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E D I TO R I A L
E D I TO R I A L
Driving profound changes‌! The emergence of smart, safe and sustainable manufacturing is driving profound changes in the global manufacturing industry. Smart manufacturing will transform industry in a similar way to how the strategic use of information technology transformed the business model and consumer shopping behaviour, for example, at Amazon.com. Smart manufacturing will deliver a similar, extraordinary shift in the competitive landscape of the global industry. It will reverse the flow of the 100-year-old industrial supply chains that forced consumers to accept whatever was mass produced. Flexible factories and demand-driven supply chains will change manufacturing processes to allow manufacturers to customise products to individual needs. These will be game-changing, market-disruptive innovations in products and processes. The question is whether India is ready for this? What change will this bring in the Indian industry? I got an opportunity to deliberate on this and other similar issues in a panel discussion, conducted recently during the Symposium on Smart Manufacturing, organised by IMTMA, with EM as the Media Partner. Almost everyone in the discussion was of the opinion that we have to first concentrate on making Indian factories present-ready and then develop a roadmap for making them future-ready. The software service sector is the key knowledge component in India, and since Industry 4.0 combines traditional manufacturing with IT and IoT, India can become the major industrial hub in Asia if it plays its cards right. I am sure together we can achieve this goal, as soon as possible! I would be happy to receive your thoughts/feedback on this.
EDITORIAL ADVISORY BOARD
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net Sonali Kulkarni President & CEO Fanuc India Satish Godbole Vice President, Motion Control Div Siemens Ltd S Ravishankar Managing Director DMG MORI India Vivek Sharma Managing Director Yamazaki Mazak India
Vineet Seth Managing Director India & Middle East Delcam Plc
Dr K Subramanian President, STIMS Institute, USA Training Advisor, IMTMA
N K Dhand CMD, Micromatic Grinding Technologies
Raghavendra Rao Vice President Manufacturing & Process Consulting Frost & Sullivan
Dr P N Rao Professor of Manufacturing Technology, Department of Technology, University of Northern Iowa, USA
Dr Wilfried Aulbur Managing Partner Roland Berger Strategy Consultant
Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
EM | Mar 2016
7
CONTENTS
Market
10
Management
NEWS
INTERVIEW 30
VIEWPOINT 16
Focus
Moving the needle‌
DIE & MOULD
“India has to become a manufacturing service base for MNCs�
38
The article highlights the technology behind robotic deflashing and how it can be successfully deployed across the aluminium die casting industry
Interview with Ranjit Date, President & JMD, Precision Automation & Robotics India
The feature compiles the views from industry stalwarts on the implication of the Union Budget 2016-17 across the Indian manufacturing sector
Breaking the moulds‌
ROUND-TABLE EVENT REPORT 78
Platform for forming technologies
A post-event report on IMTEX FORMING 2016, held recently at Bengaluru 81
32
Are factories in India future-ready?
The round-table discusses present situation and the factors to be considered enabling Indian factories to be future-ready
Adopting new grinding practices
A post-event report on United Grinding Motion Meeting 2016, recently held at Thun, Switzerland
22
COVER STORY Manufacturing trends
The feature provides an in-depth insight on the industry growth in 2015, as well as touching upon the 2016 industry trends, including new technologies
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EM | Feb 2016
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CONTENTS
Technology
HIGH SPEED MACHINING 42
Metalworking fluid performance in aluminium HSM
MANUFACTURING IT 66
The article discusses the differences in aluminium machining performance obtained at high versus low cutting speeds, as well as the influence of metalworking fluid in HSM
Program execution excellence in aerospace
A read on how a process-driven approach helps aerospace companies shift decisions earlier in the lifecycle and integrate manufacturing considerations throughout each phase of the lifecycle
MILLING MACHINES 48
Expanding capacity & capability
70
An application story on how a mould manufacturer expands capacity & capability with automated hard milling system
Applying Big Data in manufacturing industry
The article discusses the characteristics of Big Data and illustrates six sample Big Data use cases in the manufacturing industry
New Products 84 Oil-free compressor; 5-axis machining solution; Gear hobbing machines; Gear shaping machine; 85 Scanning probes; Quick jaw change system; Taper-face toolholders; Cylindrical grinding machine; 86 Modular system for profile machining; Precision metalworking tools; Cassette sealing solutions
TEST & MEASUREMENT 54
Touch probe halves production costs
An application story on how laser measuring system for tool measurement, touch probe and measurement software helps to produce optimum quality at the milling centre 60
Process control with gauging system
An application story on how gauging system helps High-Tech to reduce the cost of producing aerospace parts by 27% and meet the cycle requirements for the part
EM | Feb 2016
SPECIAL FEATURE 74
Simulating welding process
The article illustrates on how Owens Corning shortens design cycle and optimises component design with the help of CD-adapco’s simulation software
Columns 07 08 88 88
Editorial Contents Highlights – Next issue Company index
9
MARKET | NEWS
IMTMA completes 25 batches in Finishing School
JUNKER Group awarded SGM Technology Prize for 2nd time
The Finishing School in Production Engineering, an initiative by the Indian Machine Tool Manufacturers’ Association (IMTMA) to train engineers on all aspects of production engineering, has recently completed 25 batches of training, ever since it began with the first batch in September 2010. Expressing his views on the impact on manufacturing sector, P G Jadeja, President, IMTMA, said, “A well-trained manpower is essential to give strong support to manufacturing and increase productivity. The The course enhances the skill-sets IMTMA Productivity Institute has of fresh engineers in mechanical been conducting a Finishing engineering School to train engineers on all aspects of manufacturing with CNC technologies.” Concurring with Jadeja’s statement, V Anbu, Director General, IMTMA, said, “The course enhances the skill-sets of fresh engineers in mechanical engineering. We give students a blend of theory and practical sessions, hands-on training on CNC turning and machining centres with industry visits. It acts as a major cost effective option for industry in training their fresh recruits and ensuring that their engineers are prepared to take up job responsibilities.”
The JUNKER Group was recently felicitated with the ‘Leading Technology Award’ from SAIC General Motors (SGM). SGM presents this prestigious award to its best suppliers from around the world in a number of categories. The JUNKER Group is the only European machine builder amongst the winners to have received this award twice. On receiving the award, Rochus Mayer, CEO, JUNKER Group, said, “This is a confirmation of the expertise, knowhow and efficiency of SGM presents this prestigious award to its best the JUNKER Group.” In suppliers from around the world in a number of order to achieve this categories degree of success both now and in the future, the company invests both capital and capacity into the research and development of new technologies and processes. “We are number one and we aim to maintain our pole position in the field of grinding”, adds Mayer. The company is the partner worldwide in areas of grinding & air filtration technology, and its innovative solutions are trusted by acclaimed automotive manufacturers.
CII Maharashtra elects new council
Building Future Ready Factories
Sunil Khanna, President & MD, Emerson Network Power, India, has been elected as the Chairman, CII Maharashtra State Council and Rishi Kumar Bagla, Director, OMR Bagla Automotive Systems India, has been elected as Vice Chairman of the CII Maharashtra State Council for the year 2016-17. The theme for CII Maharashtra for 2016-17 is ‘Building Maharashtra: Innovation, integration and investments for the state.’ Speaking on the new management, Khanna shared, “Following the Hon'ble PM’s clarion call to ‘Make in India’ and the Hon'ble Chief Minister's focus on enhancing ease of business, manufacturing in the state has come into focus. CII Maharashtra wants to work towards transforming the state into a Sunil Khanna, President & global manufacturing hub with a special MD, Emerson Network Power, thrust on ease of doing business, India, has been elected as the innovation, integration and investments.” Chairman, CII Maharashtra Maharashtra has always led India’s industrial development scenario and continues to attract the largest quantum of investments— domestic & foreign. With the new council body, it is expected that the manufacturing sector of Maharashtra will be enhanced.
Frost & Sullivan recently announced the launch of the 2016 edition India Manufacturing Excellence Awards (IMEA). Through the IMEA platform, Frost & Sullivan has been accelerating the manufacturing competitiveness of the country through knowledge sharing, benchmarking and assisting adoption of best manufacturing practices. On the occasion, Nitin Kalothia, Director – Manufacturing & Process Consulting, Frost & Sullivan, said, “The future of manufacturing lies with nations who would build capabilities to collaborate and compete at global levels. Choice of appropriate technology for the manufacturing philosophy aptly supported by strong innovation culture will be the key characteristics of future-ready factories. The company identifies ‘Future Ready Factories’, in each industry sector that display best practices in manufacturing. The most coveted recognition ‘The Indian Manufacturer of the Year’ award, also to be held, goes to the company that has demonstrated excellence and leadership across the entire value chain. The IMEA has been at the forefront of celebrating excellence and implementation of best practices in manufacturing units. The event to be held on December 9th, 2016 at Hyatt Regency, Mumbai, will be the platform for recognising these companies and celebrating their stellar achievements. The IMEA banquet will see an elite roster including the crème-de-la-crème of the Indian manufacturing sector.
10
EM | Mar 2016
MARKET | NEWS
BFW inaugurates R&D centre in Bengaluru Bharat Fritz Werner (BFW) recently inaugurated the Dr Kalam Center for acquired the turning business of Chennai-based engineering firm Proteck Innovation at its premises in Bengaluru. This world class R&D centre, which Machinery 9 months ago. has been set up with an According to A K investment of `25 Kothari, Chairman, million, is a step forward BFW, “Our Group towards increasing companies, stress a BFW’s global footprint, lot on R&D irrespective while simultaneously of the industry to retaining its position in which they cater. India. The innovation Innovation is at the centre is spread over centre-stage of our 3000 sq feet, and was corporate philosophy. inaugurated by Shri A S At BFW, we believe our Kiran Kumar, Chairman, The R&D centre is a step forward towards increasing BFW’s global footprint customers deserve Indian Space Research innovative machine Organisation. tools and, we are committed to making the right investments to reinforce Scientists at this centre will work on core research to improve and customers’ trust in us.” develop energy efficient and alternative material machine tools. Also Further, highlighting on R&D, Ravi Raghavan, MD & CEO, BFW, said, present on the occasion were G K Moinudeen, Director & Head, Karnataka “We recognise our responsibility as one of the leaders and being a pioneer State Office, CII and J Sheik Saleem, grandnephews of Dr Kalam. in this industry, we are striving to drive progress by singularly focusing on Speaking on the occasion, Kumar said, “R&D is vital for India’s R&D. Our ambition is to be a strong global player and research is the manufacturing capabilities. At a time when we are looking at Indian backbone of our plans. In the coming years, we will continue to invest in manufacturing moving to the next level, BFW’s approach is laudable.” BFW cutting edge technology.”
Making zero-defect & zero-effect a way of life Kaizen Institute Consulting Group (KICG) recently hosted Indizen—The Excellence Inside tours (visits to world-class facilities/factories) and National Convention for Operational Excellence at Pune. This year, Indizen National Operational Excellence (OE) Case Study Competition. Senior 2016 returned in its 7 th officials from HDFC Life, Mahindra, edition with the theme, Daimler, Dr Reddy’s, ITC, Marico, ‘Making Zero Defect & Zero Thermax, Bosch, Sandvik Asia, etc Effect a Way of Life’. The participated in the event. The keynote event witnessed around speakers of the event were Prakash M 200 senior industry Telang, Chairman, Tata Hitachi professionals on the same Construction and former MD—India platform. Operations, Tata Motors; Tony Henshaw, Speaking on the event, Chief Sustainability Officer, Aditya Birla Vinod Grover, Founding Group, and R Mukundan, MD, Tata Director, Kaizen Institute Chemicals. Consulting Group, India, Indizen 2016 also saw the launch of said, “We have always KMAX (Kaizen Institute’s Maturity believed that to fully Assessment for Excellence), a new capitalise on domestic and The event saw the launch of the KMAX 2016 at the 7th National Convention on initiative by Kaizen Institute Consulting global opportunities and in Operational Excellence by Kaizen Institute Consulting Group (KICG) Group, India, to identify and reward order to promote Indian companies for operational manufacturing excellence, various platforms must be created – platforms excellence. Manufacturing facilities of companies across sectors and that offer an opportunity to share, learn and benchmark. This is how ranging from small to large sized businesses that have been practicing Indizen was born.” any operational excellence system for at least two years will be eligible to The two-day event comprised of stimulating knowledge sessions, participate in the inaugural edition of KMAX.
12
EM | Mar 2016
MARKET | NEWS
Manus Award at Auto Expo 2016 Every two years, interesting applications using polymer plain bearings are or maintain continually. Moving ahead, a screening device from Tuscano chosen for the manus awards represented by igus. These applications Equipment for diaganosing breast cancer secured a second place. In this stand out due to their technical and application, the thermal radiation of economical efficiency as well as the the breast is recorded and a thermal creativity and boldness of the map is created. Thanks to the developer. The entries from all over installed iglidur PRT slewing ring the world demonstrate the diverse bearings, linear slides SLW & ZLW, range of application possibilities for the machine runs smoothly with low polymer plain bearings, from noise. The bronze manus went to prototype to serial application. Most SRG Machines for egg sorting of the applications for the manus machines. These machines 2015 competition came from India. segregate eggs into four different From these, the three most innovative weight classes. A lubrication-free applications were chosen in a local and dirt-resistant drylin N system manus competition and the prizes from igus was installed here, which were awarded during the recently is resistant to corrosion and thus held Auto Expo 2016 at New Delhi. perfect for use in the machines. With At the event, the manufacturer (L to R) Mihir Garware (3rd from left), V Mahesh Kumar (4th from left) and this application, that ensured high ATS ELGI received the golden manus Sudhan Chandrasekaran (5th from left) receiving the local manus awards hygiene standards by eliminating award. The company relies on robust lubrication SRG Machines won the iglidur bearings for the underbody washing system at its carwash. Since third place. The competition awards bold applications with plastic bearings, these polymer plain bearings do not corrode, downtimes at the carwash are which distinguish themselves through technical and economic efficiency, reduced. Besides, the self lubricating bearings eliminate, the need to grease creativity and surprising results.
