VOL 08 | DEC 2016 | ` 100 www.industr.com
EFFICIENT MANUFACTURING
FOCUS EM - Interview Ashwani Maheshwari,
President - Forging business Varroc (p. 26)
Medical Machining P. 38
SPECIAL FEATURE
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E D I TO R I A L
Going with the trend! “Those who will embrace the potential of disruptive technologies & strategically respond to make the transformation will be able to enter the next industrial revolution with confidence”
Are manufacturing businesses all over the world facing strong headwinds that are forcing them to re-examine their business models, build new capabilities and deal with new technologies? Are they feeling the effect of disruptive technologies and the power of the digital economy, which have already had an impact on other sectors? The answer is, of course, yes! The digital technologies are bringing major changes in the nature of demand, causing shifts in customer relationships, and affecting the distribution of profits across many value chains. For example, Industry 4.0 (along with Industrial Internet of Things) is offering improved linkages between the digital and physical worlds, which, in turn, is transforming many sectors and causing headaches for many companies with traditional business models. At the same time, new competitors and participants in sector value chains, as well as increasingly influential digital giants such as Google, Amazon and Apple, are disrupting traditional competitive structures. This is presenting manufacturing incumbents with a number of opportunities and challenges, asking for agile strategic responses from them. Those who will embrace the potential of disruptive technologies & strategically respond to make the transformation will be able to enter the next industrial revolution with confidence. At this juncture, we are excited to announce the launch of our brand new website with a fresh look – www.industr.com! Our goal with this new website is to provide our readers a better platform to know about the manufacturing industry in a more appropriate way – be it developments in the market or trends in technology or strategies in management. We will be constantly updating our contents with latest market news, interesting articles, thought-provoking interviews, new product & technology updates, and a lot more. We hope you will find the new website fresh, modern & user-friendly. Please do visit and write to us with your feedback!
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net EDITORIAL ADVISORY BOARD Raghavendra Rao Senior Vice President Manufacturing & Process Consulting Frost & Sullivan
Dr N Ravichandran Former Executive Director Lucas-TVS Chief Mentor, UCAL Fuel Systems
Satish Godbole Vice President, Motion Control Div Siemens Ltd
Vineet Seth Managing Director Mastercam India
N K Dhand CMD, Micromatic Grinding Technologies
Dr K Subramanian President, STIMS Institute, USA Training Advisor, IMTMA
Dr P N Rao Professor of Manufacturing Technology, Department of Technology, University of Northern Iowa, USA
Sonali Kulkarni President & CEO Fanuc India
Dr Wilfried Aulbur Managing Partner Roland Berger Pvt Ltd Dr Ravi M Damodaran President Technology & Strategy Varroc
Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
EM | Dec 2016
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CONTENTS
Market
Management
10 NEWS
INTERVIEW 26
14
“Making complex machining easy”
Interview with Vineet Seth, Managing Director, Mastercam India 16
Focus
Autodesk to end sale of perpetual licenses of Delcam software
MEDICAL MACHINING
“Creating value propositions”
38
Ashwani Maheshwari, President – Forging Business, Varroc
An application story on the usage of DMG MORI’s machine tools by a medical implant manufacturer that provides efficient CNC technology for more productivity
COMPANY PROFILE 34
Raising the bar on tooling
A report on the visit to TaeguTec India’s manufacturing facility at Bengaluru
VIEWPOINT
Interview with Pankaj Gauba, Head – Digital Manufacturing, Autodesk India & Middle East
28
Impact of GST on manufacturing sector
A discussion on how the GST will be transformational and its implications on the manufacturing sector
EVENT REPORT 68
Boosting productivity and efficiency
Taking smart manufacturing forward A report on the recently held four-day factory tour of the Taiwanese machine tools industry
72
Decoding industry technology A post-event report on IMTMA National Productivity Summit held in Bengaluru
74
Addressing automated welding in India
A post-event report on CII welding conference held in Mumbai
COVER STORY 18
Titanium machining
While Titanium alloys are extensively used for specialised applications, they are a difficult material for machining. The cover story discusses a systematic approach to turning and milling while machining titanium to get the best out of the machining processes.
EM – the only industrial magazine in India that offers a three-dimensional perspective on technology, market and management aspects of manufacturing
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CONTENTS
Technology
Cover image courtesy: Shutterstock
LOGISTICS & SUPPLY CHAIN 42
Industry 4.0: The supply chain perspective
INDUSTRIAL PARTS CLEANING 58
The article details on how digitisation makes the supply chain more efficient, agile, and customer-focused
Precision cleaning in metalworking industry
This article talks about the tightened cleaning standards which are required for components of assemblies with close operating tolerances
GEAR CHAMFERING 48
Achieving smooth gear transmissions
The article explains the sophistication required in tools for chamfering and deburring of gears in production process GRINDING MACHINES 52
Rebuilding and retrofitting
The article highlights the key life cycle options for grinding machines to recover grinding production capacity
EM | Nov 2016
SPECIAL FEATURE 64
Kaizen: A beneficial change
A read on Kaizen which means continous improvement to engagae everyone in the organisation’s quest for improvement
New Products 76 CNC fibre laser cutting machine; Tooling assistance system; CNC tool grinders; Embedded PCs 77 Modular system for line production; Imaging multimeter; Tube cutting software 78 Energy chains for robots; Face milling tools; Multi-axis calibrator; Toolholders
Columns 07 08 80 80
Editorial Contents Highlights – Next issue Company index
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MARKET | NEWS
Grind Master recognised for innovation
World’s premier trade fair to be held in Hannover
Confederation of Indian Industry (CII) instituted the CII Industrial Innovation Awards in 2014 and Grind Master has been the recipient of the CII Industrial Innovations Award 2016 in Manufacturing – Medium Scaled Enterprise. The awards were presented on November 8, 2016 as part of the Indo-US Tech Summit in New Delhi. Grind Master has developed breakthrough technologies with its commitment to making innovative products. The award Grind Master has been the recipient of the CII is recognition of this Industrial Innovations Award 2016 track record of 30 years of quality machine building with more than 4,000 installations worldwide and 60% exports that account for 25% of the Indian machine tool exports. Speaking on this achievement, Sameer Kelkar, CEO, Grind Master, shared, “Our NANOFINISH range of machines is a market driven innovation wherein reliable technology in sophisticated microfinishing and superfinishing processes is developed to grab opportunities in major automotive OEMs to whom we are a trusted supplier now. This award gives a boost to our dreams and encourages us to go to a higher level of R&D.”
EMO Hannover, the world’s premier trade fair for the metalworking sector will be held in Hannover, from September 18 to 23, 2017. Under the motto of ‘Connecting systems for intelligent production’, manufacturers of production technology from all over the world will be showcasing what needs to be done in order to generate maximised customer benefits from digitisation and networking of production operations. “Although there is no product called Industry 4.0, trade visitors will be encountering digitisation and networking at the fair in multifarious manifestations,” Carl Weckler, General Commissioner said Carl Martin Welcker, General of the EMO Hannover 2017, says that Commissioner of the EMO Hannover trade visitors will be encountering 2017 and added, “The organisers of digitisation at the EMO Hannover the EMO Hannover have expanded the event’s nomenclature in order to render this important issue transparent for the visitors.” He further lauded the platform and explained, “The EMO Hannover is the ideal platform for obtaining a comprehensive overview of the production, consultancy and serviceoriented business models so far available, as made possible by Big Data and the networking of the entire value creation chain.”
Aerospace & Defence Electronics market to reach $72 bn
Kennametal partners with EWS Tool Technologies
Market opportunity for Aerospace and Defence (A&D) Electronics in India is pegged to be at $70-72 billion in the next 10-12 years, according to a joint report by IESA, Nasscom and Roland Berger. The report further stated that the total market opportunity for A&D electronics for India ranges from US$ 70-72 billion in the The total market opportunity for A&D electronics for India next 10-12 ranges from US$ 70-72 billion in the next 10-12 years years. It further added, “India needs to modernise its A&D capital equipment base by addressing obsolescence as well as build additional capability through new capital acquisition. This requirement is also supplemented by additional budgetary allocations of the Ministry of Home Affairs for paramilitaries and state police force requirements.” Elaborating further on this, V K Saraswat, a NITI Aayog member, said, “The size of strategic electronics is projected to grow to $72 billion from the present $1.7 billion market. Though India is considered as a ‘soft power’ in the space, we are yet to witness a single Indian company that develops strong end-to-end Aerospace and Defence software solutions.”
Kennametal and EWS Tool Technologies recently partnered with the purpose of providing the best tooling solutions to their customers. Speaking on this joint venture, Jay Verellen, Director of Global Product Management, Tooling Systems, said, “This partnership truly aims at maximising our customers’ productivity by providing the best The partnership between Kennametal and EWS tooling solution and promises to expand the company’s offering support for their CNC lathes. The KM™ quick change connection is one of the most comprehensive in the industry. Together with EWS’ global leadership in driven tooling and static tool blocks, we will provide a standard range ready to tool up many major brands of CNC turning centres with this incredible system.” Considering the concerns of their clients, Bahti Hanedar, CFO – Command Tooling Systems, a wholly-owned subsidiary of EWS, shared, “Our customers do not have to wait two weeks for a worn tool to be replaced. We have manufacturing locations in Germany, USA, Korea, China, and Russia, so no matter where your shop is located, service is never more than a day away.”
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EM | Dec 2016
NEWS | MARKET
BEC and NEBEXT to stage an industrial event
Trumpf & Siemens to drive additive manufacturing
Bilbao Exhibition Centre and Next Business Exhibitions (NEBEXT) have recently signed an agreement to stage an industrial event combining a congress and exhibition under the brand ‘Advanced Factories by BIEMH’ in Barcelona next year. The idea is to provide a continuation for the business contacts made at the BIEMH Machine Tool Biennial in Bilbao and other industrial trade shows at BEC, and to provide a meeting point and a forum for the transfer of knowledge to energise the domestic market, particularly in Catalonia and Spain’s Eastern seaboard. According to Xabier Basañez, General Manager, Bilbao Exhibition Centre, “This will be the first time that we are organising an event of this nature. It is An agreement between BEC and a step forward in our strategy to expand NEBEXT has been signed to stage our services.” The first edition of an industrial event next year in Advanced Factories by BIEMH will take Barcelona place on April 4-6, 2017, and will feature advanced manufacturing solutions for sectors associated with machine tools, such as machinery, tools, components, accessories, automation of processes and manufacturing.
Siemens and Trumpf, a laser system manufacturer announced a new partnership to help industrialise laser metal fusion technology and make the additive manufacturing process for metal parts an integral part of the production process. The two companies are working together to develop a software solution for the design and preparation of 3D printed metal parts. The aim is to integrate and streamline the entire powderbed-based laser metal fusion (LMF) process for Trumpf printing machines into Siemens NX™ software. Elaborating on this collaboration, Tony Hemmelgarn, CEO and President, Trumpf and Siemens are developing Siemens PLM Software, said, “Our software for the design and combined solution will offer customers preparation of 3D printed metal parts a high degree of process reliability thanks to its use of smart product models through all phases of the process.” Speaking on the industrial application, Peter Leibinger, Head – Electronics Division, Trumpf Laser Technology, added, “These are decisive factors in making additive manufacturing a realistic proposition for industrial applications. Our partnership will result in an optimum interaction between machines and softwares.”
New engine facility of Perkins inaugurated
Global Aerospace Summit 2016 held at Bengaluru
Perkins’ world-class engine manufacturing facility in Aurangabad was recently inaugurated by the Hon’ble Chief Minister of Maharashtra, Devendra Fadnavis. Located in the Shendra Industrial Estate in Aurangabad, Perkins has invested more than $150 million developing a state-of-the-art engine manufacturing facility which is also strategically located within the Delhi-Mumbai industrial corridor. During the inaugural ceremony, Fadnavis Perkins has invested $150 million in said, “This facility encapsulates developing a engine manufacturing facility the ‘Make in India’ dream of our Hon’ble Prime Minister to produce world-class products with zero defects.” Elaborating further on the manufacturing strategy, Richard Cotterell, Chairman, Perkins India, shared, “In keeping with our Perkins brand values, from the outset, our manufacturing strategy for Aurangabad has been to deliver high quality engines, establish global standards, employ the best team and partner with a world-class local supply base.” He further emphasised that the Aurangabad facility typifies today’s modern manufacturing and assembly plant where the quality of engines being produced are second to none, with special care being given to processes and quality control.
Seco Tools recently organised the ‘Global Aerospace Summit 2016’ in Bengaluru. The event highlighted the machining of trending materials in aerospace. As the aerospace industry faces many challenges, the primary focus is on reducing weight and increasing fuel efficiency. Today, metallurgists, chemists and plastic engineers work constantly to develop the materials of the future. The event also emphasised the latest machining methods which include thin wall machining and dynamic milling. Component solutions for engine component, landing gear component and Seco Tool’s Global Aerospace Summit airframe components were also 2016 was held in Bengaluru highlighted. In this regard, Seco’s Component Engineered Tooling (CET) was brought to light which is a comprehensive approach to process design and optimisation that ensures one achieves the highest levels of productivity, efficiency and cost effectiveness. The company’s engineering service offering was also discussed and it is believed that when striving to perfect a manufacturing process, having the right tooling partner is critical. Thus, the company provides unique engineering service, providing full applications support and the necessary expertise.
EM | Dec 2016
11
MARKET | NEWS
United Grinding organised press conference at JIMTOF 2016 The United Grinding Group recently organised a press conference at the He further highlighted, “The aviation and space industry as well as the JIMTOF 2016, held at Tokyo, Japan. Addressing the occasion was Stephen automotive sectors are focusing on light-weight yet durable materials, Nell, CEO, United Grinding, who spoke on how machines today can such as high-strength aluminium and carbon fibre-reinforced plastics. become faster & efficient and how Tools with particularly hard blades saving resources are crucial in the made of polycrystalline diamond current scenario. (PCD) and complex geometries are According to Nell, “We have a required for machining such market share of 27% of the relevant materials. There is a clear grinding market. We are largely development in the designing of present at Japan too. Today, machines these tools.” are becoming precise to meet the The session was also briefed on industry requirements. So, we have Fine Pulse Technology, by Walter partnered with renowned universities Group. Launched in October 2016, in Switzerland, making our research this new eroding concept will be available to customers worldwide.” installed as standard in all WALTER Speaking on STUDER replacing erosion machines. “This technology the successful CT models, he introduces a new eroding concept opined, “A higher level of technology that sets new standards in terms of has been achieved with the new Nell addressed on how machines today can become faster & efficient and how surface and cutting edge quality and radius grinding machines. This is saving resources are crucial during JIMTOF 2016 consequently the process reliability evident in the machine bed, which of PCD tools,” he added. now comprises of Granitan® and, thus, offers higher dampening levels, At JIMTOF 2016, the Group showcased machines including MÄGERLE thermal stability and guidance accuracy.” MFP, MFP 100.
German machine tool industry continues to grow
Reduction in order of machine tools globally
VDW (German Machine Tool Builders’ Association) recently highlighted some interesting facts about the German machine tool industry. According to them, in the third quarter of 2016, the German machine tool industry’s order bookings rose by 8 per Order Intake of the German Machine Tool Industry Still on course for further growth cent compared to the preceding year’s equivalent period. Also, domestic orders were down by 14 per cent, while demand from abroad increased The graph shows that the German Machine Tool Industry is by 22 per cent. still on course for further growth Further, in the first nine months of 2016, order bookings were up by 11 per cent compared to the preceding year. Additionally, domestic orders showed a slight rise of 2 per cent while demand from abroad is up by 16 per cent. Speaking on this, Wilfried Schäfer, ED, VDW, said, “In the year’s third quarter, our sector has been able to build on the encouraging business trends of 2016’s first half. The good order situation here is being crucially boosted by demand from abroad. This applies for the Eurozone and to an even greater extent for the non-eurozone.”
The Studies Department of UCIMU-SISTEMI PER PRODURRE recently recorded a 5.8% decrease in the index of machine tool orders in the third quarter of 2016 compared to the same period in the previous year. Similar to what had happened in the second quarter of 2016, the outcome was due to the negative trend of foreign markets. The index of foreign orders registered a 6.8% drop, compared with the period July-September 2015, showing the weakness of international demand, already evidenced by the latest available export figures. Elaborating on Massimo Carboniero, President, this, Massimo Carboniero, President, UCIMU-SISTEMI PER PRODURRE is UCIMU-SISTEMI PER PRODURRE, optimistic about the capability of stated, “We are not pleased with the Italian manufacturers slight slowdown shown by the index. However, we don't worry as our history teaches us that Italian manufacturers are really capable of re-orienting the offering towards the liveliest areas. This time, they are precisely starting from Italy, which is experiencing a definitely positive situation: the demand for machine tools is running due to the need for modernising production plants in the country.”
