide scrap collected from all over the world have been recovered. This competent centre will add a significant capacity this year to take the process ahead. Sandvik has also launched a series of CSR engagement programmes in India with focus on the areas of education, health and vocational training for the underprivileged. Ajay Sambrani, MD, Sandvik Asia Pvt Ltd, said, “We have identified mining and construction as a major growth area in India, which will significantly contribute to the company’s top line.”

L-R: Olof Faxander, President & CEO, Sandvik; Ajay Sambrani, MD, Sandvik Asia Pvt Ltd .

At Intersolar Europe, the Lapp Group and FPE Fischer will present the Epic® Solar Map

Set, a modular connection system. The innovative solution has been nominated for the Intersolar Award 2013. The Epic® Solar Map Set helps cut the cost of connection technology while boosting the level of automation in the module manufacturing process and making modules easier to service and repower. It comprises a range of components made of high-quality, weatherproof, impact-resistant plastic, which can be combined as required to create connections between photovoltaic modules—thereby render ing conventional junction boxes redundant. These standardised components can be mounted and welded onto modules automatically, and customised solutions for varying numbers of strings and cable lengths can be easily provided even within the same production line.

Lapp and FPE Fischer’s innovative solutions nominated for Intersolar Award

MMT - June 201326


FARO Technologies, Inc, a leader in 3D measurement

technology, hosted its first 3D documentation conference in Asia Pacific. The flagship regional event held in Singapore saw more than 180 delegates from 20 countries congregating for various sessions of high-value knowledge exchange.

The conference featured latest developments as well as future perspectives relating to 3D documentation and in attendance were participants from a variety of sectors such as architecture, civil engineering, surveying, forestry, forensics, facilities management as well as mining and tunneling industries. Centred on the theme of ‘Connecting 3D Communities’, the event helped foster fruitful connections. Joseph Arezone, Senior VP

and MD, Asia Pacific, FARO Technologies, Inc, said, “We have held this conference in other regions in the past but this is the first time we have brought it to Asia, and we could not have asked for a better outcome and response.”

One of the keynote addresses was delivered by Dr Bharat Lohani, Associate Professor - Department of Civil Engineering, Indian Institute of Technology Kanpur, India. Dr Lohani shared his findings and techniques on motion correction for laser scanning of moving objects. His novel approach involves rigid mounting of GPS and INS devices on the body of the object. When the trajectory data generated by both devices is processed along with the laser scanner data, motion correction is facilitated.

Honouring Kennametal for innovative engagement in process optimisation, Parker Hannifin recently conferred the

Excellent Supplier Performance award on the company. This award recognised two successful co-engineering projects between Kennametal Deutschland GmbH and Parker Hannifin, Pump & Motor Division, Chemnitz, which resulted in savings of roughly US$80,000 for the customer. Focused on sharing knowledge and expertise to ultimately improve customers´ processes, Kennametal engineers helped realise process time reduction in turning operations on low alloy manganese steel. A capacity of 680 machine hours was saved and is now used to increase production for the soft machining of gears. In addition, the consumption of tools was reduced, significantly decreasing tooling expenses. In addition, Kennametal helped increase the life of cutting inserts on machine centres and cast iron housings for gear pumps. The milling tools were optimised, saving 85 machine hours while decreasing the frequency of cutting insert exchanges by 50%.

FARO hosts its first 3D documentation conference

Kennametal receives ‘Excellent Supplier Performance’ award from Parker Hannifin

The recent HaasTec 2013 open house was a resounding

success, attracting nearly 3,000 visitors, including 300 students from local and regional schools & colleges, to the company’s headquarters and manufacturing facility in Oxnard, California. The four-day event drew customers from 44 different countries, including the US, Canada, China, India, Korea, Latin America, the Middle East and Europe.

Alain Reynvoet, MD, HAE, said, “Haas Automation Europe was delighted to host more than 250 guests

who made the trip to Oxnard from all over the continent. For most, this was their first time to the Haas factory. Along with the latest Haas products,

they were also treated to a VIP tour to meet senior executives and personally witness the incredible infrastructure behind the company’s success.” Nineteen of the most popular Haas CNC machine tools were on display along with the brand new UMC-750 universal machining centre, all of which demonstrated the latest high-productivity features and options. Also on show were the Haas ST and DS CNC turning centres with

dual-spindle and Y-axis models; the DT-1 Drill/Tap Centre; a wide array of Haas VMCs and a pair of Haas horizontal CNC machine tools.

Visitors at the HaasTec 2013 open house

HaasTec 2013 welcomes visitors from around the world

MMT - June 201328


Siemens has been recognised by leading PLM strategic management consulting and research firm,

CIMdata Inc, as the market presence leader in the collaborative Product Definition management (cPDm) market segment for the 12th year in a row, and in the digital manufacturing market segment for the 8th year in a row. CIMdata’s findings are based on in-depth data and analysis of the PLM market and were announced late last month. Siemens‘ PLM software business unit addresses CIMdata’s cPDm category with its Teamcenter® portfolio, the world’s most widely used digital lifecycle management software, while its Tecnomatix® portfolio is the most widely used software in the

digital manufacturing market segment. “According to our market research, Siemens continues to lead in digital manufacturing with significantly more revenue than the next ranked provider. The company also continues to lead in the critical cPDm market segment,” said Peter Bilello, President, CIMdata.

According to CIMdata’s forecast, the cPDm market segment will experience a five-year Compound Annual Growth Rate (CAGR) of 7.5%, resulting in a projected cPDm market size of approximately US$16.2 billion by 2017, based on the total software and services investments. CIMdata’s forecast for digital manufacturing is estimated to maintain a steady growth with a five-

year CAGR of more than 7%. Overall, CIMdata reports that mainstream PLM is forecasted to grow at a five-year CAGR of over 8% and continues to see growth as a key enterprise investment.

“The latest CIMdata report highlights our consistent track record of leadership in some of the most important areas of PLM,” said Chuck Grindstaff, President & CEO, Siemens PLM Software. “We consider cPDm and digital manufacturing as the most critical value creators for our customers today as well as in the future. So, maintaining our leading position in these disciplines is an important part of doing business and is also part of our vision to help customers make smarter decisions resulting in better products.”

Parts cleaning technology leader Dürr Ecoclean inaugurated its new

technology centre in Pune, which is a 6,000-sqft facility equipped with the latest technology. It houses machines for aqueous as well as hydrocarbon industrial parts cleaning. The investment offers customers the opportunity to locally conduct cleaning trials and laboratory tests in order to choose the suitable cleaning process for their requirements. Conveniently located at Nagar Road, the new Dürr Ecoclean technology centre gives customers the option to locally run cleaning trials in a variety of Dürr manufactured part washers using different cleaning technologies. The laboratory is equipped with the latest technology for cleaning trials and Millipore tests offering customers the advantage of

directly experiencing the cleaning process and check results. In addition, its local presence saves costs and time for shipping sample parts to similar test centres in Germany, thereby significantly shortening the test process. The new facility is a welcome addition to Dürr Ecoclean India. “Our customers appreciate that we have expanded our activities and now offer cleaning trials in Pune. The inauguration of our technology centre has been a significant step towards strengthening our market position in India,” explains Mangesh Agarwal, GM, Dürr Ecoclean, Pune. The industrial parts cleaning market in India is developing gradually with customers especially demanding locally manufactured machines. Dürr Ecoclean meets these needs with its Universal 81W “Made in India.”

Siemens retains its leading position in two critical market segments

Dürr Ecoclean opens new technology centre in Pune

Hypertherm updates its CAD/CAM nesting software

Hypertherm, the US-based manufacturer of advanced cutting systems, announced a number of feature enhancements to

its TurboNest® and NestMaster™ CAD/CAM nesting software. The updates will make it even easier for companies that fabricate or cut metal to increase the cut quality, productivity and profitability of their operations. The added features and enhancements include:n Support for CAD fonts: TurboNest now

supports native AutoCAD® fonts (SHX) and Windows® system fonts (TrueType, OpenType, PostScript) for CAD drawings that contain text.

n 2D CAD cleanup: The enhanced 2D CAD programme in TurboNest can make quick changes to any CAD drawing before it is added to the part list.

n Unicode fonts for CAD text: NestMaster now supports Unicode fonts for CAD drawings that contain text.

n 2D CAD multi-drawing support: Multiple drawings can be opened simultaneously in 2D CAD in NestMaster.

The Version 10.1 update is available free of cost with an active TurboNest or NestMaster software subscription.

MMT - June 201330


The recently launched online job portal for the PLM industry, IndiaPLM, India’s first and

exclusive online PLM career and recruitment portal. IndiaPLM is also the world’s most comprehensive online career and recruitment portal.

Launched by Narsimhan M Tirumalai, Founder, President & CEO, IndiaPLM, the portal is dedicated to the PLM industry, which is growing at almost 15% pa. Its underlying vision is to be a premium PLM job portal with a clear focus on matching great talent with perfect opportunity.

According to Narsimhan, “With the advantages of being one-of-its-kind and operating in a specific domain, IndiaPLM offers a focused platform for both job seekers & the employers. This makes their search easier, offers them much more opportunities and fulfils their requirements in the most ideal manner. Job seekers can search hundreds of jobs, build and post their

resumes and access PLM information and career advice. IndiaPLM connects them to real-world opportunities that can help them achieve their goals and realise their dreams. Regardless of whether they are looking for a new job, a new career, a new city or a new direction, IndiaPLM helps them explore the possibilities and find opportunities that are just right for them.”

Narsimhan adds, “The employers can get instant access to IndiaPLM’s powerful hiring tools, post jobs, search resumes, screen candidates and streamline their entire hiring process.” With PLM being in vogue in India, it is not only big industries or OEMs but also SMEs & engineering services companies that implement

PLM. In this scenario, the requirement for skilled PLM professionals is growing by the day. IndiaPLM also offers unique branding solutions, threby enabling employers to increase and enhance their visibility with a job portal in their domain.”

Talking about the PLM industry, Narsimhan says, “Till a few years back, there were only a few Indian OEMs that used PLM. Two factors contributed to this. First was the affordability factor— PLM licensing cost was and is huge. Costs vary from US$50,000 to a couple of million dollars. And second was the widespread feeling that the scope of PLM in India is limited to large-sized industries only. There were certain implementations in mid-level companies but most of these were MNCs and hence did not have a driver of PLM Implementation. Indian companies not having their own products was also a key issue.”

The 9 th Doosan International Machine Tools Fair (DIMF) was

hosted by Doosan Infracore from May 14–16. Sixty-three sophisticated machines attracted 4,000 visitors including customers and dealers from 41 countries—Europe, the US, China, etc.—as well as academia, machine tool associations and partner firms.

Doosan Infracore unveiled 52 new models at the fair, including large machining centres specially designed for the aviation, oil and energy industries which show increasing demands in the recent years. Doosan also unveiled SMX (Super Multi-tasking turning centre), a next-generation machine tool with a new exterior design in the exhibition. This new product is the integration of a turning centre

and machining centre with remarkably enhanced productivity and convenience.

At the fair, Doosan Infracore also announced a new maxim for its machine tools business—‘Optimal Solutions for the Future’—which implies ‘continual innovation in all aspects of business,

including products, technologies, thinking and processes, to provide optimal solutions according to customers’ requirements’.

Jaeyoon Lee, Head, Machine Tools BG, said, “The DIMF, marking its 9th anniversary this year, is the driving force behind the present global reputation of Doosan machine tools. Our promise to customers is to continuously develop and provide innovative products equipped with high speed, high precision, multi-functions and intelligence. We also plan to realise our vision to be among the

Top 3 global machine tool companies by strengthening our partnerships with dealers.”

Doosan Infracore has been hosting its own biannual international machine tools fair (DIMF) since the year 1997.

Exclusive career & recruitment portal launched for PLM industry

Doosan Infracore hosts the 9th DIMF in Changwon

63 products including 52 new models were showcased, attracting 4,000 customers and dealers from around the world

MMT - June 201332

Technology & InnovaTIon

All the lights go out. The race starts. Full throttle. When the 230-HP motor howls, the driver uses the chunky tank to push the

centre of gravity forward. After 2.6 seconds, the speed attained is 100 km/h. And after 5 seconds, the new Suter BMW is already thundering across the asphalt at 200 km/h. This driving performance is enough to make any Porsche driver turn pale and is only possible if both the driver and the motorcycle meet the highest set of requirements. While people train hard to reach this standard, the machine must have a particularly sophisticated execution.

According to Roger Sutter, Engineer, Suter Racing, the challenge lies in building a motorcycle with the right rigidity at a low weight. “For us, every gram counts,” he says. To manage this balancing act, the use of

titanium is inevitable for motorcycle manufacturers. “The strength and light weight is perfect for us,” says Sutter. However, the light metal is also hard to cut. “It is a real challenge to find the optimum components for working with titanium,” he adds. Hansueli Looser, Director - Product Management,

KAISER, informs, “We receive calls from customers complaining about the unacceptably small life of tools used to work with titanium or inconel. The main reason behind this is the occurrence of vibrations; however, it is, in fact, quite easy to change this, adds Looser. He is firmly convinced that the right combination of metalworking fluid and tool could result in longer life when working with titanium and thus lead

to corresponding reduction in time and tool deterioration. Specific vibration-free tools are required to bring about this change. In combination with the optimum inserts, this ensures a balanced use of the insert while resulting in reduced wear. This effect is reinforced with the right metalworking fluid,

As part of a joint research project, Blaser Swisslube and KAISER worked towards attaining the optimum combination of tool and metalworking fluid for titanium cutting. By using the KAISER 655.389 insert in combination with the metalworking fluid B-Cool 755 from Blaser Swisslube, they successfully devised the best combination for boring titanium with a 20-fold increase in the life of the insert.

Titanium dances to a different beat!

Technology & InnovaTIonCutting Fluids

Rear axle of the Moto3 motorcycle; titanium screws and turnbuckles

June 2013 - MMT 33

Cutting Fluids

which minimises friction and provides the necessary cooling. Considering that little research has been carried out in this area till date, the findings are not yet backed by the industry.

In fact, a survey by the coolant manufacturer Blaser Swisslube shows that the choice of suitable tool and metalworking fluid only plays a minor role in the purchase of a new machine. This is either because no consideration is given to the significant influence of the metalworking fluid and the cause-effect relationships with the materials and tools, or because their importance in a successful cutting process is underestimated. According to Christoph Wüthrich, Head - Technology Centre, Blaser Swisslube, metalworking fluida are only of modest importance to the industry. “They are often considered just a necessary evil,” he adds.

Unique Technology CentreTo illustrate the importance of this necessary evil in the cutting process, Blaser has set up a unique Technology Centre at its main site in Hasle-Rüegsau. At the 300-sqm site, customer cutting processes are optimised and their own products are tested. Wüthrich describes the latter to be like “searching for a needle in a haystack” because a metalworking fluid consists of many different additives.

The TestsFive approved metalworking fluids and several competing products were selected for tests at KAISER. Over several months, Blaser and KAISER tested different inserts in combination with these different metalworking fluids. What emerged was the realisation that selecting the right metalworking fluid has a significant influence on the lifetime of the insert. Therefore, under favourable conditions, the life of the same insert can increase 15-fold, depending on the metalworking fluid. As envisioned, the choice of insert also plays a role in this process. The lifetime of the tested inserts differed

by up to a factor of 20. The result was surprising as

only the inserts that were recommended by manufacturers for cutting titanium were used in the tests. The combinat ion o f the B la se r coolant B-Cool 755 and the inser t 6 5 5 . 3 8 9 f r o m K A I S E R w a s particularly impressive, as it resulted in insert deterioration insert of just 0.002 mm. This was achieved after boring 81 holes with a depth of 51 mm and an average speed of

120 m/min, which is high for titanium.

n The metalworking fluid has a significant influence on the life of the insert. Depending on the product, an insert’s life can be increased 15-fold.

n With regard to the inserts, there are dramatic differences in terms of their life. In spite of the same metalworking fluid and exactly the same cutting parameter, it increases

20-fold.n The best combination for

boring titanium: KAISER 655.389 insert in combination with the metalworking fluid B-Cool 755 from Blaser Swisslube.

The resUlTs

short and sweet

Insert KAISER, TCGT110204, AlCrN, art. no. 655.389 (blue curve)

New

New

After 81 bores

After 81 bores

After 81 bores

After 81 bores After 81 bores

New

New

Competitor insert, TCMT110204, TiAlN (red curve)

Coolant Blaser B-Cool (blue curve)

Coolant competition (red curve)

The test tool precision boring head EWN 2-50XL

Courtesy: KAISER Precision Tooling Ltd. www.blaser.com

www.kaisertooling.com

MMT - June 201334

Technology & InnovaTIon

Five-axis measuring technology breaks through the limits imposed by Coordinate

Measuring Machines (CMMs) and achieves unprecedented levels of throughput whilst maintaining the current levels of metrology. In conventional measurement methods, CMM performs all the movements necessary to acquire the surface data.

Acceleration induces inertial deflections in the machine structure, which, in turn, induce measurement errors. The 5-axis CMM gives manufacturers comprehensively increases the quality of their products. Unlike systems based around indexing heads or fixed probes, 5-axis motion enables the stylus to follow a continuous path around complex components without having to leave the surface to change the stylus cluster or index the head. Controller algorithms that synchronise CMM and head motion produce an optimal tip path and minimise CMM dynamic errors.

The influence of metalworking fluids on the machining process is often underestimated. A recent

project conducted with the Technical University (Technische Hochschule) in Aachen demonstrated this clearly. The aim of this project was to reduce the machining time required to drill a deep hole in tempered steel while retaining the same standard of quality—an operation that took three minutes. Until its collaboration with Blaser Swisslube, the Technical University in Aachen used conventional cutting oil for this machining operation.

To optimise these demanding drilling operations, a process of rigorous testing and adjustment was

applied to the tool, drilling strategy, machining parameters, metalworking

fluid delivery and metalworking fluid. The water-miscible cutting and grinding fluid was pumped through the tool at high pressure (60 bar) to evacuate any chips and to prevent the downtime otherwise caused by chip removal. The key thing here is to select a metalworking fluid with no tendency to foam even at high pressures. It is essential to prevent air bubbles in the emulsion since they counteract the cooling action and obstruct the flow rate that enables chips to be cleared effectively. At the end of this project, the original time required of three minutes per hole was reduced to ten seconds for a depth of 200 mm—an 18-fold improvement in efficiency.

Deep-hole drilling 18 times faster

Five Axis CMM

starting Position

Operation: Deep hole drilling, diameter 8 to a depth of 200 mm

Material: 42 CrMo4 + QT, tensile strength 1000 MPa

Machine type: Mazak Variaxis 500

Tool: Kennametal and Titex drilling tools

Cutting parameters: Vc 120 m/min, f 0.25 mm/revolution

UsPs

Delivers unprecedented measuring speed and flexibility

Boosts measurement throughput

Minimises lead times

rAM eDM

In a RAM EDM application, a graphite electrode is machined using traditional tools. The

specially shaped electrode is connected to the power source, attached to a RAM and slowly fed into the workpiece. The entire machining operation is usually performed while submerged in a fluid bath. There are many operations wherein RAM EDM proves to be the most efficient way to machine parts. RAM EDM can machine a wide variety of shapes and sizes, including sharp corners. Also, this non-contact machining method with low-pressure flushing enables the production of produce highly thin sections.

UsPs

CNC coupled with tool changers

Close tolerances to 0.00010 in Enables Fine finishes Reduces polishing time and

overall part cycle Threads into hardened

materials

MMT - June 201338

in conversation with Satish Godbole

Q Current Industry Dynamics In the manufacturing sector, exports contribute less than 20% of the revenue—a clear indicator of the fact that Indian machine tool manufacturers are predominantly focusing on the local market. There is an increase in the domestic demand, although decisions on investments are often delayed owing to weak global sentiments. In fact, the current economic scenario has made it increasingly difficult for companies, especially Small and Medium Enterprises (SMEs), to sustain high growth rates without embracing cutting-edge technologies that optimise energy efficiency and enhance productivity. While we witness growing reluctance among our customers regarding capital expenditures, the future definitely looks highly positive considering the domestic demands. I am sure we will see double-digit growth rates again over the next 5–7 years.

Q Improving Productivity Today, the most important challenge for the Indian machine tool industry is to have ‘equal competitiveness’ in terms of productivity, performance and delivery. Producing more in less time will directly improve your competitiveness. A standard machine, for instance, will take a few days to manufacture a component, while a high-end machine will take only a few hours. In order to improve productivity,

manufacturing is moving in the direction of reducing waste. This is achieved with the help of repeatability factors that diminish variations in each manufacturing cycle while offering the same features. All this necessitates the adoption and use of right simulation technology.

Q Taking India to the Global Platform

Gone are the days when products

were launched in Europe first and introduced in India months later. Today, companies choose India as a platform to launch their products globally. This reiterates the fact that India is definitely being recognised for its growth potential. However, we have not yet ‘arrived’, owing to a few challenges along the path.

One such challenge is that many Indian manufacturers build capacity while only considering the demand from the domestic

One of the major needs of the Indian machine tool industry is to achieve high productivity with increased accuracy; India can become the market leader by using next-generation technology, Satish Godbole, Vice President, Motion Control Systems – Drive Technologies, Siemens Ltd tells Debarati Basu Das.

“Differentiation Creates value for Customers”

Satish Godbole

June 2013 - MMT 39

market. As a result, they focus less on the global demand. As a remedial measure, we need to step up local production by increasing our technology usage; thereby achieving higher productivity and quality to attain global competitiveness.

Susbequently, this would help in not only building the ‘Made in India’ brand overseas but also in reducing our dependence on imports. For instance, 60% of the machine tool consumption in India is imported. We need to step up to increase the share of domestic production and strengthen brand India in the manufacturing space.

Yet another challenge is the dearth of skilled manpower. Unavailability of skilled manpower restricts the adoption of high-end technology. We need to address this skill gap issue as quickly as possible. Not doing so will have a bearing on the productivity. Additionally, the competitiveness of the sector will suffer.

Technology adoption in India has not made inroads to the extent required as most investment decisions are based on tangible benefits i.e. the immediate Return on Investment (RoI). Intangible benefits such as productivity, energy saving and reduced time-to-market are ignored. As we partner with the manufacturing sector, we also spread awareness about the benefits of investing in innovative technologies. While conducive government plans are in place to give the sector the much needed push, it is a prerequisite for manufacturing industries to address these issues in order to find their place on the global platform.

Q Next-generation Technology Going beyond conventional use,

the trend today is to integrate manufacturing processes with IT by way of Manufacturing Execution System (MES) and Product

Lifecycle Management (PLM), so that efficiency improvement is extended beyond manufacturing processes in order to complete the organisation’s value chain. A typical product development cycle includes making a design, a prototype, modifying the design as per deviations and then converting it into the final product. The time taken for this procedure is usually 6–8 months. But with our virtual machine concept, components can be simulated on a software platform, thus eliminating the prototyping stage. Eliminating one phase of operation dramatically

reduces the manufacturing time and increases productivity.