TAGMA organises the International Tooling Summit The International Tooling Summit, brought forth in association with TAGMA technology and regulations. This offers growth opportunities to tooling India, was recently held at Mumbai. India, today, stands amongst the twenty industry, which is known for low cost manufacturing, but need to build largest producers of cutting tools in the world. The tooling industry as per world-class capabilities in design & innovation, robust processes, and the industry survey is estimated to be reduce product development time, while `15,100 crores for 2014-15 out of keeping focus on quality.” which close to `8,000 crores is met As a part of the panel ‘Making India indigenously. Sharing his views on the the manufacturing hub of the world’, event, Kamal Bali, MD, Volvo, said, Dr Wilfried G Aulbur, Managing Partner, “‘Make in India’ strikes at the root of the India, Chairman Middle-East & Africa, critical shortcomings in manufacturing, Head, Automotive Asia, Roland Berger namely the need for higher valueStrategy Consultants, said, “National capture in India. The tooling industry is manufacturing industries depend on rightfully positioned to fulfill this high-performing tool manufacturers to shortcoming by facilitating higher value bring products to market. Meeting quality, addition, thereby, creating greater performance, aesthetics and cost targets economic activity.” is impossible without reliable partners on The event saw several thought (L to R) Marya Corum, Director, Cosma International; Anoop the machine tool side. India’s machine provoking panel discussions, as a part of Chaturvedi, Sr VP – Production Engineering, Maruti Suzuki India; tool manufacturers have moved up the which Anoop Chaturvedi, VP—Production Prabhakar Kadapa, MD & CEO, AVTEC; Dr Wilfried Aulbur, Managing value chain as the increasing success in Engg, Maruti, said, “The Indian Partner & CEO, Roland Berger Strategy Consultants India and Kumar import substitution demonstrates. automobile/manufacturing industry is Kandaswami, Partner-Manufacturing, Deloitte India However, to be true partners in making rapidly evolving as a key global player. ‘Make in India’ happen, further This rapid growth coupled with globalisation has led developments in improvements across a number of process parameters are necessary.”
14
EM | Mar 2016
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MARKET | VIEWPOINT
Moving the needle... Underlining an improvement across the investment climate in India, the Union Budget 2016-17 was recently proposed addressing infrastructure development, skill enhancement, ease of doing business and tax reforms. The feature pictures a compilation by sharing the views of industry stalwarts on the implication of budget in the manufacturing sector. Read on...
Maria Jerin Features Writer maria.jerin@publish-industry.net
â&#x20AC;&#x153;A welcome progressive moveâ&#x20AC;? The budget is pro-rural, pro-farmer, pro-common man. They have rightly seen the need to increase the income of the people who virtually live on grass roots and are the grass roots of the country. This in itself will generate tremendous GDP. We acknowledge the concessions given for the export sector and simplification of tax administration and litigation. The Finance Minister has gone into great details in the agriculture sector when he has acknowledged the importance of honey in the economy and it is our wish that the sweetness and flavour of honey permeates throughout the economy. He has also promised light to all the villages throughout India in a defined timeline manner. It is a welcome progressive move to give warmth to the rural people.
Farrokh N Cooper, CMD, Cooper Corporation
16
EM | Mar 2016
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MARKET | VIEWPOINT
“Balanced perspective on the economy” Indian economy has recorded a steady growth amidst the uncertain economic prospects across the globe. The 2016-17 budget offers favourable and stable opportunities for India’s manufacturing sector. Infrastructure sector has received a huge impetus in the budget with roll out of `2.21 lakh crores for roads, railways and other facilities, which will spur manufacturing. `27,000 crores allocation to roadways will boost commercial and earth moving segments. The rail budget proposal to set up 2 new locomotive factories, 3 freight corridors and a first ever rail-auto logistics hub will spur manufacturing and will bring a boost to machine tool industry. The government’s commitment to empower farming sector and rural areas will surely lead to higher domestic consumption and demand of manufactured goods. I truly feel that government’s initiative and focus to uplift SMEs will account for growth in manufacturing sector as SMEs contributes approx 17% to our national GDP and generates approx 40% of employment. Reduction in corporate tax for small & medium enterprises will aid the production capacity of SMEs. Disbursement of `1,80,000 crores for MUDRA scheme will also ultimately benefit the SMEs. Setting up of National Board of Skill Development by allocating `1700 crores for establishing 1500 skill development centres will ensure availability of skilled manpower for the manufacturing industry. To sum up, budget 2016-17 presents a balanced perspective on the economy.
Parakramsinh Jadeja CMD, Jyoti CNC Automation, Vice President, IMTMA
“Step in the right direction” The budget seems to be a positive step in the right direction, with tax benefits to start-ups in the manufacturing sector. Revision in customs & excise duty rates would also be beneficial in sectors such as defence production, IT hardware and capital goods. The MRO sector in aerospace is likely to gain through complete exemption on customs duty on spares imported for undertaking repairs. With the push in aerospace sector that the industry has been eyeing for a while now, this should increase the potential for business. Duty benefits in renewable energy is also a very positive step. Finally, duty exemptions have been reduced on several military equipment, which shall provide a fillip to ‘Make in India’ initiatives as well as a level playing field for Indian manufacturers. The budget’s focus on infrastructure development is another very important and positive feature. I am pleased with the budget. The devil, however, lies in successful execution. I have immense faith in our system as it stands today, to propel India on the path of economic progress, strength and growth.
Vineet Seth Managing Director— South Asia & Middle East, Delcam Ltd
“Roadmap for futuristic and sustainable growth” The budget shows immense promise. A net investment of `97,000 crores in the road sector has been proposed and a total of nearly 10,000 kms of national highway has been approved by the government. With this proposed advancement in the infrastructure sector, the country shows that it is now ready for the advent of smart transport options. These initiatives are truly the right ones for stimulating the off-highway products where ZF is present and will be glad to contribute. Additionally, the setting up of 1500 multi-skill training institutes would help auto component manufacturers in acquiring skilled talent. The Finance Minister has also promised to enforce the necessary revisions in Motor Vehicle Act and open up the road transport sector in the passenger cars segment. All in all, we are looking forward to this financial year as this budget gives us the motivation to continue on our path of futuristic and sustainable growth.
Suresh KV, Country Head of ZF in India and Head of ZF India
18
EM | Mar 2016
MARKET | VIEWPOINT
“Focussed on growth and development”
V Anbu Director General IMTMA
It is heartening to note that the Union Budget has given due importance to the agriculture and the rural sector along with focus on infrastructure. The industry welcomes the government’s move to control fiscal deficit for FY16 at 3.9% and FY17 at 3.5%. Setting up of the National Board of Skill Development Certification in partnership with academia and industry will help the industry to get skilled manpower. Changes in customs and excise duties on certain inputs to reduce costs and improve competitiveness of the domestic industry across many sectors such as electronics, automobiles, defence and aviation will support ‘Make in India’. Reduction in corporate tax for small enterprises will aid the production capacities of SMEs. Development of roads, railways and airports will help ease freight movement and create job opportunities. Allocation of funds for the rural sector will lead to higher domestic consumption, industrial production and demand for manufactured goods. Introduction of entrepreneurship development courses and 100% deduction of profits for 3 out of 5 years for start-ups set-up during 2016 to 2019 will encourage entrepreneurship. In light of the slowing down of global economy the measures suggested by the budget are expected to lead to development, growth and fiscal consolidation.
“Balancing growth with fiscal prudence”
Kamal Bali Managing Director Volvo India
This is one of the most thoughtful, detailed and well-rounded budgets in a long time, with big ideas aimed at addressing the critical and fundamental imperatives of building an inclusive, equitable and sustainable India, by particularly focussing on the vulnerable areas of the society. In some ways, the budget seeks to correct the anomalies in India’s very poor Gini coefficient (which suggests the level of deviation of distribution of income amongst households), where India ranks a poor 135 amongst 187 rated countries. The budget lays stress on the insightfully selected areas for transforming India with substantially increased allocations on agriculture & farmer’s welfare, rural infrastructure & digital literacy, social sector (health care), education, skills & job creation and massive outlays and investments on roads and power infrastructure, whilst keeping the fiscal deficit number on track. A lot of focus has been on creating sustainable public transport to transform our cities and towns. Overall, considering the volatile global macroeconomic landscape and continuing headwinds, it is indeed a commendable budget and full marks to the FM for chartering out a well thought out course, balancing growth with fiscal prudence. Courtesy: ET Edge, International Tooling Summit
“Improving ease of doing business” We welcome the focus of the budget on rural, social & skill development, making it an inclusive budget as also steps, which have been proposed to simplify tax laws and improve ease of doing business. We also welcome the increased investments in railways & highways and hope that the government acts upon rationalising corporate tax & interest rates to encourage the private sector spending.
Sunil Mathur MD & CEO Siemens Ltd
20
EM | Mar 2016
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C O V E R S TO R Y
TECHNOLOGY
MANUFACTURING TRENDS
I m a g e s c o u r t e s y : Siemens
The 2016 outlook
Last year had turned out to become a pivotal year for the global manufacturing industry. As such, today, manufacturing plants are no longer dirty, dark and dangerous places to work. In fact, they house some of the world’s most sophisticated equipment, are managed using complex data and software, and run on powerful technology systems. As the concept of a ‘smart factory’ becomes more of a reality with years, the feature provides an in-depth insight on the industry growth in 2015, as well as touching upon the 2016 industry trends, including new technologies. A read on... 22
Pete Carrier Senior VP and MD—Asia Pacific Siemens PLM Software
EM | Mar 2016
TECHNOLOGY
In 2015, it was observed that the markets within the AP region had evolved away from low-skill, low-cost production. The manufacturing climate has seen several contractions across countries such as China, Korea and Singapore – and it is forecasted that the situation will not improve anytime soon. Implementing high technology systems to run effective and intelligent operations will aid in enabling success in the manufacturing sector, the region is moving ahead with capitalising on the ASEAN Economic Community (AEC) that enables greater access to markets and freer flow of goods, services and labour. With ASEAN’s efforts to lower barriers for organisations to regionalise, it is timely for businesses to upgrade their capabilities by investing in smart technology or contemplate on plans for regionalisation. Asia Pacific is moving ahead to forge a strong regional supplier ecosystem and adopting disruptive technologies that will change the way people live and create products.
Manufacturing in India India’s ‘Make in India’ campaign, introduced in September 2014 aimed at facilitating investments, encouraging innovation and building high-class manufacturing infrastructure is expected to boost manufacturing activities in key sectors including automobile, auto components, electronics & electricals, capital goods, railways, aerospace and defence. E-auctioning of coal blocks, curtailment of the discretionary powers of labour inspectors and implementation of a singlewindow compliance process on labour related issues and implementation of the Goods and Services Tax (GST), as promised by the current government will go some way in accelerating growth in the manufacturing sector and improving the likelihood of their achieving the National Manufacturing Policy (NMP) targets. Coupled with 3D printing technologies that could help overcome shortcomings of geometry, digital manufacturing and Smart Cities projects can boost the ‘Make in India’ initiative significantly.
EM | Mar 2016
C O V E R S TO R Y
Asia Pacific region The AP region as a whole remained attractive as it offers a diverse demographic base and favourable business conditions – a growing labour supply, improved productivity, increasing affluence, more attention to education and training, and with the implementation of AEC, the region holds the strongest potential for growth. If it were a single country, AP would be the seventh-largest economy in the world with a combined gross domestic product of US$ 2.4 trillion. It’s already the world’s fourth-largest exporting region, accounting for 7% of global exports – Thailand is a leading vehicle and auto-parts exporter, Philippines enjoys a thriving business-process outsourcing industry, while Vietnam is strong in apparel and textiles. With AP’s unique manufacturing industry – dynamic countries such as Australia & Singapore positioned as advanced design hubs, and Vietnam and Thailand as production hubs – the cross-collaboration divide is a result of Australia and Singapore having better infrastructure, and more advanced design capabilities and resources, while the emerging countries having lower labour costs. However, the labour crunch in Singapore remains bleak due to the tepid global business conditions that have contributed to the decline in the sector. In order to overcome this hurdle and the sluggish growth rate, the government needs to show increased recognition to smaller SME firms by giving them a shot at contributing to government projects.
2016 market outlook and trends The realisation of innovation – smart innovation that enables a model-based enterprise in which smart product development will have additional dimensions of connectedness and cognitive capability – is the realisation of automation and production in the Digital Enterprise for which digitisation is an approach to innovation. Through realising innovation only
23
C O V E R S TO R Y
TECHNOLOGY
Through realising innovation only manufacturing organisations of today can better confront complex business risks and disruptors of tomorrow
manufacturing organisations of today can better confront complex business risks and disruptors of tomorrow. Customers will benefit in this environment by harvesting data/information in the connected world – a generation of products and services that support the Industrial Internet of Everything (IIoE), and more specific in which the factory and production systems reach new levels of intelligence and autonomy. Manufacturing centres in the region are facing increased levels of competition, and many are looking for ways to optimise productivity and innovation to gain a competitive advantage. Emerging Southeast Asian markets such as Vietnam and Thailand continue to offer high-quality and more costcompetitive alternatives, affecting regional competition across the manufacturing landscape.
Towards digital transformation Digital business transformation for manufacturers will continue to evolve, with the supply chain and logistics as one of the core value drivers. Organisations will build towards the ‘second pillar’, becoming entirely digitalised, spurring on competiveness from countries such as China and India with their ‘Make in India’ and ‘Make in China 2025’ initiatives. Predictive modelling is expected to gain momentum amongst manufacturing sectors. Predictive analytics – the area of data mining concerned with forecasting probabilities and trends – will be utilised create a statistical model to determine future behaviour. With China’s ‘Internet Plus’ initiative announced in March 2015 as a driving force, many conventional businesses will connect to the internet initially, followed by digitalisation of IT systems, to increase their competitiveness. With digitalisation
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increasingly taking hold of the manufacturing sector brings forth a new wave of security concerns and issues. Increasingly, manufacturers are beginning to view data security, mobile device management and cloud computing risks top barriers to realising the value of the Internet of Everything (IoE).