Index, nominal 240
12-month moving average original values
200
160
120
80
Order Intake, %-change to previous year 3Q 2016 Total +8 Domestic -14 Foreign +22
40
1-3Q 2016 +11 +2 +16
0
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Note: Index basis shipments 2010=100, data until September 2016, Sources: VDMA, VDW VDW |
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EM | Dec 2016
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MARKET | INTERVIEW
“Making complex machining easy” Vineet Seth, Managing Director – South Asia & Middle East, Mastercam, in this interview with Suchi Adhikari, briefs on the parameters to be discussed for choosing CAM software, while highlighting the company’s in-house technology to enhance productivity. Excerpts… What are the recent advancements in the CAD/CAM industry? Can you highlight the improvements added to Mastercam 2017? Recent advancements in CAD/CAM have largely been made in the areas of speed and efficiency. High volume material removal, utilisation of full flute length of solid carbides, dynamic tool-axis control in CAM and direct modelling, quick feature modifications in CAD for manufacturing are some important advancements in recent times. The 2017 version features a more streamlined workflow, improved usability, enhancements to dynamic motion technology, etc. Complex machining is now made easy with the introduction of Maximum Stock Engagement for select 3D high speed finishing tool paths, allowing programmers to limit how deeply the cutter engages uncut material and protects smaller tools from taking too heavy of a cut. What are the essential factors to be considered by the shopfloor officials, while choosing CAM software for machining complex models? A CAM system for complex machining must have capabilities like accurately import and repair CAD models from various CAD systems; high speed & high-efficiency machining routines; speed for tool path processing as well as post processing, etc. Also, tool utilisation factor is of paramount importance considering that longer the tool life, higher the productivity. Therefore, modern strategies that assist in deriving full tool life are a must in CAM software, than those that are traditional. Can you brief us on the significance of Dynamic Motion technology and how it helps your customers? It is an in-house innovation that is now a part of most tool path strategies in Mastercam. As far as the programmer is concerned, there is no major change in the methodology of programming parts, which is good, but rather the bulk of change is in the background – in the algorithm that generates the actual toolpath. The lines of code required, algorithms
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invoked and computer processing power applied are vastly greater than what came before. The introduction was the beginning of an entirely new direction in which the toolpath itself would be expected to behave intelligently by following an expansive set of rules that include, but are not limited to minimal stepovers to avoid heat build-up and excessive lateral force; high spindle speeds, if available and continual material engagement (climb milling) to minimise air cutting. How does Mastercam 2017 offer mid-market manufacturers improvement on product innovation, engineering performance and overall productivity? Mid-market manufacturers need a watertight system that delivers consistently and creates room for profitability without the need for higher investments or equipment. Mastercam 2017 provides such manufacturers the power of Dynamic Motion technology, improved tool path processing times as also closer prediction of actual machining times. Direct modelling tool allows for quick changes to models, saving valuable time between the CAD lab and the CAM room, thereby, reducing lead times considerably. What products will you be showcasing at IMTEX 2017? We will be showcasing our full range of CAD/CAM solutions at IMTEX 2017. Integrated CAD/CAM for turning, wire EDM, multi-axis milling, mill-turn, routing and robotic machining will be displayed and demonstrated to visitors. We also intend to work with our technical machine tool and cutting tool partners to demonstrate the capabilities of our Dynamic Motion Technology, live in action. What are your company’s future plans for the Indian market? With Mastercam India, we would like to assure our customers and prospects that we are here for the long haul and we bring over 150 years of CAD/CAM experience to the table. We are looking at strengthening our presence over the coming years and ensuring that customer support is the cornerstone of our philosophy – in word and in practice. ☐
EM | Dec 2016
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MARKET | INTERVIEW
Autodesk to end sale of perpetual licenses of Delcam software Pankaj Gauba, Head – Digital Manufacturing, Autodesk India & Middle East, in this interaction with Team EM, says that Autodesk will no longer offer new perpetual licenses for Delcam software such as PowerMill, PowerShape, PowerInspect, ArtCAM, and FeatureCAM, from January 31, 2017. The purchase of new licenses by both new and existing customers will only be available by subscription wef February 1, 2017. Excerpts… Why is Autodesk transitioning to subscription licenses? Subscription licenses offer customers a lower entry price, greater choice of tools and the ability to pay-as-yougo. With its shift away from selling perpetual rights to use a specific version of software, Autodesk will continually innovate and improve products and supporting services that customers subscribe to, allowing access from multiple devices at any time, making them easier to deploy and manage, and reducing file compatibility issues. Does this affect existing software purchased under a perpetual license? No. Existing or new perpetual licenses purchased up to January 31, 2017, remain valid. Customers retain their perpetual software license and can continue to use it in accordance with their perpetual license agreement. All software products covered by a maintenance plan will continue to receive benefits such as technical support, the latest software release, previous version and other licensing rights, and product updates. What is involved in subscribing to Autodesk products? Subscribing to Autodesk products gives access to the same full version of Autodesk software as the equivalent perpetual license - but with a flexible, pay-as-you-go approach for a software budget that is easier to manage. Is Autodesk making any changes in terms of how I can subscribe to products? To provide customers with greater purchasing flexibility, Autodesk has introduced multi-year (2-year and 3-year) terms for new subscriptions. This locks customers into current subscription pricing, protecting them from any future increases.
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What is a maintenance plan? How will this change impact customer with a maintenance plan? Maintenance plan ensures that a perpetual license holder receives benefits such as basic support, options for more advanced support, and access to the latest software and product enhancements. A maintenance plan agreement must be applied to each separately purchased perpetual license. Customers with current maintenance plans will have the option to renew their maintenance plan and continue receiving the corresponding benefits. Autodesk has no plans to stop offering maintenance plan renewals. However, it is important to renew the maintenance plan on time to continue to access the benefits. If a maintenance plan is not renewed on time, customers will have to subscribe to their Autodesk product if they want access to the latest features and functionality. How long can customers continue to renew current maintenance plans? While Autodesk is discontinuing the sale of new perpetual licenses, we are not eliminating maintenance plans. Customers with maintenance plans may continue to renew their maintenance plans and receive the appropriate benefits for the foreseeable future. What happens if a customer with a perpetual license chooses to discontinue their maintenance plan? Customers with expired maintenance plans can continue using their perpetual licenses. However, they will lose the benefits of maintenance plans such as updates, technical product support, flexible license rights and cloud services. If a maintenance plan is not renewed, customers will be able to subscribe to Autodesk products to get the latest features and functionality. ☐
EM | Dec 2016
C O V E R S TO R Y | T E C H N O L O G Y
TITANIUM MACHINING Maximising machining efficiency
Titanium alloys are extensively used for specialised applications because of their beneficial properties such as low density, resistance to corrosion, higher strength to weight ratio, low elastic modulus, non-magnetic and ability to withstand high temperature, that are not available elsewhere. Unfortunately, Titanium is a difficult material for machining and therefore it is necessary that care has to be taken to see that machining efficiency is maximised to minimise the machining costs. The feature discusses a systematic approach to turning and milling while machining titanium to get the best out of the machining processes.
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Dr Nageswara Rao Posinasetti Professor, Department of Technology, University of Northern Iowa, USA posinasetti@gmail.com
EM | Dec 2016
TECHNOLOGY
C O V E R S TO R Y
The machine tool used for machining titanium should be rigid and should be able to absorb vibrations and cutting loads.
Titanium is one of the abundantly available materials in nature. Pure titanium has excellent corrosion resistance with low strength and is generally used for cryogenic applications. Very rarely pure titanium is used in engineering applications. Titanium alloys are more commonly used. Some of the examples in aerospace are components of jet engines such as combustion chambers, exhaust nozzles, blades of compressors and turbines, aircraft fuselage, etc. Because they cannot be exposed to temperatures higher than 595°C, their use in gas turbine engines is limited to cooler side such as the compressor, casing, high pressure blades and rotors. Some applications such as for structural components of aircrafts, a large amount (up to 90%) of material need to be removed to achieve the required strength to weight ratio. Another important application is for medical implants because of its excellent biocompatibility. Titanium alloys have two types of crystal structures alpha (α) and beta (β). Pure titanium below 882°C retains alpha structure, while above it changes to beta, which is an allotropic transformation. This transformation temperature is raised by some alloying elements, such as aluminium, gallium, oxygen and nitrogen, while elements such as vanadium, molybdenum, niobium, iron, chromium and nickel lower the transformation temperature. The most common alloying elements used are aluminium and vanadium. Alpha alloys contain a very small quantity of 1
EM | Dec 2016
to 2% beta stabilisers and are good for aerospace applications. With larger (4 to 6%) percentages of beta stabilisers alpha-beta alloys are formed, which can be used at a lower temperature in the range of 350 to 400°C. The most commonly used engineering material Ti-6Al-4V is part of this group. With higher percentages (10 to 15%) of beta stabilisers, beta alloys are formed, which will have high strength and toughness and are used for structural parts in aerospace applications.
Titanium machining principles The titanium alloys are not very hard, but do not have good machinability. Titanium alloys are considered as hard-to-cut materials because of the very properties that make them suited for their wide applications. As a result of the poor thermal conductivity (about 15 W/m °C) of titanium, the heat generated in the machining zone is not easily dissipated. As high as 80% of this heat may get into the cutting tool, thereby, increasing the temperature in the machining zone to as high as 1100°C. This very high temperature in the machining zone is not good for the life of the cutting tool. In view of its low modulus of elasticity titanium experiences higher strain for a given force compared to steels. This makes titanium workpiece to spring away from the cutting tool, thereby, affecting the depth of cut. Particularly slender parts deflect more from the cutting
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C O V E R S TO R Y
TECHNOLOGY
Problem
Remedy
Built-up-edge
Increase cutting speed and feed rate Increase coolant concentration Use sharp cutting edge
Torn workpiece surface finish
Decrease cutting speed and increase feed rate Increase coolant concentration Use positive rake tools
Depth of cut notch
Decrease feed rate Use strongest insert shape Increase coolant concentration Program ramp to vary depth of cut Use tougher grades of tool
Material
Pure to low alloy Titanium
Trouble shooting (Kennametal) Titanium machining problems
Cutting tool - Uncoated carbide, Tough grade
Brinell Hardness
Feed rate, mm/rev
Cutting speed, m/min
110 – 150
0.330
58
180 – 240
0.330
52
250 - 275
0.254
64
Alpha alloys and alpha-beta alloys
300 - 440
0.203
76
Beta alloys
275 - 440
0.203
46
100 - 200
0.432
131
200 - 425
0.432
104
Plain carbon steels
forces, thereby, promoting tool rubbing and causing chatter. Dimensional tolerance is going to be greatly affected by this. Also, though titanium is very inert at low temperatures, its reactivity goes high above 500°C, which affects its tool life. Titanium alloys react readily with many of the cutting tool materials, thereby, forming built-up-edge that is detrimental to the life of the cutting tool. As discussed earlier, the temperature in the machining zone goes to as high as 1100°C that allows the surface to get hardened by the diffusion of atmospheric nitrogen. Titanium retains its hardness even at higher temperatures thus making it difficult to machine. This reflects the low machinability rating of titanium, which is 0.3 and for titanium alloys it is 0.2 compared to 1.0 for free machining steels.
The right tool The machine tool used for machining titanium should be rigid and should be able to absorb vibrations and cutting loads. The most commonly suggested cutting tool materials for machining titanium are either M42 HSS or straight tungsten carbides with 6% cobalt binder and a grain size in the range of 0.8 to 1.4 μm. The cutting tools used should have positive rake angles to ensure lower cutting forces and temperatures. The tool bits utilised should have active chip
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Average Cutting speeds and feeds suggested for Turning Titanium alloys by Machinery’s Handbook
breaking to ensure that the chips leave the machining zone. The cutting speeds are used rarely goes beyond 60 m/min during roughing. The feed rates employed need to be carefully calculated basing on the chip load, cutting speed employed and final surface finish desired, etc. The feed rate should be high enough to prevent work hardening. The speed and feed employed should start from the cutting tool manufacturer’s recommended values and experimented to get the best productivity. The use of cutting fluid is generally recommended to keep the machining zone as cool as possible. A general preference is to have a little higher concentration of cutting fluid with copious quantity and high pressure pump to ensure that the chips are blasted away from the machining zone as fast possible. Use of cutting tools with through the tool cutting fluid application would greatly benefit the machining operation. It is very important that the workpiece when mounted on the machine tool table should remain closest to the strongest points of the fixture to absorb the cutting loads. Avoid any conditions that are likely to cause vibrations. The machine tool rigidity should not be compromised. When the cutting tool and workpiece are in contact, let the tool move continuously without any dwell as it is likely promote work hardening. This need to be taken care in CNC part programming.
EM | Dec 2016
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C O V E R S TO R Y
TECHNOLOGY
Turning and milling are by far the largest machining processes used with titanium machining
Turning and milling Turning and milling are by far the largest machining processes used with titanium machining. The machining principles that were mentioned earlier will certainly have to be followed in relation to turning. The following is an example where aircraft manufacturer Boeing’s machinability team has conducted turning tests on a range of popular titanium alloys. They found that all of the tested titanium variants could be turned at speeds greater than 50 m/min, for a carbide tool life of at least 15 minutes. Further, the test results revealed that alpha-dominated grades are machined more easily than beta-dominated grades. Milled titanium part geometries are more elaborate and complex. Also, many of the parts are machined from solid to remove bulk of the material to the tune of 90% to reduce the weight and at the same time to maintain the integrity and strength of the structural element. Depending on the process used to make the initial part such as casting, forging, etc they would have some built-in residual stresses. As the material is being removed layer-by-layer, these stresses get relieved and that would cause distortion of the parts, which will affect the uniformity of the cut.
Get the best out of machining In order to maintain the accuracy, there are a number of precautions to be taken during the milling operation. Since the heat needs to be removed from the machining zone, reduce the radial engagement of the cutter so that heat in the cutter gets dissipated in that part of rotation when the cutter
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is not in contact with the workpiece. Otherwise, when there is large radial engagement such as cutting a slot with the same diameter as the cutter, the cutting speed need to be reduced, thereby, increasing the machining time. Use cutters with large number of flutes. The cutter should enter the work material smoothly to reduce the impact force. That will improve the life of the cutter. Similar approach has to be taken when cutter leaves the workpiece as well. It is a good idea to vary the axial depth of the cutter for different passes so that any surface damage to the cutter will be distributed along its length. Ideally tool diameter should be smaller than the pocket size. When machining pockets with thin walls, the springiness of titanium causes it to deflect under the cutting force, thereby, reducing the depth of cut. When the cutter passes that point then the workpiece springs back, thereby, not achieving the required dimension. To remedy such a situation, use sharp cutting tools, this will reduce cutting forces and, thereby, reduce deflection. Also, add some extra finishing passes to take care of any leftover material.
Conclusion Titanium is a material that has got a lot of problems for machining. The methods used for steel machining are not applicable in this case. However, these problems can be solved by carefully analysing the requirements and controlling the process parameters accordingly. It is necessary to remember to use low cutting speed, higher feed, low depth of cut and good high pressure coolant supply to ensure good quality at low cost. �
EM | Dec 2016
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MANAGEMENT | INTERVIEW
Creating value propositions Ashwani Maheshwari, President— Forging Business, Varroc, in this interaction with Maria Jerin, discusses the challenges to be addressed and the opportunities to be leveraged in the Indian forging industry. Excerpts…
Can you brief us on Varroc’s forging business in India, its international forging plant in Italy and the market served in India as well as globally? Varroc’s forging business caters to forged & machined metallic components’ demand across multiple industries. The business serves a global clientele across Asia, Europe & United States through its six manufacturing facilities. Our four manufacturing facilities in India focus on small to heavy forgings for the global automotive industry. We also have two manufacturing facilities in Italy, focusing on heavy forgings for global mining, and oil & gas industry. As per reports, forging market in India is growing at a CAGR of 7.29% over the period 2014-2018. What are the key emerging applications driving this growth trend? Overall, 61% of the Indian forging market is shared by the automotive customers, which is growing at a CAGR of 9.4% in the last decade, acting as a key enabler for the forging market growth. Among the automotive space too, the two-wheeler segment shares 80% of the market, which is a key focus area for our forging business. With global automotive OEMs upgrading their sourcing
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strategies to procure components from India, along with the government’s thrust on 'Make in India' campaign, the growth prospects are very bright for the forging market in India. Key enablers of growth are the increased demands across urban and rural India, increased spending power, availability of variety of models serving the various needs of the customer, increased market penetration, improved infrastructure as well as the young emerging population. Indian forging industry is facing challenges with the continuous increase in imports from China. How dose your company address such challenges to tap the potential in the Indian market? Most of the imports from China are cost-advantage driven decisions. Though our products too are very cost-competitive, we are focused on establishing Varroc’s forging business as a technology partner for our customers. We are not only supplying build-to-print parts, but also are co-creating the products with OEMs. Our investment in R&D has helped us offer end-to-end solutions to our customers – from product conceptualisation, design, forging, heat treatment, precision machining, assembly, validation & testing.
