Source: Jyoti CNC Automation Ltd Young trainees at a practical sessionwith their regular academic Learning while working engineering campuses toschedule. Many students from As learning and skill upgrading motivate students and supportthese batches are offered is a continuous process, on-the- innovative designs, automationwork opportunity before they job training is one of the key and technology developmentscomplete their academics. concerns in Jyoti. Work, Learn to bring out the hidden talents and Upgrade combination has and nurture them for the futureEmpowering women in been set by the organisation, industrial developments.the industry and under this policy variousCompared to the global training programs are cond- Creating a strongstandard of women’s parti- ucted on and off campus to technological foundationcipation in the manufacturing enhance the knowledge-base of In order to contribute to theindustry, India is still far its employees. growth of the nation, Jyotibehind. As Jyoti is always Such learning sessions are has associated with higherknown as a trendsetter, women framed and executed in educational research worksempowerment and gender close association of renowned to bring innovation andequality are two ongoing academicians from the region. strengthen the country’sefforts in the organisation. This process helps to bridge technological base. Though theThe company initiates special the gap between the industry company owns a state-of-the-training programs for women requirements and academic art on-campus R&D center, itwith or without technical research. Such programs have supports various special R&Dbackground. helped in creating strong programs of different IITs forThe company has focused bonding not only within impactful innovations in thetraining schedules for women the organization, but also in machine tools sector.to impart them knowledge spreading the same to the Such programs have alreadyon CNC operations and society. Jyoti adopts active transferred a great amountprogramming. Post training, training programs of IMTMA of knowledge and experience30 women candidates were for different skilled employees between academia andabsorbed as CNC machine to boost their confidence and industry. These developmentsoperators in the company. This personal growth. are also boosting researchhas created a strong impact on The company gets involved activities and creating impact inthe conventional industrial in many technical events advanced manufacturing, andemployment pattern in India. and competitions at various defence research sectors.www.mmindia.co.in May 2017 | 51
MACHINE TOOL PROBINGSTREAMLINING COMPONENTSETTING AND INSPECTIONRead on to learn how the Pune-based Universal Manufacturing Company (Unimac) achieveda 90 percent reduction in the inspection time over four months after installing Renishaw’sPrimo system, designed for on-machine part setting, part inspection and tool setting. U niversal Manufacturing manufacturing plants and other 2.4 m X 6 m for conventional Company (Unimac) was heavy engineering applications. machines and 4.25 m x 2.7 m started in 1987 after a Unimac has grown into a for CNC machines allied with second-hand machine from versatile manufacturer aiming in-house robotic fabrication to offer one stop solution for all capability and in-house CAD/ Germany was bought for machining needs. CAM design center. The machine shop spread over manufacturing components an area of 20,000 sq ft houses The Inspection Challenge an array of large heavy duty What had to be addressed was needed in sugar and cement German conventional boring the cycle time for machining machines as well as latest CNC a turbo charger housing that plants. It later switched to machining centers which ensure would take 46 hours. During precision manufacturing along this process, at the semi-finished manufacturing general with a high production rate. stage, the part would be taken The large machining capacity to an inspection facility to be engineering components. has a table size of upto checked for flatness, squareness, Currently, the company manufactures large precision parts used for railway engines, power generation plants, cementAmazing 90% reduction Source: Renishawin inspection cycle timeon turbochargerhousingFlow line assemblyof Jobber CNC lathes52 | May 2017 Modern Manufacturing India
parallelism and positional “After installing the Primo Unimacaccuracy. The part would then system, the manpower cost,be brought back to the machine, material handling costs, material CHALLENGESand have to be realigned and equipment and power Eliminate manual setting errors,set before further machining consumption charges are saved improve accuracy and partcould take place. This process so no additional investment is conformance, whilst reducing non-would take three hours and required.” productive time and scrap..have to be carried out twice,meaning that the machine lay Ashok Mungale SOLUTIONidle for six hours during each Director Introduction of automated on-machinemanufacturing cycle. In this Unimac part setting, inspection and tool settingmanual process, part setting processes using the Primo system.itself takes 30 minutes. time and scrap. Now at Unimac, the new for the first time,” said AshokAdvantage Primo System process takes just 30 minutes, Mungale, Director, Unimac.The company installed has reduced inspection time by “Another advantage of theRenishaw’s Primo system to 90 percent, reduced cycle time Primo system is that it combinestackle the problem. by 12 percent and led to a very part set up, part inspectionThe Primo system consists of a fast return on investment (ROI) and tool setting capabilitiesPrimo Radio Part Setter and a in just four months. in one system so there is noPrimo Radio 3D Tool Setter. It It is straightforward to install need to source separate items.enables automated on-machine and use, and represents a low The Primo system is definitelypart setting, part inspection and initial financial outlay. It also worth recommending for everytool setting, removing the need has an enhanced warranty to engineering industry,” he added.to breakdown and move the offer users peace of mind.part, and reset it once it has been The Primo GoProbe training 7UXVW)DFWRUinspected. This helps eliminate kit and pocket guide help users Unimac first heard aboutmanual setting errors, improve to learn and implement the Renishaw when ten years agoaccuracy and part