A perfect example of this would be NASA, which has used Siemens’ software when launching the latest Mars Rover ‘Curiosity’ designed by NASA’s Jet Propulsion Laboratory (JPL). Siemens’ PLM software was used throughout the development process to digitally design, simulate and assemble the Rover before any physical prototypes were built. The software helped ensure that all components fit together, operated well and withstood the environmental challenges that the mission would face.

Communication between machines and humans is gaining prominence. Siemens is also present in this segment with a new generation of controls that can communicate any change in the machine. Our other endeavour concerns remote service diagnosis. We have incorporated the activities of commissioning, troubleshooting and assisting from one part of the country to another through technology upgrade in terms of control and IT infrastructure. Thus, remote service diagnosis has redefined productivity.

Q Facing Competition Competition is certainly increasing,

but it ensures that we act faster and invent with newer technologies. We believe that differentiation is the only way to create value for our customers. Our extensive portfolio, solid vertical-market expertise—demonstrated time and again throughout the world—as well as strong customer focus ensure that the right products and solutions are made available to meet every need. With our comprehensive offering of automation technology, industrial control & drive technology and industrial software & services, we supply and support our customers worldwide along the entire value chain—right from product design, production planning and engineering to production execution and maintenance. Our product portfolio helps customers increase their productivity while improving flexibility and efficiency. Thus, we improve their competitive standing and reduce the time-to-market for their products. We take immense pride in the fact that no other supplier can claim to have such a comprehensive energy efficiency and energy management portfolio.

[email protected]

We need to step up local production by increasing our technology usage; thereby achieving

higher productivity and quality to attain global

competitiveness.

June 2013 - MMT 41

42 Industry Outlook Simulating India’s Growth Pace

44 Myth Busters Ignorance vs Knowledge

45 Improving Simulation Exploring Virtual 3D Models

50 Tips & Tricks PLM Success: 10 Pointers

52 Multiphysics Analysis ANSYS Enhancing Simulation Technology

45 52

Special Focus

CAD / CAM / PLM

MMT - June 201342

Industry OutlookSpecial FocuS

For decades, Indian companies have been acquainted with shop floors sprawled with handmade sketches and designs. The depth and

intelligence of the human mind have always been favoured over computerised codes. But the transition from drawing boards to codes is becoming imperative as the industry is trying to attain international finesse in design and manufacturing.

Global DynamicsSimulation software such as Computer-aided Design (CAD), Computer-aided Manufacturing (CAM) and Computer-aided Engineering (CAE) not just provide efficient, easier and cost-effective methods for modelling and designing critical parts and components but also help enhance quality and

accuracy. The constant upgrade in these software leads to the analysis of various real-life phenomena that might affect the components and eliminate error possibilities in the design phase itself. These tools are adopted across several industrial sectors such as mechanical, civil, plant design, geo-information systems and other engineering industries. It, therefore, enables end users to develop ideas and simulate real-world products by digitally prototyping their designs.

The usage of these tools is constantly on the rise. According to a report, the global CAD market is expected to post a Compound Annual Growth Rate (CAGR) of 8.6% during the period 2012–16. Europe remains the major user of these tools followed by the Asia-Pacific (APAC) region and North America. The market is expected to garner a revenue of

US$8,295.41 million in 2016. The need for enhanced product visualisation is expected to be one of the key drivers that will drive the growth of this market.

While automotive, industrial machinery, electronics & electrical, aerospace and civil industries are the key end user segments in this market, these tools have found considerable acceptance in the medical industry as well. According to the Millennium Research Group (MRG), the global dental CAD/CAM system market will grow strongly to reach a value of more than US$540 million by 2016. Its report also mentioned that Japan will see stronger growth than Europe or the US. But how is India reacting to this dramatic change?

The Great Indian ShiftIndians do not like rampant changes, especially if they involve a cost. Comfortable using the age-old traditional methodologies of designing, the pace of switching over to simulation software has been extremely slow. However, the pressure to deliver global quality standards has led, or rather, compelled the Indian industry to meekly agree to adopt these software tools.

Elaborating further, Vivek Marwaha, Director – Marketing, Siemens PLM Software India, explains, “The scope of CAD/CAM/CAE technology has

In an age where technology travels faster than light, the industry today faces some tough challenges of meeting the ever increasing standards of precision, quality and time of production. New-age simulation technologies seem to be the most efficient way to encounter them. Debarati Basu Das discusses how the Indian industry is adapting to new ways of designing techniques in light of the current situation.

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June 2013 - MMT 43

Industry Outlook

Vivek Marwaha Director – Marketing, Siemens PLM Software India

The technology already exists, but the need for adoption has been increasing lately. Today, Indian companies are not only competing with their domestic counterparts but also with competitors who have international presence. So, they need to be effective participants in the value chains of large global manufacturing companies. For this, it is essential for them to invest in tools of this nature.

Vivek Kotru Director – Global Marketing and Business Response, Geometric Ltd

The total cost of acquiring and operationalising high-end digital technologies is still the biggest factor for SMEs and MSMEs. They are well aware of the benefits of using such technologies; however, the costs associated with the purchase of licences, training employees on tools and managing changes play a deterring role. The other aspect is the right expertise essential to actually institutionalise the methods.

Vineet Dravid MD, COMSOL Multiphysics Pvt Ltd

The simulation software sector has a lot of potential to grow due to increased usage. Industries such as automotive, electrical products, heavy electrical machines and automotive ancillaries are widely using simulation software solutions.

been growing in India over the years. The elements of time, cost, quality and innovation are the key drivers for the adoption of these tools.”

He explains, “An important consideration for manufacturers is that they want their products to reach customers before their competitors’ products do. The costs of product development, product manufacturing and the end product need to be attractive. Also, quality is a huge parameter today and these products need to be innovative in order to stand out in the competition.”

Complementing Marwaha’s views, Vineet Dravid, MD, COMSOL Multiphysics Pvt Ltd, opines, “There has been exponential growth in the usage of simulation technologies. Over the last three years, we have seen an increase in the levels of awareness and interest. People are increasingly using simulation software during the product design phase. The increased exposure to global competition is motivating the use of technology in research.”

But as Indian manufacturers are absorbing this trend, are some sections leaving themselves out of this transition?

Small Companies, Big TransitionAn industry always rests on the pillar of support from smaller companies. In India, this pillar of support constitutes 60% of the industry. Complementing this is the increasing interest among global OEMs in testing Indian waters, which has made the role of SMEs in India even more prominent.

Today, a huge chunk of Indian SMEs and MSMEs are involved in manufacturing processes as Tier III suppliers to global OEMs. This has made it imperative for SMEs to manufacture products in tune with global quality and precision standards. All this is not possible without technically upgrading their processes.

“The challenge of adopting digital technologies lies more with SMEs and MSMEs. Historically, smaller companies have manufactured products that have been designed and engineered

by customers. Hence, the need to adopt high-end digital technologies did not arise. But as these companies become a part of competitive global supply chains, they will have to differentiate their engineering capabilities. High-end digital technologies bring significant benefits for engineering and R&D teams,” says Vivek Kotru, Director – Global Marketing and Business Response, Geometric Ltd.

Solution providers are also taking proactive measures to ascertain that high-end technologies are made affordable along with providing technical support and training to help them optimally use the technology. Dravid adds, “SMEs are showing increasing interest and we have seen a spike in enquiries from them. Earlier, cost was a major factor that deterred them from using high-tech products. With investment in technology, there came an additional cost to hire highly skilled and ‘expensive’ manpower to operate these technologies. But technologies today are easy and user-friendly; they do not need highly skilled manpower to operate them.”

Setting the Growth Trend The rate at which manufacturing demands are rising, simulation technologies have to be a step ahead in matching the growing pace of manufacturing. Various available multiphysics analysis tools bring to life numerous real-life phenomenon, which helps eliminate error possibilities at the design level itself.

Further, the industry is demanding highly customised products. “The kind of data being generated is so enormous that you require specialised tools to manage and organise data during the product development or manufacturing process. The next-generation trend is high-definition PLM, which will provide customers an environment where different stakeholders in different processes have access to the data in the context and format required,” points out Marwaha.

With all these options, it is a matter

of a few more years before global reports will quote India as one of the countries that have been the fastest in adopting new-age simulation solutions.

[email protected]

Special FocuSMyth Busters

MMT - June 201344

Myth: Simulation technology is not cost-effectiveFact: India has always been a cost-sensitive country; any investment is gauged in terms of price instead of value. The industry needs to understand that the benefits of using simulation technologies are far greater. They not only eliminate the stage of prototyping but also help design components with extreme perfection. This cuts down on the manufacturing time and reduces any possibility of error while eliminating wastage and ascertaining high-quality designs, thereby increasing profitability.

Myth: Technology might be rendered useless once the operation changesFact: Technology evolves every day and so do the manufacturing demands. New-age software solutions are built in such a way that they can be upgraded constantly without the fear of losing data.

Myth: Large-scale customisation is requiredFact: This issue is constantly addressed by technology providers. Most software today eliminate the need for extensive customisation. One can deploy the application and immediately start using it; there is no need for any specific programming or coding. This makes simulation software easy, affordable and user friendly.

Myth: Simulation software is difficult to use and needs simulation expertsFact: Simulation software has evolved over the years and today provides easy-to-use interfaces for design engineers who are conversant with the actual design problem. Simulation technology providers are investing additional efforts in making the technology user friendly to the extent that operations can now be performed at the click of a button. Moreover, technology providers are also organising training programmes and seminars to keep users updated about the technology.

Myth: Simulation software does not accurately predict actual phenomenaFact: Technology today allows coupling of multiple physics to model real-life phenomena. Multiphysics software can accurately model real-life processes and help reduce prototyping costs. This software can accurately predict the real-life phenomenon that helps designers modify components during the designing phase itself.

Ignorance is bliss … but not always … and certainly not if it leaves you behind in the competition. In an age when technology is traversing across the globe with just a click, the Indian machine tool industry still remains shackled by ignorance. When it comes to the use of the latest CAD/CAM/CAE/PLM tools, the misconceptions that still surround these technologies are making industries step away from investing in them. Debarati Basu Das busts some such myths plaguing these technologies’ adoption.

Ignorance

vsKnowledge

With inputs from COMSOL India, Siemens PLM

June 2013 - MMT 45

Improving Simulation

Accurate simulation of a machining process requires virtual 3D model equivalents of fixtures, tools and the CNC machine. However,

creating these models in a CAD system, either by measuring the physical pieces or by transferring the dimensions from 2D drawings, can be tedious, costly and time consuming. While obtaining ‘simulation-ready’ 3D models from OEMs, end users do not have to create the models or hire someone for the purpose. Fortunately, several machine tool, cutting tool and fixture suppliers realise this and have taken the required steps. Major toolmakers have recently started offering 3D models to end users through their websites, thereby gaining a competitive advantage. Shops simulating CNC programmes can save a significant amount of time and improve the accuracy & reliability of their machining processes by choosing a supplier that provides 3D tool models. Customer demand has also encouraged machine tool builders to begin providing 3D models. Increasing machine complexity increases the need to include the entire machine tool and simulate the NC programme from post-processed NC code. Using simulation to detect near misses among all machine parts prevents downtime caused by catastrophic failures. Besides, it is critical for meeting the delivery demands of a lean manufacturing process.

Configuring Virtual Machines Simulating the entire machine tool requires a virtual machine configuration, consisting of machine geometry,

kinematics and CNC programmable-logic-controller emulation logic. Obtaining the virtual machine’s geometry from accurate 3D models supplied by machine tool builders is much more efficient than translating it from 2D drawings or physical measurements. Several machine tool builders offer CAD models directly to customers or software vendors. Some advanced part manufacturers, who depend on machining simulation to meet production needs, require 3D CAD models—and sometimes complete virtual machine configurations—with the purchase of a new machine. Simulation can even help a manufacturer determine if a particular machine tool will adequately meet its needs.

“There were times when we used to measure the physical parts of a real machine and then build 3D models. Now, we can get these 3D models exported to our simulation software

and visualise the kinematic behaviour of the machine. Virtual machining of these models using simulation software improves the efficiency of the machining process,” says Shivarudrappa, Team Leader – Tool Engineering, Textron India. However, 3D models for machine tools frequently have an overwhelming amount of detail, including railings, stairs, gears and even bolts & washers. These models require modifications to reduce their data size for more efficient, daily NC programme simulation. Fortunately, some machine tool builders recognise the need for efficient simulation models and provide appropriately modified 3D models.

Simulating 3D CAD ModelsMachine tool, cutting tool and fixture suppliers can also benefit from sharing their CAD models. CNC simulation software such as CGTech’s VERICUT facilitate the process of implementing

More and more part manufacturers are recognising the value of CNC simulation. Simulation software helps eliminate or significantly reduce the need to manually or physically prove-out NC programmes, thus enabling engineers, operators and expensive machines to produce good parts. Some CNC simulation software can also optimise NC programmes to decrease machining time and produce high-quality parts. However, 3D simulation requires 3D CAD models of machines, cutting tools and fixtures. Having 3D models readily available can reduce the time required to get CNC simulation up and running.

Exploring Virtual 3D Models

WFL-m120-721: Collision between tool and f ixture detected by simulation software

SpEcial FocuS

MMT - June 201346

Improving Simulation

new machines and cutting tools. NC programme simulation software may help the machine tool supplier prove a concept or machine configuration as part of a bid proposal or delivery requirement. In addition, the builder may also save money on warranty costs because simulation software users are less likely to require emergency repairs after a machine crashes.

Even with these benefits, some machine tool builders are reluctant to share CAD models of their machines for competitive reasons. To ease these concerns, simulation software can encrypt 3D models of machines and restrict their use to specific customer sites. The end user can use the virtual machine for simulations, but cannot export it to other systems or sites. According to Ravikumar, Manager – CAM, BEL Valves India, “Most models are supplied by simulation software developers. Once the models

are exported and tested on simulation software, we directly run the NC programme on the machine. We have saved considerable time when it comes to accessing, exporting and running virtual 3D models on simulation software.”

The Way ForwardThe increased willingness of machine tool builders, toolmakers and fixture providers to share 3D models is making it easier for shops to get up and running with accurate CNC simulation

software. Improving the data exchange methods and tailoring the 3D model content to work more efficiently in simulation programmes greatly simplifies implementation. When software and hardware suppliers work together for the mutual benefit of their customers, everyone wins. This eases access to machine models & configurations, increases production and saves time in the process. VERICUT72-Mazak-Rib: Simulation software detecting a

costly collision

Indudhar C Marketing Communications Specialist, CGTech India Software Solutions Pvt Ltd

He spearheads the entire marketing and communication functions for CGTech India. Founded in 1988, CGTech specialises in Numerical Control (NC/CNC) simulation, verification, optimisation and analysis software technology for manufacturing.

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Special FocuSTips & Tricks

MMT - June 201350

Product Lifecycle Management (PLM) has the potential to streamline the manufacturing process, However, integrating PLM solutions can make many business managers shudder since many traditional PLM solutions have gained the reputation of being costly, complex and difficult to integrate with existing processes. Here are 10 ways that can help you avoid some common pitfalls and increase your chances of achieving PLM success.

Invest adequate time, infrastructure and funds Successful technology implementation requires investment in three equally important areas—people, process and technology. Companies that want to ensure PLM success must pay attention to the people involved as well as analyse & update their processes. This will ensure that both people and processes are collectively taking full advantage of the new technology. If you do not address all the three factors, PLM implementation will have a lesser chance of success.

Plan for the long term For all the effort and planning that go into implementing a PLM solution, barely few companies put thought into its long-term use. Once the technology has been implemented, companies are left wondering about what needs to be done with it. Thus, PLM deployment is like a bright, shiny new car that nobody drives. You have spent a lot of money on it, but now, it is just gathering dust in the garage.

Devote executive support to ongoing management A multimillion-dollar PLM solution is typically sold from the top down; it is up to C-level executives to sell their vision to the rest of the organisation. However, PLM implementations often encounter resistance from various levels of the organisation, particularly from users who interact with the solution daily. Without a continual drumbeat of executive support, user adoption might suffer, raising the likelihood of failure.

Invest in the expertise of service providers/software vendors Ever tried to tackle a home improvement project on your own because you thought you could save costs? At a certain point, you concede defeat and bring in a professional—who has to redo everything. The project winds up taking twice as long & costing twice as much, and you realise that you should have called an expert in the first place. PLM is no different. You need very specific expertise for these types of deployments, and many companies—out of their desire to save money and reduce the initial investment—think that they can manage it internally with their IT team. Without the right level of knowledge on hand, deployments can take a lot longer and have a lower chance of success.

PLM SucceSSTo achieveWays

Tips & Tricks

June 2013 - MMT 51

Give departments access to PLM solutionsSome people believe that Product Data Management (PDM) and PLM are essentially the same and, therefore, the engineering department should be the owner and guardian of the PLM system. However, this is a mistaken approach. If you have spent an enterprise-sized amount of money on a PLM solution but are not using it enterprise-wide, then you are not tapping its full potential—and it becomes difficult to justify the investment.

Adapt PLM solutions to manufacturing processesCertainly, companies have to be willing to adjust the existing processes to take advantage of the available technology. But in some cases, organisations already have ideal processes to suit their needs. If a PLM solution is unable to accommodate these existing processes, it will not be viewed favourably.

Budget appropriately The gap is widening between the available budget and the investment required to achieve PLM goals. Like any large enterprise undertaking, a traditional PLM deployment is difficult to budget. PLM is a ‘time and materials’-type of engagement where requirements can change, unforeseen circumstances can arise and the total cost can balloon. Although these types of risks are not specific to PLM, they are particularly frequent among PLM deployments.

Do not let security concerns impede PLM functionalityMuch of the benefit of PLM comes from extending it across the organisation to different divisions and even outside the organisation to partners, suppliers and contractors. This facilitates collaboration and data repurposing, creating a continuous digital workflow. Unfortunately, securing a traditional PLM environment is easier said than done. Rather than tackling these security complexities, some companies simply deny access to outside parties, thereby breaking the digital chain and defeating much of the purpose of having a PLM system in the first place.

Ensure technology compatibilityWith complex enterprise deployments, a company must manage a multitude of components—servers, firewalls, operating systems, databases, middleware and various PLM software modules— in the technology stack. Additionally, your external partners might have technology standards or platform requirements that prevent them from connecting with your PLM system altogether. Technology incompatibilities and complexities can mar PLM implementation.

Audit existing manufacturing and supply chain practicesOne key objective of PLM should be ‘trimming the fat’ i.e. taking a close look at your processes and identifying ways to streamline and improve them. If you simply install new technology without looking at the underlying processes and identifying how technology can improve them, then you are not really solving a problem … you are just giving people a different way to perform the same inefficient processes. Understand the potential obstacles, learn how to avoid them and commit to finding a solution that is affordable, easy to use and easy to deploy.

Michael Lieberman, Product Manager, Autodesk

MMT - June 201352

Multiphysics AnalysisSpecial FocuS

A s i n g l e , u n i f i e d engineering simulation environment harnesses the core physics and enables interoperability,

which is critical to create a quality solution. It also provides common tools for interfacing with CAD, repairing geometry, creating meshes and post-processing results.

Common Multiphysics Solutions Fluid Structure Interaction (FSI)A common multiphysics solution is Fluid Structure Interaction (FSI). In such a coupled scenario, the flow of fluid causes deformation of a solid structure. This, in turn, changes the behaviour of the fluid. For example, the flow of air around an airplane wing causes the wing to deform. As the wing deforms, it causes the air pattern around it to change. By strongly coupling the physics, the analysis evolves as a system to produce an accurate solution. Thermal-Mechanical CouplingAnother multiphysics scenario is thermal-mechanical coupling wherein structures deform and their material properties change according to temperature. In electric-thermal interaction, the current flowing in conductors generates resistive/Joule heating. Multiphysics EngineeringM u l t i p h y s i c s e n g i n e e r i n g simulation offers solutions for single-physics analysis as well. Two of the main branches are mechanical or structural finite element analysis and Computational Fluid Dynamics (CFD).

Mechanical or structural analysis

simulates how structures perform under external forces or the effects of temperature. It is based on Finite Element Analysis (FEA)—a numerical method often used to model structures. CFD analysis is the simulation of fluid flow (liquids, gases and combinations of the two) as well as chemical reactions and heat transfer (temperature). It is also referred to as airflow modelling or fluid dynamics. For instance, mechanical analysis could be used to predict how the wing of a jet plane holds up in

flight under various air pressures and temperatures. The stiffness of the wing can be assessed and its operational performance thresholds identified. CFD could be used to predict air flows around the wing along with the resultant lift and drag.

FEA can also be applied to electronic design automation for designing and producing electronic systems ranging from Printed Circuit Boards (PCBs) to integrated circuits. This is sometimes referred to as Electronic Computer-aided

To create perfect products, engineering and design teams must be able to accurately predict how complex products will behave in the real world characterised by continuous changes and involving the interaction of multiple types of physics. High-fidelity multiphysics simulation software helps users create virtual prototypes of their designs operating under such real-world conditions by predicting the interactions between structural mechanics, heat transfer, fluid flow and electromagnetics.

Enhancing Simulation Technology

Fluid structure interaction of an aortic aneurysm

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Multiphysics Analysis

Design (ECAD). Engineers use these products to simulate high-performance electronics designs found in mobile communication and Internet devices, broadband networking components and systems, integrated circuits, printed circuit boards and electromechanical systems. Since electronics are now integral to many products from automobiles and coffee makers to industrial equipment, true virtual prototyping must encompass all design aspects of those products. Other engineering simulation fields include electromagnetics, which enable

the calculation of magnetic fields in products such as electric motors.

Making Manufacturing Easier Earlier, solving such coupled applications with conventional analysis programmes meant going through numerous manual file transfers, data exchanges and problem set-ups for performing each physics analysis. Such cycles were cumbersome, error-prone and time-consuming, with the analysis often taking days or weeks to perform. Moreover, users were required to learn and maintain several different software codes.

These issues are being addressed by multiphysics solutions that automatically combine the effects of two or more interrelated physics within one unified environment. Solutions from ANSYS automatically manage the data exchange

between the different physics to perform coupled analysis without requiring users to spend time manually performing these tasks. As a result, coupled analyses can be performed in a fraction of the time otherwise required, providing for greater solution accuracy and allowing users to explore a much broader range of engineering parameters in a given time to facilitate innovation in multiphysics designs.

The complex i ty being engineered into new products, such as fibre-optic and wireless networks, computers that fit into a pocket, LED

screens that mimic paper

and tracking chips in pets, implies that more capability is being crammed into smaller spaces, delivered faster at ever-lower prices. Where once it was adequate to develop a design deemed ‘acceptable’, product engineers look to develop an optimal design, not just a good design. All this leads to the need for a systems approach to design problem solving—an approach that goes beyond simply optimising parts or individual components.