EM | Dec 2016
INTERVIEW | MANAGEMENT
“Impression die forging remains the most dominant technology, providing dimensional accuracy & surface finish, necessary for automotive & aeronautical industry” Ashwani Maheshwari
Can you highlight the Indian forging standards versus global standards in terms of installed capacities, R&D, innovation & technology breakthrough? Indian forging industry has an installed capacity of 3.8 million tonnes, with 65% utilisation. 87% of this capacity rests with very small players & unorganised segment of the industry. Anticipated growth rate for the Indian forging industry is inline with global projection of 8%. Impression die forging remains the most dominant technology, providing dimensional accuracy & surface finish, necessary for automotive & aeronautical industry. Indian forging products are at par with the required global standards, capable of providing forgings of a variety of raw materials like carbon steel, alloy steel, stainless steel, super alloy, titanium, aluminium, etc. However, the technological and design expertise and knowledge rests with a limited few companies in India. Varroc forging is one of the few companies capable of offering end-to-end solutions. Our virtual manufacturing, design optimisation and process validation capabilities are highly evolved. We have CAD/CAM/CAE infrastructure for 3D modelling, NC tool path generation & FEA analysis to accelerate response time in developing new parts. We are also actively working on alternative technologies like axial-forming for transmission gears and cold-welding for die-life improvement. The Indian forging industry needs technology upgradation to be globally competitive. How can this be addressed visà-vis developments in the market and technology? While this is true that technology upgradation is needed for the Indian forging industry, this is not the only lever for gaining a global competitive advantage. There are other value propositions for global customers like integrated manufacturing capabilities. Varroc, today, caters to the needs of the complete width of automobile industry from the two wheeler segment to commercial vehicles, with forging capabilities from 0.1 kg to 300 kg components. As far as product development is concerned, we are actively enhancing our capabilities – from transmission design for high-end motorcycles, to crankshaft & clutch assembly designs for the volume segment.
EM | Dec 2016
With growing complexity of product portfolio & shorter product lifecycles, the OEMs today are looking for business partners with co-creation & scalability capabilities. The technology disruption is happening at so many fronts simultaneously that the development & upgradation challenges will best be addressed with collaboration strategies. How is your company strategising its business model to leverage the growing trend among the global automotive OEMs to outsource components from manufacturers in low-cost countries? The outsourcing trend from low-cost countries has been in place since past many years and Varroc has been an early mover to seize the opportunity. In fact, global OEMs share a significant part of our clientele. Varroc’s forging business, too, has been focused on exports, since beginning. We also supply to brands like Harley Davidson, Danfoss, Eaton, Fairfield, Thyssenkrupp, Meritor, Caterpillar, Schlumberger, etc. How do you plan to expand your market presence in India as well as globally? What are your company’s future plans in short, medium and long term? In the short term, we plan to grow organically. We are ramping up our volumes with existing customers and expect a healthy revenue growth. On the technology front, we are focused on establishing a robust capability structure in place. Globally, we are constantly assessing the opportunities to off-set the impact of slow-down in oil & gas industry, which is the main customer base for our Italy facility. Our medium term plan is focused on expanding our product portfolio for the automotive industry, especially the precision-machining category. We are also focusing on product development space with our R&D capabilities. Over the longer term, we are looking to de-risk through diversification in nonauto segments. We are excited about the opportunities we have for diversification, but we are going to be focused on specific product segments only. We also expect to develop proprietary products & technologies for the increasingly complex demands of the automotive industry. ☐
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VIEWPOINT | MARKET
Impact of GST on manufacturing sector The Goods and Services Tax (GST) is one of the most significant tax reforms post-independence and has rightly attracted heightened interest from all stakeholders. It is expected to replace our current complex Central and State indirect taxes to create a common market for India with a seamless indirect tax regime. GST will be transformational and the implication on the industry extends well beyond tax. It will affect every part of business right from financial reporting, tax accounting, supply chain, technology enablement and contracts redesign. Training people within the company and its business ecosystem will also be fundamental for the readiness of the new regime. The viewpoint section discusses the impact of GST on the manufacturing sector.
Suchi Adhikari Sub-editor & Correspondent suchi.adhikari@publish-industry.net
“GST implementation will enhance compliance” What will be the impact of GST on supply chain network and processes in the manufacturing sector? The structure of the supply chain is influenced by differential taxes based on geographical location. Elimination of multiple state taxes will encourage companies to consolidate their warehouses instead of having warehouses in multiple states. On implementation of GST, the major consideration for warehousing would be cost and customer service; that is, the taxation element would no longer be a factor to contend with.
Shilip Kumar Country President, Henkel Adhesives Technologies
How do you think the GST will aid the ‘Make in India’ initiative? ‘Make in India’ is an initiative to make India a manufacturing hub. It has been successful in attracting many foreign companies to invest in India. For carrying out businesses efficiently, there has to be a clear and standardised tax regime, which GST would be providing in contrast to the current uncertain and unpredictable indirect tax regime. Moreover, exports will be Zero rated whereas imports will attract GST to encourage manufacturing in India. GST implementation will also enhance compliance making it a level playing field for all manufacturers. What are the short-term and long-term objectives that the manufacturing industry in India can meet with the implementation of GST next year? With GST being implemented next year, there are possibilities of price revisions across value chains of the manufacturing sector. This will boost the economy. In the long term, manufacturing and warehousing decisions would be based entirely on the merits of the business case with taxation playing no role in such decision making. What would be your recommendations to get the most from the GST implementation? GST should be simple and transparent (as few rates as possible / no ambiguity in classification) and its administration needs to be corruption-free. This will help remove the current shortcomings of the supply chain owing to the multi-layered policies. GST should not be only investor or business friendly but also consumer friendly. Thirdly, Goods and Services Tax Network (GSTN) should be able to successfully manage the burden of crores of tax payers logging in at a single point in time.
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EM | Dec 2016
MARKET | VIEWPOINT
“GST will take the unnecessary cost out of the supply chain” What will be the impact of GST on the supply chain network and processes in the manufacturing sector? I believe that businesses will be able to move from a tax optimal supply chain to a cost optimal supply chain in line with what is the practice in developed economies, such as Europe. This will certainly take the unnecessary cost out of the supply chain, improve material flows as well as lower the overall cost of goods sold. How do you think the GST will aid the ‘Make in India’ initiative? The complicated and cascading tax systems are a detriment to investments. In my opinion, a single national market with a much simpler tax structure will boost the investments in the country and also lend a support to the ‘Make in India’ campaign by the Prime Minister of India. What are the short-term and long-term objectives that the manufacturing industry in India can meet with the implementation of GST next year? The objective for most manufacturing companies will be to restructure their supply chain and manufacturing processes. This is because the current processes might not prove to be efficient, post the GST implementation. In addition, governments and businesses will have to work in symbiosis for a successful implementation of this tax reform and take it ahead.
Dr Wilfried Aulbur, Managing Partner & CEO, India, Roland Berger
“Reduction in taxation could be as high as 5 to 10 per cent” What will be the impact of GST on the supply chain network and processes in the manufacturing sector? The impact is expected to be positive. Incidence of the total taxation expected is to be reduced. In the machine tools sector, reduction in taxation could be as high as 5 to 10 per cent in some cases, if the GST is at 18 per cent. How do you think the GST will aid the ‘Make in India’ initiative? The GST implementation will aid the ‘Make in India’ initiative by reduction in costs, increase in transparency and reduction of departments to coordinate with, although initially, there will be some costs for learning, systems and infrastructure. What are the short-term and long-term objectives that the manufacturing industry in India can meet with the implementation of GST next year? I believe that there will not be any short-term objectives that can be achieved. On the other hand, there will be disruptions and much learning that will need to be assimilated. Long-term competitiveness will also increase. Transparency will be better and as a result, the demand will grow.
TK Ramesh, Chief Executive Officer, Micromatic Machine Tools
What would be your recommendations to get the most from the GST implementation? To get the most from the GST implementation, we must map our entire transaction chain, understand its impact and optimise the chain. We also need to get expert help and recalibrate our IT systems to this optimisation. Businesses that still believe in doing things the manual way will face difficulties and their unforeseen costs will increase.
EM | Dec 2016
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VIEWPOINT | MARKET
“GST will simplify the complicated indirect tax system in India”
Rajesh Nath, Managing Director, VDMA India
What will be the impact of GST on the supply chain network and processes in the manufacturing sector? The final structure of GST is not yet set. However, a model Goods and Services Tax Act (Draft GST law) was released on June 14, 2016, for public comments. The Draft GST law prescribes that both the central and state governments would levy GST in parallel on supply of goods and/or services where such supply is made within the state. The tax to be levied by the central government would be referred to as Central Goods and Services Tax (CGST). The tax to be levied by state government would be known as State Goods and Services Tax (SGST). In case of inter-state supply, an Integrated Goods and Services Tax (IGST) will be levied, which would be collected and administered by the central government. Imports into India would be subject to IGST and Basic Customs Duty. Customs duty in the form of Basic Customs Duty (BCD) on import of goods into India and Research & Development Cess on import of technology into India will continue to apply. How do you think the GST will aid the ‘Make in India’ initiative? The current indirect tax regime is clearly one of the biggest hindrances which have adversely impacted the domestic manufacturing sector as well as flow of foreign investment to the sector and introduction of GST is important to alleviate the situation. GST would reduce the cost of manufacturing both from a tax perspective as well as on the compliance front. It will also boost the ‘Make in India’ campaign as it makes India a single large market by freeing it from the current mess of several complex levies along the state lines. With the implementation of GST, CST would be eliminated, most of the other indirect taxes would be subsumed into the GST, and because the GST would be applied on imports, the negative protection favouring imports over domestic manufacturing would be eliminated. What are the short-term and long-term objectives that the manufacturing industry in India can meet with the implementation of GST next year? The new GST will simplify Indian indirect taxes to a great extent. Unclear and heavily debated qualifications such as ‘manufacture’, ‘sale’ and ‘provision of service’ will lose their relevance. This will also reduce the issues of double taxation. The highly complicated customs duty structure with several duties such as BCD, CVD and SAD being levied and calculated on each other would get cleared out. Under the GST regime, import of goods would attract BCD and IGST making the structure simpler. The availability of Input Tax Credit of IGST to importing resellers would significantly improve the tax cost in the supply chain. What would be your recommendations to get the most from the GST implementation? The Indian political system witnessed a historic moment on August 3, 2016, when the Constitutional (122 nd Amendment) Bill 2014 (Constitutional Amendment Bill), which is the enabling law for implementation of Goods and Services Tax (GST) was unanimously passed by the Upper House of the Indian Parliament. The passage of the Constitutional Amendment Bill is just the beginning phase. The state governments will have to work very efficiently to get this off the ground. With the government assuring states full compensation for loss in revenue for the initial 5 years, this unified tax is not just a golden opportunity for businesses but it is a great moment for the political parties and bureaucracy to make an effective law to generate revenue and curb wanton corruption. The ball is firmly in the government’s court. Next steps will decide whether we have a real powerhouse of a GST or just another law.
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EM | Dec 2016
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VIEWPOINT | MARKET
“Industry is fed up of ‘cess’ and decimals of taxes” What will be the impact of GST on supply chain network and processes in the manufacturing sector? GST is expected to add speed and ease the movement of goods in the supply chain network in the machine tools sector in India.
Raj Singh Rathee, Managing Director, KUKA Robotics India
How do you think the GST will aid the ‘Make in India’ initiative? In general, every positive step aids the various manufacturing initiatives. We need more factors to work in the right direction for the ‘Make in India’ initiative to be successful. What are the short-term and long-term objectives that the manufacturing industry in India can meet with the implementation of GST next year? Objectives and expectations vary for every industry or even individual. The short-term objective will be the sharp rise in confidence that the government is serious about making speedy improvements to support the manufacturing industry. India can become a sustainable manufacturing hub to cater to the export as well as in-house consumption in the long-term. There are many more variables linked to this success, apart from the GST. What would be your recommendations to get the most from the GST implementation? I believe that there are two major achievements of GST that are noticeable by many companies till now. These are: a) moving to a completely digital process (free from submitting papers) and b) common process all over India making it easier for the companies with offices across states. There are also some improvements that are expected. Firstly, the industry had expected a ‘GST’ from the government. However, what we are getting are the ‘IGST’, ‘CGST’ and ‘SGST’. The government is pushing the responsibility of distribution of taxes to the industry. There should a single ‘GST’ with a rounded-off rate for every category. The industry is fed up of the ‘cess’ and decimals of taxes. Similarly, the complex credit of these various GST is not required with GST. Secondly, in the short term – with the present state of GST – software & financial consultant companies are going to get a boost in the business at the cost of the manufacturing industry. This can be avoided by simplifying the GST. Thirdly, what will not change are the people that the industry will have to deal with after GST. It is expected that honest people will be heading the GST. Finally, with respect to the various processes and dates of implementation, the state and central governments are not working in the interests of the industry. There seems to be a lack of people who would work for India as a whole, keeping the state’s and other interests at a backstage.
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C O M PA N Y P R O F I L E | M A N A G E M E N T
Raising the bar on tooling Set up amidst a thick green cover in the heart of the industrial hub of Bengaluru, TaeguTec India has been recognised today as one of the most preferred tooling partners in the metalworking industry. Team EM recently visited the Bengaluru facility to witness its innovation in bringing productive and cost-effective tooling solutions. A read on… Headquartered in Daegu, South Korea, TaeguTec is a part of the second biggest cutting tool manufacturing group in the world – the IMC International Metalworking Companies – which is now 100% owned by Warren Buffett’s Berkshire Hathaway. Set up in 2000 and spread across 10,000 sq mts in Bengaluru, TaeguTec India supplies modern machining solutions to a wide variety of industries, such as automotive, die & mould, aerospace, power generation, etc. The facility is an AS9100 Rev C & ISO 9001:2008 accredited manufacturing entity, also certified for ISO 14001 (EMS) and OSHAS 18001 (Health and Safety). According to L Krishnan, Managing Director, TaeguTec India, “Developments in the cutting tool industry, being an important subset of the overall manufacturing industry, are very much dovetailed with developments in the manufacturing
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Maria Jerin Features Writer maria.jerin@publish-industry.net
industry.” Complying with these developments, he further noted that TaeguTec has a significant focus and spends on R&D globally. “We are constantly innovating on our product offerings and solutions and upgrading our manufacturing capabilities, in addition to building our customer service capabilities so as to meet the expectations of our customers,” he said. Out of all the facilities built globally, the company takes pride in its Indian facility. The 15-year old company supplies metal cutting tools and carbide inserts with a huge assortment of turnkey solutions and tailor-mades. On that note, highlighting the range of products manufactured, K S Ravishankar, National Head – Sales, TaeguTec India, opined, “Our product lines of tungsten carbide cutting tools include inserts and holder bodies for operations, such as turning, milling, drilling, grooving,
EM | Dec 2016
M A N A G E M E N T | C O M PA N Y P R O F I L E
“Developments in the cutting tool industry are very much dovetailed with developments in the manufacturing industry” L Krishnan, Managing Director, TaeguTec India
parting applications and solid carbide tools and tooling systems. We offer both turnkey solutions and tailor-mades to customers.” When asked about the trends in the Indian market for tooling products, he said, “Indian manufacturing companies are looking at improving productivity and reducing cycle time. Our customers are finding the twin benefits in using our products. We are definitely among the top three in all our chosen areas of operation.”
Quality assurance & automation With respect to the process, the company also manufactures two distinct parts of cutting tools, namely, carbide inserts and steel carrier body, of which tailor made engineered solutions are a significant part of manufacturing activities, apart from the standard catalogue products. The production flow of carbide inserts follows the sequence of pressing, sintering, grinding, coating, and finally, finished products. For steel carrier body, the production flow series consists of pocket milling, pre-finishing & plating, assembly, inspection, marking, and packing & dispatch. “Our USP is that we are a highly automated plant, right from processing raw materials to the final dispatch,” said Gautam B A, Head – Manufacturing, TaeguTec India. “Every station and every process is automated, limiting human intervention. Each person at his own station ensures a thorough check-up and this is followed sequentially by the next operator until the final inspection is done. This eliminates the role of quality control as the whole process revolves around quality assurance,” he added. Highlighting the benefits of deploying automation, he said, “Automation ensures that human error is completely eliminated so repeatability is very high. Also, there is consistency in output, both in terms of quality and quantity. Additionally, the number of people who are required to operate gets limited, which means that manpower can be utilised in a more productive way rather than just loading and unloading a machine.” Adding to this, Ravishankar emphasised, “A combination of automation, well-trained personnel and advanced technology ensures a consistent product time after time.”