conformance, system. it purchased its CMM, whichwhilst reducing non-productive came fitted with a Renishaw %HQHƲWV$ERXQG probe. Following this, Unimac Source: Renishaw “After installing the Primo formed a relationship with system, the manpower cost, Renishaw, and received regular material handling costs, updates about new product material equipment and power developments. Its engineers consumption charges are saved analysed all of the machining so no additional investment is applications at Unimac required. This gives flexibility thoroughly, and offered best to the manufacturing unit in practice advice and guidance on accepting orders for any size which products would be most and for segments such as the suitable for Unimac’s needs. The machine tool industry. The Primo system is the company’s manual analysis of results is also first machine tool probe. avoided, as the data is available Mungale concluded, “Since we on the same controller. It’s an were convinced with the sales, amazing experience to use service and application aspects Renishaw machine tool probes, of Renishaw, we installed its which are being used by us telescoping ballbar to help maintain machine accuracy. After this, it was easy to ascertain whether the fault was during machining and the errors could then be eliminated. Results from the ballbar are always perfect so a mutual trust has developed between Renishaw and us”.www.mmindia.co.in May 2017 | 53
COOLANTSA STEP TOWARDS AGREENER PLANETA unique bactericide-free concept resulting in long-term, biologically stableand safe emulsions. Skin friendly40 years ofexperience No additives necessary Free of Environmentally boric acid and friendly formaldehyde Modern Manufacturing India Blasocut – 100% Source: Blaser Swisslube bactericide free Water-miscible metalworking fluids based on the well established term Bio-concept have been Blaser Swisslube‘s strength for over 40 years.54 | May 2017
I t is becoming a global %ODVRFXWEHQHƲWV the pH value, and cause bad requirement for all Blasocut emulsions based on odours. This is the main reason manufacturing the bio-concept enable optimal why bactericides are commonlyorganizations to contribute process reliability, long life added to metalworking fluids.towards a greener planet. These cycles, and make it one of theinitiatives are either due to mildest formulations in the Bio-Concept withglobal regulations or self- world. Apart from successful rainwater, demineralisedconsciousness towards the technical performance of or softened waterenvironment. Blaser Swisslube Blaser Swisslube metalworking Bio-Concept works every-has designed Blasocut, featuring fluids, one of the company’s where. Water of good micro-a bio-concept which works in top priorities has always been biological quality has aharmony with nature. It allows its human and environmental positive impact on emulsionthe colonization by specific, compatibility. The pH value that stability. Water with a highwaterborne bacteria (termed is of high importance for the microbiological contamination“primary bacteria”) that push stability of an emulsion remains may lead to an imbalance inback all other bacteria by constant, and there are no the emulsion. However, thisconsuming the available changes in odour. In addition, occurs rarely. The Bio-Conceptnutrition, which limits their the company has never is robust. It is important toown growth as well. The result received complaints regarding note that the primary bacteriais long-term emulsion stability skin irritations. Additionally, are not delivered with theand one of the safest there are no storage and dosing metalworking fluid concentrate.formulations to use across complications. The Bio-Concept also worksthe world. with osmosis water and sterile Bactericidal additives makeup water. Although suchBlasocut basics in conventional makeup water adds no primaryWater-miscible Blasocut emul- PHWDOZRUNLQJƳXLG bacteria to the emulsion. Evensions stay biologically inhere- emulsions though the machines havently stable, without the need Uncontrolled growth of bac- intensively and best possiblyfor bactericides – a concept teria in conventionally formu- been cleaned, the machine willBlaser Swisslube introduced lated metalworking fluid not be sterile. There are always40 years ago. Bio-concept emulsions may cause problems. some deposits that remainproducts are designed, through Such bacteria may decompose invisible to our eyes.their constituents, to become emulsion ingredients, reducenaturally populated by a Source: Blaser Swisslubesignificant number of theseharmless, environmental ba-cteria, as they contain nobactericides. Bio-concept fluidsexert a selection pressuremainly allowing the growthof these bacteria found in anysource of water.The way it worksIt is thought that primarybacteria immediately consumeforeign organic substances thatare present in or introducedinto the coolant, effectivelypreventing the establishmentof other bacterial species. Thusthey restrict the growth of allother microorganisms undernormal operating conditions.www.mmindia.co.in May 2017 | 55
GRINDING BEING ON THE EDGE OF SUCCESS To gain a competitive edge over low-cost suppliers, manufacturers of solid carbide tools should invest in the pre-requisites that guarantee optimum grinding results at significantly reduced process costs, along with a long tool life. prerequisite for producing solid carbide tools with superior lifetimes. In order to be a successful carbide tool manufacturer, optimal technical conditions such as a modern machine fleet and a wide variety of measuring devices must be paired with the lowest possible process costs. For expensive CNC machines, in particular, what counts is keeping non- productive time, e.g. for dressing the grinding wheels, to an absolute minimum in order to maximise productivity. Source: Tyrolit Innovative solutions In this backdrop, TyrolitFlute grinding with one of the world’s leadingthe new STARTEC RC producers of bonded grinding,guarantees low grinding cutting, drilling and dressingforces. tools, facilitates in providing precision tool manufacturers M anufacturers of solid the quality, performance and a competitive edge. The carbide tools are lifetime. High tool quality gives grinding spindles can not only facing strong price a decisive competitive edge, be equipped with the proven pressure, mostly from the especially for difficult tasks STARTEC flute grinding and regions where lower wage costs encountered in the aerospace cup wheels, but also with the mean that tools can be produced and automotive industry, and STARTEC XP-F polishing wheel. more cost-effectively. However, also in machine construction This enables tool manufacturers the end customer’s buying and tool making. to set themselves apart from decision is not solely determined The demands placed on carbide low-cost suppliers particularly by the price of carbide tools, but tools are also constantly with respect to lifetime and tool increasingly by criteria such as increasing: innovative cutting- quality. edge geometries with excellent Flute grinding accounts for Source: Tyrolit surface finishes and minimal an especially high proportion cutting-edge chipping are a of the overall costs of solid carbide production. Even the grinding tool is always an important factor with regard to cost efficiency. As one of the world’s leading manufacturers56 | May 2017 Modern Manufacturing India