A Holistic Approach A systems approach requires a holistic view of how subsystems of a product interact with each other and in harmony with users & complex environments. The interrelationships between facets of the system must be understood and tuned, so the system as a whole can be optimised. Finally, the product must be tested against a wide range of usage scenarios such as physical components cross talking over each other. A key enabler in solving these problems is increased computer power coupled with advanced engineering simulation capable of accurately resolving huge amounts of information. This can help ensure that products will behave as intended in a real-world environment.

Courtesy: ANSYS, Inc.

Multiple physics analyses being used to determine heat flux distribution of a turbine blade

Courtesy: Wood Group Heavy Industrial Turbines AG

A systems approach requires a holistic view

of how subsystems of a product interact

with each other and in harmony with users & complex environments.

Facility VisitTaeguTec India P Ltd

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TaeguTec made inroads into India in the year 2000. Three years down the line, it excelled to become one of the top three players in

the business of cutting tools in India. Determined to remain at the top, the company has set its sights on enhancing its growth & performance. Today, TaeguTec has made its mark on the global competitive landscape not because of its self-centric business dynamism, but because it has not shifted its focus from the core necessity of any business model—its customers.

Raising the Bar TaeguTec entered India at a time when the industry already had quite a few dominant players. Hence, creating

market share was a Herculean task for the company. Elaborating further, L Krishnan, MD, TaeguTec India P Ltd, says, “Earlier, ‘Made in India’ goods used significantly low levels of technology as compared to what was being used in other countries. Many products carried the suffix ‘I’ to distinguish them as India-specific products. Global programmes were priced at a significant premium, which meant that Indian customers were compelled to use local programmes, which implied a compromise in terms of generation of tools. The first significant transformation that we brought about in the market was to have a standard level of quality, with focus on one technology and one product.” This, in turn, created value for customers with no compromise in terms of

product technology or quality. Change continues to be the only constant here!

“The decision to make or buy in manufacturing was not based on technology, but on the scale of the industry,” avers Krishnan, adding, “Over 15 years ago, many top-class multinational players did not want to bring state-of-the-art technology into India. We delinked technology from the decision of what to produce in India. The technology did not matter ... what mattered was whether it made economic sense to produce it in the country, which creates additional value for Indian customers. This was the other important change that we introduced.”

Keeping it LeanTaeguTec believes in the philosophy

Success does not lie in being self centric; it depends on the way you align yourself with the world. TaeguTec India P Ltd has been consistently doing just that—finding its own success in the success of its customers. Debarati Basu Das, during her visit to the facility, finds out how the company weaves its business strategies to add value to customers’ demands, in line with its philosophy of being a true ‘Partner in Cost Reduction’.

Encompassing holistic growth


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TaeguTec India P Ltd

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of being lean. The company made a concerted effort to keep all its operations lean and hence, adopted automation extensively. “Automation, for us, was not a tool, but a strategy. We did not get into a lengthy debate of whether a particular automation is viable or economical or even deliberate upon the advantage of cheap labour in India. We adopted automation wherever required,” explains Krishnan.

“Philosophically, in any repetitive job, high levels of fatigue and human intervention are obvious; hence, we needed an alternative to assure quality to our customers. We opted for automation at a time when people used tweezers to handle inserts,” he continues. “We are constantly striving towards upgrading technology and automation to stay in line with world-class technologies,” Krishnan adds.

“Sometimes, we cloud our thinking by believing that cheap labour will be cost-effective. But this results in long-term damage to the quality and compromises in terms of technology. Human fatigue is something that cannot be managed in a repetitive job. There is always the possibility of an error,” cautions Krishnan.

Ever since the company was set up, its engineering centre has been


June 2013 - MMT 57


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operating in accordance with global standards and technologies. Its staff is constantly trained at global centres to assure the same technology orientation. This enables the company to engineer its standards to satisfactorily meet Indian customers’ needs.

Company’s Motto TaeguTec positions itself as customers’ ‘Partner in Cost Reduction’. “At the end of the day, you are successful if your customers are successful. If we are able to strategise and strengthen the competitiveness of our customers, it creates the possibility of long-term participation with them. So, we focus our philosophy on the fact that anything we do should add to the competitiveness of our customers,” Krishnan points out.

Best PracticesThe company takes pride in being lean. “We have an annual business of approximately `200 crore with around 180 employees,” informs Krishnan. The plan was never to be a highly manpower-oriented plant. However, to stay lean, one needs to upgrade the manufacturing technologies used and look for opportunities in stable processes that do not require much supervision. As a result, the company has a small yet highly skilled and trained workforce capable of ensuring

robust monitoring of processes. The process capability is continuously raised in order to leverage its human capital optimally.

According to Krishnan, “TaeguTec constantly tries to challenge the status quo and aims at doing things differently. So, it is important that we have people who are adventurous and willing to experiment while maintaining the basic discipline of the process. We hire people with the right attitude and train them in specific skills to ensure smooth operation. There is no standard qualification to suit our industry needs; we train our employees as per our operations.” The plant is run in an extremely eco-friendly manner

and tries to maintain a zero discharge status. While the company’s effluent is fully treated and recycled, rainwater is conserved for other uses. This eco-friendly attitude is actively encouraged within the organisation.

Envisioning the FutureInnovation is the key to success. As a Group, TaeguTec invests about 7–8% of its sales expenditure in R&D. In addition, it is globally focused on product development, which is also the reason behind the competitive advantage it has over other companies.

The company believes in regular investments in various aspects of business upgrade. “We are geared up to beat the requirements of the market for the next 2–3 years. We believe in building capacity much ahead of the demand,” states Krishnan, who also believes that it is important to keep things simple without complicating business by using jargons.

“We continue to be the dominant player. But dominance is not just in the turnover. In the metal cutting business, we aim to become and remain the preferred choice of cutting tool suppliers to our customers. Our aim is to be a customer-centric solution focused company,” concludes Krishnan.

[email protected]


“Philosophically, in any repetitive job, high levels of fatigue and human intervention are obvious; hence, we needed an alternative to assure quality to

our customers. We opted for automation at a time when people used tweezers to handle inserts.”

L Krishnan, MD, TaeguTec India P Ltd

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InsIghts & OutlOOk

60 EXIM Analysis Looking Beyond The Horizon

62 Fact Files 5 Myths Decoded

66 Opinions & More Manoj Kumar, Director, Apex Group

68 Tips & Tricks Seven Threads for Strong Export

EXIM BalancE

60 62 66

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EXIM Analysis insights & outlook

When it comes to imports, India ranks 7th in the world, but finds itself down to the 27th position when it

comes to exports. This trend started with liberalisation in 1991, when India opened its doors to global players. This move resulted in global manufacturing giants investing in the country, which, in turn, created huge demand for Indian SMEs and manufacturing technology providers. The machine tool industry, which is referred to as the backbone industry of the manufacturing sector, was bound to observe a sharp rise in the demand. This situation brought many global giants to the country and their technical capability was highly acknowledged.

Current PictureThe global machine tool industry is going through an interesting phase in different geographies. While European countries are witnessing a slowdown, the US is observing a sharp rise in the

consumption. Asia continues to be the preferred investment destination, with Africa and the Middle East creating demand as well. Also, the Indian industry saw minor growth as compared to last year. Although the industry has always been import-driven, today, many Indian companies are successfully competing with global players.

According to PJ Mohanram, Senior Adviser – Technology, IMTMA, “We rank 12th among the nations producing machines of reasonable quality and are the 7th largest nation in terms of consumption. This means that our users are far ahead of us. We consume a lot more than we produce—we hold only a 35% market share, while two-third is imported. If we want to be among the Top 5 machine tool building nations by 2020, we not only have to cover the existing gap but also have to anticipate what others will do. For all this, we have to look forward.” He adds, “On a global volume of about US$85 billion, the Indian space is less than US$1 billion.

Additionally, we do not hold even 1% of the global market, which means that there is around 99% of the world market to tap.”

Currently, the Indian machine tool industry is enjoying the demand created by customers such as automotive, infrastructure, energy, electrical & electronics and aerospace. It is expected that it will help the industry in the future as well. Mohanram believes, “If our consumption today is `11,175 crore, we expect to reach `21,666 crore by 2016–17. Hence, by 2020, we will have a consumption of `36,000 crore. If we want to hold a 30% market share, then it is imperative that we grow at a minimum rate of 15%.”

Government Initiatives To further balance India’s import and export status, the government should look at the policy framework of some of the developed machine tool countries such as Japan, Germany, Korea, Taiwan, etc. along with developing nations

India imports much more than it exports is a known fact. The reasons for this range from huge local demand and dependence on high quality to lack of innovative attitude. Nishant Kashyap analyses the current status of the Indian machine tool industry by focusing on the demand trends and analysing how the EXIM figures will be balanced in the coming years.

Looking BeyondThe Horizon

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EXIM Analysis

such as China and Russia. The Indian Government can review the different policies adopted by these countries and formulate the most suitable one that can help companies export and enhance the technical capability of Indian companies.

Apart from this, associations such as Indian Machine Tool Manufacturers’ Association (IMTMA) are doing their bit to educate engineers by conducting technical seminars. “Export of capital goods like machine tools requires the presence of showrooms and sales/service centres abroad. This is a costly venture and individual units cannot afford to do this on their own. Therefore, IMTMA has requested the government to set up Engineering Export Promotion Council (EEPC) and offer showroom space to Indian companies at an affordable cost. Also, units can focus on placing manpower as required. This initiative can boost the export of capital goods (not only machine tools). Supporting Indian units to participate in foreign exhibitions is highly important,” avers Mohanram.

Think Globally!The attitude of manufacturers needs to change significantly. They need to focus on innovation, change the way they market, think beyond their comfort zones and finally become global. We are still competing with our own standards, but to find our place in the developed market, we have to go global. If we do not act now, big players will soon be seen capturing the market and small Indian companies will find it difficult to sustain.

We know how the global market has defined ‘quality’. Hence, we need to produce goods keeping their ‘quality’ in mind rather than following the same old pattern. Small companies need to learn from those who are already exporting components. We always talk about building the ‘Brand India’ image in the global market, but we cannot expect foreign players to accept our products when we reject our own creations. While India is on the manufacturing radar of the world, it needs to respect its own competence and aim at attaining global standards.

Major DestinationsIt is rightly said that this decade belongs to Asia, with a growing consumer base and need for better infrastructure, resulting in a huge demand for machine tools in Asia. China has already become a top producer and consumer of machine tools, with India, Japan, South Korea, Singapore, Indonesia and Thailand generating huge demand. Indian companies will have to carefully choose the right destinations for export. They need to do appropriate research to find out the kind of demand in the said countries before approaching them.

“Machine tool exports will obviously go to countries or regions that are strong in manufacturing—primarily auto or auto component producers. Apart from China, South East Asian countries are emerging as important auto-centric manufacturing countries. Turkey, Brazil and Mexico are also the right destinations for machine tool export,” informs Mohanram.

Vision for Tomorrow As per IMTMA’s vision, India will be among the top five machine tool building nations by 2020. Opportunities are immense, but let’s be realistic … to achieve this, there will be challenges to face. Poor infrastructure, technical

capability, lack of innovation and competition with global players will be the main hurdles in achieving the goal.

Although the dependence on import is also a source of concern for the Indian machine tool industry, rather than thinking about imports, we need to focus on exports. We need to earn the trust of the outside world by delivering best in class products and thus make a mark in the global market.

Development in technology and compatibility will play a big role in the import and export status of India in the future. Talking about the reduction of dependence on imports, Mohanram concludes, “It can be achieved through indigenous development of new technologies and products. However, this is a long haul. To quickly reduce imports, we should encourage FDI in machine tools & related items and invite foreign firms to set up manufacturing units in India. Indian companies also have the opportunity to enter into joint ventures. Simultaneously, the government should allocate substantial grants to support indigenous development of machine tool units—individually and through industry-academia-R&D collaboration.”

[email protected]

This data was presented by PJ Mohanram, Senior Adviser - Technology, IMTMA, during LEAP 2013

Indian Machine Tool Trend

InsIghts & OutlOOkFact Files

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Myths decoded

The changing dynamics of world economy has created a lot of buzz in the Indian machine tool industry. This is the time when companies are looking for alternatives and here is where India comes into the picture; albeit, with a whole lot of perceptions and assumptions. Nishant Kashyap helps dispel some myths in the Indian industry, which will help companies optimise the situation using their cost-effective technology.

01

03

02

Our machines will not be accepted in the global marketThe biggest myth and fear among Indian manufacturers is that their machines will not be accepted in the global market. We need to understand that apart from a few sophisticated technologies, Indians have developed almost all types of machines and a few companies are even exporting to the global marketplace. Instead of worrying about customers, we should focus on developing cutting-edge technology and create awareness about the same. We should not forget that Indian engineers are highly respected worldwide, so anything produced by Indians will not be rejected just because it has the Indian tag.

China and Taiwan produce better than usWe have to accept that Chinese and Taiwanese companies are one of the biggest threats for Indian companies not only in the global market but also within the country. But it is wrong to conclude that they can produce better at a faster rate. India is known for its low-cost manufacturing capability. Many big players in the country have grown recently and now provide high-end solutions to customers. Also, the demand for machine tools in the Asian market is continuously increasing, which is the main reason why many companies in Eastern countries such as China, Taiwan and South Korea have become technically advanced. Over the years, since they have become strong in the Asian market, they pose a threat to Indian companies. In recent times, the competition from these Eastern countries has increased, which is affecting Indian business. For instance, China has, for long, been accepted as a low-cost destination for mass manufacturing; Taiwan and Korea have followed suit with better technology. All this does not implicate that we cannot produce better than them. We have the quality and capability to produce machines as per global standards to compete with China and Taiwan. Focus on export and aggressive marketing are the only areas that the Indian markets lack in.

Around 65% machines are imported Yes, the Indian machine tool industry is import driven, but we cannot conclude that more than 60% is imported and it is a threat for Indian companies. Let’s be honest … machines with sophisticated, high-end technology being imported were never produced in India. We were never in that space to be worried about the fact that it is all being imported. Indians were always good at producing conventional machines and the market is still dominated by them. Therefore, it is highly essential that we focus on our strengths. The second most important point is that many companies from India do not reveal their production figures. If those figures are counted, the share of Indian machine tool companies will increase substantially.

5

Fact Files

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04

05

No support from the Indian GovernmentIt is a well-known fact that government support to the Indian machine tool industry is insufficient. Agreed, the government needs to give more thrust to the machine tool industry. But how many of us have actually optimised on the available options? Companies need to do their bit and enhance their awareness about the schemes and programmes available for SMEs in the sector, such as financial activities, marketing support and consultation for the export and improvement of their business. Every year, Engineering Export Promotion Council (EEPC) takes a few companies to international exhibitions and government-supported associations support companies in educating employees and increasing their awareness about the industry’s know-how.

We cannot export to developed marketsIndian companies mostly do business with emerging markets like Thailand, Indonesia, Singapore, the Middle East and Africa. These are some of the promising markets, as the industry is growing and their condition is almost the same as the Indian market. SMEs in these countries usually opt for cost-effective solutions, which is the main reason for their success. As per statistics, China, Japan, Germany, Italy, the US and South Korea are the topmost consumers of machine tools. These six countries collectively amount to about 70% of the total machine tool consumption in the world. If the consumption is huge, it translates into a huge opportunity for businesses. Besides, Indian companies should also focus on developed markets apart from emerging countries.

[email protected]

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OpiniOns & MOre Manoj KumarQ How can we reduce the Indian

machine tool industry’s dependence on imports?

In my view, the Indian machine tool industry should be more concerned about the balance of import and export, i.e. exports being more than imports, rather than focusing only on the import of machine tools. This should be the foundation that the machine tool industry should work on rather than expecting the government to cut down on imports or increase the import duty. We should have a positive approach towards improving our exports. If you try to cut down on imports, it will ultimately prove harmful to the economy, because the end user may end up paying more. Also, it is much better to produce goods in the country rather than importing finished products. So, my suggestion would be to focus on increasing exports rather than decreasing imports.

Q How we can improve our exports?

The Indian machine tool industry should essentially focus on a wide range of markets, from emerging markets such as South Africa, the Middle East, South America, Vietnam, Philippines to Europe and the US. Emerging economies should be focused upon more because they have more potential for us. I think we should be more proactive and service them well. Manufacturers should focus on

using e-commerce to promote their brands and sell their products. For example, a company in Rajkot can become savvier by using e-commerce to drive its business in emerging markets. We should be realistic and acknowledge that we have lost the race to China, and to gain lost ground, we have to look at proactive measures to capture the developed market. We can still export to Europe and the

US—not machines but services in machine tools such as maintenance and refurbishment. For instance, take gas engines. They use gas to produce power, are very costly and need to be overhauled after 20,000 hours. This is where the Indian machine tool industry can find a huge opportunity. Thus, we can export maintenance, services, start refurbishing components for developed economies and export our

Shaping the Future of ExportsTalking about emphasis on e-commerce, focus on emerging markets and successful alliances,

Manoj Kumar, Director, Apex Group, in conversation with Nishant Kashyap, says, “e-commerce is a highly futuristic business module and selling tool. It has proved to be a successful concept in

apparel, merchandise, electronic gadgets, among others and can be implemented in the industrial equipment industry as well.”

Manoj Kumar

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machines to emerging economies. For this, we will have to work on our education system as well. In the US and Europe, people get practical experience after completing high school. So, a machine tools person works in shop floors for some time after finishing high school and is trained by the industry through vocational training/programmes. I think that we should adopt this model in India as well. We should encourage young people to get into manufacturing after higher secondary school. We should also have more vocational training programmes/master programmes. We also need to encourage practical learning.

Q The US and European markets are more technology driven. Do you think Indian machines will be accepted in these markets?

Similar to the model adopted by IT companies, where we have offshore as well as onsite support, the Indian machine tool industry can gain from its technical expertise to furbish and maintain machines from the US and Europe. They can also get the machines to any of the SEZs in India for offshore work. The manufacturing in developed markets is gradually decreasing and is swamped with cost-effective competitors like China, South Korea and Taiwan. The Indian machine tool industry should look at untappd markets such as Africa, South East Asia and the Middle East for exporting machines. I would also recommend taking up the challenge of exporting machines, such as small lathe machines, laser machines and presses, to China by innovating and making better machines.

Q Are South Eastern countries a threat to India in terms of doing business overseas?

They are obviously affecting

our business and this is why it is essential for Indian machine tool manufacturers to enter into joint ventures and alliances with European and American companies. This way, they will get access to the best of technology and expertise to compete with China and other Asian countries. For instance, in the current scenario, for German and Italian companies that have the technical capability but problematic markets and cost structures, it’s a big challenge to manufacture in their own countries. This is when Indian companies can look to enter into collaborations and leverage their expertise. This would be the best strategy to capture the western market and compete with China.

Q How does the usage of e-commerce boost exports?

E-commerce is a futuristic business module and selling tool. For instance, for a company in Rajkot that makes 60 lathes in a month but does not have presence in Egypt, e-commerce is the only way to sell in that market. In our company Apex Auction, we

have only 50 people working all over the world with transactions in around 63 countries wherein we sell machines from one country to another. The Indian machine tool industry is generally conservative; much importance is not given to e-commerce and social networking platforms. The industry is still not comfortable with selling or buying machines over the Internet. But why not try selling something online to overseas customers? The industry is more happy setting up a showroom and a dealer network rather than optimising the web. If Indian SMEs need to export, they need to open up e-commerce channels and use social media as a marketing tool. It is the cheapest way to sell and promote one’s products. Just consider how many Indian SMEs have social network presence. Your customers are online, vendors are online, they are buying online … but you are offline.

Q How do you envisage the Indian machine tool industry’s future?

The US market is picking up but we also have to understand that it is looking at manufacturing from a completely new viewpoint. For example, they are talking about 3D printing of an entire component. So, they are moving away from generic machines to futuristic technology. Generic machines can be made cheaper in China and Taiwan any day, but what India should look at is special purpose machines. We should focus on emerging markets to export in the short run, while in the long strategic run, the focus should be on Special Purpose Machines (SPMs) and partnering with companies that make futuristic technology. We should become an R&D, service and maintenance hub by working with companies from the western world.

[email protected]

Generic machines can be made cheaper in China

and Taiwan any day, but what India should look at

is special purpose machines. We should focus on

emerging markets to export in the short run, while for the long strategic run, the focus should be on Special

Purpose Machines.

InsIghts & OutlOOkTips & Tricks

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Seven ThreadS for STrong exporT

India has established itself in the global metalworking industry due to the advantages it provides in terms of low-cost manufacturing certification.

The country is now in a very good position to capitalise on the new opportunities that are coming its way. Yet, the industry still has a long way to go before it can be termed as ‘developed’ in all aspects. As

customers are gradually prioritising quality and technology over price, the road to development seems smoother for the machine tool industry. In the year 2012, despite the global slowdown, the industry observed an increase in investment in terms of facility expansion, increment in output, new technology centres and new entrants, which is expected to continue in the coming years. The

demand in the country has not only attracted global players but has also partially restricted Indian companies to focus on the overseas market, as they are happy serving local orders. However, this scenario will not make Indian companies global players; they have to look beyond India to strengthen their competitive streak in the global market.

Work on Training & DevelopmentHuman capital

is one of the most vital assets of any organisation as it ensures efficient and effective functioning. As a result, companies need to heavily invest in training & development to attain a competitive advantage and increase value. Since there are no special courses on machine tools in the country’s premier technical institutes, companies will have to invest extra effort in training young engineers. This is because companies have come to understand that investing in human capital is the key to a company’s growth and success.

Economic Slowdown: Optimising ItThe entire Indian industry ssems to have returned to its shell and is refraining from making any major investments, as it is

skeptical of what the global ‘economic slowdown’ has in store. However, the economic slowdown has motivated the industry to work in new ways that can be advantageous. It is a natural phenomenon that in good times, people look for the best in class. It happened in the machine tool industry as well. When the economy was at its best, companies favoured European and Japanese technologies. However, during recession, everyone started looking for alternatives. It is at this time that India came into the picture! This is the opportunity that Indian companies should capture in order to shine. Indian companies are not far behind their foreign counterparts in terms of technology. Many Indian companies provide cutting-edge solutions. Our positives lie in our cost-effectiveness while providing almost the same level of technology. This makes India the best place to manufacture during global slowdown. Therefore, instead of thinking about global situations, we should capitalise on our own strengths. However, we have to be alert and aware of the changing situation. During such times, cost becomes one of the critical factors while purchasing any product. Another factor that makes India the favourite manufacturing destination is that the country is not much affected by the global slowdown because of its high local consumption base.

If we go by the projections, India will figure in the top five machine tool building nations by the year 2020. This clearly shows that the future of the Indian machine tool industry is promising. Albeit, to be recognised globally, Indian companies need to focus on the export factor and make their mark in the overseas market. Nishant Kashyap shares some tips that will help companies boost their exports.

Tips & Tricks

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Increase R&D InvestmentInvesting in better products or solutions always pays back, sooner or later. The

biggest and most essential investment in the manufacturing of any product lies in R&D, which defines the future of any product. Barring a few companies, no one in the Indian machine tool industry is keen on investing money and time in R&D. This mindset has to change in order to survive in the competitive global world.