Upcoming trends Internet of Everything (IoE): IoT (Internet of Things) has evolved into IoE over the past year, due to involvement from cars to wearables. IoE is gaining traction and becoming more personalised, not just affecting devices. A clear value in connecting products to the internet – manage the connection of the [product] operations world and production world to optimise innovation. A report forecasts that the Global IoE market will grow up to 15.3% throughout 2015-2020. This growth is attributed to the rising demand for mobile applications from enables. Manufacturing, consumer electronic and retail verticals are major contributors to the IoE growth. Big Data: In this new world of intelligent, connected products, data collected about a product’s operating environment and about how customers use the product (utilisation) can be tapped by product designers as they consider improvements for the next generation (ideation). But the value of that information is only optimised when designers apply intelligence and action to this data to improve product automation and production (realisation). IDC recently forecasted that the Big Data technology and services market will grow at a 26.4% compound annual growth rate to $41.5 billion through 2018, or about six times the growth rate of the overall information technology market. Additionally, by 2020 IDC believes that line of business buyers will help drive analytics beyond its
EM | Mar 2016
C O V E R S TO R Y
TECHNOLOGY
Manufacturers can utilise data analytics to optimise factory operations that maximises equipment utilisation and product quality
historical sweet spot of relational (performance management) to the double-digit growth rates of real-time intelligence and exploration/discovery of the unstructured worlds. Digital manufacturing: A key point of integration between PLM and various shopfloor applications and equipment, enabling the exchange of product-related information between design and manufacturing groups. Manufacturers can utilise data analytics to optimise factory operations that maximises equipment utilisation and product quality. With these new supply-network management tools, organisations have a clearer picture of raw materials and manufactured parts that flow through the network that could aid departments in improvising factory operations and product deliveries to enhance efficiency. Through digital manufacturing, smart connected products are also able to share real-time customer experience to product managers that allows them to anticipate or manage demand and maintenance needs. Furthermore, through mining data engineers can gain new insights into why certain equipment modes fail and move onto making continuous improvements in its reliability. For example, McKinsey suggests that a major metal plant could expect to use condition monitoring and predictive maintenance, in conjunction with process controls and automated material tracking that is made possible with Big Data analysis. This could drive up to a 30% increase in production without having to chalk up substantial operational costs. 3D Printing: The past year has seen improved resolution in 3D printing and the ability to print in new materials. It is expected that there will be increased affordability in the upcoming year, addressing complex issues within the healthcare sector particularly. This disruptive technology is quickly is displacing
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automation equipment, including machine vision, motion control and robotics. In a report conducted by Wohlers Associates, the worldwide 3D printing industry is now expected to grow from $3.07 bn in revenue in 2013 to $12.8 bn by 2018, and exceed $21 bn in worldwide revenue by 2020. 3D printing enables manufacturers to shrink their supply chains by saving product development time in areas such as developing prototypes to the mass production of final products. This disruptive technology allows increased customisation offerings to consumers with varying expectations and preferences. 3D printing also wields potential for organisations to rethink on their approach to keeping inventory, especially in the case for low-volume, obsolete parts that are still required to be made available to consumers. Printed parts that are currently warehoused could potentially save manufacturers—especially those with globally diverse distribution systems—logistics costs and get products to customers faster. Next-shoring: The rise of an technical labour force in order to manage supply chain operations — combined with rising wages in Asia, higher shipping costs and the need to accelerate time to market to meet retailer and consumer demands has led to more companies shifting their manufacturing strategies from outsourcing overseas to developing products closer to where they will be sold. Thanks to heightened communicative technology and efficient transport systems, the next-shoring business model is becoming increasingly viable for manufacturing firms. It is now possible for organisations to develop multiple, collaborative innovative centres while maintaining production centres in close proximity to specific markets. This provides a flexible solution to the varying cultural and market trends – ultimately increasing accuracy and reducing lead times.
EM | Mar 2016
Headquarters, Hasle-Rüegsau, Switzerland
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Blaser Swisslube India Pvt. Ltd.
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High-quality metalworking fluids.
C O V E R S TO R Y
TECHNOLOGY
APAC is emerging as a leader in robotics adoption due to the economic progress in the region fuelling manufacturing
Through marrying supply and demand, next-shoring allows emerging markets to exploit proximity in order to reach their stakeholders. In the case of China with its recently implemented minimum wage laws, businesses realise that they need to take a more flexible approach in their supply chain management to accommodate a more global customer base precipitated by rises in purchasing power. By incorporating ASEAN Economic Community (AEC) and next-shoring, regional policies will help promote free movement of goods and services across the area. Mobility manufacturing: The power and potential of cloud computing, properly leveraged and deployed, can have a significant impact on the PLM industry. In AP, mobility is gaining traction due to high mobile device penetration rates and is expected to achieve 33% of growth by 2017. This will certainly have a strong impact on the manufacturing sector in the region. Mobility in manufacturing has tremendous potential for streamlining production processes and delivering significant time and cost savings for the industry. Shopfloor management, supply chain management and business intelligence are but a few of the avenues that are seeing increased adoption. It can be employed to processes along the entire design and production cycle for bringing greater accuracy, speed and efficiency to manufacturing outcomes. To industrial manufacturing CEOs, the top three technology priorities are mobility (73%), cybersecurity (72%) and data mining analysis (70%). However, there are challenges that may hinder the growth in Asia Pacific. Costs and security risks
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remain the top challenges the region faces in mobility adoption. Despite this, mobility in manufacturing has tremendous potential for streamlining production processes and delivering significant time and cost savings for the industry. Shopfloor management, supply chain management and business intelligence are but a few of the avenues that are seeing increased adoption. Robotics: PwC observes that robots are now equipped to handle a wider variety of jobs in multiple industries. They can help companies complete tasks that previously required precision that only human beings could offer. This would impact the manufacturing industry in markets where skill deficit and ageing population pose major challenges for the sector. According to recent reports, APAC is emerging as a leader in robotics adoption due to the economic progress in the region fuelling manufacturing. The rise of mobile adoption has spurred users to take up robotics due to the ubiquity of smartphones and tablets that has made it easier to develop robots thanks to consumer and office applications. For example, mobile devices could offer manufacturing design departments the opportunity to â&#x20AC;&#x2DC;outsourceâ&#x20AC;&#x2122; computing tasks to companion devices, which allows software developers to produce app-controlled robots at more accessible price points. Because of their enhanced precision, fewer errors are made during the manufacturing process that results in less wastage and is capable of producing higher quality products that comes with fresh variations assisting organisations in disrupting the market. â&#x2DC;?
EM | Mar 2016
MANAGEMENT | INTERVIEW
“India has to become a manufacturing service base for MNCs… ” …says Ranjit Date, President and Joint Managing Director, Precision Automation & Robotics India (PARI), in this interaction with Shekhar Jitkar & Megha Roy, while discussing how line automation is aligned with ‘Make in India’ to help transforming SMEs to global manufacturing centres. Excerpts… How will ‘Make in India’ help transforming SMEs to global manufacturing centres of the Indian or global MNCs? The idea of ‘Make in India’ is to gather manufacturing expertise & infrastructure to such high levels that effectively meets the manufacturing needs at a higher value spectrum. To make ‘Make in India’ a success, India has to become a manufacturing service base for multinationals, be it Indian or global. It may not be done by only Indian entrepreneurs, but also by a German company, for example, by having a manufacturing base in India and catering to the requirements from all across the globe from India. This will make the needs of manufacturing industry enhanced and the entire picture will shift to a different business model. That’s where the paradigm changes—it’s not just doing a little more of what we are doing today, but doing things differently. This will also provide an opportunity for some SMEs to strategise effectively so as to meet the standards of the global manufacturing value-chain. Can you highlight on the Indian manufacturing standards versus global standards in terms of manufacturing capacity,
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R&D, innovation & technology breakthrough? With automation as one of the majors, India is currently at least 50% behind, as compared to the developed nations. Human productivity issues and defect rates are higher in India. In terms of products and corresponding R&D and innovation on the products, it’s not a fair comparison. To meet the global players, R&D, innovation and expansion of products should meet the expectations of the global market. This is also a challenge for ‘Make in India’. To meet this, we have to innovate and invest more in terms of R&D, manufacturing capacity & facilities, quality of facilities, process capabilities of the manufacturing capacities, etc. With line automation, there is a paradigm shift in the business model today. What should be the approach in this area? Line automation caters to the end-to-end requirements and challenges of the manufacturing industry through automation. It integrates the automation solutions, not only to solve local errors, but is also responsible for end-to-end delivery. This way,
EM | Mar 2016
INTERVIEW | MANAGEMENT
“The idea of ‘Make in India’ is to gather manufacturing expertise & infrastructure to such high levels that effectively meets the manufacturing needs at a higher value spectrum” Ranjit Date
the manufacturer is guaranteed to have many products coming out of the line, irrespective of the product mix & variety, attrition profile, process variabilities, issues of manual errors, etc, and the manufacturer is able to deliver his global commitments as a part of the model. Line automation delivers assured process, quality and rate of delivery, without any variabilities associated with human process. Hence, the paradigm shift is moving from a revenue cost model to a capital investment model. The ‘Make in India’ model is designed for export products and generally supported by foreign exchange reserves. Since the cost of capital goes down drastically for the foreign exchange reserves, the revenue effect of the capital cost can be controlled by ‘Make in India’, and therefore, effectively reduces risks. It also provides longer time to ramp up volumes, because the additional revenue expenditure of manpower, its costs & defects are not incurred in the process. Can you brief us on your company’s latest offerings to support advanced factory automation systems? How does PARI help to enhance productivity and achieve the manufacturing goals of its customers? PARI’s strength in terms of manufacturing automation covers precision components, machining & assembly processes and related quality assurance processes required in the manufacturing world today. As such, we focus on machining, assembly and its various quality assurance parameters like quality control, anti-falsing, in-process verification, etc. We offer turnkey solutions by delivering good part at the rate that the line is designed for, for example, automotive products. We have successfully automated most machining processes like turning, milling, grinding, drilling, gear cutting and finishing operations. We also have consistent focus on improving product performance. For example, we have recently developed the 4th generation of gantry robots, with a gantry speed of 4 m/sec. Our customer base is mainly in automotive, automotive ancillaries and engineering components industries. We serve customers who require high throughput, high quality, flexibility, traceability and cost-effectiveness. The automation
EM | Mar 2016
system that we deliver has the ability to track parts and capture data that is compiled together as a traceability picture of the entire process. PARI has recently expanded its production facility in India. On this, what is your investment percentage in terms of technology adoption, design and manufacturing verticals? We have recently enhanced our production facility in India, both on the production & engineering sides. We believe that we have to create investment first, so that when the demand develops, we don’t let our markets down. Over last four years, we have aggressively invested in terms of physical infrastructure facility, shopfloor space, machines and people. From these investments, we can easily grow our business to two-folds of what we are today. We are ready for a significant expansion of our offerings. On investments side, technological development and R&D is around 8-10% of our total capacity, design and engineering covers 30%, and execution of business covers 60% which includes manufacturing, site services, corporate infrastructure, etc. Our current turnover is `400 crores. How do you strategise your approach to achieve a competitive edge overseas vis-a-vis western suppliers across the export market? PARI follows a three-fold strategy to achieve a competitive edge in the western market. We are aligned with our customers’ requirements and challenges. In doing so, we aim to become the ‘supplier of choice’ for them, rather than being counted as one of the suppliers. Secondly, we utilise a very large amount of engineering strengths in terms of in-house training, skill enhancement and supervision by seniors. We have created a large talent pool to implement changes or modifications from the customer’s end as well. Thirdly, we value engineering on our products. This helps us generate a global supply base and incur the Indian cost-effectiveness into a value proposition for customers that delivers the same or better performance more competitively, cost-wise. ☐
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R O U N D - TA B L E | M A N A G E M E N T
Are factories in India future-ready? It is believed that the future of manufacturing is smart. Smart manufacturing marries information, technology and human ingenuity to bring about a rapid revolution in the development and application of manufacturing intelligence to every aspect of business. Is India ready for this? EM along with IMTMA had organised a panel discussion on this topic during the 1st Symposium on Smart Manufacturing, held recently in Bengaluru. The discussion was moderated by Shekhar Jitkar, Publisher & Chief Editor, EM. Excerpts... According to experts from the global industry, today, smart manufacturing is on a transformation journey. Flexible factories and demand-driven supply chains will change manufacturing processes to allow manufacturers to customise products to individual needs. Customers will ‘tell’ a factory what car to manufacture, what features to build into a personal computer or how to tailor a pair of jeans for a perfect fit.
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Maria Jerin Features Writer maria.jerin@publish-industry.net
These will not be incremental or gradual changes — they will be game-changing, market-disruptive innovations in products and processes. It is also believed that smart manufacturing will deliver a similar, extraordinary shift in the competitive landscape of the Indian industry. The software services sector is the key knowledge component in India, and since Industry 4.0 combines traditional manufacturing with IT and the
EM | Mar 2016
M A N A G E M E N T | R O U N D - TA B L E
“Future factories require us to upgrade on all three fronts – people, processes and technology”
Amit Kumar Srivastava, Regional Sales Head - India & Asia Pacific, Robert Bosch Engineering & Business Solutions
Internet of Things (IoT), India can become the major industrial hub in Asia if it plays its cards right. Sharing insights on the present situation and the factors to be considered enabling Indian factories to be future ready are industry experts Chandrashekar Bharathi, Managing Director, AceMicromatic MIT; Amit Kumar Srivastava, Regional Sales Head - India & Asia Pacific, Robert Bosch Engineering & Business Solutions; Rajesh Khatri, Executive Director, TAL Manufacturing Solutions and Arunkumar Janarthanan, Associate Director, Automation & Electronics Practice, Frost & Sullivan.
Future-ready factories in real terms ‘Future-ready’ will be driven by ‘present-ready’ and extensibility to emerging standards / platforms / use cases. Highlighting the need of the hour for factories, Bharathi says, “Today, it is being able to eliminate operational losses and significantly ramp up shopfloor productivity horizontally and de-skilling of operational staff, by being able to seamlessly access key production and asset data electronically; and have analytics from run-time data drive optimisation. Extensibility can take the form of supporting generic IoT frameworks, support for protocols, and connecting disparate islands of data to provide true shopfloor to top-floor integration and visibility.” Janarthanan opines that future-ready factories are those that have adopted profitable and innovative manufacturing practices, thereby, enabling optimal resource utilisation with a continuously shrinking carbon footprint. He further shares, “Real-time visibility of distinct supply-chain activities fostering process improvements, and fast response to changing market demands are important characteristics of any future-ready factory. Facilitating business centricity instead of plant centricity is the ultimate aim of any futureready factory.” He also avers, “Seamless interface and connectivity between different equipment and ultimately an integrated shopfloor and board room are important characteristics of a smart factory.” Speaking on the benefits of establishing industrial mobility, cloud, Big Data and advanced cyber security solutions, he adds that this would help manufacturers to optimise the implementation process and create fast track and seamless approach for future technology adoption.