“Our application engineerswork on site with ourcustomers worldwide andfocus on process optimisationin terms of cost reduction,quality assurance, reducednon-productive time andscrap.”Martin PilzMarketing ManagerTooling Industry, Tyrolitof grinding solutions, Tyrolit Source: Tyrolithas for many years offered Source: Tyrolitgrinding wheels in a wide 1 2variety of shapes, dimensions Source: Tyrolit 1 Theand specifications. The profile wear, while still offering 3 STARTEC RCSTARTEC XP-P flute grinding easy dressing of the grindingwheel, with its high cutting wheel. production of stepped tools for from TYROLITperformance and long intervals the aerospace and automotive for producingbetween sharpening cycles, has Polishing wheels industry, as cracks are avoided. standard tools.established itself in the flute The company’s engineers have They are also very well suitedgrinding field. The company’s succeeded in developing an to the production of tools made 2 The newcustomers have successfully innovative specification with from very brittle cemented STARTECused the STARTEC XP-P new diamond grades and a carbide types. The STARTECcup wheels for grinding the new bond system for polishing. XP-F polishing wheels, which XP-F grindingface geometry and clearance These polishing wheels are are available ex stock and in wheel forsurfaces. They are ideal for adaptive, in other words they customer-specific designs, can polishing chipgrinding geometries requiring enable selective stock removal efficiently polish chip flutes flutes on shaftthe best possible surface finish of up to 0.2mm. Apart from a and clearance surfaces and tools made ofand lowest possible cutting- precise tool shape, a surface significantly improve tool tungsten carbide.edge chipping. with a mirror finish is produced. quality. As was already the case with In the face of competition 3 TheLow grinding forces the proven STARTEC XP-P flute from low-cost suppliers these semi-mattThe development of the grinding wheels, high feed rates are the best preconditions forSTARTEC RC product line was are also achieved with the new tool manufacturers’ market chip flute of adriven by specific customer polishing wheels. At the same success. VHM drill bitrequirements from the area of time, the high profile stability produced byspecial tool production. The and low grinding forces of the STARTEC XP-Fmain focus of development was new specification ensure long- polishing wheels.reducing the normal grinding lasting profile accuracy.force produced during flute Tool manufacturers can nowgrinding. This is the main cause optimally equip their grindingof the friction and, therefore, spindles as appropriate to thegeneration of heat in the process. required tool properties andExcessively high temperatures process parameters. STARTECand adverse tool geometries can XP-P wheels offer a provenalso result in cracks in the tool, standard product for fluteincreasing the scrap rate. grinding. The low grinding forcesThe new STARTEC RC combines of the STARTEC RC grindingspecial diamond grades with wheels make them ideal forgood cutting ability with producing tools requiring largeunique bond architecture. This stock-removal. Especially goodcombination permits a low results are achieved in thenormal grinding force and lowwww.mmindia.co.in May 2017 | 57
BEST PRACTICESINNOVATION ON THEASSEMBLY FLOORIn order to boost the productivity of its most famous product and gain the most sought aftercompetitive edge, this largest manufacturer of CNC lathes in the country had to resort to anunconventional approach. Read on to learn about the revamping it brought to the product’smanufacturing and assembly and the radical results thereafter. I N line with its vision of enough features that can be used High Volume Machines division being a ‘Large Scale in Small & Medium Scale ‘Job decided to implement a radical producer of World Class Shops’. However, in the past change, internally referred to as Turning Machines’, Ace five years, many domestic ‘Half-Day Indexing’. Designers Ltd, the flagship manufacturers benchmarked company of the `15 billion Ace this machine, and this model Setting itself apart Micromatic Group, manufactures became the most copied one. At In the mid-1990s, Ace Designers its most popular model—the this point, R Prabhakar, Chief transformed the assembly of Jobber. This model is a standard Operating Officer, Ace Designers, Jobber machines from the 2 Axis CNC lathe with just and his engineers from the conventional method of ‘fixedFlow line assemblyof Jobber CNC lathes R PRABHAKAR Source: Ace Designers Ltd Chief Operating Officer Ace Designers Ltd Modern Manufacturing India [email protected] | May 2017