Global CollaborationThe main aim of collaboration with foreign companies is to develop high-end technology and

increase visibility in the overseas market. Collaboration with global players will enhance the efficiency and productivity of Indian industries. These collaborations induce the required amount of technological development and promotion of technologically advanced industries. The technology tie-ups with foreign companies will not only help Indian manufacturers in the advancement of technology but will also open the doors to the global market. To improve efficiency and productivity, foreign technology collaborations are the need of the hour for Indian industries.

Extra Marketing EffortA marketing plan is used as a tool by organisations to check whether the strategies on record are being

implemented. It also works as a tool to determine or measure the performance of certain products and services. To be recognised in the global market, companies need to have a proper marketing agenda for the particular geography. Just developing a cutting-edge solution will not help if the promotions are not in place. The best way for Indian companies to increase their visibility and showcase their capability is to exhibit their products in particular countries.

Better Infrastructure Being one of the fastest growing economies in the world, the demand for machine tools in

India is set to increase. The growth has highlighted the need for better infrastructure. However, we are still struggling to develop proper roads, ports and natural resources. On the infrastructure front, there is a huge shortfall in all three arenas—road, rail and port. This acts as a huge opportunity for establishing several new public-private partnership projects. To trade with foreign companies, ports become the key factor, albeit the poor infrastructural facilities in Indian ports are affecting the exports as the ports are still not able to match the demand.

Focus on ExportIndia has considerable machine tool demand, which companies are not able

to cope with. The Indian industry is totally dependent on global companies and imports around 70% of the machine tools. One of the biggest reasons for India’s exports being less is that the country has a huge consumption base that requires companies to focus on the local market. This, coupled with technology issues, impacts the export status of the country. Hence, every company should make it imperative to reserve a percentage of production for export, which will help increase the amount of exports. This will not only improve trade relations with the said countries but will also help in enhancing technological know-how and boost business.

Indian Machine Tool Projection

This data was presented by PJ Mohanram, Senior Adviser - Technology, IMTMA, during LEAP 2013

[email protected]

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Sector Watch

AerospAce mAchining

74 76

72 Winds of Change An Air of Cautiousness

74 Growth Matters Aerospace Industry: The Technological Trendsetter

76 Opinions & More Peter Elmer, CEO, Heinz Kaiser AG

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Winds of Change

The velocity at which the Indian aerospace industry has been growing lately has astonished the world market. The industry has

been garnering attention from all across the globe. However, over the last couple of months, the staggering economy has also affected the Indian aerospace industry and stalled investments in India. “The industry has experienced a slight slowdown, and aerospace calls for higher investment in capital equipment. The manufacturing cycle time is longer and many companies are not in the position to invest,” says KSV Raghav, MD, Raghav Aerospace Technologies Pvt Ltd.

Jeldi Bala Anand, MD, Hindustan Magnesium Products Pvt Ltd, however, feels, “Aerospace is mostly a steady industry as it has a long gestation period. We have not noticed any steep

decline as the industry has kept itself steady. Aerospace has been growing progressively. The growth that we see today is the vision that was sowed almost 10 years back.” He adds, “The downslide in the global economy has affected the Indian aerospace industry in terms of cost-saving in large-scale consolidation by having fewer supply chains. This is, however, more linked to management issues followed by every industry.”

Key IssuesThe aerospace industry is still in its infancy, enjoying the global attention that it is receiving. However, there is a dire need for the Indian market to understand the real issues and needs of this industry. While the government is closely working on simplifying and defining the policies, the industry still awaits greater clarity and transparency.

Funding is an issue that is affecting the growth of the industry. “In the Indian market, banks consider aerospace and defence as any other industry. The limit given is the same as that given to any general industry that has quick production and turnaround rates. RBI needs to revise its guidelines and have customised solutions for the aerospace and defence industry,” says Raghav.

These are just some of the factors that are holding the industry back in terms of realising its potential. However, while global companies are cautious in their investment, the industry expects a revival soon. “Currently, various offsets and defence projects are in their final stages. Many tie-ups and joint ventures with foreign companies are also in the process of finalisation. Hence, by the year 2014, the aerospace

An Air of CAutiousnessThere was a time when investments in the Indian aerospace industry were on a roll. Then came the economic downturn that affected every industry in India. Considering this, the lucrative business propositions of the aerospace industry are now being considered with vigilance. Debarati Basu Das analyses the current state of the Indian aerospace industry and the steps that should be taken to strengthen this industry.

Winds of ChangeseCtor wAtCh

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Winds of Change

industry is not only expected to witness revival but also set to experience its best phase,” expects Raghav.

Getting Ready for the BoomClearly, the next six months will be a crucial period for the Indian aerospace industry to prepare itself before the global market opens up. The industry has to strengthen itself in a major way at various levels so as to effectively encompass and deliver when the need arises. Here are some of the areas that need improvement: Increase visibility: This is a time

when many MNCs are eyeing India and are identifying suitable Indian companies for partnerships and tie-ups. Indian companies need to connect, interact and increase their visibility in the market so as to be chosen by foreign companies for lucrative business propositions.

Certify yourself: Entering the aerospace industry is not easy. Companies need to undergo various certifications for processes and facilities. While the market is not encouraging investment, companies can instead invest in getting different quality certifications in place so that it makes the process of being selected for global partnership lucrative.

Build capacities: Aerospace is the future. Any global partnership will assess Indian companies for its existing facilities. This is the time to expand and build additional capacities to be ‘aero-ready’!

Train manpower: Skilled manpower for the aerospace industry is hard to find. Indian companies can utilise the time to hire and train their employees at various manufacturing operations so as to prepare them to get into the grind.

Invest in technology: This is an age when Indian companies cannot afford to be compromising

on the technology. Companies need to invest in the latest technologies and keep themselves updated.

Research & Development: Research activities are an integral part of the aerospace industry. Even though Indian companies shy away from investing in R&D activities, such an initiative in the aerospace segment can be a boon. The industry needs indegenisation, which is heavily missing from all quarters. More investment in R&D is the only solution to this issue.

Planning: Having the right plan in place is crucial for any company. This is a time when companies can spend quality time in planning their course of action for the future and put proper strategies in place. With a blueprint ready, taking the right action will be a cakewalk when the market opens up.

Financial support: The aerospace industry is widely misunderstood by the banking fraternity. With the possibility of a huge market opening up, financial institutions

need to understand the functioning of the aerospace industry, which constitutes a bigger gestation period as compared to any other industry. The banking fraternity needs to be appraised about the functioning of the aerospace industry to facilitate hassle-free financial assistance for companies.

Encourage SMEs: The growth of the aerospace industry rests on the shoulders of SMEs. However, this industry needs immense support to be a part of the exciting journey. Bigger companies need to identify the capabilities and hand-hold SMEs and MSMEs. There needs to be fund allocations for startups to initiate the first steps into this industry.

Infrastructure: This is where the Indian government has a major role to play. The country desperately needs better infrastructure and facilities as lack of such facitlities not only deters foreign investments but also delays the manufacturing processes for many. It is highly essential for the country to invest in better infrastructural facilities.

Create an ecosystem: A burgeoning industry like aerospace needs a proper ecosystem to thrive on. There need to be activities at various levels to bring together the capacities and capabilities that can optimise the opportunities offered by the global market.

Future DevelopmentsThis is a time when the industry needs to find opportunities in the slump. And yes, this is also a time when the industry can take proactive steps to prepare itself for the phase when the market will be at its best and take optimum benefit of the opportunities offered.

[email protected]

A burgeoning industry like aerospace needs a proper ecosystem to thrive on. There

need to be activities at various levels to bring together the capacities and capabilities that

can optimise the opportunities offered by

the global market.

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Growth Matterssector watch

Today, the Indian aerospace industry is witnessing unprecedented growth. The civil aviation sector, especially, is growing by

leaps and bounds, recording an annual growth in double digits for the last two years. However, this industry too faces the challenge of increasing productivity & efficiency and optimising manufacturing costs & weight of carriers.

Composite materials are gaining popularity for their role in weight reduction. This is because composites are versatile and are used for both structural applications and components, right from hot air balloon gondolas and gliders to passenger airliners, fighter planes and space shuttles. Applications range from complete airplanes to wing assemblies, helicopter rotor blades, propellers, seats and instrument enclosures. Today, aircraft manufacturers are aiming to make 50% of their airframe from composites. A higher degree of flexibility and traceability has become the need of the hour to achieve a competitive edge. However, this can be achieved only by

deploying high-performance automation solutions. Siemens, as a partner to aircraft and machine builders, has developed dedicated control solutions that guarantee the highest degree of quality and productivity.

The entire spectrum of aircraft component manufacturing primarily involves the following processes: 5-axis machining of structural parts and engine components Laser drilling Machining of gears Laser beam and water jet cutting Tape layering/Fibre placement Virtual machining and productivity enhancement 5 - A x i s C o m p o n e n t ManufacturingIn the aircraft industry, the production of highly stressed workpieces involves machining a

high proportion of material. With 5-axis machining of structural components, up to 90% of the raw material can be removed during machining. This calls for extremely high metal removal rates, which can only be achieved with highly efficient machines. The emphasis is more on maximum dimensional accuracy and surface quality rather than machining capability. The most efficient way to achieve this is with 5-axis milling—the most advanced metal cutting discipline.

In addition to high-performance hardware, the control systems used in 5-axis machining centres must incorporate specific programming, motion control and compensation functions for complex machining tasks. These functionalities simplify work for the users and guide them effectively through the entire machining process. It is also important to match and optimise motion control to the requirements of a particular machining task. The rigidity and accuracy of a machine have a considerable influence

the technological trendsetterThe aerospace industry is a technological pacemaker when it comes to state-of-the-art production techniques. While the industry has invested in innovation and responded to ever increasing challenges, designers are still striving to optimise weight in order to achieve fuel efficiency and cut down on carbon footprints.

Composite materials are gaining popularity for their role in weight reduction

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Growth Matters

Satish GodboleVice President, Motion Control Systems – Drive Technologies, Siemens Ltd

A Bachelor of Engineering (BE) in Electronics and Telecommunication from College of Engineering, Pune, he possesses over two decades of experience in various functions such as Design, Quality Planning, Manufacturing, Business Development and Strategic Planning.

on precision and surface quality, and it is also important to improve these with special control and drive functions.

Laser DrillingDrilling is another fast-growing application of laser technology, which is getting increasingly popular in the aerospace industry. Laser drilling involves applying sufficient energy to one point on the workpiece so as to achieve controlled evaporation of material. Owing to its great precision and fast machining time, it is rapidly overtaking other technologies such as conventional drilling and spark erosion as the method of choice for machining extremely hard materials from which, for example, turbine blades are made.

Laser contour drilling, an intelligent combination of laser drilling and laser carving, can provide a highly efficient way of making tapered ventilation holes in turbine blades for even better turbine performance. Like other innovative laser-based machining methods, laser drilling requires optimum adaptation of the control system for this challenging technology.

Machining of GearsA gear that runs quietly has to be produced on a machine that runs quietly because vibrations are generated during manufacturing of the gear. A machine that rises to the challenge of precision and high-quality gear production has to be mechanically and electronically stiff over a wide range of unsteady frequencies due to tooth count of the cutter and rotational velocity.

Laser Beam & Water Jet CuttingThe materials being employed in aircraft construction are extremely difficult to cut. These can be machined with conventional chip removal or Electric Discharge Machine (EDM) at a high cost, which can be used in limited circumstances only. One alternative to conventional manufacturing processes is to use a laser. In contrast to conventional methods, the laser operates without contact, force and

tools. This technology can be utilised with geometric flexibility, highest possible precision and is independent of hardness and conductivity of the material to be machined. Water jet machining, wherein high pressure water is used to cut machines, has also been adopted by a large number of aircraft builders and suppliers. The strength of high pressure is particularly apparent in cutting composite materials and temperature-sensitive lightweight metals.

Tape Layering/Fibre PlacementIn modern aircraft construction, a large quantity of aluminium components are being replaced by complex parts made of fibre-reinforced materials—primarily Carbon Fibre Reinforced Plastics (CFRP). Most are structures on fuselage, an aircraft’s main body section and wings. This reduces weight and greatly simplifies assembly and logistics. While until recently, manufacturing was mostly performed manually, the trend is now to automate the processes, two of which are particularly important: Automatic tape layering for flat and

slightly curved components such as wing cladding

Fibre placement for more curved components such as fuselage segments

Virtual Machining & Productivity EnhancementProductivity is money. Therefore, the goal must be to achieve productivity in all stages of production. With proper approach and suitable measures, existing equipment can be made significantly productive. Anyone who wishes to achieve productivity enhancement must analyse and optimise the entire CAD/CAM/CNC process chain. The CAD/CAM system, NC programme and CNC itself must be optimised without adversely affecting the ongoing production or risking machine damage. Usually, the final

stage of NC programming in work planning is the graphic simulation of the machining process and verification of workpiece.

With manufacturers having global productions facilities, it is essential that various components reach the assembly facility at the right time. To achieve this, strong Manufacturing Execution Systems (MESs) should collate data right from the shop floor to the top floor. This ensures a smooth assembly of the aircraft. All these processes can be carried out with cent percent precision and accuracy based on the choice of technology deployed at every level. Hence, it is essential for an aircraft manufacturer to opt for innovative technologies to gain a competitive edge.

A higher degree of flexibility and traceability has become the need of the hour for an aircraft manufacturer

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OpiniOns & MOre Peter Elmer

Q Changing Global Dynamics Currently, the global economy is

highly diverse. If we analyse the economy, we definitely see North America as a good market. On the other hand, in Europe, the picture is a little diverse. We see Germany and North & East Europe as the growing regions. However, South Europe is encountering growth hurdles. India, we believe, is a growing country and we already have plans to invest here in the future. Although this country does not have the same growth rate as in the past, we are still positive.

Q Investing in Indian Aerospace Each and every report today tells us

that the Indian aerospace industry will grow by 10% in the future. We have targeted different industries for different products. However, the aviation industry is one of the major targets for us worldwide. Over 20% of our total turnover is from aviation and we have gradually come up with

dedicated tools for this industry.

Q Business Opportunities in BRIC Nations

The BRIC nations have always been of interest to us. We entered Russia quite early and have been there for over 10 years. On the other hand, Brazil is a difficult nation due to its import regulations. As per my personal analysis, I foresee some dangers in moving forward in Brazil five years from now. Today, the Brazil market may be good, but we have to be careful a few years from now. This is mainly due to costs in all areas rising rapidly coupled with

the difficult labour law. India, on the other hand, has laid a favourable ground for business. With better regulations, the nation is in favour of global market players.

Q Vision Statement Kaiser is located in Switzerland and

we invest a lot in innovation. Over 10% of the total turnover of the company goes into innovation every year. Each company has a vision, and all employees of the company need to be lined up with its vision. For this, every employee needs to be enthusiastic about every product, the people and leadership behind it. Hence, we invest heavily into the right kind of people. The third most important aspect of Kaiser’s philosophy is to provide precision and quality. We spend a lot on technology, skill development and other aspects,

which will help us reach the highest level of precision and quality.

Q Challenges Faced The real challenge is to instigate

fruitful collaboration between Kaiser and its business partners who can have the same mission and work towards it to achieve the goals. The challenge here lies in getting the right people on the field as it is essential to have highly trained engineers and sales personnel. Hence, it is important to have the right collaboration to utilise our technological expertise.

Q Future Dynamics We plan to invest more in the Indian

industry to have the right people and keep them enthused about the products by bringing in more innovations. We want to bring in more precise and faster tools. Our aim is to transfer the ‘Swiss-ness’ in each and every person with our products in India.

[email protected]

“India has laid a favourable ground for global business partners”While the Indian aerospace industry is steadily gaining ground, Peter Elmer, CEO, Heinz Kaiser AG, tells Debarati Basu Das what makes India an investor-friendly nation.

What is your business motto? Together with the team, we wish to be successful worldwide and come up with great products to satisfy our customers.

You emphasise a lot on your employees. How do you choose the right person for your company? Many people come with attractive CVs but while technical skills are important, every employee should have the sparkle of enthusiasm and the hunger for knowledge & learning.

personalUP CLOSE &

MMT - June 201378

EvEnt REpoRt Hannover Messe 2013

Hannover Messe, the Mecca of all trade exhibitions, proved to be the meeting ground of the who’s who of the manufacturing

sector. Organised in 27 halls with around 9,000 exhibitors, Hannover Messe 2013 was inaugurated by HE Vladimir Putin, President, Russian Federation; Dr Angela Merkel, Chancellor, Federal Republic of Germany; Prof Dr Johanna Wanka, Federal Minister, Education and Research; Stephan Weil, Prime Minister, Lower Saxony and Friedhelm Loh, President, German Electrical and Electronic Manufacturers’ Association.

The world’s biggest showcase for industrial technology was organised in Hannover from 8–12 April, 2013.

Hannover Messe united 11 flagship fairs under a single umbrella. These included Industrial Automation, Motion, Drive & Automation, Energy, Wind, Mobilitec, Digital Factory, Comvac, Industrial Supply, Surface Technology, Industrial Greentec and Research & Technology.

Integrated IndustryThe main theme of Hannover Messe was ‘Integrated Industry’. Herein, in an attempt to provide a brilliant showcase for this theme, approximately 6,550 exhibitors highlighted innovative products and technology solutions. Commenting on the theme ‘Integrated Industry’, Friedhelm Loh, President, German Electrical and Electronic Manufacturers’ Association (ZVEI),

said, “Hannover Messe showed us what ‘Integrated Industry’ was capable of delivering, and the kind of groundbreaking developments that can be expected. The show has taken place at a very exciting time—a time of revolution in industrial processes. Industry, science and research are gearing up for the next stage in the development of integrated intelligent process structures.”

The show’s five core topics—industrial automation & IT, energy and environmental technology, fluid power & power transmission, industrial subcontracting, manufacturing technology & services and R&D—generated huge interest among exhibitors and visitors alike.

With the theme ‘Integrated Industry’, Hannover Messe 2013 clearly showcased core technologies and services that enable industrial production, innovation and efficiency. The exhibition has been acknowledged by companies and organisations around the globe as the world’s premier industrial technology showcase. Nishant Kashyap reports…

u Major German companies such as Schaeffler, KUKA, Siemens, Rittal, Schunk and Dürr Ecoclean, among others, not only launched a few products during the trade show but also showcased their latest solutions. For instance, KUKA showcased a concept at Hannover Messe featuring an industrial robot flexibly and autonomously processing XXL work pieces.

Integrating Industry For Integrating Benefits

Photo

s By N

ishan

t Kas

hyap

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June 2013 - MMT 79

Hannover Messe 2013

Partner Country Russia Every year, Hannover Messe features one of its major exhibiting nations as a partner country. The 2013 edition’s partner country was the Russian Federation—one of the biggest consumers of German machines. Russia is the fourth biggest consumer of German machinery; around 22% of all imported machines comes from Germany. Elaborating further, Hannes Hesse, Executive Director, VDMA, informed, “With export to Russia reaching a volume of about €8 billion in 2012, the country ranked fourth as a trading partner after China, the US and France.”

As a partner country, the Russian Federation focused on energy, industrial automation and new materials. More than 100 Russian companies occupied a total display area of 4,500 sqm at Hannover Messe 2013. The list of participants included big players such as Gazprom, Rosnano, Russian Railway, Rosneft, Transnest, UralVagonZavod, RAO UES of Russia, Vnesheconombank, TMK Group and Metalloinvest.

Technology Showcase Hannover Messe is literally the launching ground for many companies! Many companies eagerly await the perfect platform that Hannover Messe provides to launch their latest innovations. And this year’s Hannover Messe was no exception. Major German companies such as Schaeffler, KUKA, Siemens, Rittal, Schunk and Dürr Ecoclean, among others, not only launched a few products during the trade show but also showcased their latest solutions. For instance, KUKA showcased a concept at Hannover Messe featuring an industrial robot flexibly and autonomously processing XXL workpieces. “Hannover Messe is one of the most important shows for us. In this show, we meet many overseas buyers and our existing customers. As the Asian countries are creating huge opportunities for us, the show becomes very important as there are many visitors and exhibitors from China,

India, South Korea, Indonesia, among others,” informed Helmut Treffer, VP – Sector Management Industrial OEM, Schaeffler Technologies AG & Co KG.

India @ Hannover To optimise the advantages of this mega trade show, many Indian companies had also participated in Hannover Messe. Despite the ongoing Eurozone crisis, Indian companies were confident about the business opportunities in the region. During the exhibition, Raj Singh Rathee, MD, KUKA Robotics (India) Pvt Ltd (an Indian subsidiary of KUKA Roboter GmbH), expressed, “This is one of the most important trade fairs for almost everyone who is associated with the engineering sector. It is undoubtedly one of the best places to showcase your capabilities to the world, as there are many overseas visitors and exhibitors.”

There was also an Indian pavilion with many Indian exhibitors supported by Engineering Export Promotion Council (EEPC). “This is one of the most important events for Indian companies. Every year, we support many of them to showcase their capabilities at the biggest trade show. This provides Indian companies a fair opportunity to understand the market demands in the European region,” noted Gurvinder Singh, Joint Director - Exhibition, EEPC INDIA.

While most exhibitors were confident

of generating good business enquiries during the show, visitors from India too made the most of it at Hannover Messe 2013 and were mainly looking for new markets, latest technologies and business tie-ups.

Gaurav Sarup, Director, Marshall Machines (P) Ltd, who visited Hannover Messe 2013, was keen to know about the latest technologies. “I did not want to miss the chance to witness one of the biggest industry exhibitions. Hannover Messe is the biggest platform to observe the new happenings in the industry and understand the latest technologies,” he opined.

Looking Forward to Hannover Messe 2014 ‘Integrated Industry’, at Hannover Messe 2013, could be defined not only in terms of technical and electronic integration but also in terms of the challenges faced by all areas of industry as they seek to cooperate across corporate and sector boundaries. Integration would shorten communication channels and make collaboration more efficient. In line with this theme, Hannover Messe 2013 has left participants and visitors eager to be a part of Hannover Messe 2014, which will be held during April 7–11, 2014, in Hannover.

[email protected]

u The f ive core topics—industrial automation & IT, energy and environmental technology, fluid power & power transmission, industrial subcontracting, manufacturing technology & services and R&D—of Hannover Messe 2013 generated a huge interest among exhibitors and visitors alike.