EM | Dec 2016
“We have a highly automated plant, right from processing raw materials to final dispatch” Gautam B A, Head – Manufacturing, TaeguTec India
“It is necessary for the customers to put the right tool in the right application with the right parameters” K S Ravishankar, National Head – Sales, TaeguTec India
Lean manufacturing Focussing on operational excellence models and lean management principles, Gautam shared, “Our company is not lean in a conventional sense, but we have implemented lean initiatives in parts, such as utilising the manpower availability; following self-driven maintenance where all our processes and machines are maintained by the operator itself; and practising 5S as it brings clarity in operation. We also employ small group activities and Kaizens as these add value to productivity, safety and operator comfort.” However, he also noted that in spite of lean management principles, the company keeps stock for customer orders. In terms of real-time connectivity between the shop floor and top floor, he elaborated, “We have a strong ERP system that gives us great efficiency with productivity. Our employees have access to the data related to order bookings and delivery commitments, which ensures negligible paper communication making the system transparent.” With respect to machines deployed in the shop floor, he shared that they are specially made for the tooling industry. “Many of our machines are imported and are state-of-the-art. Besides, we follow a visual
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C O M PA N Y P R O F I L E | M A N A G E M E N T
monitoring system with charts etc. to keep track of their operations and downtimes, if any,” he mentioned.
Employee training activities To get the best out of the manpower, the company offers skill enhancement programmes for fresh graduates and critical operators. Highlighting its scope within CSR and beyond, Gautam explained, “We regularly pick students from institutes like NTTF (Nettur Technical Training Foundation) and GTTI (Gedee Technical Training Institute, Coimbatore) for internship opportunities at our shop floors. We also run a partnership programme with NTTF called ‘Learn and Earn’, as part of which they work for two years in TaeguTec (whilst attending weekend classes at the Institute). Following another two years in other companies for extended exposure, they are awarded their diplomas.” In fact, critical operators on the shop floor are even sent to company headquarters in Korea for varying time periods, based on the need and complexity of the process they are handling. “They get trained in both technical operations as well as organisational culture. We ensure that they are exposed to the best practices on all fronts,” he remarked. Gautam further highlighted that of the 26% of total female workforce in TT India, 13% of them are deployed on the shop floors.
authorities to dig recharge pits. For waste management, we segregate all waste like paper, plastic, etc that is collected and disposed separately. For hazardous waste disposal, we have a list of certified vendors who take care of it. Further, we have changed from diesel power to city power with the help of UPS, which has helped us in reducing diesel consumption to almost zero. For lighting, we have induction lights that consume 50% less power than the conventional models. More than any compliance concerns, we are proactively on the lookout to reduce our carbon footprint,” he pointed out.
Going beyond tooling
Product development is one of the big focuses for the company. “There are new products launched in the market at regular intervals, which maintains that edge over competition. A number of patents are also filed globally considering our worldwide operations,” noted Ravishankar. In providing customised solutions, he further described that the company looks at machining applications from the customer’s point of view. A suitable solution is then designed in consultation with the customer, which then goes into manufacturing and then is proven at the customer’s end in line with the commitments made. Speaking on TaeguTec’s digital outreach, he listed, “We have quite a few digital applications, each dedicated for a different purpose. TTAPP is the comprehensive technical mobile app for tablets and smartphone devices, which is like a Industrial safety & Green initiatives virtual cyber salesman offering ongoing innovative products In terms of industrial safety, the company has a zero and machining solutions. The TaeguTec Tool Advisor software accident record since its inception. “There has not been a matches the customer’s application requirements with single incident in the company. Within the plant, we have appropriate machining solutions by providing cutting tool environmental and safety committees that meet on a monthly- recommendations, cutting data, power requirements and basis to evaluate the impact of risks and counter measures that productivity results for each solution option.” The main we must take. This is a continuous ongoing process that challenge with cutting tools, he added, is that in spite of eliminates the factors for risk,” he said. optimum design and manufacturing, a customer may not get Sustainability is also a priority and the company’s green the total benefit of the product unless it is put into the right initiatives include planting trees around the facility, rainwater kind of application. “So, it is necessary for the customers to harvesting, reducing fresh water consumption and recycling it put the right tool in the right application with the right through sewage treatment. “We are collaborating with the local parameters,” he concluded. ☐
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EM | Dec 2016
MEDICAL MACHINING | FOCUS
Boosting productivity and efficiency Medical manufacturing is a growing industry in major segments such as orthopedic devices and instrumentation, implantable devices and medical instruments. Driven by both innovation and regulation, medical device manufacturing continues to outperform the economy. The article highlights the usage of DMG MORI’s machine tools by a medical implant manufacturer that provides efficient CNC technology for more productivity ensuring high degree of material efficiency. The foundation of the Königsee Implantate GmbH by Erich Orschler in 1993 was in fact a consistent continuation of the competence in medical technology that had long existed at the Aschau location in Thuringia, Germany. As early as the end of the First World War the orthopedic technician Otto Bock had started producing prostheses and orthopedic aids for war-disabled veterans at this location, before having his company expropriated and moving to Lower Saxony to continue his work. The company looks back on 20 successful years with the in-house development of its implants and instruments. For trauma surgery, the company has long gained the reputation of being one of the leading German
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suppliers of medical technology in the field osteosynthesis. One decisive factor in the success of Königsee Implantate is its expertise in metal cutting, for which the company has been using machine tools from DMG MORI since 2013 – a DMU 40 eVo and three SPRINT 20|8 linear machines equipped with a SWISSTYPEkit.
Innovating product range “Medical technology is still a growth market, one that we can substantially help shape with innovative products“, says Horst
EM | Dec 2016
FOCUS | MEDICAL MACHINING
Lindner, Head—Purchasing and Production, Königsee Implantate. The company’s enormous range of such products encompasses bone pins, screws and plates and on to include implants for spine surgery. “We have a great variety of products that are in-turn offered in a multitude of different versions,” he says. Horst Lindner sums up the common denominator of all products. “We only machine materials that are difficult-to-cut, such as steel or titanium in which we achieve top qualities. Usually this involves single pieces or small series, which require a high level of flexibility. Our vertical integration is correspondingly high so that we can also respond at a short notice,” he added. This integration starts with the development phase and goes on to include complete production right through to after-sales service. Metal cutting is the be-all and end-all of successful production at Königsee Implantate. “All that is left to do after cutting the workpiece into shape is to finish it with a galvanic surface process”, explains Lindner. The company underpins
the high priority given to metal cutting with efficient state-ofthe-art machine tools. Since 2013, for example, it has used a universal machining centre from the eVo series and three SPRINT lathes from DMG MORI.
Efficient CNC technology for more productivity The 5-axis DMU 40 eVo has been a great boost to productivity in the manufacturing of bone plates. “The use of a device for twelve plates allows us to run the machine autonomously for several hours – if necessary even right through an unmanned night shift”, says Lindner about the process. “This means we can guarantee fast availability of the products,” he adds. The production manager also sees great benefits in the compact size and excellent ergonomics of the versatile DMU 40 eVo. “The production area is always limited, so we are more than pleased with machines that have as small a footprint as possible. Despite Advt
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EM | Dec 2016
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MEDICAL MACHINING | FOCUS
The extensive product range of Königsee Implantate also includes bone screws and plates made of titanium
From the blank to a high-tech implant: the bone screw made of MAGNEZIX® – a magnesium alloy – is produced for Syntellix AG by Königsee Implantate
its size the DMU 40 eVo still offers optimum access,” he opines. Where turning is concerned Königsee Implantate decided on the SPRINT 20|8 linear equipped with a SWISSTYPEkit from DMG MORI. The focus in this case is on efficient production of bone screws. The dynamic and accurate linear drive in X1 is ideal for fulfilling the requirements of medical technology. “Not only can we produce very quickly, the standard of quality is also impressive”, claims Lindner. Eight axes and the fact that two tools can be used simultaneously also benefits productivity. The SWISSTYPEkit of the SPRINT 20|8 linear – i.e. the option of turning both long and short workpieces – rounds off the features of the automatic lathe. Thanks to the option of short part turning the material remnants can be used again for bone screws. This ensures a high degree of material efficiency.
implants have only been used for smaller bones to date, but the supplier intends to extend the fields of application and make the product suitable for mass use. Machining workpieces made of MAGNEZIX® is twice as demanding as conventional materials: firstly the same extremely high demands on quality, complexity and productivity apply here as usual and secondly strict safety requirements apply in the machining of magnesium. In this regard, Lindner points out, “Magnesium chips are easily inflammable so the machine needs special equipment that will vacuum off chips and dusts and prevent electrostatic charging.” DMG MORI worked together with Königsee Implantate to make the necessary modifications to one of the three SPRINT 20|8 linear automatic lathes. “As an extra precaution, the machine stands in a separate container outside of the company’s actual building.”
Contract manufacturer for a revolutionary technology
Future-orientated approach
Last year, Syntellix AG from Hanover presented a bone screw made of MAGNEZIX® – a magnesium alloy. The special feature of this screw is that the material dissolves in the body within one to two years, so there is no need for a second operation to remove the implants. Syntellix claims that this will save the need for thousands of operations in future. The
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The CNC machines from DMG MORI already in operation in the company are a proof of the company’s future-orientated approach and of its keeping a keen eye on modern manufacturing processes. Although he is not allowed to go into detail, Lindner does let drop that “Ultrasonic processing on ULTRASONIC machines could well help advance our development in future.” ☐ Courtesy: DMG MORI
EM | Dec 2016
IMA G E C O URT ES Y: Fraunhofer
L O G I S T I C S & S U P P LY C H A I N | T E C H N O L O G Y
Industry 4.0: The supply chain perspective Given the nature of global supply chain set up in Industry 4.0, it is critical to ensure dynamic re-configurability across the supply chain, both upstream and downstream. This necessitates the evolution of traditional supply chains towards a connected, smart and highly efficient supply chain ecosystem. The article details on how digitisation makes the supply chain more efficient, agile and customer-focused. Manufacturers around the world are preparing for the new industrial revolution, Industry 4.0, however, is it just the manufacturers who need to prepare for Industry 4.0? How does it impact the supply chains of industries globally? Industry 4.0 can be viewed as the convergence towards digitisation of global supply chains, which includes in its umbrella the entire business process of all industry segments. Its impact depends on the maturity and level of automation in the specific industry segment, but it will be omnipresent in all industries and applicable throughout the supply chain.
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A holistic approach From the perspective of a Chief Supply Chain Officer (or CSCO), it is important to view Industry 4.0 in a holistic manner and realise that information processed from manufacturing plants is all but a part of a larger agenda. Entire supply chain needs to become connected end-to-end and remain transparent for Industry 4.0 to be truly applicable for an organisation. The changes will occur in factories, where smart
EM | Dec 2016
T E C H N O L O G Y | L O G I S T I C S & S U P P LY C H A I N
Digitisation of logistic components, right from pallets to transport trucks, will allow smarter tracking. Customer feedback collected from all across the globe will be communicated with suppliers, and modifications will made based on web based communications. This way of manufacturing will mandate the CSCO to consider connectivity and communication across supply chain as a primary objective.
Big Data analytics
manufacturing will completely change the way manufacturing is currently practiced. Customer focused manufacturing will require plants to be highly automated and flexible, thereby necessitating suppliers and dealers to transform their operations to deliver more customised and demand based service. Factory layouts will change and will require business partners to adapt to changed product life cycles. Larger amounts of data will flow to and from manufacturing plants, thereby requiring the IT infrastructure across the supply chain to become capable of handling the high volumes of information being shared.
Geography does not matter Internet-based connectivity is the second major change. Because virtually connected operations will no longer require geographical connectivity - manufacturers may have RM suppliers in Japan, customers across Asia and manufacturing plant in North America - conventional business model will require supply chains to remain connected through the internet and yet be able to function in a more precise and time bound manner than ever before.
EM | Dec 2016
Industry 4.0 truly adds value to operations by providing the capability of analysing large amounts of data. Big Data analytics is one of the pillars of this new revolution and supply chain personnel need to understand that there would simply be more information coming their way. Everything involved in a process, right from a warehouse rack, to a guillotine machine, to a supply container, will have the ability to communicate, which will then require analysis and the CSCO needs to be ready for this. Highly automated process equipment and complex IT infrastructure does not eliminate the need for workers. On the contrary, it creates the need for highly skilled workers, who can effectively utilise the information available at their disposal. Future workforce would need to be competent at problem solving and systems engineering. It is crucial for a leader to understand the current workforce and their capabilities, in order to help modify the existing human resource to be ready for the challenges Industry 4.0 brings. Another key aspect for the CSCO to consider would be the end-to-end visibility across the supply chain. Given the virtual and geographically diverse set up in Industry 4.0, ensuring that suppliers are always connected with the organisation and that their IT applications in place can truly capture and make sense
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L O G I S T I C S & S U P P LY C H A I N | T E C H N O L O G Y
Entire supply chain needs to become connected end-to-end and remain transparent for Industry 4.0 to be truly applicable for an organisation
of data coming towards them is extremely important. It is also necessary that communication across the supply chain remains bilateral, data and information should flow to and from partners. Say information regarding an assembly made in China, received from a customer in Africa, and should reach to the supplier in China in real time, even if the information is communicated to the OEM located in France.
Operations in-(virtual)sync With the rise of consumerism even in B2B transactions, it is almost a compulsion for value chains to incorporate and modify their operation to suit mass customisation. Demand driven manufacturing beckons all production plants in the supply chain to modify operation and become flexible enough to change, based on the need placed by the marketplace. This kind of flexibility requires synchronisation of the virtually connected operations and thereby should be one of the top priorities of a CSCO. The entire supply chain should react or rather act in unison based on fluctuations in demand and thereby prevent imminent losses and improve chances of gaining combined profitability. Achieving mass customisation is only possible if requirements can be translated to shop floor action items in real time, irrespective of where production takes place physically.
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From connectivity perspective Given the highly demanding nature of Industry 4.0 from the agility and connectivity perspective, it is safe to say that current sort of singularly linked supply chain networks will no longer be applicable. It is important to realise that now the end customer should be the focus of each and every partner in the supply chain and this would require re-configuration and realignment of current supply chain structure. Smart devices are forming what one refers to as new ‘Product Innovation Platforms’. The leaders in supply chain thus ensure their systems are modified enough to facilitate faster product development, smarter manufacturing, better managed product life-cycles and higher process agility & resilience. Key deliverables from a supply chain perspective is to have a well-connected supply chain which is agile enough to meet demand based requirements, which can adapt to major changes with minimum effort.
Strong digital relationships As per the survey conducted by PWC, an incredible 72% of the companies which took part in the survey voted that their use of data analytics and digital technologies will focus on improving the customer relationship and customer intelligence
EM | Dec 2016
L O G I S T I C S & S U P P LY C H A I N | T E C H N O L O G Y
Industry 4.0 truly adds value to operations by providing the capability of analysing large amounts of data
along the product life cycle for the next five years. This finding clearly sets the precedent for what is to come. It is extremely important to note that the future of manufacturing will completely change: sale of products will no longer be based on the traditional ‘Push’ model, instead goods will be manufactured based of ‘Customer Pull’, demand driven production, with varied degrees of customisation subject to industry segment. In certain cases manufacturing will be so much customised that a production lot size would be limited to one item per lot. So what are manufacturers dealing with here and what is the approach recommended for them to seize the opportunities which come with the inherent challenges of these changes? With the advent of consumerism and well informed customer base, thanks to the information available in public domain, manufacturers are looking at highly demanding customers in the future. In both B2B and B2C transactions, customisations and production based on customer specifications will be the norm in the future, one size fits all sort of mentality will be completely outdated. Manufacturers around the world are already dealing with these challenges by increasing use of 3D printing and other such technological marvels, to allow for both economies of scale and higher value generation through provided customisation.