point’ assembly to ‘flow line’ Before and After Half Day Indexingassembly. Flow line is nothingbut an assembly on a conveyor Measurement Before After Parametersline where the product, as 8 stations 4 hoursit is assembled, moves from Number of stations 8 stations 2644 sq.ft.one station to another. The Takt time of the 8 hours for 50 machines flow line per month‘Takt’ time was eight hours `2X 2or one day indexing. This Space saved 2644 sq.ft. Increase in turnover for 25 machines 50 machinesaward winning concept was per month per month One line 4 modelsoperational since then, but `X 24 Members for 50 machinesthe increased competition andprice pressure drove the teaminto further improving the Takt Number of times 3 material handledtime. The target given by oneof the Managing Directors of Assembly capacity 25 machines per line per monthAce Designers, was to changethe Takt time to four hours Flexibility of line One line one modelIndexing or ‘Half Day Indexing’ Manpower per line 21 Members for 25 machineswithin a deadline of six months.The prerequisites set were—noshortcuts in the establishedprocesses, the new methodshould be process driven, no operations were done on redesign, Time study, Design components prior to assembly. and Use of correct Power tools,deterioration of end product The biggest challenge here Fixtures and other Mechanical, was to have interchangeability Electrical and Electronicsquality and the project had so that end accuracies or gadgets. After intense and performance of the product was focused implementation effort,to be done on the very latest not compromised. This activity the line became operational. took the longest time as every Since the results obtainedJobber Elite series machines. minute step of the assembly was were quite impressive, the reviewed and re-established. research paper presented byIncidentally this machine was The major steps involved in IIM-B Team on this project this period were Assembly was published by Harvardawarded the prestigious ‘India Layout redesign, Component Business Publishing.Design Mark’ by the IndiaDesign Council.Accepting this challenge,Prabhakar put together a CrossFunctional Team from ProductDesign, Engineering Methods, The Jobber XL CNC lathe has been theAssembly and Procurement. highest selling model in the countrySome of the major challengesfaced by the team was to havea buy-in from the assemblyteam on the floor, to make thembelieve that it was achievable,and not lose focus on the marketneeds of the product thatwas undergoing continuousimprovements, supplychain support and completereconfiguration of materialstorage and logistics.Targets achieved Source: Ace Designers LtdTo reduce the actual assemblytime, many of the activitiesthat were being done on theassembly floor were eliminatedthrough design changes onthe components so that thosewww.mmindia.co.in May 2017 | 59
MANUFACTURING SOFTWARE POWERED BY:CHOOSING ANERP SYSTEM FORDATA-DRIVEN MACHINE SHOPS Manufacturers with an ERP system in place should re-evaluate the system as the essential forerunner of and foundation for emerging data-driven manufacturing concepts.An ERP system is aconnector that unifiesmanagement andoperational functions. LAURI KLAUS Source: mmsonline.com CEO &Founder KeyedIn Solutions Modern Manufacturing India60 | May 2017
E nterprise Resource However, the market for ERP Speak to fellow ERP users systems is becoming more You may find it difficult to speakPlanning (ERP) emerged saturated. Whether upgrading a to direct competitors about shop control system or installing their experiences with ERP,years ago as an integr- ERP for the first time, businesses but you could communicate may find it difficult to decide on with a shop reference whoated software system to make the best option. A read on few has goals similar to yours and tips to choose the best ERP that can answer questions frommanufacturing operations, sho- meets your requirements. experience. Likewise, you could post questions to online manu-pfloor activities and front-office Consider your objectives facturing groups to gauge their and requirements opinions.management easier and more First, consider exactly what you These are good questions to ask: want from your system. Whatefficient. Business owners and issues or staff inefficiencies Were any promises not kept must be resolved? Your answers by your vendor?managers embraced ERP should be specific in order Does the product do what to narrow requirements for you expected?because they are faced with a your chosen ERP system. To Were any deadlines missed? avoid being overly influenced Are you paying for productseries of important, urgent by marketing from various extensions that you do not vendors, list your requirements need?questions every day. ERP helps before starting to research the Were hidden costs options available. Discuss these discovered aftermeet this challenge. It enabled requirements with different installation? team members to ensure thatthem to make use of a specific needs are met. Scrutinize the demo We recommend providing thecentralized solution that holds Measure return on vendor with a demo script that investment (ROI) outlines specific functions andcompany data in a single place, Very often, businesses features that you will expect researching ERP systems find to see. Approaching the demothus providing all the it difficult to measure ROI with an open but critical mind accurately. However, having will save valuable time andinformation required for each clearly defined goals and help determine whether the objectives at the start will help software meets your goals.department to carry out its role considerably. It’s possible to measure ERP performance by: Calculate the real costeffectively. Depending on the It is essential to know the true Calculating productivity cost of ERP by calculating expe-product, ERP supports such before and after nses at each stage. implementation. These include:functions as estimating and Documenting inventory improvements. Upfront costquoting, shopfloor scheduling, Counting up savings to Maintenance customers and whether User adoption and trainingjob tracking, purchasing, lifetime value has increased. Support Recurring costsproduction and manufacturing Also consider the advantages between in-house and cloud- A top priorityresource planning, shipping, based ERP. The latter is often With the intense interest in data- the most user-friendly option. driven manufacturing theseand financial management. It will probably require fewer days, it is all the more urgent for members of the in-house team manufacturing companies toMust have system to maintain it. re-evaluate the importance of aERP systems have been capable ERP system.available and were widelyimplemented long beforecompanies began to think aboutdata-driven manufacturing.Today, companies are lookingat connecting machine toolsand other devices to a computernetwork so machine-generateddata can be collected for analysisand reporting. This data canenable shop managers toboost productivity and reducedowntime. In the meantime,manufacturers with an ERPsystem in place should re-evaluate the system as theessential forerunner of andfoundation for emerging data-driven manufacturing concepts.Companies without an ERPsystem should consider migratingto one, especially as they eye amove to machine monitoringand shop networking.www.mmindia.co.in May 2017 | 61