Photo By Nishant Kashyap

Event List - National

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International Industrial Trade Fair INTEC 2013 The 14th edition of the event will showcase the latest in machine tools and accessories, hydraulics and pneumatics, material handling equipment & machinery, foundry equipment, precision tools, cutting tools & instrumentation and automation; June 06–10, 2013; Codissia Trade Fair Complex, Coimbatore, India

For details, contact:CODISSIA GD Nadiu Towers,Post Bag No-3827, Huzur Road,Coimbatore - 641 018, IndiaTel: 0422 2222396Fax: 0422 2222397E-mail: [email protected]: www.intec.codissia.com

IMTOS 2013IMTOS covers 40 sectors of the machine tools industry and more than 20 countries have participated in the last four editions since 2007; July 4–7, 2013; Pragati Maidan, New Delhi For details, contact: K & D Communication Limited. 4th Floor, Chinubhai House,7-B, Amrutbaug Society, Opp. Hindu colony,Near Sardar Patel Stadium, Navrangpura, Ahmedabad - 380 014, Gujarat, India Tel: + 9179-26469725, 26460624, 26460453Fax: + 9179-26403087

E-mail: [email protected]

MetEx India 2013MetEx India 2013 is an international exhibition on metal, metallurgical technologies, equipment and service; September 26–28, 2013; Bangalore International Exhibition Centre, Bengaluru For details, contact:Shashank Rajawat KoelnmesseYA Tradefair Pvt LtdTel: +9122-28715205 Fax: +9122-28715222 E-mail: [email protected]: www.metex-india.com

AM 2013Apart from expert talks by leading international domain experts in the 3rd International Conference on ‘Additive Manufacturing Technology’, the event will also include a parallel technology exhibition supported by leading vendors of additive manufacturing technology systems as well as 3D Scanning Devices, CAD/CAE solutions and additive manufacturing technology materials; October 07–08, 2013; NIMHANS Convention Centre, Bangalore

For details, contact:Additive Manufacturing Society of India (AMSI)No 42, BSK 3rd Stage, 3rd Phase, 3rd Block, 9th Cross, Bangalore - 560 085 Tel: 9901033712Fax: 80 26729437, 32422663

E-mail : [email protected]: www.amsi.org.in

Win India 2013World of Industry INDIA 2013 will demonstrate the complete range of products and services, ranging from hydraulics and pneumatics, pumps & valves, automation components to f actory automation systems, material handling equipment, logistics infrastructure systems; December 17–20, 2013; Pragati Maidan, New Delhi For details, contact:Hannover Milano Fairs India Pvt LtdNo 03/16, Vatika Business Centre,Wing B, 7th Floor, Supreme Business Park,Hiranandani Gardens, PowaiMumbai - 400076Tel: +9122-42369710E-mail: [email protected]: www.win-india.com

IMTEX Forming 2012 & Tooltech 2012This international exhibition focuses on an exhaustive range of forming technologies in all engineering applications. The concurrent event Tooltech 2012 is dedicated to cutting tools, tooling systems, machine tool accessories, metrology and CAD/CAM; January 23–28, 2014; Bangalore International Exhibition Centre (BIEC), Bengaluru For details, contact:Indian Machine Tool Manufacturers’ AssociationBangalore International Exhibition Centre (BIEC)10th Mile, Tumkur Road, Madavara postBangalore - 562 123Tel: +91 80 6624 6600Fax: +91 80 6624 6661E-mail: [email protected]: www.imtex.in

India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumactics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical &

Electronics, Material Handling and Safety Equipment.For details

Infomedia18 Ltd, Ruby House, 1st Floor, JK Sawant Marg, Dadar (W), Mumbai 400 028.

Mob: 09819552270 • Fax: 022 3003 4499 • Email: [email protected] • Web: www.engg-expo.com

LudhIANAPunjab

dec 21-24, 2012

ChENNAITamil Nadu

Nov 22-25, 2012

INdOrEMadhya PradeshJan 11-14, 2013

AurANgAbAdMaharastra

Feb 1-4, 2013

rudrAPuruttarakhandFeb 23-26, 2013

Event List - International

MMT - June 201382

EASTPO – 2013The 15th international edition of EASTPO on metal cutting will focus on forming machines, cutting tools, manufacturing systems, automation device, precision tools, industrial electronics and accessories; July 02–05, 2013; Shanghai New International Expo Centre, Shanghai, China

For details, contact: Mark Excellence Business Management Contact: Mr Avneet Singh Tel: 32074604/05 Fax: 26396204 E-mail: [email protected] Web: en.eastpo.net

MTA Vietnam 2013Since 2005, the exhibition has showcased the latest in manufacturing technologies and provides a platform for professional interested in Vietnam’s manufacturing market; July 02–05, 2013; Saigon Exhibition and Convention Center (SECC), Ho Chi Minh City, Vietnam

For details, contact:William Lim & Jeffrey AuTel: +65 6233 1206Fax: +65 6233 6633E-mail: [email protected] Web: www.mtavietnam.com

PDMAEC 2013The international exhibition PDMAEC 2013 will showcase metalworking machinery, equipment, accessories, hardware and other related products & services; August 28–31, 2013; Manila, Philippines For details, contact:Mai Market Access & InnovationsManagement PhilippinesUnit 315-B, 3rd Floor, LRI BusinessPlaza 210, Nicanor Garcia Street,Makati City, PhilippinesTel: +63 2 8992 642Fax: +63 2 8982 198E-mail: [email protected]: www.maimanagement.net

AsiaMold 2013The 6th edition of the event will showcase the latest in press tools & machine tools and industrial dies & moulds from around the globe; September 24–26, 2011; Poly World Trade Centre, China For details, contact:DEMAT GmbHCarl-von-Noorden-Platz 5,60596 Frankfurt / Main,GermanyTel: +49 6927 4003Fax: +49 6927 4003Email: [email protected]: www.asiamold.de

METALEX Vietnam 2013METALEX Vietnam 2013 is a comprehensive machine tool and metalworking technology trade exhibition and conference; October 10–12, 2013; Saigon Exhibition & Convention Center (SECC), Ho Chi Minh City, Vietnam

For details, contact:Reed Tradex Company32nd floor, Sathorn Nakorn Tower,100/68-69 North Sathon Road,Silom, Bangrak,Bangkok 10500 ThailandTel: +66 2686 7299Fax: +66 2686-7288E-mail: [email protected]: www.reedtradex.com

China (Beijing) International Forging ExpoIt is a leading trade fair for professionals from the casting & forging industry; October 16–18, 2011; Beijing China International Exhibition Center (CIEC), China For details, contact:Beijing Hiven Exhibition Co LtdRoom 216, Hua Yue Long Plaza,No 7 Jingyuan Road,Beijing, ChinaTel: +86 10 6863 8450

Fax: +86 10 8868 0811E-mail: [email protected]: www.hwexpo.com

China International Industry FairThe event will focus on the latest in manufacturing technology; November 05–09, 2013; Shanghai New International Expo, Shanghai, China

For details, contact:Shanghai Eastbest International (Group) Co LtdCIIF Breach, Add No - 837 Yan’an Road (C)Shanghai 200040, ChinaTel: 86-21-62892666Fax: 86-21-62895703, 62790302

Machine Tool IndonesiaThe international exhibition on metal cutting machine tools, metal forming machine tools, presses (mechanical, hydraulic, pneumatic), sheet and plate metalworking tools, machinery and accessories, surface treatment, wire and tube forming equipment, precision measurement and testing technology; December 4–7, 2013; Jakarta, Indonesia

For details, contact:PT Pamerindo Buana AbadiDeutsche Bank Building13th floor, Jl Imam Bonjol No 80Jakarta 10310, IndonesiaTel: +62 (021) 316 2001Fax: +62 (021) 316 1981E-mail: [email protected]: www.pamerindo.com

The information published in this section is as per the

details furnished by the respective organisers.

In any case, it does not represent the views of

Tenders & Projects

MMT - June 201384

Latest Popular Tenders & Projects brought to you by www.tendersinfo.com

ORG: Organisation’s name, TRN: Tenders info Ref No, DESC: Description, DSLD: Doc Sale Last Date, BOD: Bid Opening Date, LOC: Location, BT: Bidding Type

InformatIon courtesy: tendersInfo.com1, Arch Gold, Next to MTNL Exchange, Poisar, S.V. Road, Kandivali (W), Mumbai - 400067, Maharashtra, India

Tel: +91-22-28666134 • Fax: +91-22-28013817 • Email: [email protected]

HydraulIc press - 60 tonORG : Ordnance Factory BoardTRN : 16222089DESC : Supply of hydraulic press 60 tonneBOD : June 21, 2013LOC : Pune, MaharashtraBT : Domestic (NCB)

cnc wIre cut macHIneORG : Liquid Propulsion Systems Centre (LPSC)TRN : 16217642DESC : Supply, installation & commissioning of CNC wire cut machineBOD : June 25, 2013LOC : Thirunelvelli, Tamil NaduBT : Domestic (NCB)

forged raIl wHeel manufacturIng plant ORG : Rashtriya Ispat Nigam LtdTRN : 16219134DESC : Setting up of forged rail wheel manufacturing plantBOD : July 01, 2013LOC : Visakhapatnam, Andhra PradeshBT : Domestic (NCB)

cnc HIgH precIsIon latHe ORG : Ministry of DefenceTRN : 16217717DESC : Supply of CNC high precision lathe without counter spindleBOD : July 01, 2013LOC : Dehradun, Uttarakhand BT : Global (ICB)

project - 1

org: new Holland fIat (I) pvt. ltd.Project Type: New FacilityProject News: New Holland Fiat (I) Pvt Ltd is planning a new project to make plant and machinery at Gautam Buddha Nagar, Uttar Pradesh. The project involves tractors, harvesters and other heavy machinery to be used in agriculture.Loc: Gautam Buddha Nagar, Uttar PradeshProject Cost: NAImplementation Stage: PlanningContact: New Holland Fiat (I) Pvt Ltd, Plot No 3, Udyog Kendra, Greater Noida, Gautam Buddha Nagar, Uttar Pradesh – 201306, India.

project - 2

org: vIsHnu fabrIcsProject Type: New FacilityProject News: Vishnu Fabrics is planning to set up a new plant and machinery project at Dindigul Mannar Thirumalai, Tamil Nadu. The project involves manufacturing of power looms machines.Loc: Dindigul Mannar Thirumalai, Tamil Nadu Project Cost: NAImplementation Stage: PlanningContact: Vishnu Fabrics Thadicombu, Dindigul – 624709, Tamil Nadu, India

project - 3

org: napIno auto & electronIcs ltdProject Type: New FacilityProject News: Napino Auto & Electronics Ltd is planning to set up a new industrial products project at Haridwar, Uttaranchal. The project involves manufacturing of capacitor discharge ignition.Loc: Haridwar, Uttaranchal Project Cost: NAImplementation Stage: PlanningContact: Napino Auto & Electronics Ltd, Plot No 3/P4, Sector-10, IIE, Sidcul, Haridwar, Uttrakhand – 249440, India

Tenders ProjecTs

MMT - June 201386

Launch Pad

Seco introduces X4 for parting off and grooving small components

L&T ISCAR launches new porcupine cutters

Seco has recently announced the introduction of X4, a new multi-edged, tangential tool for

parting off and grooving small components. The product is available in cutting widths from 0.5–3.0 mm (.031”–.093”). X4’s inserts minimise material consumption in parting off and enable precise grooving and copying of small and medium-sized complex parts. Performance is further enhanced through X4’s tangential insert bodies that ensure high rigidity, stability and productivity. To increase flexibility, every specific X4 insert seat can accommodate all X4 insert types, allowing for the reduction of tooling inventory. Depending on the cutting-edge width, the tool’s maximum cutting depth ranges from 2.6–6.5 mm (.102”–.256”) and can cut off maximum bar diameters from 5.2–13 mm (.205”–.512”). X4 inserts are

available in neutral, right-hand angled and left-hand angled cutting-edge options.

Ideal for a wide variety of common workpiece materials, X4 uses CP500 and CP600 insert grades. CP600 features a mix of toughness and wear resistance suitable for most general applications, while CP500 provides increased wear resistance for more challenging applications. To further increase X4’s performance, inserts with the MC chip breaking geometry can be applied. This versatile geometry achieves excellent formation of comma and clock-spring chips in a variety of materials and uses a straight front-edge line to guarantee a straight bottom within a groove.

All toolholders provide the unique Jetstream Tooling® Duo technology to further enhance productivity, lengthen tool life and improve chip control. By delivering coolant from two outlets to optimal points in the cutting and heat zones, Jetstream Tooling Duo contributes to efficient cooling, improved chip control and high part quality.

ISCAR offers customers a rich choice of extended flute cutters with tangentially clamped inserts of the

HELITANG T490 milling line. The tangential clamping principle features an extremely strong and rigid cutter body, which is vital for heavy-duty machining of wide edges and deep shoulders & cavities. In these applications, an extended flute tool works both with high depth of cut (several times more than the cutting length of a separate insert) and considerable overhang. Therefore, the strength and rigidity of the tool are of top priority for efficient cutting.

The inserts, mounted on the HELITANG T490 extended flute cutters, have four cutting edges that make the insert cost-effective. There are three insert sizes, which differ by the length of cutting edge—8 mm, 13 mm and 16 mm—and are divided into three subfamilies. The inserts are produced with several cutting geometries for machining the main types of engineering materials with various corner radii. Additionally, the inserts are available with chip splitting action for separating a

wide chip into small segments. The latter improves chip evacuation, reduces power consumption and strengthens vibration dampening. Moreover, using the inserts with chip splitting cutting edges enables a substantial increase in the width of cut.

All the above inserts are manufactured using the latest ISCAR carbide grades with the advantageous SUMO TEC post-coating treatment. HELITANG T490 extended flute cutters are available in two configurations—shank-type end mills and arbor-type shell mills. The end mills include various designs with cylindrical shanks such as straight, Weldon and

CLICKFIT or tapered shanks such as DIN, BT-MAS and CAMFIX.

The shell mills comprise cutters with an integral body and modular tools. The flexible modular tools feature a rigid connection between sections and enable assembling a tool with necessary dimensions and improving the tool life of a cutter. As a rule, the most loaded inserts of the extended flute cutters are those that work both by main (peripheral) and secondary (face) cutting edges, e.g. the inserts mounted on the cutter face. The breakage of such an insert may cause failure of the whole cutter. In this case, the use of replaceable caps—faces milling sections of the modular tools—can solve the problem.

Together with the widespread 90° porcupine, there are HELITANG T490 extended flute cutters with 30°, 45° and 60° cutting-edge angles for machining wide chamfers and inclined surfaces. A wide variety of porcupine-type tools, in combination with a broad selection of appropriate inserts, makes ISCAR’s HELITANG T490 line a real workhorse for extended flute milling cutters.

Launch Pad

June 2013 - MMT 87

SAFE-LOCK™: Next-generation pull-out protection for end mills

Kennametal launches the new 6-flute Beyond KYS40 solid ceramic end mill

WIDIA has teamed up with Haimer GmbH to offer the SAFE-LOCK™, a pull-

out protection and adapter system for round-shanked cutting tools. It enhances security in heavy-duty cutting and combines a positive locking feature with on-center high accuracy for improved process reliability, longer cutting tool life and higher productivity. “Many industries are upgrading their manufacturing resources (machine tools, cutting tools and toolholding systems) that can withstand the high torques, feeds and forces to ensure that the operation does not fail and potentially scrap expensive parts,” says Doug Ewald, Lead Product Manager, WIDIA Tooling Systems.

The danger of milling cutters being pulled out of the toolholder at extreme forces has significantly increased. Such toolholders work with friction alone for locking. They have high levels of accuracy, but their clamping force can be insufficient for roughing operations. The standard industry response for years has been to use Weldon® shanks for

cutting tools. The Weldon straight shank was developed to compensate for pull-out forces and to drive the end mill as hard as possible in roughing and other high-metal-removal operations. It is estimated that 70% of users use standard Weldon holders for heavy roughing due to security concerns considering the clamping screw creates a positive locking.

However, the tool accuracy and run-out is poor due to characteristic offset and one-line contact of the cutting tool in the holder bore. This also contributes to a shorter tool life. SAFE-LOCK™ is a pull-out protection system for round-shanked cutting tools. Helical grooves are ground into the shank of the tool and together with the respective pin drivers in the holder, they prevent the tool from spinning or being pulled out of the holder altogether under extreme machining conditions. Because the helical path of the SAFE-LOCK™

grooves means that the length of the tools can be adjusted, tools can be reground and preset. SAFE-LOCK™ can be combined with the latest toolholder systems because it can be used for both high-speed as well as heavy chip removal situations. The chuck is heated and the tool is inserted with a slight twisted movement. The locking elements of SAFE-LOCK™ find their own way into the grooves when the tool is turned into the locking position.

A spring can be used to aid the play-free positioning of the tool. The holder cools down after a few seconds, creating the press fit and positive locking. A concentric accuracy of <3 µm (0.00012”) is achieved during shrinking. The stable and accurate tool clamping achieved allows users to machine even greater cutting depths with higher feed rates. The tangible benefits are time saving, enhanced productivity, lower scrap rates, less vibration and operators’ peace of mind.

Perhaps the most basic assumption in machining is that cutting high-strength materials requires

high-strength tools. Proprietary nickel-based alloys used in gas and steam turbines, for example, are among the world’s strongest materials. They are continually being developed to allow power plants to run at much higher temperatures. This not only provides more power but also increases plant efficiency and reduces harmful emissions. Superalloys such as Inconel®, Waspaloy®, Rene® etc. come into play in turbine blades and other parts that require high strength, excellent high-temperature creep resistance, phase stability and resistance to corrosion.

Machining such materials can be a slow, laborious and cost-intensive experience. In general, solid carbide tooling commonly runs at speeds between

65 and 200 SFM (20 to 60 m/min) in materials with limited tool life. The new Beyond KYS40™-grade solid ceramic end mills from Kennametal, however, present orders-of-magnitude improvements in machining high-strength nickel-based alloys, roughing at cutting speeds of up to 3,300 SFM (1,000 m/min) with the tool life 2–3 times more than comparable solid-carbide tools. Kennametal’s new SiAlON KYS40 ceramic grade and the overall design of the solid ceramic end mill now offer the most effective way to rough nickel-based high-temperature alloys. “Cutting speeds on nickel-based super alloys can be up to 20 times higher as compared to solid carbide end mills. Also, due to ceramic’s outstanding heat

resistance and stronger cutting edges (negative rake), tool life can last five times longer or more,” says Thilo Mueller, Global Product Manager, Kennametal.

There are two types of KYS40 solid ceramic end mills available—a 6-fluted version for face milling & profiling and a 4-fluted, necked version for slot milling & pocketing. Both product lines allow ramping, helical interpolation and trochoidal machining strategies. The wear mechanisms and wear indication on solid ceramic end mills are different from carbide, ensuring that ceramic end mills run far beyond the point where carbide tooling needs to be replaced. This is also the reason that the new KYS40 grade end mill allows usage beyond the regular type of wear.

MMT - June 201388

Launch Pad

Schaeffler introduces X-life cylindrical and tapered roller bearings

Schaeffler is expanding its range of large-sized bearings in X-life quality. In the future, two- and

four-row tapered roller bearings with outside diameters of 320 mm to 625 mm and cylindrical roller bearings with outside diameters of 320 mm to 1,600 mm will be available as X-life products. With their improved product characteristics and a load rating that is approximately 20% higher, they make it possible to improve performance and optimise the design envelope and reduce weight in machines and plants.

X-life bearings have a significantly longer operating life under the same operating conditions. Alternatively, higher loads can now be applied while maintaining the same life values. State-of-the-art manufacturing technologies enable a better, more uniform surface

to be achieved over the entire contact surface between the rolling elements and raceway. The internal construction is designed for optimum functionality using state-of-the-art analysis and evaluation tools and ensures optimised contact surface geometry and internal load distribution in the bearing. As a result, there is a significant reduction in the stress conditions

present on the rolling elements and mating track under identical load. This produces higher dynamic load ratings, a longer nominal rating life, less friction, lower bearing temperatures as well as reduction in the strain placed on the lubricant.

As an option, the service life of X-life cylindrical and tapered roller bearings can be further increased by carbonitriding, a special heat treatment process in which the surface layers of bearing rings are enriched with carbon and nitrogen. Carbonitriding provides a higher level of wear protection and surface hardness and thus significantly increases the efficiency of the machine depending on the application, especially in the case of extreme operating conditions such as contamination, particle overrolling, mixed friction and boundary lubrication conditions.

A twistable optical fibre cable for 3D movements in energy chains

Bus system problems often occur during twisting applications in energy chains, particularly with

shielded data cables if the shields get damaged or open up. This is not the case with glass fibre optic cables as they do not have a mechanically vulnerable shield braid and are insensitive to EMC whilst transferring high-speed bus signals up to a length of 400 m. Following comprehensive tests, the Cologne-based company Igus GmbH has now developed a new twistable fibre optic cable for all 3D movements in energy chains to ensure reliable bus systems.

The twistable TPE fibre optic cable ‘Chainflex CF Robot-LWL’ makes high data rates possible and can be routed directly alongside high-capacity electrical power cables. The special design uses twist-optimised compensating elements, and the mechanically strong fibre optic cable is absolutely robust even with rotary angles of +180°, e.g. on a robot arm.

The new fibre optic cable has been running on a 1 m long test set-up in the Igus technical centre for more than 1 million double cycles. There is no change in the excellent data transfer rates even at a torsion angle of 360°. The fibre optic cable has a 2-fibre optic core, is resistant to oil, bio-oil & UV light and remains flexible in the cold. The FOC wires with high-tensile aramid fibres and dampers are stranded firmly around a GRP core. The pressure-extruded outer sheath is made of a halogen-free TPE mixture. Highly dynamic in continuous movement, the cable can be used for indoor and outdoor applications at temperatures ranging from -20 to +60°C.

The ‘Chainflex CF Robot-LWL’ has a fibre diameter of 50/125 µm and is suitable for almost all high-speed buses provided that suitable converters

are used. This covers a wide range of uses in torsional applications, such as in energy chains on robots and machine handling, where vision technology plays a prominent role. This helps meet the requirements on moving quality control monitoring, which are becoming even more demanding. The new fibre optic cable is a solution suitable for industrial applications for image transmission for GigE, FireWire IEEE1394a/b and USB.

REPORT CARD

MMT - June 201390

Vertical Articulated Robot

Spot On!

Specifications

Manufacturer: Yaskawa Robotics India Ltd

Yaskawa Motoman has been delivering innovative robotic automation solutions since 1989 to virtually every industrial and robotic application, including arc welding, assembly, coating, dispensing, material cutting (laser, plasma, waterjet), material handling (diecast, machine loading, packaging, palletising, part transfer, press tending), material removal (deburring, polishing, sanding) and spot welding. Motoman innovations in the robotic spot welding market include ES-series ‘Expert Spot’ robots with an integrated spot harness. With spot utilities (power, water, air, motor and signal lines) integrated into the profile of robot arm, automotive OEMs and Tier 1 suppliers realise increased flexibility and higher uptime. Motoman’s patented multiple robot control technology allows close interaction of several arms working on a car body without the fear of collision. Motoman’s latest innovation is the 7-axis VS50 spot welding robot. Designed to take full advantage of proven Direct Current (DC) weld timers and servo controlled actuators, Motoman has introduced a series of lightweight ‘mini-guns’. These powerful, compact spot guns weigh less than 50 kg, but deliver high performance with clamping pressure of 600 kgf and welding current of 15,000 Amps. The low profile and ‘elbow’ on the VS50 robot allows it to be positioned close to the vehicle. It can reach underneath or inside confined spaces. With lighter load and faster speed, this Motoman results in increased productivity and shorter time frame.