Connecting shop floor to top floor Software applications like the MES, which act as a connector
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between the shop-floor and the top-floor applications will play a major role in helping organizations digitise their product offerings and form customer intelligent platforms. MES applications will help seamless transfer of data and orchestrate operation in a way the PLM can best utilise the market intelligence collected from customer to help modify manufacturing operation both within the organisation and for key value chain partners. First movers in the Industry 4.0 are already at advanced stages where they have been able to offer customers the interactive digital platform. The customer’s opinion is converted to actual product and services. The future of manufacturing will be governed by such customer empowering, intelligence based platforms, which are characterised by the nexus of information exchange and interoperable technology. Key for manufacturers who are still at the Digital Novice stage of digital maturity, is to see the big picture and plan their digitisation. The focus has to be on the customer and not on the product. What is important to recognise here is the need for harnessing the modern software technology (MES, ERP, PLM, SCM, CRM, etc.) on offer today along with other technological advances like 3D printing, Augmented Reality, Artificial Intelligence, etc to devise a way to channel benefits to the customer, while reducing operational costs and increasing overall efficiencies. ☐ Courtesy: Critical Manufacturing Deutschland GmbH
EM | Dec 2016
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GEAR CHAMFERING | TECHNOLOGY
Achieving smooth gear transmissions The chamfering and deburring of gears is often an undervalued process in gear production. However, it has great influence on the usage characteristics of the work piece. Improvement in ratings for gear shifting in vehicles also depends on the process used in this operation. The article explains the sophistication required in tools using plastic deformation for chamfering and rolling and cutting action for deburring. Gears need to be chamfered and deburred with a controlled, high quality process so as to avoid breakage as excessive carburising along the tooth edges can often cause breakage when the gear is running. It also helps to avoid damaging gears and bearings as, if burrs are not removed, they may chip off during the running cycle and cause damage to the other gears and bearings. Additionally, it aids in avoiding poor tool life in the finishing processes and helps in removal of very sharp burrs, which reduces the risk of tool handling injuries. Chamfering specified on gears is of the following types - in only one or in both flanks, with a constant size along the
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Sameer Kelkar Chief Executive Officer Grind Master Machines
Francesco Grippo Chief Technical Officer Samputensili Machine Tools
profile, with or without chamfer in root diameter. Sometimes, a further rolling operation is required as well.
Chamfering with plastic deformation tools Advanced chamfering tools use compression (as against cutting) for creating chamfers on the edge. The pressure and deformation of the material may modify the structure of the steel. The chamfering tool is like taper gear, with a width of roughly 10–15 mm, and normally is very well finished, with a surface like a mirror in order to prevent a quick wear.
EM | Dec 2016
GEAR CHAMFERING | TECHNOLOGY
The key benefits of chamfering with such tools are stronger gear tooth due to better material flow and accurate chamfer angles. The angles of the chamfers are definite by the tool drawing, but the size depends on the rolling time and the pressure of tool against the gear. If the contact time between the tool and piece increases, the chamfer becomes bigger. The pressure, which defines the deformation force, is generated with a pneumatic cylinder. This method guarantees an ‘elastic force’ that prevents some breakages. Self-centered tools guarantee symmetrical chamfers on both sides of the work piece, even in the instance of slight displacements between adjacent teeth (for example, in a cluster gear). This results in symmetrical and constant chamfer in all teeth.
Rolling operation Gears require a rolling operation after chamfering due to the plastic deformation caused by this operation and to eliminate the ‘burs’ or swellings that form on the material. Whilst burs on the gear face may be removed by deburring tool, those on the lead remain. These burs, usually in the range of 0.05–0.07 mm, cause problems in subsequent grinding phases and actually put the grinding wheel at risk. At this point, a rolling operation on the gears becomes necessary. The Samputensili method of chamfering-rolling uses a common chamfering/rolling tool and a deburring tool to complete the chamfer-roll-deburr simultaneously.
Results Before hardening, chamfering and rolling cause structural deformations so that they render the structure more compact. Chamfering causes a build-up of excess material along the profile. Rolling is necessary in order to smooth over this material and it causes the material to become more compact. After the heat treatment, the following is observed: • Cracks do not form in the rolled area • The structure is normal and corresponds to all the structural characteristics of the material • Cracks do not form in the area of material build-up
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Tool configuration options Chamfering/deburring tools can be organised in various configurations for different types of gears, geared shafts and sprockets. For example, cluster gears can be processed in a single operation with multiple chamfer/deburr tools.
Typical tool life Tool life can be affected by the type of steel, work piece burrs or a particular customer’s requirements. Typical tool life observed in production is as follows: • Deburring tools: 10,000 pieces for each sharpening, maximum 5 sharpenings (6 usages for each tool) and 60,000 workpieces for each deburring tool • Standard chamfering tools: 50,000 pieces for each sharpening (approximately 1.5 milion teeth), maximum 2 sharpenings (3 usages for each tool) and 150,000 workpieces for each chamfering tool • Chamfering/rolling tools: 35,000 workpieces (approximately 1 million teeth) and no sharpening
Machine configurations Gear chamfering/deburring machines require being sufficiently rigid with accurate alignments to ensure best results. Machine configurations based on the chamfering/deburring process are typically either on the horizontal axis (for both shaft type gears and loose gears) or vertical axis (for loose gears). While the horizontal axis configuration is the most versatile, the vertical axis configuration is also popular due to its compactness.
Conclusion Gear chamfering/deburring is a key process technology in automotive powertrain for achieving smooth gear transmissions. The capability to produce strong accurate chamfers is essential. In addition, for gears that are later finished, a rolling operation can be integrated with chamfering/deburring. Multiple configuration options in tooling enable a solution for a wide variety of automotive gears.☐
EM | Dec 2016
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GRINDING MACHINES | TECHNOLOGY
Rebuilding and retrofitting... As your business needs change, the machines need to change, depending on the requirements. The article highlights the key life cycle options for grinding machines to recover grinding production capacity. The productive life cycle of any machine tool is limited. Be it a lathe, mill or grinder, a machine’s accuracy and reliability eventually will deteriorate. How long that takes depends on the machine’s basic structure; how often and hard it is used; and how it is maintained. Shops that carefully track machine utilisation find that downtime of 20% or more of available machine time – due to unanticipated stoppages, adjustment & maintenance – generally represents an unacceptable burden on scheduling, maintenance operations and profitability. Two key options available to recover grinding production capacity include rebuilding the machine and retrofitting it with selected upgraded technology. Shops can also repurpose existing grinders for work different than their original intent, or replace them with brand new grinders.
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Rebuild/overhaul Rebuilding or overhauling a grinding machine involves disassembling it entirely and examining every mechanical, electrical, pneumatic and hydraulic system. Components are replaced or repaired where necessary and re-qualified to OEM standards. Every bolt, nut, rivet, hose and pipe gets the same treatment. Newer technologies such as monitoring devices may be added. Other updates can include items such as LED lighting and controls. Except for its basic structure, which is abrasive blasted and repainted, the reassembled machine is essentially brand new. A full rebuild costs about 75% as much as a new machine. The typical rebuild cycle might be 15 years; longer if the machine
EM | Dec 2016
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Transform your manufacturing Intelligent machining processes are a critical element in advanced manufacturing technology. Widely publicised trends such as Industry 4.0, the Industrial Internet of Things, cloud computing and data mobility provide manufacturers with an unparalleled opportunity to develop processes which deliver improved productivity and process capability. Automation, measurement and feedback can deliver process control throughout the stages of manufacturing. Optimised processes monitor not only the condition of parts, but also the performance of machines, process trends, interventions and environmental effects. Renishaw provides the technologies required to measure and control many of the key process variables in CNC machining and other forms of manufacturing. Talk to us about how we can help transform your manufacturing.
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GRINDING MACHINES | TECHNOLOGY
Depending on a machine’s overall condition and how it has been used, a possible approach is a partial rebuild that retrofits a machine with newer technology
is lightly used and well maintained. But that span is much shorter if the machine runs three shifts a day, every day, with minimal maintenance. Large, specialised grinding machines such as those used in critical aerospace applications are prime candidates for renewal via a comprehensive overhaul.
Retrofit Depending on a machine’s overall condition and how it has been used, a possible approach is a partial rebuild that retrofits a machine with newer technology. If a machine’s electrical systems and control are in top shape but the machine has been worked very hard and/or received minimal maintenance, only the mechanical systems may need to be overhauled. This involves a replacement of mechanical elements that are worn out or damaged beyond repair. On the other hand, a machine’s mechanical systems may be in excellent condition, with inspections confirming that axes and accuracy match OEM standards. In that case, an electrical overhaul including replacement of the electrical cabinet, all wiring and the servomotors may be appropriate. The mechanics of the machine and the original enclosure would remain. If a machine’s CNC unit is outdated, a new control will increase operational speed, productivity and convenience. An important consideration is the life cycle of the control itself. Control makers such as Fanuc and Siemens typically introduce new control technology about every ten years. So when needing a new control, it may be advantageous to look for a replacement control that is in the early phase of its cycle to benefit from the longer planned lifespan and control maker’s support. A key element of control technology is the humanmachine interface, or HMI. A control with a state-of-the-art HMI will incorporate an interactive, question-and-answer procedure that enables an operator who is far from an expert
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in programming to create productive grinding programs by simply answering questions and entering relevant part, wheel and machine data. Some machines may work well overall but possess outdated subsystems. Many elements of machine technology have changed significantly over the last 15 to 20 years. The feedback systems that locate machine axes are good examples. Machines with older motion encoders that do not feature glass scales must execute a multi-minute homing process to establish the positions of the machine axes each time the machine is turned on. The absolute encoders in glass scale systems, on the other hand, store the position of axes when the machine is shut off or if power fails. This eliminates the need for a homing routine when the machine powers back on. The new encoders also offer resolution 100 times higher than previous measurement methods. Servomotors have improved over recent decades as well, and are perhaps 50 times more accurate than earlier machine motion technology. If a machine has not been updated in 15 to 20 years, adding new and upgraded technologies can extend the next rebuild cycle. For example, retrofitting a ball screw lubricating system that was unavailable on the machine twenty years ago will enable the ball screws to last significantly longer. If the machine’s ongoing workload remains unchanged, the time between rebuilds lengthens significantly.
Repurpose In general, approximately 60% of overhauled machines return to their facilities to handle basically the same operations and workload they did prior. The remaining machines undergo additional changes intended to repurpose them for upgraded or different tasks. The percentage of machines being repurposed will continue to grow as the industry continues to
EM | Dec 2016
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GRINDING MACHINES | TECHNOLOGY
An obvious alternative to a worn and unreliable grinder is replacing it with a new machine
move away from long-term contracts for large volumes of identical parts to more flexible and dynamic manufacturing scenarios of rapidly changing part types and volumes. Repurposing a grinding machine typically involves adding features that will enable it to carry out more complex and productive grinding or to work with ancillary systems such as automation. A machine originally built in an open configuration may require the design, fabrication and addition of an enclosure to permit use of high-pressure coolant and advanced technology grinding wheels. Another machine might be repurposed to employ robotic automation by fitting automatic doors with opening/closing drives and laser-based safety systems. A machine without the capability for rotary dressing can be fitted with a rotary dresser and related drives and controls. True reverse engineering is rarely needed, but adding new systems can require re-engineering of hydraulic or pneumatic systems and design and fabrication of new sheet metal components.
Replace An obvious alternative to a worn and unreliable grinder is replacing it with a new machine. In many cases, however, the choice between rebuilding and replacing is not so obvious. Cost considerations play a key role in the decision to rebuild or buy new. The 25% savings of a rebuild compared with the price of a new machine is much less significant when applied to the price of a new, basic 3-axis production grinder than it is relative to the purchase of a multi-million dollar machine engineered for specialised work. A perfect example of such systems is those that grind aerospace blades and vanes. Lead times are another important factor. The lead time
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for a new machine’s basic welded or cast iron structure alone can be four to six months, depending on the size of the machine. Adding those months to the time required to construct the rest of the machine results in an eight to fourteen month or longer total lead time — dependent again on the machine’s size, type and brand. The lead time for a rebuild may be only half that of a new machine because the rebuild utilises the machine’s existing structure. But even that shorter delay can disrupt production excessively. For example, a busy shop with five 3-axis grinders that all perform similar operations will lose significant capacity during the months while a machine is off the floor for a rebuild. Buying a new grinder enables the shop to use the old machine to grind parts without interruption until the replacement is ready to install. Corporate budgeting policies may be a final determining factor in the choice to rebuild or replace a grinding machine. Restrictions on capital spending can make an overhaul, which usually is considered a maintenance expense, the only way to reclaim the production capacity of a worn machine. On the other hand, some companies’ capital spending strategies and allocations promote purchase of new machines. Depreciation, incentives and other tax-related issues can vary in relation to the age of a machine. Advanced grinding machines from United Grinding are engineered and manufactured to provide many years of trouble-free, accurate and profitable service. Ongoing maintenance, per manufacturer’s recommendations, will further extend service life. And when a machine moves toward the end of its initial life cycle, users have a range of options regarding the best path to continued productivity. ☐ Courtesy: United Grinding
EM | Dec 2016
I N D U S T R I A L PA R T S C L E A N I N G | T E C H N O L O G Y
Precision cleaning in metalworking industry Today, cleanliness standards are becoming more stringent and precisely defined. These tightened cleaning standards are required for components of assemblies with close operating tolerances, such as automotive powertrain components. In these applications, loose foreign particles can result in costly repairs or even loss of life as in the case of braking and traction controls systems. A read on‌ Lets refer to precision cleaning as applications, where cleanliness specifications limit maximum permissible contamination to a particle size less than 500 micron or weight of less than 10 milligrams per part. These limits are typically applied to new manufactured parts after the final wash prior to testing or assembly. The actual cleanliness specifications are normally determined by the OEM – based upon clearances between mating parts or the size of orifice a fluid must pass through. Residual particle analysis, commonly referred to as the Millipore test, is typically specified to verify the cleanliness achieved.
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Garth Weston, Technical Director (Retd) Proceco Ltd cleaning@proceco.com
In this test, the cleaned part is manually washed in a defined manner with a special cleaning solvent that is captured and filtered through a pre-weighed Millipore filter with a precise pore size. The filters are then weighed and examined (with a microscope) to determine the physical properties of the residual contamination for comparison with the particle quantity, weight, size and composition limits specified. In precision cleaning applications, these specifications are good for both the cleaning equipment manufacturer and the OEM, clearly defining the cleaning requirements at RFQ stage and providing a fair and impartial method of evaluating
EM | Dec 2016
The interface to Industry 4.0
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electronic ifm electronic India Private Limited Plot No. P-39/1, MIDC Gokul Sirgaon, Kolhapur - 416234 Maharashtra Ph: 0231-2672770 E-mail: info.india@ifm.com Toll Free: 1800 233 2065
I N D U S T R I A L PA R T S C L E A N I N G | T E C H N O L O G Y
The 1 st step in selecting a precision cleaning system is for the potential equipment supplier to properly analyse the application and the contaminated workpiece
performance after a contract has been issued. Standard catalogue item aqueous spray or immersion washers will not reliably meet any strict cleanliness specifications. For precision cleaning, special features must be added or an entirely new system specifically engineered for the application may be required.
Choosing a precision cleaning system The 1st step in selecting a precision cleaning system is for the potential equipment supplier to properly analyse the application and the contaminated workpiece. Laboratory testing will then determine the process parameters. This is critical as upstream manufacturing processes, production rates, type of contamination, workpiece base material and geometry – all have a significant effect on how to clean and what type of equipment is required. A couple of examples are described below: • Workpiece base material and manufacturing process can have a major impact on the ability of a system to clean effectively. Porous materials, such as cast iron or sintered metals may continue to release particles even after extensive cleaning of the same sample. While these particles may be below the maximum permissible size limit in a cleanliness specification, their combined total weight will add to contaminant counted and may cause the cleaning to fail the Millipore test. • If in-process cleaning prior to heat treating is not adequate, residual oils & cutting fluids will not only adversely affect the hardening process, but leave the byproducts of their reaction in the process embedded in the workpiece surface. This type of contamination is extremely difficult to remove in the final precision cleaning stage without resorting to high strength detergents that can potentially damage the
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workpiece. This problem is obviously more economical to correct in process cleaning than over-sizing the final precision cleaning system. With aqueous cleaning technology, there are two different methods used to achieve the cleanliness required: Positive, precision approach: Precision-aimed spray nozzles attack each orifice or area of the workpiece, where contamination can be trapped to ensure its removal. If, due to workpiece geometry, there are internal passages that are shielded from direct spray contact, special tooling can be clamped to the workpiece and cleaning fluid is forced under pressure through the passages. For more-difficult-to-remove contamination, this power flushing can be reversed and/or pulsed to improve cleaning. The workpiece itself may be manipulated for better access to cleaning components and provide better draining. This method is typically the most energy-efficient, requires the least floor space and minimises work in process. Engineering costs are usually higher and adaptability to different types of workpieces may be limited. Intensified cleaning approach: The basic cleaning mechanisms and factors that affect performance of any aqueous system – exposure time, flow, impact, heat and detergent action, are applied in sufficient quantity to achieve the required results. A system using immersion, ultrasonics, spray or a combination of these will clean to the required level if the workpiece is exposed for a long enough time and handled appropriately. This method generally has the advantage of reduced engineering costs and greater flexibility to process different workpieces. Generally, a combination of both of these methods is used.