EM | Mar 2016
“The reality is that standardisation has become a necessity to remain competitive in market” Rajesh Khatri, ED & CEO—TAL Manufacturing Solutions
Taking forward the factors driving towards smart manufacturing, Srivastava says, “1970s was the era of production of goods in mass, but now our customers are asking for customised products in mass. They also want to give their input during the design and production stage. All this requires your factories to be flexible and networked so that it responds to your customer needs.” Further explaining this, he adds, “Flexibility will require a very high availability of operating resources. The shopfloor will be networked. It means relevant information like machine break-down, delays to order, missing parts, personnel or resources will be shared in real time between people and systems involved in the process. This means that by just putting latest machines and systems, we will not build factories, but that will require us to upgrade on all three fronts – people, processes and technology.” Sharing his thoughts on the driving factors, Khatri says, “The need for manufacturing organisations to be hyperefficient while providing extreme flexibility with mass production capabilities for individual customisation is driving companies to consider ‘factory of the future’ initiatives. Cost-competitiveness with agility, innovation and flexibility are the new mantras for success.” He further perceives that the smart factories of the future will be a product of IoT, automation and IT working together connecting equipment, eliminating silos, exploiting data and taking automation to a whole new level. However, moving from a traditional factory to a next-generation factory is a daunting task, he feels. “It requires not only an empowered management team to drive the change and implement the vision, but also the need for rethinking the traditional organisation and a substantial investment in new technologies,” he shares.
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R O U N D - TA B L E | M A N A G E M E N T
“Implementing a focused pilot would enable buy-in, awareness and foster a value oriented outcomes based culture”
Chandrashekar Bharati, Managing Director, AceMicromatic MIT
Are we future-ready? Bharathi opines in short that factories in India are not future ready. He further clarifies, “While there is increasing awareness and some of the top tier companies have initiatives in that direction, the majority of companies may still view such efforts are a ‘nice to have,’ rather than a value-added competitive edge. Where companies do realise that, they may be hobbled by allocation of priority and resources to manage and drive initiatives to make factories future ready.” Srivastava also agrees that today majority don’t seem to be future ready. However, he conceives that heavily regulated companies like pharma and healthcare have good level of automation and systems in place, whereas Janarthanan observes that oil & gas and automotive industries are at par with global trends. However, he envisages that adoption of advanced manufacturing solutions has not been uniform across sectors - such as in food and beverages, consumer packaged goods, mining, water and waste water, etc, where the investment in automation solutions is not at par with global norms. Further explaining on the nature of factories, Srivastava points out, “We have two kinds of factories in India – one which has been set up by large MNCs whose parent companies are quite matured and automated. Hence, when they set up plants, they use a template, which ensures certain degree of maturity in terms of process and systems. There are other set of companies who have grown ground up and, hence, they have legacy systems and machines. But both of them have to go through this journey.” Given the perspective of most factories in India are not future-ready, Khatri notes that the adoption of MES / PLM at an integrated level still is at low levels. He adds, “With the density of robots at ~ 2 per 10,000 industrial workers, automation also is at a very low level as compared to developed countries where the density is > 350400. Internet connectivity remains unreliable.”
‘Factory of the future’ initiatives Addressing the specific pain points, Bharthi remarks, “Implementing a focused pilot would enable buy-in, awareness and foster a value oriented outcomes based culture – making the intangible tangible, and create the foundation for building towards a technology enabled smart factory.” Srivastava
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“Facilitating business centricity instead of plant centricity is the ultimate aim of any future-ready factory” Arunkumar Janarthanan, Associate Director, Automation & Electronics Practice, Frost & Sullivan
recommends that companies should evaluate how their business is changing and design a roadmap to build a smart factory, which can adjust to their customer needs. “The integration of information across machines, systems and people is a key element in this journey and, hence, they should definitely build a consolidated view of their operation,” he shares. Khatri asserts that a systems approach to manufacturing processes, standardisation, adoption of automation and IoT seem to be the first steps to make the business enterprises future-ready. “In order for the plant to operate in a dynamic, integrated, mobile, real-time connected environment, it is essential to have shopfloor connectivity and collaboration, logistics, asset and supply chain tracking, operations workflow automation, unified communications, control system flexibility, security and personnel tracking, and integrated business and plant data,” he states. Janarthanan perceives that as a starting point, a smart factory in India can be expected to focus on enhancing operational excellence, rather than on capacity creation. “As manufacturing facilities move towards the smart factory concept, there will be a need for real-time performance management across multiple facilities. Adoption of advanced solutions leads to high levels of data availability, which will further create a need for robust control, capable of converting it into actionable intelligence and enhanced operational excellence,” he adds.
Focus on standardisation Industry 4.0 will require standardisation at multiple levels – processes, connectivity, systems and people maturity. With the advent of newer technologies, the technological integration can be achieved especially in India, where there
EM | Mar 2016
R O U N D - TA B L E | M A N A G E M E N T
is large IT workforce. Srivastava claims that the challenge will be at people and process level. Emplacing his thoughts, he further emphasises, “The need for integration will itself drive this standardisation and this is what we are seeing in Europe, where home appliance companies are collaborating with energy producers and forming consortiums like EEBus or projects like AllJoyn by Qualcomm which facilitates interoperability among connected products and software. We will initially see such standardisation happening in specific eco-systems which will expand to other industries. Any open source project will speed up such standardisation.” However, he insists that excessive process standardisation will not be in line with smart factories principles, which promote de-centralisation of decision making. Commenting on the initiatives to be taken for standardisation, Bharathi states, “Larger companies can play a key role in making themselves future-ready, and may demonstrate such concepts through vendor development activities. Incentivising their supply chain to adopt such initiatives will go a long way in getting the entire value chain to consider standardisation. Government actions to encourage adoption of future-ready technology initiatives using tax and fiscal policy may also serve as a catalyst.” Khatri accords that industry focus has already shifted towards modular manufacturing and standardisation. Citing an example from the automotive segment he says that today the variants of vehicles are built on a common platform. “More and more producers are embracing the Made-toOrder (MTO) and Configure / Engineer-to-Order (CTO/ ETO) production models as against the Make-to-Stock (MTS) – this is possible only through standardisation and analysing the complete product life cycle. The reality is that standardisation has become a necessity to remain competitive in market,” he explains. Janarthanan mentions that open and standard protocols that are vendor agnostic is an important requirement for any smart factory. “Adoption of platform based approach can also help simplify the complexity associated with multiple hardware and software solutions. It can facilitate smooth integration of multiple devices leading to effective monitoring and reduced development time,” he notes. “In the Indian context, it is important for solution providers to understand the end users’ requirement and offer solutions that are customised and specific towards addressing the challenges of a particular user,” he adds.
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Ensuring data security Smart factory definitely requires a lot of integration and data exchange between the various partners in the ecosystem. And hence they are exposed to cyber-attacks and industrial espionage. Contributing to the subject further, Srivastava adds, “Reliability of network and resources is very crucial for guaranteeing uninterrupted running of the plant. The telecom network has to highly reliable and should have back-up layer incorporated in it. As far as accessibility of data security technology goes – yes it does exist and we have seen how Indian IT companies use this technology to service their multinational clients in financial and insurance domain. In terms of reliability of the network, well with frequent call drops, it does put a question mark. But for sure this can be achieved by having primary and secondary lines in place. The companies will also have to invest in DR/BCP processes designed specifically for the plants.” Bharathi also feels that penetration of high grade data and security frameworks is currently low at most factories. However, with data bandwidth now becoming available, he says, “Reliable and affordable, data security and protocols may be implemented using cloud concepts, which can usher in rapid scaling as well as lowered operational costs.” Taking a different approach, Khatri believes that though most factories are equipped with the latest enterprise systems, seldom are these systems deployed across business processes to have totally integrated operations. He further says, “Telecom and IT infrastructure in the country is still evolving and remains at best unreliable. The manufacturing set-ups do not have large enough scale to support investments for big data and connectivity with a reasonable ROI.” He also avers, “With connected factories, the risks come in the form of hacking, data theft, and industrial espionage. Cyber-attacks and viruses can potentially bring networked and smart production systems to a standstill. Robust cyber security standards may have to be introduced in order to provide a secured communication environment.” On a concluding note, Janarthanan adds, “Business continuity measures in the age of disruptions holds prime importance. Increasing regulatory pressure across different industries has necessitated serious focus on data security and reliability by various solution providers. Solution providers are already offering solutions and services that can help end users address their cyber security and reliability concerns.” ☐
EM | Mar 2016
DIE & MOULD | FOCUS
BREAKING THE MOULDS... The article highlights the technology behind robotic deflashing and how it may be successfully deployed across the aluminium die casting industry, with references from the industry serving as guides of doâ&#x20AC;&#x2122;s and donâ&#x20AC;&#x2122;ts for good executions Manufacturing industry is undergoing a revolution in productivity, quality and EHS. The foundry sector in general and aluminium die casting industry in particular, have been slower than other manufacturing sectors to adopt automation and robotics as a way forward. Deflashing is a particularly dirty application requiring lots of manual labour working in unsafe unhealthy conditions. A revolution is coming in this sector, with the advent of robotic deflashing for aluminium die castings.
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Sameer Kelkar Executive Director Grind Master Machines sales@grindmaster.co.in
Robotic deflashing Robotic automation has come a long way in the past 20-30 years. Robots have become the workhorse for manufacturing setups in applications such as welding and machine handling in automotive industries. Applications of industrial robots in foundry and aluminium casting industries include pouring, extraction and handling. Deflashing is a process in aluminium casting industry which is almost entirely manual and labour
EM | Mar 2016
FOCUS | DIE & MOULD
Typical components before and after deflashing
intensive. It consists of removal of all extra material in the conditions in die castings shops automation is possible. casting after the trimming operation. Machine selection must carefully consider the conditions Automation of this process brings several key benefits to specific to the deployment area to ensure reliability over a the manufacturers of castings – namely increase in productivity long period. (2-3 folds), dramatic upgradation in quality and entirely Consistency required: Many aluminium cast parts are visible healthy and safe working atmosphere. class A parts in automobiles, scooters and motorcycles. Deflashing has been difficult to automate and prove, as Inconsistency in deflashing leaves marks, scratches, dents, etc demonstrated by numerous failures visible in the market in on visible surfaces. There is a very high consistency requirement form of systems lying idle or underutilised. System and for such parts. application engineering for deflashing requires domain High production volumes: Most aluminium die casting knowledge and expertise in deburring processes. In aluminium components are made in volumes of more than 2000-3000 castings shops, typical process sequences are followed for parts/day, especially ones catering to the two-wheeler industry. pressure die castings and gravity die castings. Deflashing is the Any automation system must be scalable, fast producing and last process in most casting shops. Subsequently the workpiece extremely reliable to cater to this requirement. is sent for machining to machine shop. Manual deflashing of Component variations: Deflashing operation is done on ‘as aluminium castings is done by operators using a variety of cast’ parts, which have part to part variations inherent to the tools, including belt grinders, files, pneumatic deburring tools, casting process. These variations pose challenges in deflashing chisels and hammers. automation – starting from location and fixturing, to uniformity of pressure application during deflashing, to making adjustments for part variations. Challenges in automation of deflashing Tool selection: Robotic deflashing systems deploy a Complex shapes: Aluminium castings have some of the most combination of tools for completing the requirements. A complex shapes in manufactured parts, with holes, recesses, knowledgeable system integrator is able to choose wisely inaccessible areas and corners. Further, most aluminium the tools to be used for a specific job requirement. Tool castings are used in automotive industry, where product selection is critical because process reliability, cycle time lifecycles have been becoming shorter and shorter over the and running cost of the system are majorly based on the years. This necessitates changes in the design of components, type of tools used. In certain cases, it is observed that and automation must be ready for the same. selecting an ‘optimal’ tool can reduce cycle time and running Hazardous conditions: Temperature, fumes, dust are tough costs by as much as 90%. The most commonly used tools in conditions for man and machine alike. With the advent of robotic deflashing include flexible pneumatic deburring rugged foundry grade industrial robots that can withstand the tool and flexible belt grinding tool.
EM | Mar 2016
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DIE & MOULD | FOCUS
Comparison between manual (L) and robotic (R) deflashing
Quality improvements: Robotic deflashing gives tremendous improvements in the consistency and completeness of deflashing. Manual operations are subject to numerous variations through the days, weeks and months of the year. Also two operators are never working in exactly the same style. Component handling with a robot is much nicer and leaves no marks/dents/damages. Cell configurations: Robotic deflashing systems can range from simple single robot deflashing machines to multiple robot high volume manufacturing systems. The basic modular element is a robotic deflashing machine with one robot deflashing a component loaded on a fixture. Such a setup operates just like any other machine. An operator loads/unloads the component manually, and the robot completes the deflashing operation in an automatic cycle. Different parts can be processed in the same machine by changing the fixture and selecting the part program. Such machines give cycle times between 20-60 secs for components upto 500 mm in size, typical components include â&#x20AC;&#x2DC;back restâ&#x20AC;&#x2122; of two-wheelers and alloy wheel rims. For high volume manufacturing requirements of more than 4-5 parts/minute, 2 or more deflashing machines may be combined using automation (typically another robot) for handling. For several PDC parts, instead of having standalone machines, it makes more sense to integrate
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deflashing operation as a one piece flow from the casting machine. In such cases, robotic deflashing cells include robots performing multiple operations such as extraction, checking/testing, quenching, handling in trimming press and deflashing. The advantage of such a setup is that the entire die casting line is automated, and one piece flow is reliably ensured. Selection of the correct configuration is critical for operational and economical success of the system. Cost of operations and feasibility: Robotic automation systems have various costs associated with them which have to be considered in calculating cost per piece over the long run such as maintenance costs (annual maintenance, spares, etc), energy costs, air costs (most automation systems use pneumatics for gripping and deburring tools), consumables costs (use of customised tools for robotic application can save significantly this cost), retooling, reprogramming costs and labour costs (including future rise in the same). Significant improvements in quality must be considered while calculating the investment returns of a robotic deflashing system. A drastic reduction in rejection rate, and removal of rework/checking stations required also brings about space savings. Correct selection of application and wise implementation can ensure a return on investment of robotic deflashing systems within 2 years.
EM | Mar 2016
FOCUS | DIE & MOULD
Key steps for deploying robotic deflashing Most aluminium casters have a large number of manual operators for deflashing operation. In order to successfully implement robotic automation across the manufacturing setup, following key steps must be considered: t L ong term commitment to deploy automationâ&#x20AC;&#x201D;Deflashing automation will go through learning, implementation, horizontal deployment phases and management must have long term commitment to do this. t R eliable partner for deflashingâ&#x20AC;&#x201D;Deburring and grinding process know-how are key ingredients of any success in robotic deflashing. Robotic deflashing is more like a â&#x20AC;&#x2DC;machine toolâ&#x20AC;&#x2122; than an â&#x20AC;&#x2DC;automation system.â&#x20AC;&#x2122; Choose a competent machinery maker with this expertise as your partner for robotic deflashing. t S election of first applicationsâ&#x20AC;&#x201D;Pluck the low hanging
fruits first. Your partner will help you identify the components which will give fastest economical return and impact. Successful implementation of the first application is a key for confidence in the team about robotic deflashing.