EVENT SNAPSHOT Source: IMTMAKey dignitaries from CIMT 2017:the internationalmachine tool A STEPassociations at the TOWARDSopening ceremony. GROWTHPOONAM PEDNEKAR China International Machine Tool Show (CIMT) 2017 once again lived up toChief Copy Editor its reputation of being one of the most influential machine tool shows in theMagic Wand Media Inc world as it unfolded its 15th edition in Beijing last month. With advancedpoonam.pednekar@ manufacturing technology and equipment on display, the biennial event was amagicwandmedia.org haven for buyers and suppliers from the world over.62 | May 2017 Modern Manufacturing India
“Chinese machine tool HIGHLIGHTS Source: IMTMAconsumption is expected togrow almost by 50 percent in CIMT 2017 VOUCHED FOR THE Machine tool companiesthe coming years, which gives a FOLLOWING FOUR ASPECTS from India made impactclear indication for greater at the show.opportunity for Indian machine Digital manufacturing and solutiontool builders to penetrate Intelligent technology Spain, Taiwan, the UK and thedeeper in the Chinese machine É 'HFG DɭBHDMBX @MC @TSNL@SHNM USA organized their officialtool market.” Professionalism pavilions. India pavilion had participation from machine toolPG Jadeja, President of the demand structure. In builder (MTB).Indian Machine Tool Manufacturers’ order to adapt to the market Among the products thatAssociation & CMD demand changes, machine provided a wide choice toJyoti CNC Automation Ltd tool manufacturers must purchasers and also piqued the proceed with the supply side, interest of those visiting theW ith the support of and provide customers with event were products named China Machine Tool satisfying products, technology “China Debut” “Asia Debut” and & Tool Builders’ and service model to obtain a “World Debut”.Association (CMTBA), this year’s new development momentum The opening ceremony wasCIMT was held with a theme of through adjustment and presided by Wang Liming,“New demand, New supply, transformation. Executive Vice President,New Momentum”. The theme CMTBA, followed by a welcomeresonates with the role it plays, The who’s who present note by Chen Huiren, Presidentwhich is being the best window The event that sprawled over an and CEO, CMTBA. Membersof the world’s ever-changing area of 131,000 sq mt attracted of the Machine Tool Industrymachine tool market demands. 1,652 exhibitors from 28 Association and relatedSince its establishment in countries and regions, increasing industry organizations from1989, the exhibition has been by 5.5 percent over the previous Italy, Germany, Japan, theshowcasing world’s advanced session. Twelve foreign countries United States, China, Taiwan,manufacturing technology and and regions such as China Switzerland, Korea, Spain, India,machine tool products. It is Mainland, Czech, Germany, Britain, Czech Republic, France,an important platform for Hong Kong, Italy, Japan, Korea, Russia, Austria, Argentina andthe promotion of Chinese andforeign technical exchanges andChina’s technological progress.China is the world’s largestmachine tool market. Theindustry in the country isexperiencing profound changesand the major feature of thechanges is the rapid upgradingwww.mmindia.co.in May 2017 | 63
EVENT SNAPSHOTother countries and regions also “The demand for quality Ltd, “There is still a greater needtook part. machine tools is high in China. and scope to establish Make in Indian machine tools which are India brand in China, it beingOn the showcase customized or specialized, and one of the highest machineCIMT 2017 vouched for the provide a ‘turnkey solutions’ tools consumer of machine toolsfollowing four aspects: digital have a good chance of success across the globe.”manufacturing and solution, in this market.” “Indian presence in China isintelligent technology, high negligible compared to the localefficiency and automation, and Sameer Kelkar and other global machine toolprofessionalism. CEO & R&D Head players but there is a growingThe show distinguished itself Grind Master Machines Pvt Ltd acceptance for Indian brands,”with the scale and kinds of seconds Dr Vishwas R Puttige,exhibits that comprised machine According to PG Jadeja, Head, Business Development,tools, functional parts, CNC President, Indian Machine Ace Manufacturing Systemssystems, measurers, machine Tool Manufacturers’ Association Ltd.tool electronics, tools, and and CEO, Jyoti CNC Automation The company was presentaccessories for metal cutting, at CIMT this year as one ofmetal forming, gear machining, the exhibitors and receivedspecial machining. a positive response from the customers and dealers forKnowledge sharing its products and solutions.platform “The CIMT Show has seen anCIMT 2017 meant more than the increased presence of Indiandisplay and trade of the latest manufacturers. Indian machineproducts and technologies. It tool industry, especially the Aceprovided a platform ideal for Micromatic Group, has beeninformation exchange. Nearly able to penetrate into different100 technical seminars and market sectors winning theactivities - such as International confidence of customers inCEO Forum, InternationalConference on Advanced Indian exhibitorsManufacturing Technology, displaying theirEnterprise day and News latest innovations atBriefings - were organised to CIMT 2017.meet the multi-level needs ofparticipating organizations andexhibitors who found themto be conducive to discusstechnologies, trade and businessco-operation.China favourable for Source: IMTMAIndian machine toolmanufacturersChina has been one of the largestconsumers of machine tools inthe world, and therefore is acompetitive market to sell in. Allindustry segments thrive here,with each sector having its ownunique requirement in terms ofspecifications and performance.The country is now focusing onbolstering its manufacturingcapabilities and has laid out bigplans for the next decade.64 | May 2017 Modern Manufacturing India