Design & construction features Stainless steel construction: This is important not just for the
EM | Dec 2016
Warning! Machine tools without linear encoders may be inaccurate.
HEIDENHAIN shows the way to precision.
Machine tools without linear encoders use the pitch of the ball screw as the measuring standard. But at the same time, the ball screw transfers enormous forces at high traverse speeds and deforms due to thermal changes. Result: the position values become inaccurate. Machine tools with linear encoders are statically, dynamically and thermally more precise—advantages that we symbolize with a sign. Most linear encoders installed on machine tools have it: our sign of precision. For more information, visit: www.heidenhain.in
HEIDENHAIN OPTICS & ELECTRONICS INDIA PRIVATE LIMITED
Chennai 600031, India
phone +91 44 3023 4000
angle encoders linear encoders contouring controls position displays length gauges rotary encoders
I N D U S T R I A L PA R T S C L E A N I N G | T E C H N O L O G Y
Generally, a combination of positive, precision approach and intensified cleaning approach is used for achieving cleanliness
piping system, but also for the actual cleaning/drying enclosures and the workpiece handling system. Corrosion on these surfaces can detach and re-contaminate a cleaned workpiece. Filtration: In addition to the basic filtration required to protect the machinery and prolong solution life, the full flow of any solution that will contact the workpieces must be properly filtered. High-efficiency cartridge filters are commonly installed on the pump discharge. Standard bag filters will not reliably trap fine particles. For high production environments, automatic indexing vacuum bed filters can be installed. Special piping design: Systems must be designed to eliminate dead ends that trap contamination and reduce the use of threaded fittings that can introduce contamination at a later date. Sampling ports and valves must be installed at appropriate points so system performance can be analysed, once in production. Critical spray piping and precision manifolds must be easily removed for cleaning to maintain performance. Special cleaning procedures: During the manufacturing process, piping systems and other components must be carefully cleaned and then flushed after assembly to ensure that no contamination is introduced by the cleaning system itself. The completed washer is also cleaned with strong alkali and/or acid detergents to remove all contamination from construction. Drying and cooling: Most precision cleaning applications also require drying and cooling the workpiece so that it can be tested or assembled. Many of the features used for the precision washer are applicable to drying and cooling systems. Stainless steel construction for air supply ducting and blow-off nozzles, and filtration on blower suctions are required. Controls & monitoring: In a high production environment, cleanliness verification is typically performed on only a small sample of workpieces. In order to avoid costly rework due to improperly cleaned parts, the cleaning system process parameters and machine functions must be continuously monitored and maintenance warnings automatically issued
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before performance reaches unacceptable levels. Other features that may be required include: Multiple stages: In some applications, multiple wet stages are required. If production rates are high and workpiece contamination is excessive, multiple cleaning stages, each one progressively cleaner are used. If strong detergents are needed, rinse stages are added to remove detergent residue, which may in itself be an unacceptable contaminant. De-magnetiser: When processing ferrous workpieces, residual magnetism can make particle removal extremely difficult and should be reduced to levels under 3 gauss. Self–cleaning feature: Contamination removed from workpieces will deposit on internal washer surfaces and can detach and recontaminate cleaned parts. In high production environments, special manifolds are installed to clean the washer interior. These are actuated manually or automatically depending on application.
The right cleanliness specification Obviously, the capital expenditure for a precision cleaning system will be more than that required for a standard washer used in non-precision applications. When purchasing new equipment, it is important not to needlessly specify tighter cleanliness standards than are actually required. One should keep in mind that cleanliness levels with maximum particle dimension under 100 microns are extremely difficult to meet in an aqueous type washer. Proceco can produce equipment to meet these specs, however this requires that parts are discharged into a clean room environment. Airborne particles in shop atmospheres are typically larger than 100 microns. Also, cleanliness levels that specify a maximum particle dimension under 50 micron for parts with complex geometry are unreasonable and cannot be reliably achieved with the present aqueous spray cleaning technology. �
EM | Dec 2016
P R O D U C T I V I T Y I M P R O V E M E N T TO O L S | S P E C I A L F E AT U R E
Kaizen: A beneficial change Kaizen is neither a problem solving technique nor a suggestion scheme but it is a concept which creates a situation where entire organisation engages itself in the quest for improvement. Kaizen basically needs only common sense approach. It is working for continuous improvement as a habitual way of life. Kaizen is combination of two words - ‘Kai’ meaning change and ‘Zen’ meaning good. Thus Kaizen means change for good, a beneficial change. Kaizen means ongoing improvement in all spheres of life - be it our family, social or work life. When applied to work life, Kaizen means continuous improvement involving everyone - managers and workers alike. Kaizen has joined worldwide vocabulary, together with other Japanese words like Zen, karate, sushi or tempura. Most of Japanese words adopted were from culture, art or cuisine. As Japan’s post war economic miracle, its industrial growth and product quality that attracted the global attention, the words from these areas have now been accepted and adopted in other languages. The 1993 edition of new
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shorter oxford dictionary defines Kaizen as continuous improvement of work practices, personal efficiency, etc as a business philosophy. Japan has introduced many management practices like Total Quality Control (TQC), QC circles, small group activities, Total Productive Maintenance (TPM), Just-InTime (JIT), Zero defects, Poka-Yoke, 5S, Kanban, etc. All the above practices can be reduced to one word - KAIZEN. Kaizen is an umbrella concept covering all these practices. Basic Kaizen concepts include the following: • Kaizen and management • Process versus performance & the next process is customer. • PDCA/SDCA cycles
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S P E C I A L F E AT U R E | P R O D U C T I V I T Y I M P R O V E M E N T TO O L S
KAIZEN AND MANAGEMENT MANAGEMENT LEVELS TOP MIDDLE
INNOVATION KAIZEN MAINTENANCE
SUPERVISOR WORKMAN Kaizen means continuous improvement involving everyone - managers and workers alike
Kaizen and management Every job has two important components. One of them is maintenance. Maintenance refers to activities towards maintaining status quo - technological, managerial and operating standards. Under maintenance function, established standard operating procedure (SOP) is to be followed. This means, first management must establish policies, rules and procedures for all major operations and ensure that all SOP are followed. If people are unable to follow SOP, management must either provide training, or review and revise SOP so that people can follow it. If people are capable to follow the standard but do not follow, management must introduce discipline. The other important component of the job is improvement. Improvement refers to activities directed towards upgrading current standards i.e. to establish higher standards. Once this is achieved it becomes management’s maintenance job to see that the new standard is practiced.
Innovation & Kaizen Improvement can be classified as either continuous improvement, i.e. Kaizen or innovation. Kaizen and innovation methods are like path leading up a hill versus a staircase. Through innovation, an organisation makes dramatic progress like a hare leaping up a staircase. Through Kaizen, progress is like that of a tortoise, climbing path slowly but steadily. Kaizen signifies small improvements as a result of ongoing efforts. Innovation on the other hand involves drastic improvement, which may be result of a large investment or effort in new technology or equipment, etc. There is relationship between maintenance and improvement activities with the hierarchy of the company. The proportion of time and effort devoted to maintenance and improvement will largely be determined by seniority of the person in the organisation.
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MANAGEMENT FUNCTIONS
Kaizen and innovation are both indispensable for any good organisation. Innovation brings revolutionary changes. Even if great system is established through major innovation, maintaining and improving this system requires lot of effort. Any established system corrodes faster than steel. Hence one should not be blinded by revolutionary innovation and neglect minor or incremental daily improvements. Any lack of focus will result in natural decline away from standard. At the end, one loses the race like the foolish hare who fell asleep after gaining initial lead. On the other hand, a series of small improvements bring steady upliftment. Continuous improvement not only maintains existing standard but also raise those standards. The examples given below shall help in understanding the difference between innovation and Kaizen. • If we install a robotic spot welding line, against conventional welding system that is an innovation. When it is ensured that robots are maintained, well lubricated and worn out parts replaced to minimize potential breakdown, then that is maintenance. When the operator reprograms the robots to perform a more efficient sequence of motions between spot- welds in order to shorten the machine cycle then it is Kaizen. • When we use inspection to ensure that out of tolerance product do not reach the customer, or a next process, then that is maintenance. When we use control charts, cause and effect diagram, Taguchi techniques to solve problem so that all parts produced are much closer to that nominal value and therefore well within the limits defined by quality standards, then it is Kaizen.
Process versus performance Processes must be improved for results to improve. Kaizen fosters process-oriented thinking. Process is things we do to transform inputs into specified outputs (goods or services) to be used by next process or person.
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P R O D U C T I V I T Y I M P R O V E M E N T TO O L S | S P E C I A L F E AT U R E
PDCA CYCLE OF IMPROVEMENT
SDCA CYCLE FOR STANDARDISATION
DO Carry Out Plan PLAN Improvement
ACT on Evaluation CHECK for Work against Standard
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STANDARDISE know the Standard DO Work according to standard
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PDCA and SDCA cycles are essential and need to be used always in combination. It is worthwhile to observe that SDCA means maintenance and PDCA refers to improvement
Process orientation involves review of the variables in any process in order to improve its effectiveness. This helps to improve the organisation’s performance. Various processes in any organisation are interdependent. Each has customers as well as suppliers. Customers are those people or departments who receive work or output of earlier people or departments. Similarly suppliers are those people or departments whose work or output is used by next process or department. In short next process is customer. Internal customers and suppliers have to be looked upon in the same manner as one looks at external customers and suppliers. The internal supplier and customer relationship works like a chain throughout the organisation. It is as strong or as weak as the weakest link. The entire process fails if there are weak links in this chain. The next process should always be treated as customer. The realisation of this axiom should lead to a commitment never to send or deliver defective parts or inaccurate information to next process. When everybody in the organisation practices this axiom, the external customer in the market receives high quality product or service as a result. Organisational performance is the result of the sum total of all processes employed in the organisation. Improving organisational performance requires focussed attention and improvement on various processes. Managing a business by reacting to the results is like driving a car by looking only to rear-view mirror. Results are the after-the-fact measure of performance, a rear-view mirror. Process orientation opens gates to improve performance and devoids inferior products or services to be produced or delivered to the customer.
PDCA / SDCA cycle Edward Deming’s most significant contribution to Japan’s
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industrial regeneration was Deming cycle. It is also called Deming wheel, Shewhart, improvement, management, PDCA cycle. Plan-Do-Check-Act (PDCA) operates in cycle which begins with study of current situation, during which data are collected for formulating plan of improvement. ‘Plan’ envisages a target of improvement i.e. it means what to do & how to do. ‘Do’ refers to implementing the plan. After implementation, ‘Check’ stage comes in where results are evaluated to measure about realisation of anticipated improvement. ‘Act’ is the corrective action or countermeasure stage. After evaluation the plan is either revised or repeated or standardisation is done to regularise practicing of new method introduced. This ensures continuous sustained improvement. PDCA is closed loop cycle meaning endless drive to the destination. There is always scope for further improvement. It is a race without finish line. PDCA cycle goes round & round. No sooner improvement is made, and then it becomes a standard to be challenged with new plans for improvement. It is also necessary to stabilise the standards. The process of stabilisation is called SDCA (Standardise-Do-Check-Action) cycle. Upgradation of the current standards through PDCA cycle is possible only when SDCA cycle is at work. Thus both PDCA and SDCA cycles are essential and need to be used always in combination. It is worthwhile to observe that SDCA means maintenance and PDCA refers to improvement. Kaizen is neither a problem solving technique nor a suggestion scheme but it is a concept which creates a situation where entire organisation engages itself in the quest for improvement. Kaizen is about doing, not putting a proposal or suggestion. Any proposal or suggestion if not implemented or cannot be implemented, is of no practical value. Kaizen basically needs only common sense approach. It is working for continuous improvement as a habitual way of life. ☐
EM | Dec 2016
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EVENT | REPORT
Taking smart manufacturing forward With the advent of Industry 4.0, the Taiwan machine tool sector is gearing up to compete in the global market. Keeping this in mind, the Taiwan External Trade Development Council (TAITRA) had recently organised a four-day factory tour, which gave an in-depth exposure into the Taiwanese machine tools industry. The tour also had a presentation on TIMTOS 2017. A report from EM… According to the latest research, the production value of the Taiwanese machine tool industry is around US $4.49 billion and ranks seventh in the world. This value is estimated to reach US $ 6.91 billion by 2020. The growth is expected to be generated by industrial needs from aerospace, submarines, precision machinery, medical material and consumer electronics manufacturing. To facilitate this growth, the government of Taiwan is promoting the Taiwanese machine tools industry globally. Keeping this in mind, the Taiwan External Trade Development Council (TAITRA) had recently held a four-day factory tour, which provided us with the opportunity to interact with seven
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Suchi Adhikari Sub-editor & Correspondent suchi.adhikari@publish-industry.net
prominent machine tool manufacturers of Taiwan through plant facility visits and exposed us to their latest products, technology and manufacturing practices.
Tongtai Machine & Tool The first day of the factory tour included a visit to the Tongtai Machine & Tool. Based in Kaohsiung Science Park, the company’s main products include customised machine tools, machining centres, CNC lathes and PCB drilling machines. The company’s turnkey solutions include management of the entire machine manufacturing process. Tongtai has also established the Tongtai
EM | Dec 2016
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Technical Application Center (T-TAC) to provide advanced machining technologies, machining solutions and trial operation to customers. Their customers include companies in the automotive, aerospace, electronics, mould and general part machining industries. Speaking on the company’s vision, Lin Yen, Assistant of Chairman, Chairman Office, Tongtai Machine & Tool, said, “We hope to become the total solution provider in the metal machining industry with our strong R&D team. Our target right now is ‘Double 20’, which means to double the revenue and be amongst the top 20 machine tools group in the world by 2020.”
Falcon Machine Tools The second day of the media tour included a visit to the Falcon Machine Tools, also known as Chevalier. This company is a leading manufacturer of grinding, turning and milling (machining) centres. Their machines are assembled in their own ISO 9001-certified factories that include departments of R&D, machining, sheet metal production and electronics. Their customers include companies from aerospace, automotive manufacturing, construction, defense, wind power, medicine, printing, semiconductors, energy, moulds and machine tools. Speaking of their manufacturing facilities, Michael Chang, Vice President – Marketing, Falcon Machine Tools Co, said, “Most precision machining process are completed in-house with dedicated, top-notch CNC manufacturing machines. All structural assembly work, including electrical and controls, are assembled by our team of highly trained and experienced assembly engineers.” He further added, “After assembly, all of our machines are measured and calibrated by laser calibration and ball bar test equipment. This ensures precise verification and compensation of our machines, resulting in increased accuracy and repeatability.” Commenting on their plans to strengthen their market share in India and confirming their participation at IMTEX, Chang said, “We are planning to promote our hi-precision machines in India, which is an untapped sector there. We also wish to focus on custom-made machines in India and are planning to target their upcoming aerospace industry.”
EM | Dec 2016
Vision Wide Tech The third day of the factory visit included a visit to Vision Wide Tech. Their main products include vertical machining centres, bridge-type machining centres with vertical, 5-face, 5-axis fixed-beam, moving-beam hard rail and linear guide models, and gantry-type machining centres. As a manufacturer of double column machining centres, the company develops equipments of key machining technology in accordance with the demands of different industries. Their products are applied in the field of components machining, plastic, motor, train, aerospace, vessel and power industries. Sharing the company’s vision, Michael Chen, General Manager, Vision Wide Tech, said, “We keep the core values of employees’ education through the operating management of TQM system, Numerical Objective Management and teachingtraining system, to create an active-thinking work environment, implementing continual improvement, creativity and execution. We encourage our members to embrace the shared company vision to achieve the mission of contributing to human society.” Recognising India as a potential market, Chen emphasised, “India has ranked sixth in the global automobile market. This has attracted our attention for its upcoming transport manufacturing market, especially in aerospace, automobile and railways and its strong government support for transport infrastructure. For instance, India recently bought 250 aircrafts and there would be an additional demand for 1,290 new aircrafts in the next 20 years. Keeping this in mind, we plan to start a new factory in India in the coming 5 years, and the factory will be our main supplying centre to meet the global demand.”