Yaskawa Motoman Versatile Spot

Other RobotFeatures Advantages

Design Versatile spot Vertical articulated arm Unique slim design optimises automotive applications using DC spot guns with compact servo actuators

Payload (kg) 50 70 Base axes move 30% faster than heavy payload robots, resulting in shorter takt times and higher throughput

Repeatability ± 0.1 mm ± 0.3 mm High precision with repeatability ensures that the robot reaches the programmed position in its work envelope time after time

Reach 2,597 mm 1,706 mm Ultra compact design with an elbow provides maximum flexibility, ensuring shorter product changeover times and high-process reliability

Motion Range S-Axis (Turning/Sweep) ±180°L-Axis (Lower Arm) +125°/-60°E-Axis (Elbow) ±170°U-Axis (Upper Arm) +215°/-35°R-Axis (Wrist Roll) ±170°B-Axis (Bend/Pitch/Yaw) ±125°T-Axis (Wrist Twist) ±180°

S-Axis (Turning/Sweep) ±170°L-Axis (Lower Arm) +130°/-65°U-Axis (Upper Arm) +70°/-100°R-Axis (Wrist Roll) ±190°B-Axis (Bend/Pitch/Yaw) ±120°T-Axis (Wrist Twist) ±360°

Advantage of the elbow with an extra degree of freedom for precise welding

Mass (kg) 640 600 Due to lighter gun, robot uses less power, even at faster speeds. When combined with improved efficiency of smaller DC guns, VS50 robot offers 50% power savings compared to traditional robots and guns

Axis 7 6 Seven degrees of freedom provides ability to reorient manipulator axes without changing gun position in space. Multi-jointed arm can fold down into a very low profile

Vertical Articulated Robot

June 2013 - MMT 91

ApplicAtiOnS And induStRieS

VAlue AdditiOnS tO the ApplicAtiOn AReAS

AccuracyIt is determined on the basis of how closely a robot can reach a commanded position. When the absolute position of the robot is measured and compared to the commanded position, the error is a measure of accuracy. Accuracy can be improved with external sensing (for example, a vision system or infrared). Accuracy can vary with speed and position within the working envelope and with payload.

RepeatabilityRepeatability will give an insight into how well the robot returns to a programmed position. It is not the same as accuracy. When a robot goes to a certain X-Y-Z position and reaches within 1 mm of that position, its accuracy can be improved by calibration. But if that position is taught into controller memory and each time it is sent there, it returns to within 0.1 mm of the taught position in that case, the repeatability will be within 0.1 mm.

Optimised efficiency with the use of DX100 CONTROLLER

• Patented multiple robot controlsupports up to 8 robots/72 axes

• Windows® CE programmingpendant with colour touch screen and USB interface

• Faster processing speeds forsmoother interpolation. Quicker I/O response accelerated ethernet communication

• Extensive I/O suite includesintegral PLC and touchscreen HMI, 2048 I/O and graphical ladder editor

• Supports all major fieldbusnetworks, including EtherNet/IP, DeviceNet, Profibus-DP and many others

• Compliant toANSI/RIA15.06-1999 and other relevant ISO and CSA safety standards. Optional Category 3 functional safety unit

• Thisparticular controllerhas thecapacity to store 200,000 steps and 100,000 instructions

• Itiscapableofdoingmultitaskingto an extent of 16 concurrent jobs and four system jobs

Product USPs • Duetolightergun,therobotuseslesspowerevenatfasterspeed• Idealforflexible,high-densitylayoutsthatreducecycletimes,takttime• Providesflexiblereachandenlargedmotionrange• Integratedspotharnessfacilitatesprogramming,reducesmaintenance• Compactservogunsprovideclampingforceandcurrentcapacityoflargerguns

n Automotiven Industrial productsn Electronicsn Sheet metal n Assembly linesn Chemical

Sagar ShindePhD Research Scholar Machine Tools Laboratory Indian Institute of Technology, Mumbai

Academia Speak

Compiled by Rishabh Kothari & Avinash [email protected]

Products Products - General

MMT- June 201392

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

Looking For A Specific Product?Searching and sourcing products were never so easy.


eg. MMT EDM and send it to 51818

Cylindrical Grinding MachineThis machine base is manufactured from high-quality cast iron FC30, is tempered and stress relieved for maximum stability of material and assures maximum rigidity. The base permits fast coolant exhaust, preventing thermal deformation from influencing machine accuracy. The forced lubrication system of the grinding wheel spindle features vibration absorbing function. The oil film pressure created by the hydrodynamic bearings automatically absorbs vibration according to the current working condition. The grinding wheel spindle is supported by two special hydrodynamic bearings on the ends with five-point support, providing maximum rigidity and stability of spindle running. In case insufficient lubrication oil occurs, the spindle stops automatically to avoid wearing on the spindle and bearings. Cylindrical grinding machine can be applied several different controller as customer request and it combines various grinding functions in one machine, effective improve grinding precision and operational convenience, such as, tapered grinding, curve and end face grinding and forming grinding etc. It is suitable for manufacture and process components such as machine spindle, roller shafts, large or small motor spindles, module accessories, etc.

Jainnher Machine Co LtdTaichung, TaiwanTel: +886-4-23585299Fax: +886-4-23594803E-mail: [email protected]: www.jainnher.com

Ultrasonic Assisted Machining CenterThe ultrasonic assisted machining center, T51-USA, inherits the concept of aesthetic sheet metal design. With excellent industrial design, user-friendly operation interface, and outstanding machining precision for obtaining the best machining results. For hard and brittle materials, the company has developed a non-contact electricity supplying and ultrasonic machining technologies. The advantage of electricity without contact is eliminating oxidation so there is no chance of unstable machining and electric leakage. With the ultrasonic machining device, the machining efficiency of the original spindle has been improved from three to five times. The material eligible for ultrasonic machining includes aluminum alloy, hardened steel, glass, sapphire and ceramic materials.T51-USA is available with various spindles to reach max speed 15,000/20,000/24,000 rpm. Those are combined with a spindle cooling system that uses recycled coolant to avoid thermal distortion during long-term machining. Furthermore, the direct-drive type spindle connects with the motor by coupling to ensure the best output in horsepower and torque.

Tongtai Machine & Tool Co LtdKaohsiung, TaiwanTel:+886-7-976-1588Fax: +886-7-976-1589E-mail: [email protected]: www.tongtai.com.tw

Power Shearing Machine Shearing Machine is constructed sturdily and designed for accuracy and dependability by employment of latest technology and experience. Side walls are designed from Mild Steel to take heavy loads. Bed and upper beam fabricated from mild steel to withstand and absorb heavy loads designed specially to adjust the blade clearance as required. Pressure Plate fabricated from Mild spring loaded. Revolving key Clutch linked with the main Gear Engages every time when the foot pedal is pressed. Drive provided V-Belts and all the journals are fitted in Gun Metal Bearings. Brake is adjustable one incorporated on the end of the

Crank Shaft. Back Gauge in GSH-1-2-3-4 is Screw Drive where as in GSL1-2-3-4 and GSL1-2-3 is of Rack Pinion Type designed to accurately and easily. Blades are generally four edged and Grade-1 with single segment. Lubrication oil cups provided connected with various pipes rendering supply of oil. Lubrication hand pump is provided in Model No GSH-1-2-3-4 & GSL-4. Standard Equipments Back Gauge, Front Gauges, Wheel and Gear Guards, Foot pedal and Pulley.

Godson Bending Systems Pvt LtdRajkot, Gujarat Tel: +91-281-2361467, 2361449Fax +91-281-2361873E-mail: [email protected]: www.godson-india.com

World Radio SystemWRS system is a high precision gauge composed by a probe/transmitter module (WRP) and a receiver/interface one (WRI). The applied transmission frequency band is 2.4 GHz, allowing that this single system is suitable for use in any application


MMT- June 201394

Grinding Machine This high precision double-sided fine grinding machine model DSG 720 is capable of fine grind less than 100 micron parts. It provides flatness less than 1 micron, parallelism less than 1 micron, surface finish of 0.25Ra to 0.15Ra. It has Siemens PLC interface & has auto thickness control (with non-contact measuring 0.08 Mic.). It incorporates easy wheel change-over from diamond / CBN / conventional.

Lapmaster India Pvt LtdChennai - Tamil NaduTel: 044-2834 4041E-mail: [email protected]: www.lapmaster.co.in

Turning CentersThe Haas ST-20 Series high-performance turning centers were designed from the ground up to provide set-up flexibility, extreme rigidity, and high thermal stability. Available in standard and Super Speed

models, these 8” chuck machines offer the most performance for the money in their class. With available high-torque live tooling and C axis, it’s possible to machine multiple features and perform secondary operations in a single setup. Other features included A2-6 spindle nose, 2” Bar capacity, 15” colour LCD monitor, built-in USB port and 1 MB program memory.

Haas Automation India Pvt LtdNavi Mumbai - MaharashtraTel: +91-22-66098830E-mail: [email protected]: www.haascnc.com

in most parts of the world. The spherical transmission characteristics and 15 m operating range make the WRS both flexible and powerful. The system automatically searches for the best signal among the 74 available radio channels in order to guarantee optimum communication conditions between the probe and the receiver at all times. Additional 4 sub-channels permit to use multiple probes on the same machine by means of a simple NC selection code and extend the working channels up to 316. The WRI receiver interface features a unique remote programming and a four digit display, ensuring that important user messages are clear, immediate and precise, enabling the user to easy program and check the system.

Marposs India Pvt LtdGurgaon - HaryanaTel: +91-124-4735700E-mail: [email protected]: www.marposs.in

Products - General

June 2013 - MMT 95

Geared Head Light Duty Lathe MachineGeared head light duty lathe machine series has height of centre 165mm, length of bed ranging up to 1820 mm, admit between centres up to 1135 mm. main spindle hollow is 38 mm. main spindle nose is A2- 4 or threaded type. Dynamically balanced spindle enable the spindle run at vibration free motion at 1200 rpm. All gears are made of 20MN CR5 material and fully induction hardened and teeth grinding. At the Norton gear box is able to cut the any of metric, modules and pitch (D.P). the bed is made from graded cast iron and flam hardened up to 400 BHN diametric. Also offered are face plate, carrier plate, steady rest, and follow rest, motorized coolant pump with tank and fittings, rear tool post, quick change tool post. The machine is maintenance free and easy to use. The parts of the machine are interchangeable and stock in regional dealer office.

Vinit Engimech Pvt LtdRajkot - GujaratTel: 2312091 / 2311734 Fax: (0281) 2311935 E-mail: [email protected] Website: www.balajilathe.com


MMT- June 201396

Large Through-Hole Air Chuck‘Large through-hole air chuck’, model name ‘AP’ is the newest product of autogrip. AP has very large through-hole for maximum use of the spindle’s capacity, and it is ideal for pipe machining. This machine is equipped with an integrated pneumatic cylinder. The force transmission is effected by the proven wedge hook system. With the patent air supply system, therefore no rotary feed through are necessary especially on machines without hydraulic cylinders. AP and the manual chucks can be easily exchanged. This machine operates as opening and closing is only possible at stopped machine spindle and the pneumatic cylinder is filled with the air by the patent air supply system. The reached air pressure is maintained permanently through a non-return valve in the chuck then the chuck can start to rotate. Advantages are patent air supply system, easily and fast to install, without abrasion of sealed ring, reduce the cost of maintenance and installation.

Autogrip Machinery Co Ltd Tel: 886-4-822-8719Fax: 886-4-823-5719E-mail: [email protected]: www.autogrip.com.tw

Mechatronic GripperWith the Innovative mechatronic gripper with integrated web server, the competence leader for clamping technology and gripping systems belongs to a new generation of mechatronic high-tech grippers. Beside Profibus DP, CAN and RS232, the WSG 50 for the first time disposes of an ethernet TCP/IP interface. Via a typical web browser, the WSG 50 can be commissioned quickly and easily, without the installation of new software. Due to the integrated “gripped component detection“ and the high positioning accuracy, the WSG 50 is for the first time able to carry out a gripping command in a shorter cycle time, and the superior process control is significantly relieved. The contained scripts are filed on the built-in SD card. The WSG 50 is the first gripper which disposes of an electric sensor interface in the base jaws. This is the basis for a direct integration of different sensor systems in gripping processes. Thus it is an ideal helper for sophisticated automation solutions, where a high flexibility or sensitivity of the gripping process is required. With the optional WSG-FMF force-measuring finger, forces which occur during the gripping process can be precisely recognized and controlled. The WSG 50 provides a stroke of 110 mm and a variable gripping force from 5 to120 N.

Schunk Intec India Pvt LtdBengaluru, Karnataka Tel: 080-40538999E-mail: [email protected]: www.schunk.com

Face Milling SolutionHelido S890 is a new economical high efficiency solution for face milling. S890 FSN is a new family of right-hand index able face mills with an 88º cutting edge angle (2° lead) with 8 helical cutting edges, which can be used for up to 9 mm depth of cut. The new family was designed for rough to semi-finish, high-efficiency face milling, primarily on cast iron and steel components. The helido S890 FSN face mills carry square-shaped inserts: S890 SNMU 1305 PN with 8 helical cutting edges, which can be used for up to 9 mm depth of cut. These face mills are available in a diameter range of 50 to 160 mm in coarse and fine pitch configurations. Every cutter body features coolant holes directed to the insert cutting edges, for the most efficient cooling effect. The inserts feature an advanced cutting geometry with positive rake.

L&T-ISCARMumbai , MaharashtraTel: 022 6705 4015, 9833215872E-mail: [email protected]: www.larsentoubro.com

Magnetic Gripper For Machine SpindlesThe GSW-M magnetic gripper is equipped with a 20 mm shank interface, which clamps in a conventional toolholders, and is also connected with the machine spindle. Ferromagnetic components, such as sheet metal, bearing rings, or workpieces with complex contours can be handled via the machine’s own axes. Moreover, it can be used for bar gripping and finished part acceptance in lathes. Since the magnetic gripper of the innovative family-owned company is equipped with permanent-magnets, coolant or compressed air is only required for depositing the workpieces. Thus energy is saved, and ensures that the parts remain gripped in case of a sudden pressure drop. Without adjustment or exchange of fingers, the GSW-M can handle various workpieces, even if they are provided with bores or undercuts. On request, several components can be mounted or stacked in piles. The magnetic gripper has a gripping force of 20 N, and is designed for a 1 kg workpiece weight. Schunk Intec India Private LimitedBengaluru, Karnataka Tel: 080-40538999E-mail: [email protected]: www.schunk.com


MMT- June 201398

Tool Grinder The ANCA FG5 is an entry level CNC grinding machine designed for the tool re-sharpening industry. This machine offers all of the benefits that ANCA customers have enjoyed for many years at an extremely affordable price. The FG5 is a versatile and flexible machine and is suited to a wide variety of industries and applications. It provides opportunities for companies to reduce costs by bringing regrinding in-house and is also ideally suited to companies looking for reduced risk in making the transition into CNC grinding technology. The FG5 has all of the essential elements the industry demands for cost-effective tool grinding, including: quick and easy setup, superior tool accuracy high quality surface finish, flexibility to grind a large variety of tool types and machine reliability and accuracy

Anca Machine Tools Pvt Ltd Yeshwantpur, Karnataka Tel: +91 80 42198107/08Fax: +91 80 42198109E-mail:[email protected]

3D Scanning SystemA non-contact scanning system has been developed on Rapid-I, Vision Measuring systems platform, which can scan at high density and very high resolution (<4µm @ 67x) of intricate small and medium sized parts. Rapid-I’s unique auto-focus technology, combined with CNC capability and powerful software helps to quickly and easily generate cloud points (in .dxf and .txt formats) or surface files (.stl) that can be easily processed. With .stl files, you can directly work with other CAM software to edit and generate CNC programs for machining, completing your reverse-engineering work-flow at very low cost. The system allows the user to choose the density of points, and can scan complex 3D shapes and small surface details that are usually lost in hand-held white light and laser-based scanning systems. The systems are also offered with Renishaw’s touch probes or Scanning probes and non-contact 3D Scanning to give a complete reverse engineering solution.

Customised Technologies Pvt LtdBengaluru , KarnatakaTel: 080-28522858 / 9880022400E-mail:[email protected]: www.customisedtechnologies.com

ChipformerChipformer, under the designation of M3M, was designed especially for machining stainless and low carbon steel. In addition, it was designed with geometric features that improve the tool’s life due to a reinforced cutting edge at the area where VG (notch wear) wear tends to occur when machining stainless steel, causing poor surface finish and risk of edge breakage.Additional geometric elements such as optimal positive rake angle feature a smooth cutting process and reduced cutting forces (by 5 to 10%), thus reducing the wear and dramatically increasing tool life. The M3M has a wide chipbreaking range, making it the first choice in most stainless steel applications. The combination of the new advanced SUMO TEC grades IC6015 and IC6025, together with the unique and innovative M3M chipformer, ensures higher productivity over any other insert existing in the market for machining stainless steel.

Larsen & Toubro Ltd –ISCARMumbai, MaharashtraTel: 022 6705 4015, 9833215872E-mail: [email protected]: www.larsentoubro.com

Portable WeldersThe welding machines are strictly manufactured & are confirming to IS, incorporating latest technological developments and controls with highest order of quality & performance. The machine also has modern looks, novel design concepts, Light weight and compact. Real Portability for one person to do welding at odd places like civial work sites etc. Sturdy belt provided for carrying and hanging. It is made from high-grade materials, with protection against overload by thermal cut-out. Works even on domestic power line, Reliable and durable, Epoxy powder coated body for long life, Coil varnishing by vacuum pressurised impregnating varnishing system.

Canary Electricals LtdGujarat Tel: +91-2822-250431Fax: 91-2822-250433Email: [email protected], [email protected]

Products - General

June 2013 - MMT 99

Tool SettersThese tool setters for CNC lathes are used to detect the position of the tool (inserts) for compensation. When the tool is pressed against the H4A contact surface, high-accuracy signal is transmitted to the CNC controller indicating the position of the tool and the same is updated automatically. As a result, it is no longer necessary to repeat the process of trial grinding, measurement calculation, and inputting the data to CNC controller, thereby eliminating the need for expertise in tool setting. Moreover, tool wear and breakage can also be detected. The tool length can be automatically compensated in CNC controller by contacting the tool in single operation, hence avoiding the rejection of work piece.

Metrol Corporation IndiaBangalore - KarnatakaTel: +91-080-42105031E-mail: [email protected]: http://www.metrol.co.jp/en/


MMT- June 2013100

Super Finish Spm For Piston RodThe hard chrome plated and ground piston rod is mounted on the SPM between centers. The tail stock has a motorised to and fro movement for rapid coarse movement. It also has a hand wheel operated fine quill movement for applying the required holding pressure on the job between the centers. The SPM has both auto & manual mode through a selector switch. VFD controlled 5 HP motor provides the rotational drive to the head stock spindle from 800 to 1,800 RPM in stepless range. The belt polishing unit has a manually operated cross verse traverse of 150 mm with provision for fine depth of cut setting through graduated collar in both the modes – belt polishing mode & buffing mode. The longitudinal axis movement of the belt polishing & buffing unit is through screw rod/rack & pinion mechanism. An independent drive unit, consisting of 2 HP motor & worm reduction gear box provides the longitudinal movement to the saddle, on which the buffing unit is mounted. A VFD interface facilitates the longitudinal movement of the saddle a stepless feed range of 100 mm to 1,000 mm per minute.

Shenoy Engg Pvt LtdBengaluru, KarnatakaTel: 91-80-28361767, 00-9243437487 Fax: 91-80-28361725 E-mail: [email protected]: www.shenoyengineering.com

Robotic Snake-Arm A robot as agile as a snake can explore almost any hidden nook and cranny. Problems often occur in confined and hazardous spaces, and whilst these spaces are difficult for humans to work in, a snake-arm robot has no issue. Whether in aircraft assembly, nuclear power stations or the inspection of sewage systems: maxon motors are responsible for the high-precision movements of the multiple degree-of-freedom robotic snake-arms. Snake-arm robots have been used in aerospace assembly, in the nuclear energy sector, in medical technology and in security applications. Depending on the customer’s requirements, the snake-arm robot is available in different lengths and diameters. The standard sizes vary from 40 mm to 150 mm in diameter and have a length of 1 m to 3.25 m; if required, lengths of up to 10 m are possible, or diameters down to 12.5mm. The diameter of the snake-arm determines its functionality - the larger the diameter, the more weight the robot can lift.

Maxon Precision Motor India Pvt Ltd Bengaluru, Karnataka Tel: 91 80 41734132 E-mail: [email protected] Web site: www.maxonmotor.in

Fibre Laser Fibre laser sheet metal cutting machine is opening a new page in the sheet metal processing technology. Nukon fiber laser cutting system has been manufactured to the highest standards of quality to meet the demands of rapidly growing industry. This machine can be custom manufactured in various dimensions. Resonator is designed with modular structure with provision for capacity upgrade without need for change of machine. Mechanical Structure of the machine is designed with robots and rigid body machine has versatility to cut Stainless Steel, Aluminium, Copper, brass and other reflection materials. Capacity 500 W, 1 KW, 2 KW, 3 KW & 4 KW, table size: 1530X3050mm, 2000X4000 mm 2050X6050mm/4000 X 8000 mm. Materials to cut MS, Steel, Aluminum, Brass, copper and other reflecting materials. Fibre laser has advantages like 80% savings in electrical power consumption, rapid – high speeds, double cutting speeds with fine cut.

Fabmatic Engineering Pvt LtdBengaluru, Karnataka Tel: - +91- 9845068437 / 9916616257 E-mail: [email protected], [email protected] Website: www.fabmatic.in

Grinding Machine GRIT GX and GRIT GI is high-performance grinding machine. This machine offers a modular belt grinder range for professional metal and stainless steel machining. GRIT GX for tradesmen and smaller operations, and GRIT GI for use in the series production metalworking industry. The GRIT grinding ranges are modular and are quick to retool and upgrade. This modular system is unique in the industry and offers significant advantages. Dealers require less warehousing space and users benefit from high flexibility. Furthermore, the costs of purchase are lower, as customers only invest in modules that they actually need. The powerful modular GRIT GX system can be used throughout the entire range of steel and stainless steel machining applications. The grinding machines are suitable for every application from the initial rough grind to surface finishing - coarse cut, circular grinding, grinding out, deburring, chamfering and planing. Different models and maintainance are also available on request.