terms of quality expectations,” Hence, it is important to “It has been an industrious effort he adds. establish a brand recognized of 10 years by the Ace Sameer Kelkar, CEO and R&D for technology, reliability and Micromatic Group to build the Head, Grind Master Machines good support services to meet Brand India in China. Indian Pvt Ltd opines that CIMT requirements of mission critical presence here is negligible exhibition is a very important operations, opines Kelkar. compared to the local and other show for establishing a brand Grind Master’s microfinishing global machine tool players. and name in this economy. The machines for crankshafts and However, there has been a company has been present in camshafts are highly sought growing acceptance for Indian China for over seven years. after in China, with around brands.” It recently celebrated its 75th 25 percent market share. machine dispatched for the “Chinese machine tool market Dr Vishwas R Puttige China market. “Most of our has enough demand to consume Head, Business Development machines are in Automotive CNC machines in greater volume Ace Manufacturing Systems Ltd Powertrain Manufacturing when offered at a competitive operations for critical shafts price with advanced techn- demand for niche products and such as crankshafts and ological solutions,” says Jadeja. solutions such as the CNC twin camshafts. CIMT 2017 was Apart from standard entry- spindle machining centers and important to showcase this level machines, Jyoti CNC’s CNC turning machines with experience and capability and automation series of machines built-in automation solutions. meet new customers. We had such as TACHYON, TMX, TS 120, The automotive industry in over 200 footfalls including ATM 160 are more in demand in China manufactures high- customers, business partners, Chinese market. quality world-class cars and agents, etc.,” informs Kelkar. According to Puttige, turning the factories are also state- centers and machining centers of-the-art facilities for mass Made in India, employed are also required in China. Its production. Kelkar believes that in China standard 2 and 3 axes machines high performance machines for Chinese customers have a are consumed in high volumes. specific applications are well reputation of being demanding. There is also an increasing received in these setups.Visitors thronged at thebooths to witness thelatest displays duringthe show. Source: IMTMA Positive scene for India “Chinese machine tool consum- ption is expected to grow almost by 50 percent in the coming years, which gives a clear indication for greater opportunity for Indian machine tool builders to penetrate deeper in Chinese machine tool market,” says Jadeja. This edition of CIMT was a small progress towards this. The show has given a clear indication about the acceptance of Indian products in China.www.mmindia.co.in May 2017 | 65
PRODUCT Part Machining TaeguTec’s Insert for Parting and Grooving The line comes in C and J type chip breakers and is available in a range of grades to machine a variety of materials. TaeguTec’s newly released optimized line, the RHINOGROOVE, is an optimized insert with an overall reduced length developed for efficiency in shallow depth of cut parting and grooving machining. Its center of gravity promotes better stability while the vibration during machining is minimized by the optimized holder pocket design that enables powerful clamping of the insert. Since vibration is the single greatest influence on tool life in parting and grooving, the RHINOGROOVE claims to offer improved stability and longer tool life due to minimized vibration during machining. The line comes in C and J type chip breakers which are available as standard items in either 2-3mm insert widths. The line is also available in a range of grades – TT9080, TT7220, TT8020 – to machine several types of materials. Renishaw Metrology Systems Ltd TaeguTec India Pvt Ltd T: +91 (20) 66746772 T: +91 (08) 027839111 E: [email protected] E: [email protected] www.renishaw.com www.taegutec-india.comBroken Tool Detection Corrosion Preventive SolutionLaser Tool Corrosion Inhibiting PackingRecognitionSystem VCI Paper and Films provide excellent rust protection in high humidity and sea conditions.The system is suitable for a widerange of machines and is optimised Daubert VCI Paper and Films provide long term preservation in storage andfor use at distances of up to 1.0 m. transit. The main benefits of the VCI technology lie in its ability to self-applyThe Renishaw TRS2 tool recognitionsystem is a cost-effective solution and dissipate and it is based on the combined principles of polarity and volatility.for rapid broken tool detection on arange of machine tools and tool types, Metals in the vicinity of VCI products undergo a chemical reaction and formeliminating the problems caused bybroken tools in terms of scrap, re-work a protective molecular layer, which prevents moisture, salt, dirt, oxygen andand downtime. Using Renishaw’sToolWise technology, tools as small other materials from depositing on the metals and inhibits corrosion. Thereas 0.2 mm diameter can be checked at300 mm range. With tools typically are two main product categoriesspending one second in the laser beam,the TRS2 is also suitable for use in high – VCI Papers and VCI Film.volume production environments andfor low, medium and high speed spindle The technology is based on themachines. It comprises a single compactunit containing the laser source and concept of volatility and polarity,detection electronics. It is easy toinstall and can be mounted outside the where volatile “V” componentsmachine’s working envelope. are added to Corrosion Inhibiting “CI” Components. Benefits include: Excellent rust protection, protection in sea conditions and good strength Zavenir Daubert India and quality. Pvt Ltd T: +91 124 4981000 E: [email protected] www.zavenir.com66 | May 2017 Modern Manufacturing India