Everising Machine The next company that we visited was Everising Machine. They specialise in mid to large-size band saws and circular saws. Their R&D innovations have yielded a series of breakthroughs that have helped drive output at their factories in Taichung, Taiwan and Kunshan, China beyond 2,000 units per year. They provide full-scale sawing technologies and sell to over 60 countries through a network of over 40 distributors.
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Vision Wide Tech has achieved rapid growth as a result of its sophisticated machining technology
The company follows lean manufacturing system in its factories and focuses on accuracy in the process. Elaborating on the company’s core values, Scart Chiao, President, Everising Machine, said, “We have consistently made quality, innovation and leading technology as our priority. This customer-focused strategy has enabled the company to achieve sustained growth as well as enabled us to receive international certification including the CE mark and successive versions of ISO 9001.” Speaking on the Indian market, Chiao shared, “We are doing business with India for the last 12 years and have made sales worth US$ 1 million in the last two years. Thus, we consider India an important market for us. While we have no concrete plans of opening a facility in India yet, it is an on-going discussion that we are taking part in.”
do the assembly of our machines in-house while the making of the machines is outsourced.” Their industrial applications include sectors such as transportation, electronics, precision machine tools, molding industry, tool industry, dentistry, recreation industry, consumer products and the energy sector. As per future plans, Chen said that they would continue to develop new types of grinders and improve their machinery structure and design so that machine operation is made easy with more friendly controllers and is more efficient by saving time and reducing the cost. Confirming their participation at IMTEX 2017, she said that they will highlight the centreless grinding machine at the exhibition.
Jainnher Machine
On the last day of the factory tour, we visited SEYI Machinery Industry. This company has been a part of the metal forming industry for the past 50 years. It manufactures mechanical presses, ranging in size from 25 to 4,000 tonnes at manufacturing facilities in Taiwan and China. The company is also expanding its Total Solution Service to highlight the importance of peripherals such as feed mechanisms and transfer equipment in maximising the productivity of SEYI presses. Future growth areas for the company include the automotive, aviation machinery and medical equipment industries. Speaking on the company’s core values, Tony Tseng, Special Assistant, Chairman Office, SEYI Machinery Industry, said, “Our company’s core values include integrity, which means delivering our promise, accountability which stands for taking responsibility
The next company that we visited was Jainnher Machine. This company is a specialist in centreless grinding technology. It is focused on the development of high-precision centreless grinders, cylindrical grinders and internal grinding machines, and also develops a range of NC and CNC automatic loading and unloading systems. With sales in over 40 countries, they are known to provide customised solutions. Discussing the management philosophy of the company, Yi-Tung Chen, Vice President, Jainnher Machine Co, said, “Our focus is on quality, which includes putting the customer first, taking part in quality control and giving priority to innovative technologies.” In terms of their products, she further shared, “We
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SEYI Machinery Industry
EM | Dec 2016
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SEYI has been a part of the metal forming industry for the past 50 years
for our commitment, service which means giving our best and innovation which involves monitoring our system and transforming from manufacturing style to service style of operation.” He further elaborated on his company’s competitive advantage and shared, “Our servo press technology is over 10 years old and this eco-friendly smart device finds application in sectors like automobile, aviation, electronics, home appliance and medical appliance.” Also showing optimism for the Indian market, Tseng noted that they have been doing business in India for more than 20 years. He spoke of the company’s future plans with regards to the Indian market and added, “We want to focus on Tier I and Tier II cities in India and are looking forward to our major clients setting up offices in India. Some of our clients are moving to India as early as next year. This will help us penetrate the Indian market with our already established clientele to whom we can continue to provide after-sales service.”
DEES Group The last company that we visited was DEES Hydraulic Industrial. It specialises in manufacturing an array of hydraulic machinery. Spread over 50 countries across the globe, the company has built over 3000 machines. Infact, it has developed Taiwan’s first CNC press brake with Bosch and Cybelec. Headquartered at Taipei, it has also developed hi-precision closed loop servo hydraulic die spotting press. Some of the major industry verticals that the company caters to includes the automotive industry, electronics, home appliances and aerospace. As per HH Huang, President, DEES Hydraulic Industrial, “The company has over 70 engineers across Taiwan and China
EM | Dec 2016
and incorporates automation system, including robotics in the factory. The company’s USP includes space-saving technologies, for instance, usage of one machine instead of four; labour-saving methodology, for instance, employing only one or two operators for each machinery, and cost and energy saving modules implemented on the factory floors.” Huang further believes that manufacturing is a perfectly orchestrated department and the company claims to have over 95% of customised machines. Expressing keen interest over India’s growing economy and labour price stability, he stated that they have plans to increase their market share in India in the future run.
Towards future technologies Summarising the advantages of the Taiwan machine tools sector, Thomas Huang, Deputy Executive Director, Exhibition Department, TAITRA, concluded, “Our companies continue to provide high quality and competitive pricing products and apply flexible manufacturing in response to the rapidly changing needs of the market.” He further added that they plan to showcase these customised smart manufacturing technologies at the 26th Taipei International Machine Tool Show (TIMTOS), which is being held on March 7-12, 2017 in Taiwan. It will be centered on the procurement of top-quality ‘Made in Taiwan’ machine tool products and total solutions for the machine tools industry. The international exhibition is expected to attract over 55,000 visitors including 7,500 foreign buyers. The topic of the expo will be ‘Industry 4.0 Plus and Smart Manufacturing’ and it will integrate the advantages of Taiwan ICT technology with IoT and big data to provide the Industry 4.0 whole-plant output technology of ‘Smart Manufacturing’ and ‘Smart Factory’. ☐
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EVENT | REPORT
Decoding industry technology... Organised by the Indian Machine Tool Manufacturer’s Association, the 10th edition of the National Productivity Summit was recently held at Bengaluru. The two-day summit addressed the key challenges to achieving productivity, while sharing know-how on generating substantial productivity results. A post-event report… Today, a growing and competitive manufacturing sector has become the prime mover of the modern economy. Given the forces at work, manufacturing firms are taking a variety of approaches to radically transform their businesses and find new ways to differentiate themselves. This has necessitated companies to constantly innovate, redefine paradigms, adopt cutting-edge technology, enhance productivity and optimise resources. Keeping this in the backdrop, IMTMA had recently organised the National Productivity Summit at BIEC, Bengaluru. Inaugurated by L Ganesh, Chairman, Rane Group; B Muthuraman, former Vice Chairman, Tata Steel; Parakramsinh G Jadeja, President, IMTMA and V Anbu, Director General & CEO, IMTMA, the 10th edition of the summit showcased the
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Megha Roy Senior Features Writer megha.roy@publish-industry.net
best practices in manufacturing through inspiring keynotes, live case study presentations, plant visits, focused technical sessions and success stories. Speaking on the occasion, Ganesh said, “Productivity is achieved over a long period of time. It's a marathon and Indian companies in manufacturing sector need to constantly work on skill enhancement of their employees and push for labour laws that will enable re-skilling of workers for future jobs.”
Highlights Day 1 started with a keynote session by Muthuraman, who traced back the major transformation of the Indian industry and
EM | Dec 2016
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enforced that the industry must realise that the labour issue will go away in due course of time. He said, “Amidst the rebalancing of the world economy, manufacturing needs to adopt technology from other fields too, like the IoT practices, Additive Manufacturing and prototyping techniques.” Moving on, an interactive success story was presented by MS Shankar, Senior Director—Technology & Innovation, Anand Automotive, where he pointed out the parameters to track improvement in productivity. “This can be done by attracting stakeholder groups, top leaders and each employee of an organisation to create business. The concept of manufacturing excellence involves problem solving techniques, continuous improvement methodology and achieving a quantum leap,” he added.
Productivity Championship Awards • Toyota Kirloskar Auto Parts bagged the first prize and won Rs 3 lakhs cash prize • Mahindra and Mahindra, Mumbai, bagged the second position with Rs 2 lakhs cash prize • VE Commercial Vehicles bagged the third position with Rs 1 lakh cash price • Certificates of merit were given to Brakes India, Super Auto Forge and TTK Prestige • Vox Populi Award was given to Toyota Kirloskar Auto Parts
Enhanced productivity methodology The first case study of the event was presented by Vijay Mewada, Senior Manager—Foundry, Mahindra & Mahindra, on “Journey towards excellence through technology upgradation”. This was followed by a presentation on “Productivity improvement of hole drilling by innovative production techniques,” by R Sahayasubramanian, Senior Manager—Projects, Super Auto Forge. Next, R Saravana Kumar, Senior Manager—TPM & EHS, TTK Prestige, spoke on “Improved productivity by eliminating man and machine efficiency losses”. The day was concluded with a success story on “Operational excellence: Scaling up to meet market demand,” by R Prabhakar, Chief Operating Officer, Ace Designers. He, along with his team members, delivered an interesting presentation on how the previous method of assembly has now evolved.
EM | Dec 2016
Meeting competitive standards Day 2 began with a case study on “Reducing the fettling content and improving the aesthetic look of sand foundry casting” by R Ramsharan, General Manager—Technical, Brakes India. The next case study was on “Productivity enhancements - chipless machining” by Dilip Rathod, DGM— Head of Manufacturing, VE Commercial Vehicles. This was followed by a case study on “Productivity improvement in transmission assembly line through Jishuken and low-cost automation (Karakuri)”, by Tabrez Ahmed, DGM— Manufacturing 2 department (R T/M & C T/M), Toyota Kirloskar Auto Parts. The first keynote of the day was addressed by Dr Andreas Wolf, Senior Executive Vice President, Bosch, on “Productivity, quality and cost—3 nodes of manufacturing competitiveness triangle”. Here, Wolf discussed the manufacturing triangle comprising quality, cost and delivery that are centred around the roadmap to achieve excellence. Then, the second keynote was presented by Anoop Chaturvedi, Senior Advisor—Production & Engineering, Maruti Suzuki, on “Innovation for manufacturing excellence—Maruti Suzuki’s success story”. The session was addressed on leveraging technology & IT systems, enhancing quality, importance of timely communication, having a robust traceability process, etc.
Key takeaways Concluding the event was Shailesh Sheth, Corporate Strategy Advisor, IMTMA, who briefed the session on how the world will look like with future factories by 2020 and also moderated the Productivity Championship Awards. Speaking on how the summit will act as a platform to meet the evolving knowledge and skill requirements of overall manufacturing industry in India, Jadeja said, “The manufacturing industry is growing rapidly in India and is at the cusp of embracing Industry 4.0 that offers huge growth prospects for the industry. Summits like these are the key enablers to address learning and best practices requirements of manufacturing industry and raising its competitiveness.” Besides the two-day summit, IMTMA also organised plant tours of Toyota Kirloskar Auto Parts & Toyota Kirloskar Motor and Volvo Buses and Honda Motorcycle & Scooters, India. The next edition of the National Productivity Summit will be held in August 2017 at Pune. ☐
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EVENT | REPORT
Addressing automated welding in India The Confederation of Indian Industry recently held a one-day conference in Mumbai to address the challenges being faced by the welding industry in India. A post-event report…
Suchi Adhikari Sub-editor & Correspondent suchi.adhikari@publish-industry.net
Today, welding is one of the core modern technologies going through a complete evolution. In India, welding contributes significantly to the GDP in several ways, such as welding intensive industries, auxiliary products, complementary goods, employment, and user industries. On these lines, CII recently organised the first edition of the CII Welding Conference 2016 held in Mumbai. The one-day conference provided multiple opportunities to understand the advancements and innovations in welding process and also the problems it faces in India, discussing the ways to solve and overcome them.
former Chief Executive, EWAC Alloys. This was followed by an overview of the survey report, given by Chetan Ligade, Director – Projects, BDB India. The next address was delivered by the guest of honour, Y S Trivedi, Executive Vice President and Member of the Board, Heavy Engineering IC, Larsen & Tourbo, who discussed the advancements of welding in manufacturing, construction and country-wide infrastructures and also focused on the stopgaps it faces in India. The final address of the first session was given by Subhash Desai, Hon’ble Minister of Industries and Mining, Government of Maharashtra.
Advancements in welding
Future trends
The first session of the conference covered the topic of advancements and challenges faced in the sector. The welcome address was given by A Shivkumar, Conference Chairman &
The next session focused on the future trends, which include Internet of Things, automated welding and Additive Manufacturing in India. The keynote for this session was given by
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REPORT | EVENT
The last session covered the topic of safety and non-destructive testing for welding in India
S Sundarram, Managing Director, Lincoln Electric, who emphasised on the need for global knowhow and advancements in this sector. Speaking further on this, the next speaker, Rashmi Ranjan Mohapatra, Managing Director, Kemppi India, opined that intelligent and interconnected systems need to be adopted to enhance automated welding. Then, Gautam Banerjee, Managing Director, Kaiyuan Welding & Cutting Automation, spoke of smarter products and services by adopting smart manufacturing practices. The final remarks for the session were given by Jonathan Martin, Friction Stir Welding Section Manager, TWI and the session was moderated by Shivkumar.
next speaker was Pabitra Das, International Adviser – India American Welding Society, who noted that there is a lack of skills necessary in the labour force in the welding sector in India. The subsequent speaker was GA Soman, Principal, Don Bosco Maritime Institute, followed by Shrihari Mandaogane, TQM Head, Tata Motors. The final speaker of the session was Amlan Saha, Segment Manager – Automation & Engineering Fronius India and the session was moderated by L Sundar, Chief Technical Officer, Ador Welding.
Challenges in welding sector
The last session covered the topic of safety and non-destructive testing for welding in India. The keynote for this session was given by Chris Wiseman, Industry Sector Manager, TWI, which was followed by the next speaker, Arvind Bhide, Bhide Institute of Testing Technology. The third speaker was NH Singh, Technical Director, Institute of Welding and Testing Technology, who shared, “Regulations and standards, with emphasis on safety need to be considered by the government to limit environmental impact. There is also a widespread requirement for nondestructive testing during the manufacturing process so that the risk is reduced, thus facilitating durability and long lasting capacity.” The last speaker of the session was Piyush Tripathy, Business Development Leader, Sure Safety India and the session was moderated by R Srivastava, Deputy Director General, National Safety Council.
The next session revolved around the topic of the evolution of material sciences, future prospects and challenges in the welding sector. The first speaker of this session was Abby Joseph, Managing Director, Voestalpine Bohler Welding India, who spoke of advanced technologies, such as lasers and plasma arcs, used in this sector today. The next speaker was G Padmanabham, Director, International Advanced Research Centre for Powder Metallurgy and New Materials. The third speaker, PV Venkitakrishnan, Deputy Director, Materials and Mechanical Entity, Vikram Sarabhai Space Centre, ISRO, spoke on how research and development is the key to the overall growth of this crucial sector. The final speaker for the session was Jon Blackburn, Section Manager and Lead – Laser Processing, TWI and the session was moderated by VS Raja, Professor, Aqueous Corrosion Laboratory, IIT Bombay.
Skill development & training The fourth session covered the topic of skill development and training in the welding sector in India. The first speaker here was N Srinivasan, President, Indian Institute of Welding, who shared that the current average demography in the Indian welding sector is above 50 years of age, which is worrisome. The
EM | Dec 2016
Safety & non-destructive testing
Conclusion Welding is the most widely used technique by manufacturers in India, to join metals and alloys efficiently so as to add value to their products. Thus, to remain a player in the rapidly changing, global, manufacturing environment of the future, the welding industry must consider a refined system of codes and standards and also induct various methods of NDT that will be beneficial in due course. ☐
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TECHNOLOGY | NEWS
CNC fibre laser cutting machine
Tooling assistance system
Dongguan GloryStar Laser Technology offers CNC fibre laser cutting machine with fully enclosed exchangeable worktable model GS-3015CE. The model of GS-3015CE is popular and widely received all over the world and has sold in more than 108 countries and regions. It is equipped with the most advanced main parts such as IPG laser generator, HIWIN liner guide, imported servo motor from Japan, and adopts German CNC system GS-3015CE to ensure high performance and precision. With the exchangeable worktable, the GS-3015CE can increase the working efficiency and reduce the time of loading and unloading of the materials, so that it can save more time and create more value for customers. This model also has a special design which includes a protection cover to reduce the slags fly to workshop, and the most important part is that the protection cover can greatly reduce laser radiation. It finds application in all kinds of sheet metal materials such as carbon steel, stainless steel, manganese steel, aluminium, copper, etc.