Fein Power Tools India Pvt LtdChennai, Tamil Nadu Tel: 044- 43578680 – 683Fax: 044-24837788E-mail: [email protected] Website: www.fein.in

Products - General

June 2013 - MMT 101

Mini Arc Welding TransformersRegulator type mini welder medium duty machines are available in 150, 200 & 250 Amps. They are compact, light weight arc welders used for repair and maintenance jobs in medium duty cycles, light fabrication works, light production jobs in farms and small workshops, automobile garage and repair workshops. Yielding quite higher performance to cost ratio compared to any other machine in the market. Built with latest trends in design and manufacturing and tested to most stringent standards to offer years of trouble free service.

Canary Electricals LtdMORBI, GujaratPhone: +91-2822-250431Fax: 91-2822-250433E-mail: [email protected], [email protected]: www.vulcanwelding.net

Drill Re-Sharpening MachineThis machine has the “CE safety authentication”, which originated with up to down way of grind drill. This new research and develop about swing the drill from up to down made the finished of drill more sharpen and more durable than the traditional swing way. Easy to operate, easy to understand and the point angles are from 90°~135°. Chisel edge grinding can adjusting by your demand.

Jin year precision Co LtdTaiwanTel: +886-4-25232817Fax: +886-4-25151230E-mail: [email protected]: www.jinyear.com.tw

CNC Rotary TableThe product range includes, we provide DR – Dual type (Vertical and Horizontal) CNC Rotary Table, TR – CNC Tilting Rotary Table, HR – CNC Horizontal Rotary Table. In recent upgrade for the products, the company has dual worm and dual shaft in internal rotary table design. This design increases the durability, flexibility, and capability for CNC rotary tables.

Ganro Industrial CorporationTaichung, TaiwanTel: 886-4-25376266Fax: 886-4-25378066E-mail: [email protected]: www.ganro.com


MMT- June 2013102

TurbomillFully waterproof, the turbomill 50SQ magnetic chuck is distinguished by high holding force concentrated near its active surface (possibility to clamp thin elements) as well as a low residual magnetism remaining after the demagnetization cycle. This makes the removal of elements after their machining very easy. Also the current required for magnetization and demagnetization of the chuck is much lower than in case of other electro permanent magnetic chucks available on the market. The above advantages combined with basic advantage of electro permanent chucks which is the full safety in case of power supply problems (the chucks need electric energy exclusively in short magnetization and demagnetisation phases) make of this chuck the universal tool for clamping of various elements on milling machines and machining canters.

Braillon MagneticsFranceE-mail: [email protected] Website: www.braillon.com

CNC Turning Grinding Compound Machine Owing to excessive deformation after heat treatment or too much tolerance left to be ground, the workpiece requires more time for grinding. With a newly developed CNC grinding machine BMT-D320GT with turning function, the complicated machining can be accomplished in one setup of workpiece, including internal turning, internal grinding, external turning, external grinding, tapered surface turning and grinding. The turning spindle can be mounted on Y axis or Z axis to cut the excessive tolerance before performing fine grinding. Then the grinding spindles on the Y, Z axis can perform coarse and fine grinding. As turning and grinding operations done on this machine, workpiece concentricity and accuracy can be assured. Moreover, both spindles can do grinding processes, one for internal grinding and one for external grinding or any combination, so many more complex grinding procedures can all be completed on this same machine to speed up the process and to be more accurate. Benign Enterprise Co LtdTaichung, TaiwanTel: 886-4-2323-3016Fax: 886-4-2323-2826 / 886-4-2323-8341E-mail: [email protected]: www.e-bemato.com

One must consider the cost of the product before

purchasing so as to secure definite and assured

returns over the period of time.

Manisha Kadam (Assistant Manager)Ashok Industry

Angle Lock Vise The angle vise comes in two operating methods mechanical and hydraulic. Vise body is made of ductile iron FCD-60.Vise bed is hardened to HRC45 and maintains accuracy for long. Vise bed height-size and the guide block side are all made with full control. The machine has 4 ways of clamping. It also has a down thrust with ‘semi-sphere’ to prevent work piece lift.

Jin Year Precision Co Ltd TaiwanTel: 886-4-25232817E-mail: [email protected], [email protected]: www.jinyear.com.tw

Modular Spray Lubrication System An autojet model 1550 modular spray lubrication system equipped with pulsajet automatic nozzles replaced the drip system. A precise volume of lubricant is now applied to the machine only when needed, instead of constantly using the PWM flow control with pulsajet automatic spray nozzles. There is no waste , therefore there is less lubricant used without any need of compressed air. Spills and leaks have been eliminated and safety concerns have been alleviated. It is compact and easy to add to existing operation. The system is ready to go out of the box and no set up time required with re circulated lubricants. This system is applicable in die lubrication, mold release, stamping and forming.

Spraying Systems (India) Pvt LtdBengaluru - karnataka Tel: +91-80-39853200Fax: +91-80-39853377E-mail: [email protected]: www.spray.com

Products - General

June 2013 - MMT 103

Solidworks ProductSolidWorks 3D CAD software offers three package as below building in functionality and is tiered to best suit the needs of any organisation. All package utilise the intuitive SolidWorks user interface to speed the design process and make it instantly productive. Machining intelligence is the most advanced CAM programming software available for getting products to market faster, more efficiently and within budget. It is a next generation best-of-class CNC programming solution for producing moulded parts from solid models. It is a Certified Gold Product for manufacturing/CAM software that provides state-of-the-art machining capabilities seamlessly integrated into SolidWorks design software. It leads the way in advancements in Automatic Feature Recognition (AFR) and Interactive Feature Recognition (IFR). Its modules are available in a variety of bundles and combinations such as 2.5 axis, 3 axis, 4 and 5 axis prepositioning, 4 and 5 axis, simultaneous milling, 2 and 4 axis turning, rotary milling, 2 and 4 axis wire EDM.

Ezar Engineering Pvt LtdPune, MaharashtraTel: 020-27111704, 09552593842E-mail: [email protected], [email protected]: www.ezarengg.com

Advertorial


MMT- June 2013104

Cryo HiFeedMillA Cryogenic CYCLO CUT® Hi-Feed milling cutter designed for Minimum Quantity C r y o g e n i c s m a c h i n i n g discharges liquid nitrogen through cutter inserts. New model 5-axis HMC 1600 patented t h r o u g h - t o o l system dramatically increases material removal rates and/or tool life on difficult-to-machine materials. The machine can be combined with Minimum Quantity Lubrication for further optimization. The multi-patented MQC technology facilitates increased process speeds, lower cutting forces, longer tool life, and reduced heat. It is also eco-friendly, yielding dry chips without releasing coolant mist or greenhouse gases. MQC delivers liquid nitrogen at -321°F (-196°C) through the spindle, directly to the tool tip and cutting zone.

MAG India Industrial Automation Systems Pvt Ltd Bengaluru, KarnatakaTel: +91 80 4067 7000Fax: +91 80 4160 0777E-mail: [email protected]: www.mag-ias.com

Synthetic High Speed GreasePremium synthetic high speed grease is made with technology from UK for high speed CNC machine spindles which operate upto 12 lacs DmN value.The product is trusted by the major auto component manufacturers.The major content mixed in the grease are PAO base oils so that the grease provides excellent performance at low operating and start up temperatures. The product is a blend of synthetic oils and additive package that offers excellent lubricity even at high speeds. It offers Lower friction when operating therefore lower running temperatures and also,quiet in running and suitable for silent running electric motors.The synthetic base oils offer longer grease life. Compatabile with bearing seal materials like NBR, FKM, PTFE etc.The High Speed grease is recommended for high speed applications in machine tools, textile Industries: small electric motors in medical & dental equipment etc. It is available in 1, 3 & 18 Kg packs.

Raj Petro Specialities Pvt Ltd Chennai, TamilnaduTel: (O44) - 42288900Fax: (044) - 42288912E-mail: [email protected] Website: www.rajgrp.com

Tool Grinding Machine The machine is elaborately designed by Germany and equipped with Swiss top 5-axis NUM Flexium CNC controller and 3D tool grinding software NUMROTO plus. It offers maximum tool length 210mm/Ø120mm. Also, it has mineral-casting machine base with great performance in damping, deformation, and thermal conductivity. Nimble machine design for choice placing of electrical cabinet on either left or right side. Worldwide-patented with double-support B-axis and most distinguished kinematic design to allow 5-axis optimal movement. The machine is Equipped with Marposs 3D automatic tool measurement system, making the tool measuring process more precise and easy. It can perform complete measuring, multi-process shape processing and Radius grinding in one clamping. The machine effectively upgrades the efficiency and production capacity of tool machining. Paragon Machinery Co LtdTaichung, TaiwanTel: 886-4-2539-5678Fax: 886-4-2539-3399

Email: [email protected]: www.paragoncnc.com

Boring ToolBoring tools comes in different ranges ranging from 0.4mm to 3,255mm hole diameters. The complete range is available in analog & digital types with 2 micron diametrical adjustment. The size adjustment is easy and ISO inserts can be used, the connection of tools is modular type and the clamping is done on serrated slides to ensure strong mounting. When the tool size increases the tool body is provided in aluminium alloy to reduce the weight. We also provide tools which can do roughing & finishing in a single go thus reducing the cycle time. We also offer a range of tool holders, turn mill machine tools, boring & facing heads, customized tools etc to cater to your machining requirements. The tools can be easily serviced in India.

Wohlhaupter India Pvt Ltd.New DelhiTel: 011-32227044Fax: 011-26131690E-mail: [email protected]; [email protected]

Products - General

June 2013 - MMT 107

increased stock removal, up to 30% lower work piece temperature & up to 30% longer service life; saves time by up to 75% through fast disc change, greater user comfort, reduced stress on power tool, lower noise generation & less vibration.

PFERD-SWITBengaluru - KarnatakaTel: 080-4218 7117,097414 81117E-mail: [email protected]

CNC Punching SoftwareThe Radpunch is a CNC punching software having several enhanced features wherein the sheets can be automatically cut off on punching and combination machines, to create offcuts. It has the provision of sophisticated tagging, securing the remnant in place while unloading the sheet skeleton. The rectangular nesting algorithm for single parts has been enhanced to show increase in material utilisation. Visual feedback in the order mode list shows the stages of processing i.e. whether the tool is not processed/partially processed/all processed.

RadCAM Software solutionsBengaluru - KarnatakaTel: +91-080-42007936E-mail: [email protected] Website: www.radcamsoftware.com

Fibre DiscsThe COMBICLICK fibre discs comes with differing grit sizes to suit a multitude of applications, from coarse grinding to fine finishing. They are used with matching backing pads and conform to ISO 15636 on standard commercial angle grinders. Other features are provisions up to 25%

Line Shafts These line shafts are with split hubs and metal bellows or servo inserts. They have features like backlash-free, high torsional stiffness, precise transmission of rotational angle, maintenance free, low inertia, compensation of radial, axial and angular misalignment etc. They are available upto torques of 525 Nm in case of servo insert type and 500Nm in case of metal bellow type. Normally, it is available with split hub type. The maximum length of the line shafts with servo inserts/metal bellows are 4000mm.

Rotolinear SystemsBengaluru - KarnatakaTel: +91-080-23572855,9845196751E-mail: [email protected]: www.rotolinearindia.com


MMT- June 2013108

Cnc Milling Machine This machine has a rigid body structure which makes it stable; wide linear guide-ways support axis weight proportionally. Cast iron bed is mounted on wide gap to absorb workpiece weight & vibration. Bigger diameter high precision ball screw ensures accuracy and repeatability for faster & smooth operation. High frequency spindle is most suitable for polish finish and small diameter cutter at high RPM. Fully enclosed body prevents chip evacuation from harming operator. Other features include low power consumption, single/3-phase option, and automatic lubrication to ensure all axis lubrication properly.

Multi Axis CNC RoboticsGurgaon-HaryanaTel: 98104-55354E-mail:[email protected],[email protected]: www.multiaxisrobotics.com

Formdrill This machine is used for thermal drilling and forming bushings. All malleable materials can be thermal drilled. There is absolutely no cutting involved during the creation of the hole. A standard drill press, milling machine or CNC machining center is suitable. Thermal Drilling is ideal for automation because it is a chipless process, produces accurate holes, and has a long tool life. No secondary equipment is required here.

Unimex Formdrill India Pvt Ltd.Bangalore - Karnataka. Ph: 080-41229402, Mob: 09036291674 E-mail: [email protected] Website: www.formdrill-india.com

Production GrinderThe ANCA MX5 is the latest machine tailored to meet the needs of volume tool production customers. It is a powerful, versatile, next- generation grinding machine. The MX5 is a hard-working, high-productivity system with unique features that make it capable of handling varied batch sizes with minimum set-up time. It is optimized to grind tools up to 16 mm (5/8”) diameter. It has the option to be fitted with the RoboMate loader, which provides high-capacity loading with a small footprint. Other features include diameter range between 3 mm to 32 mm, tool length up to 250 mm, tool head diameter up to 32 mm & 15-second tool change time.

ANCA Machine Tools Pvt LtdBangalore - KarnatakaTel: +91-80-42198107E-mail: [email protected]: www.anca.com

Boring Tool SystemThe new large diameter boring tool system by KAISER combines various technical highlights like super light execution, which ensures minor stress for operators and presetter spindles & offers operating safety up to Vc 2’000 m/min and therefore full HSC capability. The boring range is Ø 200 – 340 mm for ISO 40 and HSK-A63 spindles; Ø 200 – 620 mm, extendable up to 3’000 mm for ISO 50 /HSK-A100 and larger spindles. The simple handling of the components virtually eliminates operator error during assembly and leads to almost 100% safety during operation. High strength and hard coated aluminium and nickel coated steel components provide scratch resistant and rust protected surfaces and ensure a long tool life.

Quattro Engineering India LtdBangalore - KarnatakaTel: +91-80-25585439E-mail: [email protected]: www.quattroengg.com

Cylindrical Grinding MachinesCNC cylindrical grinding machines (model SWIFT-500) are designed to cater to customers’ requirements of high accuracy, productivity and reliability of performance. These machines are suitable for production as well as toolroom applications. The machines come with Siemens 802D CNC system and are 2-axis and single spindle controlled.

Hi-Life Machine Tools (P) LtdAhmedabad - GujaratTel: 079-22821615, Mob: 09898083890E-mail: [email protected]: www.hilifegroup.com

Portable Radial DrillsThese portable radial drills are available with universal drill heads designed to offer rigidity, precision and flexibility to drill at any angular direction. The drill head swivels on 2 planes, 90-degree up and down, and the 360-degree rotational movement makes possible the drilling operation at any angular direction. Model UR30 has a 30-mm drilling capacity in steel.

Arsun EngineersBhavnagar - GujaratTel: 0278-2514076, Mob: 9426816961E-mail: [email protected]: www.arsun.com

Products - General

June 2013 - MMT 109

Parallel & Woodruff KeysParallel keys are manufactured as per IS:2048/83 and woodruff keys as per IS:2294. These are made from EN-8/9 material in soft condition. They can also be made from SS-410 and SS-316. These keys are used in automobile industries, textile industries, machine tool industries, motor and pump industries & cement industries.

R K Engineering CompanyMumbai - MaharashtraTel: +91-022-22671141E-mail: [email protected]: www.rkengineeringco.com

Electronic Level This high precision electronic level has a magnetic base that securely attaches the gauge to any metal surface. It has a large LCD display reads upright at any angle. It has the provision of absolute measurement and reference measurement conversion, degree/slope conversion & measure data holding. Other features include back-light, buzzer & auto power off. The battery type is 3V CR2032X3.

India Tools & Instruments CoMumbai - MaharashtraTel: 022-2342 8862,09819345050E-mail: [email protected]


MMT- June 2013110

Bench Grinder Bench grinder with built in dust collector is specially designed for collecting dust generated during the grinding process. It is mounted on a rigid steel frame and has high filtering efficiency, enabling it to grasp even the finest dust particles. It has features like low power consumption and low noise level. Cotton filtering sleeves provide total security against inflammation. It has a 1.0 HP, 3 phase 2800 RPM grinding motor, 3 phase dust collector motor and is fitted with a manual shaker. The machine has dimensions of 775 x 800 x 1050 mm..

Prem BrothersNew DelhiTel: 011-28117456, 28117464, 45595068E-mail: [email protected] Website: www.powermaster-india.com

Cathodic Electrocoating Cathodic electro deposited coating is used extensively in the automotive industry. In this process, the component after phosphate pre-treatment is dipped in the bath of ecoat chemicals and is given an electric charge. The coating gets deposited on the component. The component is removed from the bath, washed and then baked. This process requires the following auxiliary equipment: hot water generator, RO water system, DI water system, laboratory and effluent treatment plant.

Coatec India Mohali, PunjabTel: 0172 - 5090231Fax: 0172 - 50963469Website: www.coatecindia.com

Flap Disc It can be used for quick grinding due to consistent high abrasive quality right up to the last abrasive grain. Maximum economic efficiency due to increased performance per time unit and less wear on discs is attained. Grinding work with high stock removal performance is achieved. It features largest possible stock removal. The innovative design of the ceramic grit abrasive reduces sparks to a minimum. This means that damage to stainless steel work pieces caused by glowing sparks flying around is almost excluded. The surface temperature is reduced by

Fiber LaserOptical fiber is used to generate the beam inside the electronic source and transport the beam from the source to the cutting head. It offers a large number of advantage such as elimination of optical path and laser gas as well as the creation of a more simple and compact layout. The single cutting head uses only one lens for high-quality cutting across the entire range of thicknesses. The wavelength typical of fiber means that highly reflective materials, such as high-purity aluminium alloys, brass, copper and galvanised steel can be cut successfully. The airplane structure carriage design is extremely rigid and allows fast and accurate positioning together with easy access to the work piece.

Salvagnini Machinery India Pvt LtdBengaluru, KarnatakaTel: 09913815775E-mail: [email protected]: www.salvagninigroup.com

Gear HeadPlanetary gear-boxes for Servo Motors offer high precision, low backlash unit. They are available as both inline units and in right angle configuration. These units are available in 3 levels of backlash: Precision which has less than 3 arc minutes, Low Back Lash which has less than 5 arc minutes and Standard which has less than 15 arc minutes. These gear heads come in various frame size which range from A to E with allowable torques upto 92 Nm and peak Torques of upto 274 Nm. The motor mounting side is made-to-order in order to match the Servo Motor. Gear ratios are available from 1:3 to 1:100. The gear heads have a lifetime lubrication and need no periodic maintenance. They are silent operation gear heads in its class. Applications abound in packaging, pharma, machine tools, etc.

Strategi Automation Solutions Pvt LtdBengaluru, KarnatakaTel: 080-32329798, 32467879Fax: 080-41163047E-mail:[email protected]: www.strategiautomation.com

30 % during the grinding process which makes sure that there is no heat accumulation, no deformation, no thermal damage to the joints in the work piece. Tool life and aggressiveness for surface grinding and for the leveling of welds are 50 % higher than those of conventional flap discs. Besides, there is no glazing and constant use right down to the last grit.

SWIT IndiaBangalore, KarnatakaTel: 080 – 42187117, 09741481117E-mail: [email protected]: www.pferd.com, www.swit.in

Products - General

June 2013 - MMT 111

Universal Grinding Machine The universal grinding machine HEW 600 mm is used for high precision grinding of gauges dies & punches dies & punches for tool room application with an accuracy on diameter 0.002 micron. The one piece machine body is made from closed grain casting maximum grinding length 600 mm, height center 150 mm. The grinding wheel spindle is made form EN-24 material case hardened and super finished runs in the white metal bush for smooth running of grinding wheel.

Hitesh Engineering WorksWadhwan, GujaratTel: 91-0275-02752-241926,09879877780Mob: 09879877780E-mail: [email protected]: www.precisiongrinders.com

Drilling Cum Milling MachinesThese pillar type drilling cum milling machines (model SI-6DMU) are used for drilling, milling, tapping, lapping and counter boring. The drilling capacity of these machines is 40 mm, with face mill capacity of 25 mm, tapping capacity of 22 mm in cast iron and drilling capacity of 35 mm in mild steel. Quill spacers are made from steel while main spindle are made EN Steel with 6 slots. Spindle nose is MT-4, spindle travel is 170 mm, spindle speed of 8 gears made from best quality material and helical teethed for smooth and noiseless running. These can be applied for better and accurate square and parallel cutting.

Siddhapura IndustiresBhavnagar, GujaratTel: +91-0278-2445148Mob: 9824246655E-mail: [email protected]: www.siddhapuradrills.com

Mini Hydraulic Power PacksThese Winde DC/AC mini hydraulic power packs are available with 12 V / 24 V DC power supply. These have multiple option of valve configuration suiting to the application. Also available are AC hydraulic power packs. The DC power packs are available for various applications, such as scissor lifts, tail gates, pallet trucks, dump bodies, wheel chairs, personal lifts, aerial ladders, car carriers, mobile platforms, tippers and dock levelers.

Shree Saikrupa Hydro MarketingAhmedabad, GujaratTel: 91-079-65414515,91-079-29296646Mob: 09426510338E-mail: [email protected]: www.bosspumps.in


MMT- June 2013112

Laser Cutting SystemsThese TLM series 5-axis laser cutting systems simplify the processing of 3-dimensional workpieces to perform any number of cutting tasks. Run programs from G code or an NTC-developed simplified coding process. A simple-to-use teach-mode makes cutting path generation easy and takes the guesswork out of virtually all 3-dimensional cutting applications.

Laser Technologies Pvt LtdPune, MaharashtraTel: +91-020-65208337Mob: 08080593077E-mail: [email protected]: www.lasertechnik.co.in

Laser ScannersThe laser scanners are used for detailed measurement and documentation. They use laser technology to produce incredibly detailed three-dimensional images of complex environments and geometries. These create a precise, virtual copy of reality in millimeter-accuracy at a blazing speed of up to 9,76,000 measurement points per second.

FARO Business Technologies India Pvt LtdNew DelhiTel: +91-011-46465656E-mail: [email protected] Website: www.faro.com

Chilly Cutting MachinesThese have durable SS cutting blades and a feeding arm that takes chilly to the cutting blades. These machines are used for chilly cutting as per one’s required size. The machines are user-friendly and have inbuilt conveyor for conveying the chillies. Capacity is 2000 kgs to 10 tonne /day.

Varada Engineers Pune, MaharashtraTel: 91-020-26989087Mob: 09823076601E-mail: [email protected] Website: www.foodequipmentvarada.com

Honing MachineThe numeric controlled E – series honing machines are developed to deliver complete honing solution for the production of small to medium batch sizes and prototypes. It is equipped with Siemens touch-pad numeric controls provides precise, efficient, repeatable honing on through and blind bores for a wide range of components like rocker arm, con-rod, fork shifter, fuel injection

parts, aerospace components and dies. Some of the special features are compactness with stability, assured by rigid module plate design, providing repeatability of stroke and size, for accurate bore geometry across a broad range of applications. Interlocking guard ensures operator safety. E Series honing machine is available in 2 versions namely E 1000S and E 2000S for diameter range of 1.14mm - 25mm and 1.14mm – 120mm respectively with fully adjustable stroke length of 300mm.