Honing CNC Vertical Machining CentersIncreasing Jyoti develops High Speed Drill-Productivity tap centers - the Tachyon SeriesthroughInnovation! The moving column centers are ideally fit for small and mid-sized components for continuous drilling-tapping operations.Multiple spindle machines offeringhigh accuracy and high productivity. Designed for faster drill-tap operations to cater the most sophisticatedThe New SP425 Single Pass Honing applications of automobile, surgical and telecommunication industries, JyotiMachine from Khushbu Engineers ismade for processes where productivity has developed high speed drill-tap center called the Tachyon Series. The seriesand high accuracy are of utmostimportance. In multi-spindle, single is equipped with fast electro-mechanical type integral pallet changer, fast toolpass honing, the component advancesautomatically to next station—the changer and dynamic rapid of 60 m/min for axis. These moving column drill-diamond tool/spindle—and the bore sizeis progressively corrected by 0.03–0.04 tap centers are ideally fit for small and mid-sized components for continuousmm at the end of 4th spindle.Very close tolerances can be achieved drilling-tapping operations with greater productivity offering.consistently with the required surfacefinish through the single pass honing The key features of this series include optimized construction to supportprocess. This machine is suitable fordiameters of 5–15 mm and lengths up to 60 m/min rapid rates, high acceleration up to 15 m/sec2, roller type high50 mm. Bore accuracy of 0.003 and Raof 0.4–0.6 micron can be easily achieved precision linear motionwith a production rate of 2500 to 3500pieces/day. Blind/through bores can guideways, directlyalso be honed. It is a very simple processas compared to conventional honing. coupled high speedThe diamond tool just passes into thebore and the required size is achieved. BT-30 spindle, integralThis method is more cost effective andreliable as it does not require a skilled work-piece changeroperator. Equipped with a simple CNCcontrol, the operation of the machine (APC) with a changingis user friendly and has a low set-uptime; thereby increasing productivity. time of 4 sec, 16 toolThe machines are designed to caterto precise requirements. The design is drum type ATC withcompact and sturdy. tool changing time of Khushbu Engineers T: 0230 2468859, 2460060 1 sec, and 90° tilting Jyoti CNC Automation Ltd E: [email protected] operating panel to view T: +91 (28) 27287081/082 www.khushbuindia.com the machining area. E: [email protected] www.jyoti.co.in Grinding Machines Wendt Rotary Surface Grinder The grinder can be used for precision grinding of parts such as piston ring, rocker arm, connecting rod, valve plate, compressor plate, ceramic parts, tools, moulds and dies, used in the automobile and engineering industries. Wendt Rotary Surface Grinder (WRS Series) is a 3 axis-grinding machine and is driven by Siemens controls. WRS Series of machines WRS 300H/V and WRS 600H/V are available in both horizontal and vertical spindle arrangement. The machines are manufactured with and without electromagnetic chuck. Its special feature is the massive, multi-piece gray cast iron column, housing all the assembly units. Some of its exclusive features are: a rotary table with a diameter ranging from 630mm to 1200mm; user-friendly operating cycles for rough, semi-finish, finish grinding, spark out and dressing; ESR (extended stop & retract) feature to address power supply failure and sudden stoppage of the machine; a choice of CNC controls Siemens 840DE/ Wendt (India) Ltd 810DE/ 802DSL; and custom- T: +91 (43) 44405500 built accessories and tooling. E: SajuAbraham@wendtindia www.wendtindia.comwww.mmindia.co.in May 2017 | 67
PRODUCTServo-Drive Technology SCHUNK Intec India Pvt Ltd T: +91 (80) 40538999Kollmorgen E: [email protected] its AKM www.in.schunk.comServomotor SeriesExtra-low-voltage motors serves as a solution formachine modules and retrofitting.The new AKM DC servo motor low voltage with its 48 Clamping technologyV design was originally intended as a customer-specificsolution for special areas of use. Kollmorgen, a specialist in SCHUNK’s Hydraulicservo-drive technology and motion control will now offer Expansion Toolholderthis as a standard add-on to the AKM series, and thus asa new series product. There are many potential uses for The slim precision mounting makes it ideal for use in48 V DC servo motor low voltage. The same applies to two series production, particularly in the automotive industry.new variants with a 24 V power supply.Further variants of Kollmorgen AKM low voltage DC SCHUNK TENDO Slim 4ax hydraulic expansion toolholderservo motor include two 48 V motors with less power, and aims to combine the complete outside geometry of heattwo drives with windings tailored to 24V. shrinking mountings according to DIN 69882-8. The slimSize 3 AKM low voltage servo motors of 48 V provides up precision mounting is meant for use in series production,to 300 watts of power at a current of 6 A – sufficient, for particularly in the automotive industry. It was particularlyexample, for accurate drive tasks in packaging machines or designed for axial operations, and shows its strength duringfor dynamic movement in autonomous transport systems. milling close to interfering contours, countersinking, reaming and thread milling in 5-axis centers, prototype construction, Kollmorgen India and the die and mold industry. T: +91 (22) 42270300 SCHUNK TENDO Slim 4ax can be used without expensive E: [email protected] peripheral devices. It has a run-out accuracy of < 0.003 mm www.kollmorgen.com/hi-in/home at an unclamped length of 2.5 x D and a balance grade of G 2.5 at 25,000 rpm. The mountings are available for the interfaces HSK-A63 with ø 10 mm/L1=120 mm, ø 12 mm/L1=90 mm, ø 12 mm/L1=120 mm, ø 14 mm/L1=90 mm, ø 14 mm/L1=120 mm, and ø 20 mm/L1=90 mm. Further variants with ø 6 mm bis 32 mm and L1-dimension of 90 mm, 120 mm, and 160 mm are already planned.Complex MachiningLMW’s Machining Center for Critical ComponentsIt is ideal for highly complex components used in Aerospace, Die & Mould, Oil & Gas Lakshmi Machine Works Ltdand Medical industries. T: +04 (22) 302 1393 E: [email protected] JU 40, from Lakshmi Machine Works Ltd, is a 5-axis simultaneous machining www.lmwcnc.comcenter. This machine completes high accuracy complex components in a single setup,ensuring easy and quick production of close tolerance components. It is ideal for highlycomplex components for Aerospace, Die & Mould, Oil & Gas and Medical industries.The JU 40 comes with a BBT40 spindle taper and direct driven 12,000 rpm spindle.The machine has a Ø500 x 400 mm tilting rotary table with A & C axis and X, Y, Zaxis travel of 400 mm, 550 mm & 550 mm respectively. Excellent repeatability, highreliability and performance are the key features of this machine. LMW has beencontinuously upgrading its capabilities to tackle the manufacturing issues faced by avariety of industries that is to produce parts of varying material compositions, volumesand complexities. The company has come up with the solution in the form of JU 40.68 | May 2017 Modern Manufacturing India