Summary Robotic deflashing is a revolutionary technology in aluminium casting industry. It leads to key benefits such as consistency in quality, high productivity and health and safety on shopfloor. Aluminium casters can deploy this technology in foundry by taking certain precautions to ensure success. In the near future, robotic deflashing is likely to sweep the Indian aluminium casting industry setting new benchmark for shopfloor practices and methodologies, especially for deburring and deflashing. â&#x2DC;?
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EM | Mar 2016
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HIGH SPEED MACHINING | TECHNOLGY
Metalworking fluid performance in aluminium HSM The article discusses the differences in aluminium machining performance obtained at high versus low cutting speeds, as well as the influence of the metalworking fluid. This provides insight into how important highly engineered aluminium machining fluids are, and will be, as high speed cutting operations continue to be used in industry High speed machining (HSM) offers the potential for increased productivity and improved part quality in the production of aluminium engine and transmission components for the automotive industry. While generally accepted that the use of high speeds and feed rates in a machining operation can yield increased rates of productivity, use of HSM can also result in improved machined surface finish and reduced machining forces. Such effects are thought
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to result from reduced heat generation during cutting, reduced contact time between the tool and workpiece surfaces, and also from the limiting shear stress properties of the metal, which are often exceeded under high speed machining conditions. With regard to water-based metalworking fluids used in HSM operations, while an understanding currently exists of the importance of fluid properties such as coolant stability
EM | Mar 2016
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HIGH SPEED MACHINING | TECHNOLGY
To better understand the influence of metalworking fluids in aluminium high speed machining, machining tests were performed at both lower conventional speeds and at high speed conditions
and foam behaviour, less is known about the demands on the fluid for lubrication and cooling, and how these demands may differ from a fluidâ&#x20AC;&#x2122;s use in conventional lower speed machining. To be more specific, with the knowledge that under high speed conditions lower machining forces and improved machined surface finish can be achieved, do the metalworking fluids used need to be as effective and as high quality as those currently used at lower speeds, specifically with regard to the lubrication and cooling provided? With these questions in mind, the article provides insight into how important highly engineered aluminium machining fluids.
High versus conventional speed machining To better understand the influence of metalworking fluids in aluminium high speed machining, machining tests were performed at both lower conventional speeds and at high speed conditions. In considering some of the history of the origins of HSM, Dr Carl Salomon, in his original investigations on high speed machining, determined that the heat generated between the chip and the cutting tool would increase with increasing cutting speed, up to a critical speed dependant upon the metal being cut. With further increase a critical speed would be reached, at which point the chip removal temperature would decrease with further increasing speeds. Given this analysis, and the presumption that machining
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performance (forces, BUE formation, tool wear, etc) are all largely influenced by the heat generated at the tool chip interface, it would be expected that overall machining performance would decrease with increasing cutting speeds prior to the peak cutting speeds, and then begin to improve as speeds exceed the peak value. To assess the machining performance at cutting speeds corresponding to one below, one at, and one beyond the critical speeds, the axial machining forces, tool flank face wear, machined surface finish, and hole dimensions were measured. The axial machining forces, while providing a measure of the energy required for the operation, also provide a useful indirect measure of the mechanical and thermal demands on the tooling and the potential tool life to be expected in a given operation. The test illustrates the mean axial machining forces measured at the three cutting speeds, the machining forces climb considerably when speeds are increased from 2,900 RPM up to 10,000 RPMs. However, as the speeds increase further to the HSM conditions (18,000 RPMs), the cutting forces level off and actually start to decrease. Thus, it can be concluded that the mechanical and thermal demands on the tooling are reduced at HSM conditions and improved tool wear will likely be obtained. To support such conclusions, the tool flank face wear was measured following chemical removal of the built up edge from the tool cutting surface.
EM | Mar 2016
TNC 640 â&#x20AC;&#x201C; The new High-End Control for Milling and Turning Operations The new TNC 640: for the first time, milling and turning are combined in one TNC. Now users can switch as desired between milling and turningâ&#x20AC;&#x201D;within the same NC program. Switchover is independent of the machine kinematics. It automatically takes the respective operating mode into account and without any additional action.This new simplicity is complemented by dialog-guided plain language programming, the optimized user interface, powerful programming aids as well as comprehensive cycle packets taken from amply field-proven HEIDENHAIN controls into the new TNC 640.
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HIGH SPEED MACHINING | TECHNOLGY
High speed machining tests were conducted to assess the properties of various water-based aluminium machining fluids
The test also reveals the flank face wear length on the tools used at the three cutting speeds, wear is significantly reduced as the cutting speeds increase from 2900 RPM to 10,000 RPM with a further wear reduction obtained at the high speed conditions of 18,000 RPMs. While tool wear is an important issue in aluminium machining, the amount or degree of built up edge formed on the cutting tool can be an equally or often more critical parameter to be considered. Built-up edge when formed often leads to a degradation of the machined surface finish, as well as loss of accuracy of size or dimensions of the holes produced. To assess the impact of HSM conditions on this parameter, the degree of BUE formed on the cutting tools, and subsequently the hole finish and form, were measured for each of the three cutting speeds utilised. While BUE formation is an extremely dynamic process with formation and loss of adhered metal from the cutting edge constantly occurring, examination of the tooling following the machining operation still offers a useful assessment of the tendency for this to happen. While it might be initially thought that high speed machining would yield significantly more severe machining conditions with resultant higher machining forces, tool wear, BUE, and poorer machined surface finish, it is seen from the results presented in this study that as the machining operation tends to higher cutting speeds, the overall quality of the tool and the hole produced improves. Thus consistent with earlier reports, high speed machining offers benefit with regard to the quality of the operation and part produced,
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as well as the gains in productivity which can be obtained.
Metalworking fluids performance in high speed aluminium machining With an understanding that at high cutting speeds, lower machining forces, reduced tool wear, and improved machined surface finish can be obtained, a question to be asked is: do the metalworking fluids used need to be as effective and as high quality as those currently used at lower speeds, specifically with regard to the lubrication and cooling provided? To address this question, high speed machining tests were conducted to assess the properties of various waterbased aluminium machining fluids and determine if machining performance could be influenced by the quality of the fluid used. For this study, four fluids currently widely used in the industry and considered to represent the stateof-the-art in fluid technology for aluminium machining operations, were each tested under high speed machining conditions. While all four of these water-based fluids are considered to be effective, there are observable performance differences between them when utilised at lower, more conventional machining speeds. Such differences may arise from the composition and type of lubricating additives, their emulsion properties, or a combination of such factors. Nevertheless, it was felt that if the fluid used can be a significant factor in the level of machining performance
EM | Mar 2016
TECHNOLOGY | HIGH SPEED MACHINING
TECHNOLOGY | HIGH SPEED MACHINING
obtained in HSM, then differences in their machining performances should be observed at the high cutting speeds of 18,000 RPMs. The microphotographs study of all four fluids showed that these are considered to be oil-in-water macroemulsions, a noticeable difference in the sizes of the oil droplets dispersed in the water phase of the fluids can be seen. Such differences can influence fluid properties and performance, and, therefore, while not always be of highest importance, is nevertheless useful information to obtain when assessing the nature and potential use of a water- based fluid. Following the machining of Al 380 at 18,000 RPM, the machined surface finish and tool flank wear were measured for each of the four fluids tested. The results clearly show that tool wear and finish are significantly influenced by the fluid used, with Fluids Q81 and Q30-P yielding the best tool life and machined hole finish. Thus from the study, the use and selection of the metalworking fluid can impact the machining performance and potentially yield further improvements in the quality of the part produced as well as the tool life obtained. While the determination of the specific reasons for the fluid performance differences observed are not discussed, they are likely a result of compositional differences between the fluids giving rise to varied levels of the lubrication, cooling, and chip removal capabilities. The results of machining tests conducted at lower, more conventional cutting speeds, and also at high speed machining conditions, show that along with gains in productivity under HSM conditions, improvement in the machining operation and quality of the part produced can be obtained. Such improvement is seen in the reduced wear and built-up edge observed on the cutting tool used at the 18,000 RPMs, as well as in the improved machined surface finish obtained at HSM conditions. While improved machining can be obtained at higher speeds, it was also seen in the test results obtained that the machining fluid used can still have a significant influence on important measured parameters, such as tool wear and part quality. Thus it is felt that the composition and resultant performance properties of the metalworking fluid will continue to play an important role in the quality of the operation, as the use of high speed machining continues to grow in industry. â&#x2DC;? Courtesy: Quaker Chemical Corporation
EM | Mar 2016
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MILLING MACHINES | TECHNOLGY
Expanding capacity and capability Streamlining a die/mould manufacturing process can be accomplished through automation, enabling companies to increase throughput without adding real estate. However, as workpiece designs continue to grow in complexity, manufacturers must support these automated systems with accurate, repeatable and reliable milling technologies. Located in German town, Wis, MGS has produced and sold over 400 moulds for a broad customer base, including consumer products, medical, electronics and automotive. Based on the diversity of MGS’s ‘one-off ’ production, automation systems have been a key component to the shop’s flexibility and scheduling management. “The benefits of work cells are no longer exclusive to part production environments. In fact, the influence of today’s global marketplace has made these capabilities essential to the competitiveness of North American mould manufacturers,” said Scott Matenaer, Tool-room Operations Manager, MGS Mfg Group. “By embracing this level of technology and
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focusing our efforts on the engineering and production of complex tools, we are able to offer our customers unprecedented flexibility, quality and delivery at an affordable price.” The one commonality that exists between the applications produced at MGS is the level of complexity. According to MGS, recent designs have included 64 HRc steels with required tolerances of plus or minus 0.0003 inches with repeatability within 0.0002 inches. “In nearly all cases, designing and building the style of production moulds that move through this facility involves a great deal of development and prototyping—engineering the part for manufacture,” said Matenaer. “To accomplish this in a lights-out environment
EM | Mar 2016
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MILLING MACHINES | TECHNOLGY
In the case of automation, the company bases its investments on output per square foot of floor space, output per employee and output per machine
requires access to reliable, accurate and efficient machining technologies. When faced with hard-milling limitations in 2011, we decided to update our machining technologies with investments in two Makino V33i vertical machining centres. The investment has proven to be a sound business decision that has enabled us to get the most out of our automated work cells, improving workflow and adding new capabilities to build on our history of innovation.”
Up for a challenge Founded in 1982 by CEO, Mark G Sellers, who happened to be a state of Wisconsin journeyman toolmaker, MGS began its operations as an injection-mould tool shop. While moulding operations now make up over 60% of the company’s revenue, its ability to successfully engineer, design and build plastic injection moulds remains the foundation. Engineers at MGS understand the impact that technology has in overcoming challenges, and they have high expectations for time-sensitive delivery of consistent and repeatable workpieces. In the case of automation, the company bases its investments on output per square foot of floor space, output per employee and output per machine. “We first began implementing automated capabilities in 2000, starting with simple pairing of individual machines with robots, which we knew would improve productivity simply by reducing downtimes incurred by manual setups and teardowns. In the following years, we applied simple work cells into several different process environments, which ultimately led us to build more complex automated systems that combine various machine processes into a single cell,” added Matenaer. MGS applied this experience to its recent V33i investments, which have been integrated into two robot-tended work cells that share a common coordinate measurement machine
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(CMM). MGS attests that the speed, accuracy and consistency afforded by this configuration have dramatically enhanced prove-out processes and overall workflow of its precision hardmilling applications. As per Jeff Kolbow, COO, MGS, “The key to investing in new machinery is to get more work done with the same amount of people, not the same amount of work with fewer people. To accomplish this, you need automated machining capabilities that are both flexible and reliable. Our goal in hard-milling applications is to maximise our spindle time. The performance and reliability of the V33i machines have enabled us to routinely exceed this goal with up to 20 hours of operation per day in certain applications.”
Reliable hard milling solutions The V33i investments were a natural next step for MGS, following more than a decade of experience with Makino milling and EDM equipment. In 2001, the company invested in a Makino SNC64 vertical machining centre, which has been deployed as both a graphite and hard-milling machine. With approximately 50,000 hours of machine time logged, the SNC64 remains a workhorse for one of the tool shop’s neighbouring MGS facilities. “When our toolmakers recognise a need for new equipment, we organise a group together to determine exact needs, such as size, horsepower, accuracy and spindle speed, in order to narrow down a list of equipment to evaluate,” said Matenaer. “In our recent graphite machining selection, we designed five test pieces featuring geometries common to our EDM applications. Results were judged on speed, accuracy and repeatability. The V33i graphite machine was one of the only technologies to meet and exceed our expectations across all criteria, producing accuracies as precise as 0.0001 inches.”
EM | Mar 2016
MILLING MACHINES | TECHNOLGY
According to MGS, the accuracy and reliability of a machine are not just important to meeting specifications, but also in maintaining consistent workflow
Based on these experiences, MGS was quick to identify the V33i as a potential investment for its precision hard-milling applications. This addition would also enable the company to combine its graphite and hard-milling operators based on their familiarity with the control system. In addition, the predominant use of automation had further increased the company’s needs for machine reliability and serviceability.
Accurate, repeatable hard milling According to MGS, the accuracy and reliability of a machine are not just important to meeting specifications, but also in maintaining consistent workflow. Due to the volume and variety of workpieces, the company must operate under a tight timeline that cannot afford recutting of workpieces. All jobs are scheduled and stacked up, waiting to be loaded into the hard-milling work cells. “There are a lot of machines available on the market that can produce the tolerances we require, but few with the level of repeatability to feel confident running them fully unattended overnight,” said Don Rafko, toolmaker at MGS. “In our razor-blade moulds, we’re expected to machine five identical seats that hold each blade at a precise pitch and distance. These have to be repeated anywhere from 24 to 64 times, oftentimes in multi-shot moulds with zero tolerance. On many machine platforms, this would be a concern for us, but not the V33i.” Rafko attested that no matter what level of accuracy a machine can provide, the overall performance can only be as good as the cutters allow. The company addresses these considerations in its hard-milling work cells by incorporating laser-tool-monitoring systems that interface with the machine controls to check and verify tool diameters, dimensions and sizes. By ensuring consistency among tooling, MGS is repeatedly achieving tolerances within plus or minus 0.0003 inches.