WENDT (INDIA) LtdHosur, Tamil NaduTel: +91-4344 276851, 276852, 276854, 405500, 405501Website: www.wendtindia.com

Hydraulic Guillotine ShearsThese are high-performance hydraulic guillotine shears for requirements of high-precision sheet metal cutting for small and high volume production setups for sheet thicknesses ranging from 0.6 to 25 mm and the length up to 6000 mm. The shears come with electro-hydraulic rake angle adjustment, blade gap adjustment and top beam with vertical movement. These shears are also available with CNC controls.

Kawa Press Systems Pvt LtdRajkot, GujaratTel: +91-281--2461102Mob: 09825389169E-mail: [email protected]: www.shaileshmachines.com

Hydraulic Press BrakesThe NC synchro hydraulic press brakes are available in the capacity of 20 MT x 1500 to 500 MT x 6000 mm. The tough, well dimensioned all-welded structure is made out of IS2062 gr B silicon killed and ultrasonically tested steel plates to withstand continuous & minimum deflection under full load.

NuGen Machineries LtdAhmedabad - GujaratTel: 02717-250380, Mob: 09374698657E-mail: [email protected]: www.nugenindia.com

Products - General

June 2013 - MMT 113

Cutting & Boring SystemsThe cutting & boring system series of cutting tools features excellent dynamic balance up to G2.5. For eg, a BT40, H•BOR50P tungsten carbide arbour with MR or MK cutting insert holder, tool ranges from Ø11 mm to Ø32 mm, spindle speed 12000 RPM, the boring diameter/depth ratio can be 1:7.

Stanny Machine Tools Co LtdTaiwanTel: +886-4-26710805Email: [email protected]: www.stanny-tool.com

Vertical Machining CentreThe model VM-2 vertical machining centre is designed for mould industries. It is a high-performance machine with a 30” x 20” x 20” work cube, 36” x 18” table, 12000 rpm inline direct-drive spindle and high-speed control with full look-ahead. High-precision linear guides on all axes further increase rigidity and stiffness, while providing a low coefficient of friction and long-term reliability. High-speed brushless servos, combined with fine-pitch ball screws and high-resolution digital encoders,

ensure ultra-precise positioning and extreme repeatability.

Haas Automation, IncCalifornia, USATel: +1-805-2781800Email: [email protected]: www.haascnc.com

Laser Cutting SystemThe Sirius automation-ready flying optics laser cutting system is used for fast, efficient sheet metal processing. This system is designed to provide efficient processing of parts at optimal speeds and accelerations to suit the part geometry, offering reliable cutting performance at an affordable price-performance ratio. It is optimised with additional features and automation capabilities and provides quick and precise positioning and consistently accurate laser processing. The combination of a dynamic machine with an excellent laser beam quality allows high-speed laser cutting.LVD Company NV, BelgiumBelgiumTel: +32-56-430511Email: [email protected] Website: www.lvdgroup.com


MMT- June 2013114

Products - General

June 2013 - MMT 115

Fiber Laser Cutting Systems Two new HyIntensity fiber laser cutting systems are available, ie, the 2 kW HFL020 and 1 kW HFL010. These two new systems join a 1.5 kW system designed specifically for cutting applications, including marking and fine-feature cutting. The powerful systems deliver a number of advantages to owners, including performance on a wide range of applications and consistent cut quality across a number of material types, including brass and copper, and thicknesses up to 16mm (5/8”) on mild steel.

Hypertherm (S) Pte LtdAbu Road, SingaporeTel: +65-+65-68412489Email: [email protected]: www.hypertherm.com

Wire Cutting EDMsThe TP series wire cutting EDMs incorporate various innovative proprietary technology and patents. WEDM allows for non-streak surface for unmatched machining roughness and multi-cutting capabilities for high precision

Accu-Line LaserThe model Z3A accu-line laser’s power supply is provided by a standard accumulator and is equipped with an on/off switch. There is no transformer or annoying cable any more. The accu-line laser is developed for small machines like band saws, radial saws, mitre circular sawing machines, etc, and is therefore easy to use and install. The semiconductor laser projects a very sharp red line of approximately 1 m length. The very precise accu-line laser makes users work a lot easier and helps to achieve good quality.

Z-Laser Optoelektronik GmbHGermanyTel: 49-761-2964432Email: [email protected]

accuracy. In addition, also offered are 2 distinctive and award-winning wire cutting EDM products based on the TP series, TP-W series and TP-SD series.

Troop Investments Pte Ltd Singapore Tel: 65-67420778Email: [email protected]: www.troop-online.com

List of Products

MMT - June 2013118

Product Pg No Product Pg No Product Pg No

3 axes high speed machining center.................73d CAD software ...................................... FIC3D Scanning System ....................................984 stage pressure regulator .............................645 axes high speed machining center.................75 axis machining centers ............................. 1195 face machining centre .......................... 20, 485 faces double column milling machine ....... 130Additional piece model ................................46Aerosol multi spray ......................................49Aerospace machine .................................... 129Air circuit breaker ........................................47Airline fluid .................................................49All geared auto feed pillar drilling machine ....... 113Angle encoders .........................................BICAngle Lock Vise ......................................... 102Appliance switches .......................................25

Assembly & high temperature greases ..........49Auto feed radial drilling machine................ 113Automation ............................................... 103Bearing ........................................................22Bench Grinder ........................................... 110Bench type drilling machine .........................94Bending .......................................................93Boring Tool ............................................... 104Boring Tool System ................................... 108Bt-401 iso-40 adopters ............................... 107Cable carriers ...............................................22Cable conduit ..............................................25Cable connector ...........................................22CAD CAM software ............................... 18,77CAD/CAM solution. ................................. 118Cam follower ...............................................99Carbide end mill tool ................................. BC

Carrier oil .................................................. 125Cathodic Electrocoating............................. 110Chain ..........................................................22Chain oil .....................................................49Chiller ....................................................... 111Chilly Cutting Machine ............................. 112Chipformer ..................................................98Clamp with serrated jaw ...............................46Clamp with smooth jaw ................................46Clamping repeatability of 0.01mm ................64Clamping tool ............................................ BCClamps machinable jaw ................................46Clamps with self-adjustable jaw ....................46CNC ..........................................................5,7CNC collet chuck ...................................... 107CNC double column machining centre. ........10CNC equipment ..........................................29

Looking For A Specific Product?Searching and sourcing products were never so easy.


eg. MMT EDM and send it to 51818

Product Pg No Product Pg No Product Pg NoList of Products

MMT - June 2013120

CNC horizontal borer ................................ 119CNC horizontal boring & milling machine ......... 10CNC horizontal machining centre ................10CNC horizontal turning centre ....................10CNC lathe ................................................. 119CNC machine .......................................7,20,48CNC machine tool .......................................12CNC machining center ............................. 7,16CNC Milling Machine .............................. 108CNC multi-tasking centre ............................10CNC Punching Software ............................ 107CNC Rotary Table .................................... 101CNC small machining center .......................16CNC turning center .......................................7CNC Turning Grinding Compound Machine ...........102CNC turn-mill centre ..................................10CNC vertical machining center ................ 7, 10CNC vertical turning lathe ...........................10Collets sleeves ........................................... 107Compressor oils ...........................................49Conductor ................................................. 103Connector ............................................. 22, 53Contactor & motor starter ...........................47Control cabinet ............................................53Control panel ..............................................53Control panel accessories .............................25Control system.............................................53Controlling machine tools .........................BICCountersinks ........................................... 8, 35Cryo HiFeedMill ....................................... 104Custom & turnkey .......................................63Cutting & Boring System .......................... 113Cutting oil & water soluble tapping oil ....... 125Cutting tool ..........................................13, 116Cylindrical Grinding Machine ................... 108Cylindrical Grinding Machine .....................92Dead length collet ...................................... 107Demo & refurb ............................................63Desiccant compressed air dryers ................. 115Diamond tool .......................................... 8, 35Didactic equipments for training ..................53Die coater .................................................. 116Die/mould machine ................................... 130Double angle collet .................................... 107Draw - in type collet .................................. 107Drill Re-Sharpening Machine .................... 101Drill tool ................................................... BCDrilling .......................................................85Drilling Cum Milling Machine .................. 111Drilling machine ......................20,48,63,94,113

Drilling tool .........................................8,13,35Drills .....................................................94,113Drive technology ......................................BICDrives / invertor ..........................................47EDM oil .................................................... 125Electrical connectivity ................................ 103Electronic Level ......................................... 109Element shrink disc .....................................99ER collet ................................................... 107Erickson collets ......................................... 107Exhibition- Deimouldindia’2014 ................ 114Exhibition- Engineering Expo ......................70Expanding collet ........................................ 107Exposed linear encoder .............................BICExternal feed fingers .................................. 107Face Milling Solution ..................................96Fiber Laser ................................................ 110Fibre Disc .................................................. 107Fibre Laser ................................................ 100Flap Disc ................................................... 110Formdrill ................................................... 108Freewheel-one-way-clutches ........................99Gang drill machine ......................................94Gear cutting machine ................................. 130Gear Head ................................................. 110Gear milling solution ................................ 123Geared drill machine ....................................94Geared Head Light Duty Lathe Machine .....95Glass linear encoder ................................... 109Grease .........................................................49Grinding machine ........................... 81, 94, 100Grinding tool for hard material ....................81Gun drill ................................................. 8, 35Handling system module ..............................53High speed drill tap centers ........................ 119HMI ...........................................................47Hold back ....................................................99Hole making tools ..................................... 116Honing Machine ....................................... 112Horizontal boring mill ............................... 130Horizontal machining center ...............5, 7, 119Horizontal milling machine ....................... 130Hot forging lubricant ................................. 125Human-machine interface ............................47Hydraulic & gear oils ...................................49Hydraulic Guillotine Shear ........................ 112Hydraulic Press Brakes .............................. 112Hyper CAD ........................................... 18, 77Indexing & non- indexing fixtures .............. 107Induction seals / wad ................................. 103

Inductive proximity switch ...........................25Interface electronics ..................................BICInternal clamping possible ...........................64Iso collets .................................................. 107Job hold down mechanism ............................64Keyless transmission element .......................99Large size horizontal machining center ... 20, 48Large size machining centre ....................... 130Large Through-Hole Air Chuck...................96Laser cutting ................................................93Laser Cutting System ..........................112, 113Laser Scanner ............................................ 112Laser shaping ...............................................81Lathes ...........................................................5LED ............................................................25Length gauge ............................................BICLens mold iron & steel parts mold components crush blade ultra high pressure apparatus .... 116Line Shaft .................................................. 107Load break switches .....................................25Lubricant ..............................................83, 103LVS .............................................................47Machine measurement ..............................BICMachining center .........................................14Magnetic Gripper For Machine Spindle .......96Magnetic linear encoder ............................. 109Magnetic modular encoder ........................BICMaintenance lubricant .................................95Max clamping pressure up to 5000 kgf ..........64Max opening up to 486mm ...........................64Measured value acquisition and display .....BICMechatronic Gripper ...................................96Membrane dryer ........................................ 115Metal cleaners ........................................... 125Metal cutting tool ........................................11Metal working fluid .....................................95Micron drill ............................................... 116Milling ............................................... 13, BICMilling cutters ......................................5, 8, 35Milling head .......................................... 20, 48Milling machine .................................20,48,63Milling tool ........................................ 116, BCMini Arc Welding Transformer ................. 101Mini Hydraulic Power Pack ....................... 111Modular Spray Lubrication System ............ 102Modular tooling system............................ 8, 35Motor protection circuit breaker...................25Multi bore collet ........................................ 107NC lathe ......................................................14Oil coolers ................................................. 111

Product Pg No Product Pg No Product Pg NoList of Products

MMT - June 2013122

INTERNATIONALAutomatic lathe ..................................................... 36Bench grinder ........................................................ 36Boring bar ............................................................. 36Built-in motor spindle ......................................... 109Center hole grinder .............................................. 101Center lathe ........................................................... 36Center less grinder ............................................... 101Center less grinding machine ................................. 27Chuck arbor ........................................................... 36CNC angular cylindrical grinding machine ............. 27CNC internal grinding spindle ............................. 109CNC lathe ............................................................. 36CNC machining center spindle ............................ 109CNC milling machine ............................................ 36CNC surface grinding spindle .............................. 109Collet .................................................................... 36Combination type tool cabinet & cart ..................... 36Cutting tool ........................................................... 95Cylindrical grinder ............................................... 101Electric discharge machine ..................................... 36Electric power tool ................................................. 36End mill ................................................................ 95Engraving machine ................................................ 36Grinding machine .................................................. 36Hand tools ............................................................. 36High-speed center less grinding machine ................ 27Hoists electric ........................................................ 36Hydraulic jack........................................................ 36Hydraulic presses brake .......................................... 36Index table ............................................................. 36Internal grinding machine ...................................... 27Machine center ...................................................... 36Magnetic chuck ..................................................... 36Master cam ............................................................ 31Milling machines ................................................... 36NC/CNC internal grinder .................................... 101Plastic injection molding machine .......................... 36Pneumatic power tool ............................................ 36Presses hydraulic .................................................... 36Radial drilling machine .......................................... 36Sawing machines.................................................... 36Side milling cutter ................................................. 36Slotting machine .................................................... 36Spindles ................................................................. 99Spindles for PCB drill & mill ............................... 109Turning center spindle ......................................... 109Twin-spindle compound grinding machine ............. 27Universal cylindrical grinding machine ................... 27Universal vise ......................................................... 36Vise ...................................................................... 36

P4-1612 panel bender ...................................93P4-2220 panel bender & material handling ...93Packaging solution ..................................... 103Packaging test equipment........................... 103Paint stripper ............................................. 125Panel coolers ............................................. 111Parallel & Woodruff Key ........................... 109PCB drills.................................................. 116Penta IQ grip for grooving and parting ..... FGFPillar drill machine ......................................94Pillar drilling machine ............................... 113Pilot light ....................................................25PLC ............................................................47Plugs and sockets .........................................25Portable Radial Drill .................................. 108Portable Welder ...........................................98Position display unit .................................BICPost processor ........................................ 18, 77Power Shearing Machine .............................92Power sources ..............................................89Precision gear cutting tool .......................... 130Precision steel ..............................................81Precision switch ...........................................25Precision switches single & multiple ............25Process automation and control equipment...53Production Grinder ................................... 108Punching .....................................................93Push button .................................................25Radial drilling machine .............................. 113Reamers .................................................. 8, 35Reaming ......................................................85Robotic Snake-Arm ................................... 100Rotary ...........................................................5Rotary encoder..........................................BICRotary switch ...............................................25Rotating electrical connector ...................... 103Run out chart ............................................ 107S4 punching-shearing system .......................93Safety light curtains .....................................97Safety light grid ...........................................97Safety protection device ...............................25Sealed linear encoder ................................BICServo ...........................................................47Sheet metal working machinery .................. 127Single limit switch .......................................25Single piece body avoids deformation ...........64Slant / flat bed ........................................... 119Solder paste ............................................... 103

Solid carbide drill .........................................11Solid carbide drills with IC...........................11Solid carbide mill .........................................11Solid carbide reamer.....................................11Solid carbide reamers with IC ......................11Solid carbide special drill..............................11Solid carbide special mill ..............................11Solid carbide special reamer .........................11Solidworks Product .................................... 103Special collets customised special collet ...... 107Special induction hardening machine ...........89Specialty lubricant .......................................95Standard feed finger ................................... 107Standard induction hardening machine ........89Submicron filter ......................................... 115Super Finish Spm For Piston Rod .............. 100Surface grinder .......................................... 119Synthetic High Speed Grease ..................... 104Tap .................................................. 8, 35, 121Tapping holder ..............................................6Tensioner nut ..............................................99Thread mill................................................ 123Thread milling cutters & taps holder .......... 121Threading ....................................................85Threading tool ........................................... BCTool Grinder ...............................................98Tool Grinding Machine ............................. 104Tool Setters .................................................99Tooling system .......................................... BCTouch probes ............................................BICTrack roller .................................................99Transparent gel............................................49Tubing accessories .......................................53Turbomill .................................................. 102Turning .............................................. 13 ,BICTurning centers .................................20,48, 94Turning tool ....................................... 116, BCUltrasonic Assisted Machining Center ..........92Universal Grinding Machine ...................... 111Validation of pack ...................................... 103Valve ...........................................................53Valve terminal .............................................53Vertical machining center .......................... 5,55Vertical machining centers-single / double column ........... 119Vertical Machining Centre ......................... 113Vertical turret milling machine ................... 109Wear resistant tool ..................................... 116World Radio System ....................................92

Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No

List of Advertisers

MMT - June 2013124

Fresmak Arnold Precision Engg Pvt Ltd 64

T: +91-80-40224250

E: [email protected]

W: www.fresmak.com

G W Precision Tools India Pvt Ltd 11

T: +91-80-40431252


W: www.gwindia.in

Gsk CNC Equipment Co. Ltd 29

T: +91-9886835186


W: www.gsk.com.cn

Haas Automation India Pvt Ltd 5

T: +91-22-61392800


W: www.haascnc.com

Heidenhain Optics & Electronics (I) BIC

T: +91-44-30234000


W: www.heidenhain.in

HG Technology Co., Ltd. 95

T: +886-4-736-2725


W: www.hgt.com.tw

Hyundai Wia India Pvt. Ltd. 12

T: +91-9940653703


W: www.hyundai-wia.com

Doosan Infracore India Pvt Ltd 10

T: +91-80-42660122


W: www.doosaninfracore.com

EFD Induction Limited 89

T: +91-80-7820404

E: [email protected].

W: www.efd-induction.com

Emuge India Pvt Ltd 121

T: +91-20-39310000


W: www.emugeindia.com

Ermaksan sheet Metal Working Machinery 127

T: +90-224-2947500


W: www.ermaksan.com.tr

Exxon Mobil Lubricants Pvt Ltd 83, 103

T: +91-124-4951300


W: www.exxonmobil.com

Festo Controls Ltd 53

T: +91-80-22894100


W: www.festo.com

Freeze Tech Equipments Pvt Ltd 111

T: +91-44-42152387


W: www.freezetechequip.com

ACE Micromatic Group 55

T: +91-80-41492285


W: www.acemicromatic.net

Allied Machince & Engg Corp / key T 85

T: +91-330-343428

E:

W: www.alliedmachine.com

Benign Enterprise Co. Ltd. 36

T: +886-4-2323-3016

E: [email protected];

W: www.bemato.com.tw

Brisloy Tools India Private Limited 129

T: +91-124-4283106


W: www.brisloy.com

Cgtech India software solutions (P) Ltd 70

T: +91-9845212147


W: www.cgtech.com

CNC software, Inc. 31

T: +1-860-875-5006


W: www.mastercam.com

Designcell CAD-CAM solutions Pvt Ltd. 118

T: +91-22-28256599


W: [email protected]


List of Advertisers

MMT - June 2013126

Nmtg Mechtrans Techniques Pvt Ltd. 99

T: +91-79-22821527


W: www.nmtgindia.com

Openmind Cadcam Technologies (I) Pvt 18, 77

T: +91-80-30504647


W: www.openmind-tech.com

Paragon Machinery Co., Ltd. 27

T: +886-4-2539-5678


W: www.paragoncnc.com

Parametric Technology India Pvt Ltd FIC

T: +91-80-42526300


W: www.ptc.com

Progressive Engineers 103

T: +91-22-32944289


W: www.progressiveengineers.net

Quickmill Inc. 63


W: www.quickmill.com

Raj Petro specialities Private Limited 49

T: +91-44-42288900


W: www.rajgrp.com

korloy India Tooling Pvt. Ltd. 13

T: +91-124-4930080


W: www.korloy.com

Larsen & Toubro Limited FGF

T: +91-22-67051093


W: www.larsentoubro.com

Makson Machines Pvt Ltd 113

T: +91-278-2446437


W: www.makwanaeng.com

Metrol Corporation India Branch Off 16

T: +91-80-42105031


W: www.toolsensor.com

Mitsubishi Electrical India Private Limited 47

T: +91-20-27102000


W: www.MitsubishiElectric.in

Mitsubishi Heavy Industries India Pvt Ltd 130

T: +91-11-41021234


W: www.mhiindia.com

Motul 95

T: +33-148117030

W: www.motul.com

IFM Electronics India Pvt Ltd 97

T: +91-231-2672770


W: www.ifm.com/in

Igus India Pvt Ltd 22

T: +91-80-39127800


W: www.igus.in

Indian Tool Manufacturers (Div Of Birla

Precision Technologies Limited) 6

T: +91-253-2350320


W: www.indiantool.com

Isgec Heavy Engineering Ltd 119

T: +91-120-4085001


W: www.isgec.com

Jainnher Machine Co.,Ltd. 101

T: +886-4-2358-5299


W: www.jainnher.com.tw

Jyoti CNC Automation Pvt. Ltd. 7

T: +91-2827-287081


W: www.jyoti.co.in

kenturn Nano. Tec. Co., Ltd. 109

T: +886-4-791-0271


W: www.kenturn-machinery.com.tw


List of Advertisers

MMT - June 2013128

Teknic 25

T: +91-22-26592392


W: www.teknic.co.in

Tooling summit 40

T: +91-22-30034650


W:

Trident Pneumatics Pvt Ltd 115

T: +91-422-2400492


W: www.tridentpneumatics.com

Tungaloy India Pvt Ltd 116-117

T: +91-22-61248888


W: www.tungaloy.co.jp.in

Tyrolit India superabrasive Pvt. Ltd 81

T: +91-80-40953259


W: www.tylolit.com

Vargus Limited 123

T: +91-9730028248


W: www.vargus.com

YG Cutting Tools Corporation Pvt Ltd 8, 35

T: +91-80-43543636


W: www.yg1.co.kr

siddhapura Engineering Works 94

T: +91-278-2428054


W: www.siddhapuradrills.com

siemens Ltd 65

W: siemens.com/sinumerik

srujan solutions 46

T: +91 20 64004102


W: www.ok-vise.com

Taegutec India Ltd BC

T: +91-80-27839111


W: www.taegutec-india.com

Tagma India 114

T: +91-22-28526876


W: www.tagmaindia.org

Techtronics India Limited 20, 48

T: +91-124-2370555


W: www.techtronics.in

Ramm Precision Products (P) Ltd 107

T: +91-422-2566489


W: www.rmcollet.com

Royal Precision Tools Corporation 99

T: +886-4-2338-2068


W: www.royal-spindles.com.tw

salvagnini Machinery India Pvt Ltd 93

T: +91-80-32214123


W: www.salvangninigroup.com

samchully Machinery Co Ltd 14

T: +82-32-822-4811


W: www.samchully.com

see Lube Technologies P Ltd 125


W: www.oilandlubncant.com

shri shyam Enterprises 109

T: +91-9316056942


132

Reg No: MH / MR / WEST / 235 / 2012 – 2014 RNI No: MAHENG / 2008 / 24347 Licence to Post at Mumbai Patrika Channel Sorting Office, Mumbai GPO., Mumbai 400 001

Date Of Posting 5th & 6th Of Every Month / English & Monthly. Date Of Publication: 28th of Every Month

June 2013

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Mmt june 2013