KOMET GROUP has developed ToolScope, an assistance system which does more than monitor tool breakage and wear. It turns a machine into a production system with Industry 4.0 capability. The tool manufacturer presented the latest version, which is particularly impressive due to its flexibility and user-friendliness. For instance, customers can select the functions of KOMET® ToolScope entirely according to their requirements and can also operate the system using mobile terminals. KOMET® ToolScope monitors and records the machine's internal ToolScope signals, such as the torque of a spindle or the feed force of an axis. It also detects events such as tool changes and machine stoppages. Using its knowledge of process identifiers such as range, tool, sequence number, etc., which can be read from the control system, the software is able to calculate parameters and deduce trends after the process is complete. In order to design ToolScope so that it offers the user as many added benefits as possible, the company has developed a number of apps.
Dongguan GloryStar Laser Technology | China
KOMET Precision Tools India | Bengaluru E-mail: info.in@kometgroup.com | Tel: +91-80-6772-8000
Email: joychen@glorylaser.com | Tel: +86-136-31703966
CNC tool grinders
Embedded PCs
ANCA offers 3 new machines in its FX Linear range of tool grinders such as FX3 Linear, FX5 Linear and FX7 Linear. The FX Linear includes a significant number of important new technology releases and a complete body redesign that is both aesthetically pleasing and technologically beneficial. The range is ideal for everything from light manufacturing to regrinding and even full production. Its best performance and productivity range is for tools up to a diameter of 12 mm (1/2”). It can grind tools up to a diameter of 200 mm features have been included in the range to make an FX LINEAR operator’s work easy. These include a new touchscreen customisable with Windows, hand-held pendant for easier set-up and an easy-to-access loader door for slide out pallets. The FX Linear machine is compact but also has a large working envelope. It, of course, benefits from ANCA’s 40 years of experience in designing tool grinders and developing user-friendly, versatile ToolRoom software. The company's tool grinders are suit for the production and resharpening of HSS and carbide cutting tools.
Beckhoff offers many core processing power in a DIN rail-mountable format with the new CX2000 series Embedded PCs. The new Embedded PCs use Intel® Xeon® D processors, each with 4, 8 or 12 CPU cores of the 5th generation Intel® Core™ micro-architecture, and manufactured using 14 nm process technology. Three units are being introduced, which differ with respect to the CPU used such as CX2042 (Intel® Xeon® D-1529 at 1.3 GHz, 4 Cores), CX2062 (Intel® Xeon® D-1539 at 1.6 GHz, 8 Cores) and CX2072 CX20x2 Embedded PCs (Intel® Xeon® D-1559 at 1.5 GHz, 12 Cores). The 4, 8 and 12 processor cores offer ample processing power and parallelism, even for extremely demanding automation tasks. Optimal multi-core support from TwinCAT 3 automation software makes it possible to distribute the individual tasks of a control process across the available CPU cores. This means that the computing load can be planned in fine detail to achieve the best possible processor efficiency. Another important feature enabling the performance increase is the separate graphics card.
ANCA Machine Tools | Bengaluru Email: indiainfo@anca.com | Tel: +91-80- 42198107
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Beckhoff Automation | Pune Email: info@beckhoff.co.in | Tel: + 91-20-4000-4800
EM | Dec 2016
NEWS | TECHNOLOGY
Modular system for line production EMAG has introduced VL Series of vertical production machines that are part of the company's modular standard series. These machines are built on a common machine base but allow the use of an extremely wide range of technologies, similar to the modular platform systems seen in the automotive industry. There are now modular machines available for turning, gear hobbing and chamfering Vertical pick-up turning centres of the VL series processes; for grinding (chucked parts and shaft parts); for induction hardening; and also in special designs for laser welding or PECM technology. The machine base of these modular machines is made out of Mineralit® polymer concrete. This material has exceptional vibration damping properties, which is the basis for the machines' excellent process quality. The machine base supports a compound slide rest equipped with an X-axis and a Z-axis, which allows the working spindle to move. The working spindle is the heart of the pick-up automation system, which is an essential part of
every modular machine. It includes a parts storage unit in every machine, from which the pick-up spindle loads and unloads itself independently. This lowers non-productive time to an absolute minimum as there are only a few seconds between the machining processes. An optional measuring probe can be installed directly alongside the loading position, allowing time-optimised measuring of the parts. The vertical pickup turning centres of the VL series were developed particularly for the production of precise chucked parts. There are now five versions of the VL machine to cover the widest possible range of parts. The smallest machine is the VL 2, designed for chucked parts with a diameter of up to 100 mm. It is followed by the VL 4, VL 6, and VL 8 machines, which allow for an increase of 100 mm in diameter with each model increase. These additional models allow the VL series to cover workpieces up to 400 mm in diameter. The fifth machine in the set is the VL 3 DUO with dual spindle. EMAG India | Bengaluru Email: HAshwini@emag.com | Tel: +91-80-4254-4400
Imaging multimeter
Tube cutting software
FLIR has introduced DM284 imaging multimeter with Infrared Guided Measurement (IGM). The DM284 is an all-inone true RMS digital multimeter with built-in 160 x 120 FLIR thermal imager that shows where an electrical problem is to speed up troubleshooting. It visually guides one to the precise location of an electrical problem and helps to pinpoint hot spots faster and more efficiently. IGM also helps to scan panels, connectors and wires without requiring any direct contact. So that one can do the job from a safe distance. In case of an issue with IGM, the DM284 can verify and confirm findings with advanced contact measurement features to help solve the most complex electrical issues. It is ideal for field electronics, FLIR DM284 commercial electric, light industrial, field service and HVAC work. It incorporates 18 functions of DMM including True RMS, VFD mode, LoZ, NCV, and also includes high-quality test probes and a type K thermocouple input, simple user interface and various thermal colour palettes to choose from, which include Iron, Rainbow & Greyscale.
Hypertherm has announced the release of Rotary Tube Pro™, a software that makes it easier to design and cut tube and pipe parts with no 3D CAD experience required. The software features a parametric design interface that allows main tubes and side-wall cutouts to be added from a list of predefined shapes. Alternatively, users can add tubes and cutouts directly from a CAD program. This flexibility means fabricators and manufacturers can enjoy greater productivity by increasing programming speed and improving cut quality for improved fit- Rotary Tube Pro up with fewer secondary operations. The software also includes an optional rotary bevel interface provided with bevel cut charts based on True Bevel™ technology, which greatly reduces bevel setup time. The Rotary Tube Pro software includes more embedded cut process expertise in the NC code than other tube and pipe software. By drawing on years of research and development, Hypertherm software developers were able to deliver optimal outcomes based on factory-tested and proven job parameters including leads, separations, kerf, feedrate and cutting techniques.
FLIR Systems | New Delhi Email: flirindia@flir.com.hk | Tel: +91-11-45603555
EM | Dec 2016
Hypertherm India Thermal & Cutting | Chennai Email: info@hypertherm.com | Tel: +91-44-23845361
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TECHNOLOGY | NEWS
Energy chains for robots
Face milling tools
igus has expanded its range of multi-axis energy chains and introduces a new size for the lightweight triflex TRLF. With 125 mm diameter, this is the largest in the range and can safely guide even more cables and hoses. The e-chain for torsional movements is impressive with very fast assembly and disassembly, which significantly reduces shut-downs. For this reason, it is popular with robot manufacturers and users. The 'L' in the product name TRLF stands for 'light' because material is saved through the open triflex TRLF design of the individual links, but at the same time, the cables and hoses are still guided safely. The 'F' stands for 'flip open' and describes the mechanism very well. With the new size TRLF.125 with a nominal diameter of 125 mm, even large and stiff hoses or a large number of individual cables can be inserted quickly and easily. By dispensing with continuous support elements like steel cables or spring elements, the assembly and disassembly of triflex TRLF is as easy as the filling.
Kennametal has introduced a new face milling tool Mill 16, which has a wedge-style clamping system, numbered pockets and inserts and an open pocket design to increase chip flow in heavy roughing. As automakers strive for increasingly fuel efficient and environmentally friendly vehicles, they are turning away from traditional iron favourites such as gray and ductile iron (GCI and DCI) to compacted graphite iron, or CGI. Unfortunately, CGI is also more difficult to machine, requiring cutting tools both tough and wear-resistant. Due to the continuing Mill 16 call for cost-effective machining solutions across all manufacturing industries, these tools must also offer a low cost per part and predictable tool life. To overcome these challenges, Kennametal has developed Mill 16™ for face milling applications. The Mill 16 has a fine-pitch and medium pitch cutter body equipped with an innovative single-screw, wedge-style clamping system. This reduces time spent in the tool crib setting the tool and assures rigid, no-fail tool placement. Mill 16 is available in cutter diameters ranging from 50 mm to 250 mm.
igus (India) | Bengaluru
Kennametal India | Bengaluru Email: bangalore.information@kennametal.com | Tel: +91-80-480-57369
Email: Harish@igus.in | Tel: +91-80-49127809
Multi-axis calibrator
Toolholders
Renishaw has introduced the new XM-60 multi-axis calibrator that is capable of measuring all six degrees of freedom from a single set-up, in any orientation for linear axes. The XM-60 offers significant improvement in simplicity and time saving over conventional laser measurement techniques. As demands on component tolerances increase, manufacturers are now required to consider all error sources from the machines producing parts; angular errors as well as linear XM-60 and straightness errors. XM-60 captures all these errors in a single setup. Designed for the machine tool market, the XM-60 multi-axis calibrator complements Renishaw’s calibration product line which includes the XL-80 laser system, XR20-W rotary axis calibrator and QC20-W wireless ballbar. The XM-60 uses the XC-80 environmental compensator as correction for environmental conditions. It provides an accurate laser system that incorporates a unique technology with a patented optical roll measurement and fibre optic launch system. It has been designed to measure machine errors directly, reducing the inaccuracies which can result from complex mathematics used in some alternative measurement techniques.
SCHUNK has expanded the position of its hydraulic expansion toolholder TENDO E compact with the SCHUNK CAPTO interface. SCHUNK TENDO E compact CAPTO combines high clamping forces and excellent vibration damping with extraordinary bending and torsional strength. The precision toolholder ensures high stability even in the case of abrupt load alterations and allows unprecedented performance in a hydraulic expansion holder, while providing brilliant surfaces and significantly reducing wear. As part of the longstanding partnership with Sandvik Coromant, SCHUNK manufactures all toolholders with a SCHUNK CAPTO interface. The main feature of SCHUNK TENDO the interface is a polygonal taper, which ensures E compact CAPTO stable holding without play. The expansion sleeves and oil-filled expansion chambers damp the vibrations that occur during machining and absorb peak loads. This stabilises the engagement of the tools. In addition, the more even load profile increases the life of the spindle and spindle bearing. SCHUNK TENDO E compact CAPTO is available for the interfaces C4 (ø 12 mm, 20 mm), C5 (ø 12 mm, 20 mm) and C6 (ø12 mm, 20 mm and 32 mm).
Renishaw | Pune Email: samina.khalid@renishaw.com | Tel: +91-20-4900-1589
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SCHUNK Intec India | Bengaluru Email: info@in.schunk.com | Tel: +91-80-40538999
EM | Dec 2016
H I G H L I G H T S | C O M PA N Y I N D E X | I M P R I N T
Highlights - Jan 2017 IMPRINT Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Senior Features Writer Megha Roy megha.roy@publish-industry.net
» Metal cutting technology Achieving maximum productivity, efficiency and profitability in machining operations result from optimisation of the entire metal cutting process. The next issue will talk about a basic approach to machine tool utilisation and the latest trends and advancements in metal-cutting technologies.
» CAD/CAM CAD/CAM technologies for superior product modelling in the intelligence of designing complete product variants become more and more pertinent in future. The next issue will highlight the technology advances in this area. » Rapid prototyping Rapid prototyping decreases development time by allowing corrections to a product to be made early in the process. The forthcoming issue will look at the advances in rapid prototyping, which will eventually lead to improved product development.
» Composite machining Composite parts are finish-machined by way of turning, milling, slitting, drilling, routing, etc. Associated critical aspects must be carefully considered for successfully machining composites and the machine tool employed should be constructed accordingly. The upcoming issue will highlight these trends.
COMPANY INDEX
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An initiative of IMTMA, IMTEX is a flagship event for the Indian metal cutting industry, showcasing the latest trends as well as technological refinements from India and other global players. Tooltech is a concurrent event showcasing machine tool accessories, metrology & CAD/CAM, tooling systems and current trends in the tooling industry. The Jan issue will present the highlights of the event along with interviews of exhibitors.
Name . . . . . . . . . . . . . . . . . . . . . . .Page Hypertherm India . . . . . . . . . . . . . . . . . .77 Hyundai WIA . . . . . . . . . . Back Inside Cover ifm electronic India . . . . . . . . . . . . . . . . .59 igus (India) . . . . . . . . . . . . . . . . . . . . 2, 78 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . .72 Jyoti CNC Automation . . . . . . . . . . . . . . . .3 Kennametal India . . . . . . . . . . . . 10, 15, 78 Komet Group . . . . . . . . . Front Gate Fold, 76 KUKA Robotics India . . . . . . . . . . . . . . . .32 Mastercam India . . . . . . . . . . . . . . . . . .14 Micromatic Machine Tools . . . . . . . . . . . .29 MMC Hardmetal . . . . . . . . . . . . . . . . . . .17 MotulTech India . . . . . . . . . . . . . . . . . . .39 Perkins . . . . . . . . . . . . . . . . . . . . . . . . .11 Proceco . . . . . . . . . . . . . . . . . . . . . . . .58 Renishaw . . . . . . . . . . . . . . . . . . . . 53, 78 Roland Berger . . . . . . . . . . . . . . . . . . . .29 Rollomatic India . . . . . . . . . . . . . . . . . . .51 Schunk Intec India . . . .Front Inside Cover, 78
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IMTEX 2017 & TOOLTECH 2017
Name . . . . . . . . . . . . . . . . . . . . . . .Page Ace Micromatic Group . . . . . . . . . . . . . .63 ANCA Machine Tools . . . . . . . . . . . . . . .76 Autodesk Inc . . . . . . . . . . . . . . . . . . . 1, 16 Beckhoff Automation . . . . . . . . . . . . . . .76 Bharat Fritz Werner . . . . . . . . . . . . . . . . .37 Blaser Swisslube . . . . . . . . . . . . . Cover, 23 Chiron India . . . . . . . . . . . . . . . . . . . . .13 CII . . . . . . . . . . . . . . . . . . . . . . 10, 74, 79 Critical Manufacturing Deutschland GmbH . .42 DMG Mori . . . . . . . . . . . . . . . . . . . . . . .38 Dongguan Glorystar Laser Technology . .9, 76 EMAG India . . . . . . . . . . . . . . . . . . . 47, 77 FEMCO India . . . . . . . . . . . . . . . . . . . . .41 FLIR Systems . . . . . . . . . . . . . . . . . 45, 77 Frost & Sullivan . . . . . . . . . . . . . . . . . . .67 Grind Master Machines . . . . . . . . . . . . . .48 HEIDENHAIN Optics & Electronics India . . .61 Henkel Adhesives Technologies . . . . . . . . .28 Hoffmann Quality Tools . . . . . . . . . . . . . .31
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Name . . . . . . . . . . . . . . . . . . . . . . .Page Seco Tools . . . . . . . . . . . . . . . . . . . . . .11 Siemens PLM Software . . . . . . . . . . . . . .11 Starrag India . . . . . . . . . . . . . . . . . . . . .21 TaeguTec India . . . . . . . . . . Back Cover, 34 TAITRA . . . . . . . . . . . . . . . . . . . . . . . . .68 Taiwan Association of Machinery Industry . .57 Tyrolit India Superabrasives . . . . . . . . . . .55 UCAM India . . . . . . . . . . . . . . . . . . . . . .33 UCIMU . . . . . . . . . . . . . . . . . . . . . . . . .12 United Grinding Group . . . . . . . . . . . . 12, 52 University of Northern Iowa . . . . . . . . . . .18 UTech Associates . . . . . . . . . . . . . . . . . .49 Vargus India . . . . . . . . . . . . . . . . . . . . . .6 Varroc . . . . . . . . . . . . . . . . . . . . . . . . .26 VDMA . . . . . . . . . . . . . . . . . . . . . . . . .30 VDW . . . . . . . . . . . . . . . . . . . . . . . . . .12 Yamazaki Mazak India . . . . . . . . . . . . 24, 25 YG1 Cutting Tools . . . . . . . . . . . . . . . . .4, 5
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EM | Dec 2016
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HYUNDAI WIA INDIA PVT. LTD. #4/169, Rajiv Gandhi Salai, (OMR), Kandanchavadi, Chennai - 600 096, Tamilnadu, India Tel. +91 76049 03348 e-mail. sales@hyundai-wia.com, service@hyundai-wia.com http://www.machine.hyundai-wia.com
during IMTEX 2017 2017. 1. 26 ~ 2. 1 Booth No.
Hall 4, Stall No. A134
RNI No. MAH/ENG/2010/34603