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A secondary benefit that MGS has experienced as a result of its newfound hard-milling accuracy is the ability to reduce or eliminate EDM operations. This capability has enabled the company to trim lead-times, while removing manual handwork and improving the surface integrity of its moulds. “We’ve been slowly reducing EDM processes over the last decade due to higher spindle speeds and better tooling options. In some cases our hard-milling machines are now producing better quality, consistency and accuracy straight out of the machine than what can be accomplished through EDM processes,” highlighted Matenaer. “Our ability to substitute hard milling in place of EDM processes has influenced the way that we design blocks, cavities and cores. Corner radii that once would have remained sharp for EDM processing are now designed into the milling process. Parting lines are cut directly in the mill, which not only saves us time, but graphite production and expenses as well. And while there are still features that require EDM processing, it remains our goal to continue eliminating as much EDM time as possible,” he added.
Expanding opportunities According to the engineering team at MGS, current applications are only scratching the surface of what they can potentially accomplish within precision hard milling. The company anticipates that further optimisation of these technologies is likely to enable MGS to expand into more complex markets, such as micromachining. “As a North American mould manufacturer, you must continually seek out new challenges and opportunities to remain competitive. This is why proper machining investments are critical to the expansion of your business. It’s not enough to just replace equipment. Technology has to add capabilities and remain a catalyst for engineering leadership,” said Kolbow. ☐ Courtesy: Makino
EM | Mar 2016
T E S T & M E A S U R E M E N T | A P P L I C AT I O N
Touch probe halves production costs An application story on how laser measuring system for tool measurement, touch probe and measurement software by Blum-Novotest has helped G.RAU to produce optimum quality at the milling centre The requirements in terms of quality and accuracy in the automotive industry, and in other sectors, are continuously increasing. This also has consequences for toolmaking because the basis for low tolerances in subsequent end products is created here. At G.RAU in Pforzheim, laser measuring systems for tool measurement, workpiece touch probes and the associated FormControl software from Blum-Novotest are used to produce optimum quality at the milling centre. The results can be measuredâ&#x20AC;&#x201C;both literally and figuratively. G.RAU develops, produces and distributes products to customer-specific requirements made of stainless steel and
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B V Shyam Managing Director Blum-Novotest India shyambv@blumnovotestindia.in
base metals, from alloys and composite materials, solid or plated. The requirements regarding the five-axis milling centre, which was acquired as part of a modernisation programme at the department in 2010, are equally diverse. It must be capable of machining parts to one metre long on the one hand, while meeting extreme requirements in terms of accuracy on the other. In the end, the company opted for a DMG DMU 80 monoBLOCK that provided the machining space required. To facilitate the use of very small tools as well, it was equipped with a higher-speed spindle, which can reach up to 24,000 rpm. Included in the machineâ&#x20AC;&#x2122;s scope of delivery were a laser
EM | Mar 2016
T E S T & M E A S U R E M E N T | A P P L I C AT I O N
Thanks to the multi-directional measuring mechanism, the BLUM probe system does not return different measurement results when probing in different directions compared with many other probes
tool measuring system from Blum-Novotest GmbH as well as a touch probe from another manufacturer. The LaserControl Micro Compact NT tool measuring system is located on the rear edge of the machine table and is used for calibrating new tools and for wear measurement and compensation. The focussed laser beam makes it possible to measure the length of even extremely thin tools just as precisely as the actual diameter.
For accurate measurement With the help of these measurements, worn and chipped spots on the cutting edges can be measured very precisely. All tools are measured, from the spherical cutter with a diameter of 0.5 millimetres to the cutter head measuring 50 mm across. For Marcel Heinz, who heads the tool making production team, the advantages of tool setting in the machine are obvious. “It completely eliminates the need for tool pre-setters. Instead of painstakingly measuring new tools on an external measuring station and entering the values manually into the control system, the geometry is recorded directly in the machine and stored in the tool database in the control system. This eliminates errors on the one hand, while reassuring us that the values recorded are actually correct on the other. Ultimately, the tools are measured using the laser system under the same conditions in which they are subsequently used for machining, that is, clamped in the spindle and operating at nominal spindle speeds.” Due to the stylus with a diameter of 4 mm, the touch probe supplied with the machine proved to be useless particularly on very small workpieces. A stylus tip with a diameter of no more than 0.5 mm is required for measuring inside contours. According to the manufacturer, this was not possible with the
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existing touch probe, which is why G.RAU finally turned to Blum-Novotest. Since its laser tool measuring system had already performed impressively, the new touch probe was also ordered from BLUM. As it turned out, the measurement technology specialist from Upper Swabia delivered exactly what was required: The TC52 LF is a compact touch probe, whose low-force version operates with a very low measuring force and can therefore be equipped with a 0.5 millimetre stylus tip. Thanks to the multi-directional measuring mechanism, the BLUM probe system does not return different measurement results when probing in different directions compared with many other probes, which also helps to meet the high level of accuracy required here. Constant measuring forces in any probing direction are the prerequisite for precise measurement results. The probe system is automatically substituted from the tool magazine into the spindle just like a tool. The power supply is provided by a long-life battery and the data is transmitted by infra-red communication to the receiver fitted to the spindle head of the machine.
FormControl “A key factor that influenced the decision in favour of the TC52 LF was that BLUM could also supply measuring software with the touch probe “, recalls Heinz. “Until then, we could only approach the workpiece using the touch probe and read the measurement from the screen of the machine.” The FormControl software allows us to do a great deal more. “Machine operator, Ralph Bauer loads the CAD model of the workpiece, which is provided in Pro/Engineer format by the design department, into FormControl, which runs on the same computer at G.RAU as the hyperMill CAM software. On the
EM | Mar 2016
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T E S T & M E A S U R E M E N T | A P P L I C AT I O N
The cutting knives used to trim the upper edge of a ‘cup-shaped’ workpiece are a good example of what the BLUM probe system is capable of in practice
displayed geometry, Bauer can now define the desired measuring points, the permitted tolerances, and the measuring sequence. From this, FormControl generates an NC programme that is transferred to the machine. After the measurement is complete, the values determined are fed back into the software. These can be issued as a measuring report or graphically displayed on the monitor, e.g, using coloured needles. To do this, FormControl compares the measured values with the CAD geometry and the tolerances entered, and then marks values that are outside the tolerance in red, and values within the specifications in green. Likewise, undersized and oversized areas can be highlighted in colour. “This gives us a quick overview,” says Bauer. The cutting knives used to trim the upper edge of a ‘cupshaped’ workpiece are a good example of what the BLUM probe system is capable of in practice. Heinz outlines the challenges: “The tolerances on these components are extremely fine, just as they are on the cutting knives – whose blade clearance is just 5 micrometres wide. The blades are arranged in a star formation and cut outwards in a radial movement. We manufacture the cutting knives from a single block of powder injected steel. One block provides two sets of twelve knives. First of all, the geometry is milled and then the cuts eroded. It all has to fit perfectly.” Bauer mills the blocks in several steps. To begin with, he stays one or two hundredths of a millimetre outside the final geometry, and then reduces the measurements accordingly by a process of measurement and further milling. In doing so, he benefits from the BLUM touch probe’s ability to perform contour measurements. He creates a 3D model of the actual contour of the important geometrical areas of the block and knows exactly where and how much he needs to mill in the next machining step. The colour coding of oversize dimensions in the measuring report helps him quickly identify the areas to
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be machined. Two very precise bores, which Bauer creates during the milling operation, connect the machining processes and are used to position the workpiece in the EDM machine.
Conclusion The precision enabled by measuring in the chuck on the machine tool is an important factor, as Bauer explains, “If we manufacture and measure the tool ourselves, we can be sure that all dimensions are correct down to a few micrometres. There is nothing worse than having a tool on the production line break, only to discover that the available replacement does not meet the tolerances required. In the worst case, this can result in the machine standing idle for an extended period – and then the costs really start to mount.” The LaserControl Micro Compact NT laser measuring system also saves time, as Bauer sums up, “Instead of carrying out external measurements on presetting equipment, which then have to be manually transferred, the results are transmitted directly to the machine control system in less than one minute. This is very quick and it allows us to measure the tools during every tool change without losing too much time. This in turn also helps us achieve the high precision of our workpieces.” “If you consider that we take measurements on a machining system in a hall that is not air-conditioned, the accuracy that we need to achieve is pretty astonishing,” agrees Marcel Heinz. “The BLUM products really impressed us! With the help of the FormControl measuring software and the touch probe, we can achieve our high accuracies without difficulty. An additional machine with a pre-installed laser measuring system by BlumNovotest is already in the pipeline. We have completed all preparations to enable the use of the touch probe and FormControl on another machine.” ☐ Courtesy: Blum-Novotest
EM | Mar 2016
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JUNKER Lean Selection speed High-speed cylindrical grinding. The Lean Selection speed grinds shaft-type components and cutting tool blanks at impressive speeds. One or two high-performance grinding spindles mounted at the swivel-action wheelhead (B axis) work using both the plunge-cut and QUICKPOINT grinding methods. This facility makes the grinding machine extremely flexible and capable of implementing several grinding operations in a single clamping. The Lean Selection speed cylindrical grinding machine is ideally suited for the grinding of small and medium-sized series: It not only operates with outstanding cost efficiency, but also benefits from operating simplicity and fast retooling.
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T E S T & M E A S U R E M E N T | A P P L I C AT I O N
Process control with gauging system An application story on how Renishaw’s Equator gauging system has helped High-Tech reduce the cost of producing aerospace parts by 27% and meet the cycle time requirements for the part High-Tech Engineering, a precision engineering company based in Dunstable, Bedfordshire, UK, has always focused on the quality of the parts it produces. Now with its latest addition, a Renishaw Equator gauging system, it is reaching 100% part inspection and zero scrap, whilst halving the operator requirements and reducing part production costs by 27%. Started in 1985 by Managing Director, Steve Tickner, HighTech Engineering built a reputation in the motorsport industry for delivering high quality machined parts. The company has since moved into the aerospace sector and gained some key industry approvals, including becoming a preferred supplier to Rolls-Royce and BAE Systems.
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Recently, the company won a contract to produce precision milled titanium parts for a large aerospace customer. Due to the nature of the parts, High-Tech was instructed to carry out 100% part inspection. Tickner explains, “We knew from the start that we would need to find an inspection method, which could not only meet the cycle time requirements for the part, but would be a cost effective solution for us as well. Relying on the CMM we already had wasn’t going to be an option. We couldn’t risk any bottlenecks. We knew that we would either need another CMM or something else, which could give us the measuring capacity. That’s what led us to the Renishaw Equator.”
EM | Mar 2016
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T E S T & M E A S U R E M E N T | A P P L I C AT I O N
The shop floor at High-Tech Engineering
Equator™ gauging system acquisition After some research and following meetings with representatives from Renishaw, High-Tech was impressed with what the Equator gauging system could offer, and was particularly pleased with the overall price of the system. Commenting on why High-Tech bought the Renishaw Equator gauging system, Steve says, “Space on our factory floor is at a premium. Within the space we set aside for this cell, we had to include faster and more efficient technology. This meant that a co-ordinate measuring machine (CMM) with a temperature controlled environment was far too big to be practical. The Equator suited the space perfectly as it’s a compact machine. The added bonus is the fact it is thermally insensitive and doesn’t require any air supply, meaning we didn’t need to spend additional time, money and effort putting in another temperature controlled room or extra piping.” The company is currently using the Renishaw Equator gauging system to perform 100% inspection of a complex aerospace part. It works by comparing the manufactured parts against a matching master part, gauging all the features in a single operation with an immediate pass/fail decision, along with a report of the component dimensions. The Equator gauging system is used to gauge around 150 features including a number of bores, thicknesses and form measurements on the
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part with typical tolerances of ±25 μm. The Equator gauging system does this within 10 minutes and well within the production requirements, far less than the machining time. This is almost a 50% reduction in cycle time compared to running the program on High-Tech’s CMMs.
Process control, run by the machine tool operator Production at High-Tech runs 24 hours per day, 5 days per week and is split into 2 overlapping shifts. During this time, Equator is used by a number of operators with varying skill sets. Previously, the company would have relied on its CMMs, housed away from the machine tool in a temperature-controlled quality room. Using the CMM for the latest job would have involved two separate operators, firstly the operator machining the part and secondly the operator with the specialist skills to operate the CMM. By using an Equator instead, newly trained staff can use dimensions from a certified component, approved by the QC operators, to “zero” the Equator gauging system and set its accuracy for subsequent measurements. This has allowed the same operator who machined the part to measure the part, halving the operator time required. The Equator™ gauging system is fully programmable and can be used on multiple parts, meaning High-Tech Engineering
EM | Mar 2016
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T E S T & M E A S U R E M E N T | A P P L I C AT I O N
High-Tech_example_parts
can perform highly repeatable and rapid automated routines across numerous contracts resulting in significantly reduced labour costs.
Ease of use – push-button simplicity Commenting on the ease of use of Equator™ gauging system, Tickner states, “All of the operators can use Equator. It is really easy; just load the part and push the button. It completely simplifies the process and frees up manpower, which in turn helps to deliver ROI very rapidly for the cell.” High-Tech has managed to reduce the cost of producing the aerospace part by 27% with the Equator gauging system being a factor in that. This has had a real impact on the competitiveness of this sort of production, allowing the company to make the same precision quality parts, whilst also delivering better value to its customers. It is through implementing these types of solutions and continually striving to improve their processes that the company has been awarded 6 consecutive SC21 silver awards, which is unrivalled in the UK. This award recognises excellence within the aerospace and defence industry, for the quality of the products a company produces, as well as its ability to supply them. To receive a silver award, a company must consistently achieve at least 95% for delivery performance and at least 99.5% on quality of parts to all of its customers.