SAVE THE DATES EVENT CALENDAREVENT NAME CONTACT DATE & VENUEMACHINE TOOL T: +91 (80) 66246600 August 10–13, 2017EXPO 2017 E : [email protected] Pragati Maidan, www.mtx.co.in New Delhi, IndiaEMO HANNOVER 2017 T: +91 (22) 6687550001 September 18–23, 2017 E: info@hmf-in Hannover, www.emo-hannover.de GermanyMANUFACTURING T: +65 (68) 263000 October 25–27, 2017SOLUTIONS EXPO 2017 E: [email protected] Singapore EXPO, www.ms-expo.com SingaporeBLECHEXPO 2017 T: +49 (0) 7025 9206-0 November 07–10, 2017 E: [email protected] Stuttgart, www.blechexpo-messe.de/en GermanyAUTOMOTIVE T: +91 (22) 6144 5900 November 09–11, 2017ENGINEERING SHOW E: [email protected] Chennai Trade Centre,CHENNAI www.aes-show.com IndiaMACHINE TOOL T: +62 (21) 2525320 December 06–09, 2017INDONESIA 2017 E: [email protected] The Jakarta International www.machinetoolindonesia.com Expo, Kemayoran, Jakarta, IndonesiaIMTEX 2018 T: +91 (80) 66246600 January 25–30, 2018 E: [email protected] Bangalore International www.imtex.in Exhibition Centre (BIEC), Bangalore, IndiaDIE & MOULD INDIA T: +91 (22) 28526876/28508976 April 11-14, 2018INTERNATIONAL E: [email protected] Bombay Exhibition Centre,EXHIBITION www.diemouldindia.org Goregaon, Mumbai, IndiaACMEE 2018 T: + 91 (44) 2625 0489 June 21–25, 2018 E: [email protected] Chennai Trade Centre, www.acmee.in Chennai, IndiaJIMTOF 2018 T: + 81 (03) 55301333 November 01–06, 2018 E: [email protected] Tokyo International www.jimtof.org/en Exhibition Centre, JapanTo suggest an event, please send details to [email protected] May 2017 | 69
COMPANY & ADVERTISER’S INDEX rŘÌŘOÞضōŘȖ¯OǼȖNjÞض Company IndexÝŘ_ȖǣǼNjÞsǣ˅NŸŎƼsǼÞǼÞɚsŘsǣǣ ABB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 ,0 70 $7HFKQRORJ\&HQWUH Ace Designers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Ace Manufacturing Systems Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 'PDVTFE5FDIOJDBM AFM (Machine Tool, Accessories, Component Parts and Tools Manufacturers’ 5SBJOJOH1SPHSBNNFTPO Association of Spain) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Anusaya Auto Press Parts Pvt Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 1SPEVDUJWJUZ]2VBMJUZ Automotive Component Manufacturers Association of India (ACMA) . . . . . . . . . . . . . . . . . . . . . 39 .FUBM'PSNJOH]\"VUPNBUJPO Blaser Swisslube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Faro Business Technologies India Pvt Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 %FTJHO].BJOUFOBODF Ford . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 &NFSHJOH5FDIOPMPHZ Gardener Business Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 German Engineering Federation (VDMA) India . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 ˥˥˟˟˟ ̛ German Machine Tool Builders’ Association (VDW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,32 ōŘ_ɴǣŸ¯ Grind Master Machines Pvt Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 ǼNjÞŘÞض_sĶÞɚsNjs_ Indian Machine Tool Manufacturers’ Association (IMTMA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 06,08 ˡ˟˟˨ŸŘɠNj_ǣ Jyoti CNC Automation Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49,63,67 KeyedIn Solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 ˠˤ˟ ̛ Khushbu Engineers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 ǻNjÞŘÞض Kollomorgen India . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 ƻNjŸ¶NjŎŎsǣ Lakshmi Machine Works Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 ˤ˟˟˟ ̛ NŸŎƼŘÞsǣ Mastercam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 ǻNjÞŘs_ Micromatic Machine Tools Pvt Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ONjŸǣǣÝŘ_Þ Ministry of Heavy Industries & Public Enterprises, Government of India . . . . . . . . . . . . . . . . . . 24 Renishaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52,66ZZZLP WP DWUDLQLQJLQ Schuler Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Schunk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SCHUNK Intec India Pvt Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Stratasys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 TaeguTec India Pvt Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,66 Tyrolit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 UCIMU-SISTEMI PER PRODURRE (UCIMU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Universal Manufacturing Company (Unimac) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Volvo Construction Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Wendt (India) Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Zavenir Daubert India Pvt Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Advertiser Index Ace Micromatic Group – www.acemicromatic.com. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ACMEE 2018 – www.acmee.in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02 Apex Precision – www.apexprecision.co.in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 IMTMA - Delhi Machine Tool Expo – www.mtx.co.in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 IMTMA - Training – www.imtmatraining.in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 INTEC 2019 – www.intec.codissia.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Jyoto CNC Automation Limited – www.jyoti.co.in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03 Khushbu Engineers – www.khushbuindia.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lakshmi Machine Works Limited – www.lakshmimach.com . . . . . . . . . . . . . . . . . . . . . . . . . . . 09 Mitsubishi Electric India Pvt Ltd – www.mitsubishielectric.in . . . . . . . . . . . . . . . . . . . . . . . . . . . 07 TaeguTec – www.taegutec-india.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Wendt (India) Ltd – www.wendtindia.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1570 | May 2017 Modern Manufacturing India
International Machine Tools & Industrial Trade FairINTEC 2019 18th Edition 2019 6th to 10th JUNE 2019 CODISSIA Trade Fair Complex Coimbatore, INDIA 2019 INDUSTRIAL EXPO 2019 AUTOMATION INS TR UMENTATION IT S YS TEMS Ph : +91 422 2222396 / 397 Email : [email protected] www.intec.codissia.com
y 45° entry angle face mill available with 14 corner economical double sided inserts y Ideal solution for rough machining on cast iron and steel y Efficient and smooth machining credit to its positive cutting edge geometry that lowers cutting loads during rough machiningTaeguTec India Pvt. Ltd.Plot Nos.119 & 120, Bommasandra Industrial Area, Phase 4, Bengaluru 560 099, India +91-80-2783-9111 +91-80-2783-9123 [email protected] www.taegutec.com
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