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Conclusion Speaking on Equator, Tickner explains, “Since we started using Equator we have not made a single bad part. It’s allowing the operators to operate complete process control. They all look at the process monitor screen, part of the Equator software, which lists all of the features being gauged. Next to the feature name, there is a little bar which turns from green to amber to red as the size or location for each feature begins to drift. The operators know which tool on the machine is responsible for each feature and, so can take corrective measures to occasionally tweak the process, to come back well within tolerance. As we carry out 100% inspection, it would be very hard to make a part wrong.” He continues, “We are also using the gauge data to trial different types of tool, to see which gives us the best level of efficiency – something which might save us more money in the future.” Following the success of this manufacturing cell, Tickner plans to use the Equator gauging system as part of future cells he will be commissioning for jobs in the pipeline. “When you find something which helps you make a perfect part every time, reduces manpower commitments, reduces overall costs and doesn’t cost a fortune itself, it’s a winning solution. All benefits are passed on to our customers who know they are getting the best quality at the best price,” he concludes. ☐ Courtesy: Renishaw
EM | Mar 2016
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M A N U FA C T U R I N G I T | T E C H N O L O G Y
Program execution excellence in aerospace A read on how a process-driven approach helps aerospace companies shift manufacturing decisions earlier in the lifecycle and integrate manufacturing considerations throughout each phase of the lifecycle Aerospace programs are becoming more complex as is evident in the majority of high profile programs experiencing significant cost overruns and delays. These programs continue to underperform against their plan and commitments resulting in repeated announcements of delays throughout the development program. Pressure is on both aerospace OEMs and suppliers to provide dramatically more efficiency, reduce cost and increase production flexibility. Therefore, in the race to submit competitive program bids, it requires reinventing the way a program is executed from concept development to detailed design through manufacturing planning, execution and customer delivery. The solution lies in increasing the collaboration and coordination at all stages of program execution. At Siemens PLM Software, our perspective on driving program execution excellence in the aerospace industry
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requires shifting manufacturing decision-making process to the early stages of concept development and design. Bids are awarded to those who can demonstrate that product can meet the desired cost and schedule requirements. In the aerospace industry, program profitability is heavily dependent on the manufacturing efficiency. For most in the industry, manufacturing capabilities drive competitive differentiation. Companies that are better in managing capitalintensive manufacturing resources and processes typically win. Manufacturing challenges in the aerospace industry are growing. Use of advanced materials such as composites and advanced processes such as Additive Manufacturing are driving up manufacturing complexities. Automated processes are replacing labour-intensive applications on the shop floor and this is increasing the need for specialised tools. Focus on
EM | Mar 2016
T E C H N O L O G Y | M A N U FA C T U R I N G I T
T E C H N O L O G Y | M A N U FA C T U R I N G I T
quality requires proper monitoring and traceability of tolerances and part allocation against customer requirements. Informed make vs buy decisions and subcontractor/supplier management is critical to program success.
Driving program execution excellence To drive program execution excellence, aerospace companies must rethink their approach to manufacturing by adopting the following best practice strategies: Establish a true concurrent product development and manufacturing environment: The idea here is to include manufacturing requirements and analysis as an integral part of the concept and design phases. This can drastically improve efficiency in the rapid evaluation of multiple product designs and manufacturing options and, thereby, generate a true design for manufacturability. The â&#x20AC;&#x153;Shift-Leftâ&#x20AC;? approach is the idea of moving critical product design and manufacturing decisions early in the lifecycle. This is not a new idea and has been an industry initiative for decades. Unfortunately, this initiative in the past has experienced real execution issues. The tools to manage product design and manufacturing processes in an integrated and seamless environment were lacking. Product design and manufacturing planning applications were unmanaged tools and designers and manufacturing engineers had to deal with isolated systems. Aerospace companies can gain greater efficiency by integrating the product design as well as manufacturing processes in a single environment. The key to this concurrent approach is not only to assess virtually the design for manufacturability, but also to mature the manufacturing process, plans and tooling concurrent with the design, conducting concurrent product and manufacturing design and readiness reviews. Having a single environment for all product and manufacturing data is the cornerstone of this approach. This enables companies to verify during the design stage that manufacturing is capable of meeting the program requirements and performance characteristics.
EM | Mar 2016
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M A N U FA C T U R I N G I T | T E C H N O L O G Y
In the aerospace industry, program profitability is heavily dependent on the manufacturing efficiency
Bridge the gap between engineering and production: A true bi-directional flow of information between design and manufacturing teams is key for successful program execution. Winning the bid and executing it profitably requires close collaboration and communication among the program team to maximise opportunities for design and manufacturing optimisation. Collaboration allows not only manufacturing to have access to latest design data, but also design teams to gain knowledge and experience from the shop floor. This enables a more informed decision-making. Use of 3D design and simulation technology can be used to predict manufacturing costs and timings more accurately. A closed-loop environment between design and manufacturing allows early assessment of manufacturability risks for new designs, materials and processes providing valuable feedback to design engineers so that they can optimise the design. Common change management process: The likelihood of late-cycle change requests cannot be eliminated. If a late change happens, the key is to have the ability to react quickly and take necessary corrective steps. Efficient change management tools help in minimising shop floor disruptions and controlling cost buildup. Generally, the industry focuses on design changes, but it is equally important to manage changes to manufacturing processes and tooling. With a common change management tool, design issues can be quickly traced to the tooling, work-instructions and shop floor operations. Furthermore, changes to tooling and manufacturing processes can be managed effectively using the same change management process with different approval requirements. Furthermore, when design and manufacturing changes are performed in the same environment, it ensures that necessary product and process improvements are adopted as quickly and cost effectively as possible.
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An integrated environment for part and assembly manufacturing: Aerospace companies must adopt tools that span all aspects of manufacturing. This involves managing part fabrication as well as assembly processes in a holistic approach. Part manufacturing processes such as NC programming, fibre placement for composites, Additive Manufacturing, automated inspection programming, resource libraries as well as part process planning should be managed in a database environment. The same data management technology used for part manufacturing should be extended to manage complex assembly processes. Specific assembly applications such as assembly line and plant layout design, throughput and timing analysis, automation planning, as well as ergonomics analysis of assembly workers should be all performed in a common enterprise environment. Such an integrated manufacturing environment provides aerospace companies a greater advantage when a program transitions from engineering and planning to physical production.
Conclusion For aerospace companies, successfully delivering program cost and schedule requirements will improve companyâ&#x20AC;&#x2122;s profits, reputation and the ability to invest in and win new programs. New production technologies and the growing number of variants continue to drive program complexities. A processdriven approach to shifting product and manufacturing decisions early in the lifecycle is necessary for program execution excellence. Product Realisation from Siemens PLM Software provides aerospace companies a process-driven solution to shift manufacturing decisions earlier in the lifecycle and integrate manufacturing considerations throughout each phase of the lifecycle. â&#x2DC;? Courtesy: Siemens PLM Software
EM | Mar 2016
M A N U FA C T U R I N G I T | T E C H N O L O G Y
Applying Big Data in manufacturing industry Today, Big Data has applications in just about every industry – retail, healthcare, financial services, government, etc. The feature discusses the characteristics of Big Data, and illustrates six sample Big Data use cases in the manufacturing industry. If you have been keeping an eye on the IT sector, you will notice there are three flavours of the season, they are cloud computing, Business Intelligence Tools (BI Tools) & analytics and Big Data. The term, ‘Big’ does not refer to Big volume alone. Instead, Big Data also includes data that is messy or unstructured. Big Data is comprised of text: XML, email or electronic data interchange messages (EDI). Facebook, Twitter fall in this category; web server logs and search patterns revealing an individual’s journey through a web site, whether searching, consuming content, or shopping; sensor data: sensors found in industrial control systems, major transportation systems, GPS location signals among others; documents produced in the company, images
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Nobin Pradhan Consultant—IT & Finance pradphad@gmail.com
and videos, audio files. The three characteristics of Big Data are that they occur in huge volume (scale), at a high speed or velocity (constantly streaming), and represent an enormous variety (different forms) in its media and form (structured, unstructured, multimedia). Big Data analytics help managers measure, and hence know radically more about their businesses, and directly translate that knowledge into improved decision making and performance. The 2013 TCS Big Data Global Trend Study reports that of the 1,217 firms surveyed, 53% (643 firms) had undertaken Big Data initiatives in 2012. Out of these companies, 43% predicted a return on investment of more than 25%.
EM | Mar 2016
T E C H N O L O G Y | M A N U FA C T U R I N G I T
Applications of Big Data Big Data has applications in just about every industry â&#x20AC;&#x201C; retail, healthcare, financial services, government. Any organisation that can assimilate data to answer nagging questions about their operations can benefit from Big Data. Specific applications of Big Data include: t Cities encourage residents to report potholes on the roads by sending images via smartphones t L ocal weather forecasting agencies help fans attending a major outdoor sports event track looming thunderstorms t Proctor & Gamble aligns its global supply chain dynamically using Big Data. Retail businesses track consumer buying behaviour to develop insights on consumer reaction to the weekâ&#x20AC;&#x2122;s menu of items on sale and what was purchased in response to the sales promotion.
Application in manufacturing industry Key benefits of analysing Big Data in the manufacturing industry include reduced processing flaws, improved production quality, increased efficiency, and savings in time & money. One survey conducted by Tata Consultancy Services revealed manufacturers rating Big Data benefits on a scale of one to five, of which product quality and defects
tracking was 3.37, manufacturing process defect tracking was 3.32, supplier, components and parts defect tracking was 3.11, supplier performance data to inform contract negotiators was 3.08, and output forecasting was 3.03. However, in this whole business of Big Data, we need to be mindful of one aspect. We need to narrow our query to a specific business challenge that can be revealed by patterns or examples. By so doing, we can get much value from Big Data. Sheer quantities of data for analysis will not guarantee the discovery of insight that you need. Following are six sample Big Data use cases in the manufacturing industry: Improving manufacturing processes: McKinsey and Company offers a Big Data use case in pharmaceutical manufacturing. A biopharmaceutical company had a complex manufacturing process. It had to track 200 variables that influenced the purity of its manufacturing process. The company noticed that two batches of the same product manufactured showed a yield variation. The variation ranged from 50 to 100%. Using Big Data analytics, the team assessed process interdependencies and identified nine parameters that had a direct impact on vaccine yield. Later, target processes were modified. The company could successfully increase vaccine production by 50% yielding an annual savings between $5 and $10 million!
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EM | Mar 2016
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M A N U FA C T U R I N G I T | T E C H N O L O G Y
Custom product design: Tata Consultancy Services has referred the case of a $2 billion company engaged in the manufacturing of products to order. Using Big Data analytics, this company was able to analyse the behaviour of repeat customers. This ultimately led to delivery of goods in a timely and profitable manner. The company also was able to shift to lean manufacturing to determine which products were viable and which ones needed to be scrapped. Better quality assurance: Intel has been harnessing Big Data. Applying it for predictive analytics, Intel was able to significantly reduce the number of tests required for quality assurance. The result was a savings of $3 million in manufacturing costs for a single line of Intel Core processors. Managing supply chain risk: One manufacturer is using Big Data to reduce risk in delivery of raw materials, no matter what happens in the supply chain. Using Big Data analytics, the company has overlaid potential delays on a map, analysing weather statistics for tornadoes, earthquakes, hurricanes, etc. The company uses these findings to identify backup suppliers and develop contingency plans to ensure uninterrupted production. Preventive maintenance: There is yet another success story of Big Data use in a company having cement division. This division has kilns, quarries, burner and all such kinds of equipment. Depending on the size of each of its plant, the company has assets in the range of 4,000 to 10,000! These assets operate in a hot and dirty environment. Performing preventive maintenance on these equipment using Big Data and analytics, this company has moved closer to its goal of reducing corrective maintenance to 5%. Big Data enabled
this company to analyse data and gain easy ways to make decisions in real time, with clear key indicators and the flexibility to apply data without much IT involvement in generating various ad hoc reports. Accurate sales forecasting and production planning: A leading bakery operator in Northern Europe has been experiencing exponential growth. However, it struggled to accurately forecast fluctuating sales orders across the Nordic region. Consequently, it could not effectively plan its resources and production schedule. Making use of analytics and in particular Big Data use, the company successfully identified trends in demand and generates a rolling sales forecast. The solution helped the company predict production and prepare for fluctuating sales forecast. It is now in a position to respond rapidly and fulfill 30% more orders. Likewise, many companies are using Big Data and analytics to monitor, predict and reduce risk.
Conclusion These are not just six examples of Big Data use cases in the manufacturing industry, there are dozens of others. Big Data can address almost any manufacturing problem. This holds well so long as you can narrowly define the problem and assemble the right data. As with any other major change in business, the challenges of becoming a Big Dataâ&#x20AC;&#x201C;enabled organisation can be enormous and require hands-on, or in some cases hands-off leadership. Hands-off leadership refers to the environment, where decisions are based on intuitions and gut feeling. Nevertheless, itâ&#x20AC;&#x2122;s a transition that executives need to engage today. â&#x2DC;?
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W E L D I N G & A S S E M B LY | S P E C I A L F E AT U R E
Simulating welding process Simulation of laser welding process predicts the quantities of interest well enough to specify laser processing parameters. The article illustrates on how Owens Corning shortens design cycle and optimises component design with the help of CD-adapco’s simulation software.
Byron Bemis, senior research associate at Owens Corning, and his team were asked to design a new generation of components that could be made through laser welding. In fact, with this particular R&D project, Bemis and crew were breaking new ground at Owens Corning’s Science and Technology Center in Granville, Ohio. To design and fabricate the requested parts, their initial designs called for blind keyhole welding through one sheet metal part and into another. “Developing the welding parameters to make those welds work reliably and robustly took a lot of trial and error,” Bemis says. “To accomplish these using physical prototypes meant fabricating the individual component parts and then laser welding them up using a set of pre-determined parameters to see what happens. You continue doing this until you find the right combination.”
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John Kirkley President Kirkley Communications johnkirkley@earthlink.net
Challenging aspects Bemis adds that one of the most challenging aspects of this project was the necessity to weld close to small features or near corners or edges. If the laser is running too hot or moving too slowly, the feature or edge could melt, ruining the part. These were small welds, varying in size from millimetre to sub-millimetre scale, made on very small parts that demanded high precision fabrication. Bemis says they were running very narrow weld beams — in many cases 50-micron weld spots using up to a kilowatt of laser power on an individual spot. The materials used were alloys with very high melting points, high molten metal viscosity, and surface tension. This made for some interesting, non-standard welding physics. Complex geometries were also involved, including small
EM | Mar 2016
S P E C I A L F E AT U R E | W E L D I N G & A S S E M B LY
Parameters such as laser power, travel speed, acceleration, and pulse frequency can be tuned to provide the desired optimal weld
features, edges and circular sections. Because deep penetration was necessary to make the part, a keyhole mode was required. Keyhole mode is a welding technique in which a concentrated heat source, such as a laser, penetrates completely through a work-piece, forming a hole at the leading edge of the molten weld metal. As the heat source progresses, the molten metal fills in behind the hold to form the weldbead. All of these considerations, in particular, the blind keyhole welding, meant a lot of trial and error. Running hundreds of repeated physical experiments using expensive alloys and high-value component parts was prohibitively expensive and time consuming. It was obvious that simulation was the answer. But high fidelity simulation of the complete keyhole physics was very complex, expensive and slow. The simulation had to adequately predict quantities of interest, such as weld pool diameter and zone shape as well as penetration depth, in order to specify the optimal laser process parameters.
Seeking a solution Contemplating the task at hand, Bemis recalls, “We needed an economical solution — one that was fast, robust and easy to use.” In search of this solution, he spoke with his support engineer at CD-adapco, who had experience simulating welding. Based on the guidance from CD-adapco, he decided to use STAR-CCM+® to conduct the simulations. STAR-CCM+ features met two of Bemis’ main criteria — speed and robustness. As to ease of use, the software’s powerful meshing tools cut down geometry preparation and meshing time from weeks and months to hours, while delivering a high-quality mesh on sophisticated geometries. All of these capabilities can be leveraged from within familiar CAD and PLM environments.
EM | Mar 2016
Bemis used STAR-CCM+ to simulate the welding heat transfer process. The solution proved to be excellent in predicting both the weld width and the behaviour of features affected by the blind welding. “STAR-CCM+ has the unique ability to simulate the welding process and provide insight into the thermal transient experienced during welding in a manner that is both practical and fast enough for industrial use,” Bemis says.
Power of overset meshing For the past 30 years, engineers trying to perform Computational Fluid Dynamics (CFD) simulations struggled with the interaction between multiple moving objects. Traditionally, this required the generation of an interconnected mesh between the objects, an intensive manual process that was extremely difficult and time consuming. In fact, it was almost impossible if extreme ranges of motion or close interaction between objects was involved. Overset meshing — sometimes called ‘overlapping’ or ‘chimera’ mesh — is an approach to handle the modelling and simulation of the complex physics associated with moving objects. This approach allows the user to generate an individual mesh around each moving object, which can then be moved at will over a background mesh. “In the welding process, you can either move the heat source or the material,” Bemis says. “Overset meshing allows you to simulate the relative motion between the heat source and the parts that are being welded together. That motion, along with the laser’s power, really dictates how wide the weld gets, the size of the molten zone, and the depth of penetration.” Bemis continues, “With the use of overset meshes, we were able to run a fairly coarse background mesh as well as a fine,
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W E L D I N G & A S S E M B LY | S P E C I A L F E AT U R E
One of the MDX concepts that Bemis employed to design the component was an add-on module known as STAR-CCM+ / Optimate™
detailed mesh of the weld zone. We moved rather arbitrarily through the background mesh and generated any weld pattern we wanted. Some of the welds were 100 mm long and ½ mm thick, resulting in big aspect ratios and a really large mesh count to refine the simulation in the weld zone areas.” Bemis was working with a moving target. Heat tends to build up in the weld zones resulting in changing parameters as you move from weld to weld. Overset meshing allows the designer to simulate individual welds on the component, taking into consideration the changing nature of the material being worked on due to heat transfer. An implicit unsteady simulation with a moving overset mesh permits the prediction of the extent of the molten zone as it progresses along the joint, temperatures in the work piece, and heat transfer to the fixture. Parameters such as laser power, travel speed, acceleration, and pulse frequency can be tuned to provide the desired optimal weld.
A new methodology The research team also worked with a methodology recently introduced by CD-adapco known as Multidisciplinary Design eXploration (MDX) that allows the automatic testing of designs from early in the concept stage against all of the physics that might impact performance. One of the MDX concepts that Bemis employed to design the component was an add-on module known as STAR-CCM+ / Optimate™. “We used Optimate to explore the parameter space up front and alter the process and components to get the final results we wanted,” Bemis explains. “We were able to set up weld speed, power, and field functions to mimic laser control. We could ramp the laser up and down, simulate voltage feeds, and all the other parameters that Optimate could access. We then
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used the software to run cases to determine such things as how far back from a corner we needed to slow down, and how much to drop laser power in order to make a weld around a sharp corner while maintaining the same heat effective zone in the base material components. The simulation allowed us to prescribe all the welding parameters for experimental validation early in the design process.”
‘Accurate enough’ Bemis points out that using the CD-adapco simulation solutions meant that the results were ‘accurate enough.’ Rather than attempting to generate a perfect simulation of the problem, the results they obtained provided sufficient information to accurately predict real world weld characteristics, evaluate parameters and decide which directions to take. This process, Bemis says, was very fast considering it was a fully transient simulation with motion and overset meshing. He was able to run enough cases on a high-end workstation loaded with STAR-CCM+ / Optimate to allow design space experimentation and optimization. “It’s incredible to have that kind of power at your fingertips without having to write your own C code or FORTRAN,” Bemis resumes. “We saved at least six months of trial and error development, six months of experimental lab time, which is huge. In fact, by freeing up more time for design, we managed to figure out how to avoid using blind welds, a definite plus.” Finally, he concludes, “The high quality simulation allowed us to explore the research, design and analysis of the component as well as the manufacturing process all at the same time. We were able to deliver the final component design to our manufacturing facility complete with all the fab steps and processes in place.” ☐
EM | Mar 2016
EVENT | REPORT
Platform for forming technologies Spread across 30,000 sq mts, IMTEX Forming 2016 witnessed about 485 exhibitors displaying over 500 ‘live’ machines from 23 countries. The six-day exhibition served as a driving force platform for the machine tool industry by showcasing the latest technologies in the metal forming technologies. A post-event report… The Indian Machine Tool Manufacturers’ Association (IMTMA) recently organised the 18 th edition of South East Asia’s largest industrial show, IMTEX Forming 2016 and the concurrent Tooltech 2016 from January 21 to 26, 2016, at the Bangalore International Exhibition Centre (BIEC) in Bengaluru. Sprawling over an area of 30,000 sq mts, the machine tool expo witnessed about 485 exhibitors displaying over 500 ‘live’ machines from 23 countries with a footfall of around 40,000 industry professionals. The event was inaugurated in the presence of Jamshyd N Godrej, Chairman, Exhibitions, IMTMA; Parakramsinh G Jadeja, President, IMTMA; V Anbu, Director General, IMTMA; Vishvajit Sahay, Joint Secretary, Dept of Heavy Industry, GOI; K Ratna Prabha, Additional Chief Secretary to Government, Commerce and Industries Dept,
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Megha Roy Features Writer megha.roy@publish-industry.net
Government of Karnataka; R V Deshpande, Hon’ble Minister of large & medium industries & tourism, Government of Karnataka and P Ramdas, Vice President, IMTMA. The event also saw P Ramdas, Vice President, IMTMA and Managing Director, Ace Manufacturing Systems felicitated by the Premium Outstanding Entrepreneur Award in memory of Vinod Doshi for his outstanding contribution to the Indian machine tool industry over the years. Highlighting on the technology display at the event, Jadeja said, “IMTEX 2016 exhibits technologies that will act as a driving force for the machine tool industry. In addition, the latest metal forming technologies including servo presses, high power fibre laser, hydroforming, plasma cutting, robotic welding, etc will be showcased at the event.”
EM | Mar 2016
REPORT | EVENT
“IMTEX had more than 10 companies, which follow Indian innovation, i.e our innovation” Maulik Patel, Executive Director, Sahajanand Laser
“We have had a good exhibition with over 500 leads. We’ll have a good success rate by addressing these leads and taking it ahead” Preetham Arayanveetil, Product Manager—Solid Carbide, Forbes & Company Ltd
Highlights
Product launches
The exhibition saw China, Germany, Japan and Taiwan forming country pavilions. The participation other than India came from 22 countries. Over 100 trade delegations from various industry sectors such as aerospace, auto components, automobiles, capital goods, defence, electrical & electronics, oil & gas equipment, railways, plastic machinery sector, white and brown goods, and many more visited the show. Business orders worth about ` 450 crores were generated and business enquiries worth about ` 4300 crores were obtained during the six-day event, as per the data from IMTMA. Focussing on the public sector participation, Anbu said, “Visitors at IMTEX comprised of decision makers from major public sector undertakings, national associations and large private companies who are interested in buying these machines.” Key public sector undertakings such as Bharat Heavy Electricals, Hindustan Aeronautics Limited, Indian Space Research Organisation, National Aeronautics Limited, Railways, Ordnance Factory Board, etc visited as part of trade delegations. Many private companies such as Bajaj Auto, Fiat India Automobiles, Larsen & Toubro, Robert Bosch Automotive Electronics India, Volvo Construction Equipment, Hawkins Cookers, Toyota, Maruti Suzuki, Caterpillar, PRICOL, Infosys, UTC Aerospace, Honda Cars, TVS and Kalyani Technoforge were a part of the show too. Exhibitors who attended the show felt that there is a demand base for metal forming machines in India.
The exhibition saw Forbes launching their full range of end mills for graphite milling. “Our target market includes customers using EDM to machine the graphite electrodes & dies. In many die & mould shops, the choice between EDM and CNC milling is far less clear than it was fifteen years ago. Evolving technology is changing the rules for machining these complex profiles. Today, machining centres are capable of following precise, complex tool paths at high feed rates. This has made it cost-effective for shops to use fast, light milling as an alternative to EDM in many applications involving hard metal, intricate detail and smooth finishes,” said Preetham Arayanveetil, Product Manager – Solid Carbide, Forbes. Sahajanand Laser Technology’s latest offerings were highlighted like Bhramastra Infinity Fibre laser cutting machine; SLTL automatic loading unloading machine integrated with Bhramastra Vector and compatible with any laser cutting machine; SLTL smart store; SLTL Schavi press break for sheet metal bending; Akshar Fibre Pro Laser marking system with 20W for magnificent marking experience on metal and non-metal objects; AxiFibre, a large format laser marking system and concept laser marking designed to detect orientation of the component intuitively and to mark smartly on correct orientation. On the other hand, AMADA proposed a complete solution for blank to bend with the latest & unique fibre laser cutting
EM | Mar 2016
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EVENT | REPORT
“We are focusing on skill development and it’s our endeavor to improve the customer’s profit” Niraj Seth, President, AMADA India
machine model ENSIS. The company also demonstrated the next generation software solution VPSS 3i to realise blanking to bending to welding and final assembly.
Seminars & conferences Parallel events organised during IMTEX FORMING also had good turnouts. The International Seminar on Forming Technology organised a day prior to the exhibition witnessed around 250 delegates participating in concurrent sessions on design & software, equipment & tools, and process. While Praveen Deore and Sameer Chudnaik from Godrej & Boyce presented on ‘Formability analysis & spring back compensation of HSS part’, Steffen Domay from Fibro GmbH discussed on ‘Use of hydraulics & telemetry in dies’. Also, there were presentations on ‘3D Printing-Additive Manufacturing’ by Prof Karunakaran, IIT Bombay and ‘Safety standards for presses’ by Rajendra Menon, Rockwell Automation, India.
i2 Academia Pavilion For the first time, 40 academic institutions participated in the i2 Academia Pavilion, held at the exhibition. Twelve institutions including IITs made presentations to the industry as part of the IMTMA Industry Institution Collaboration (IIIC) intiative. The best research presentations were awarded prizes as well. Around 300 students participated for ‘CONNECT’ – an awareness programme for imparting knowledge on the machine tool industry for young engineers. Students from both mechanical and electrical engineering streams availed this opportunity to gain more knowledge on machine tool & manufacturing sector and to pursue their career in these industries. By interacting with industry experts, they were able to understand how machine tool industry helps in industry growth. Also, close to 40 students participated in the “JAGRUTI”—a
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programme to familiarise engineering students with the machine tool industry and the technological happenings in this industry segment. IMTMA organises JAGRUTI with the help of UDAAN members.
Taking IMTEX a way forward… As per Maulik Patel, Executive Director, Sahajanand Laser, India being a developing country was majorly misguided by the multinational companies. He explains, “However, the time seems rewarding finally. This year’s IMTEX had more than 10 companies, which follow Indian innovation, our innovation. SLTL has supplied more than 150 fibre laser systems in India as well as overseas. It covers approx 75% share in Indian sheet metal cutting market with fibre laser technology. Talking on IMTEX as a platform to take business forward, Arayanveetil, opined that it’s a platform for meeting their customers and channel partners; look out for the next big thing and enhance brand visibility. “We have had a good exhibition with over 500 leads. I am sure we will have a good success rate by addressing these leads and taking it ahead,” he added. Discussing on the company’s future strategies post IMTEX, Niraj Seth, President, Amada India, averred, “We are focusing on skill development and it’s our endeavour to improve the customer’s profit. We have high technology machines and the best training should be given to the personnel. ‘Make in India’ with good quality should be the aim so that our product quality is accepted in the developed world.” IMTEX Forming 2016 & Tooltech 2016 was a grand success. The strong presence of business visitors and policymakers from India and overseas made it a truly pan global event and paved a way for further growth of the Indian manufacturing industry. IMTEX Forming will return in 2018 after a gap in 2017 when IMTEX (metal cutting) will take the centre stage. ☐
EM | Mar 2016
REPORT | EVENT
Adopting new grinding practices With the launch of three new grinding machines this year, Motion Meeting 2016 was recently organised at Thun, Switzerland, showcasing the latest technology advancements from the United Grinding group. The event witnessed the most extensive application knowledge, product portfolio and range of services in the market. A post-event report… Every year, United Grinding hosts a conference with its sales partners and international press to highlight the latest developments, machine sales trends, investment in production and roadmap for the upcoming years. This year, with the motto “Flame of passion”, the conference was organised to showcase its latest technology advancements at the United Grinding headquarters at Thun, Switzerland. The show witnessed the launch of three new machines—S121, S131 and S141 radius grinding machines to replace the ongoing CT700 and CT900 models. Hosted by United Grinding’s Studer, Schaudt and Mikrosa
EM | Mar 2016
Megha Roy Features Writer megha.roy@publish-industry.net
brands, this year’s edition had a friendly Olympic-style competition theme between the brands. Addressing the conference, Michael Horn, COO, United Grinding, shared that there was a positive contribution in the cost side during the last quarter for the company. “The foreign purchase part has helped us. In fact, there was a 5% increase in terms of delivered machines in 2015. We are working towards best-in-class in every respect,” he added. Highlighting the roadmap for this year, he shared, “The sales procedure and production process will be the focus areas in 2016.”
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EVENT | REPORT
“Germany is the largest market for Studer’s incoming orders, followed by Western Europe and China, and then North America” Fred Gaegauf, CEO, Fritz Studer AG
“Combined with our technology & experience, machining times of just 15 seconds can be achieved” Gerd König, Managing Director, Fritz Studer AG
The Group positioning With its eight strong corporate brands—STUDER, SCHAUDT, MIKROSA, WALTER, EWAG, MÄGERLE, BLOHM, JUNG, the group has the most extensive application knowledge, product portfolio and range of services in the market. As per Fred Gaegauf, CEO, Fritz Studer AG, “Germany is the largest market for Studer’s incoming orders, followed by Western Europe & China, with North America faltering due to the low oil price. The regional overview for SCHAUDT, MIKROSA, with approximately 30% orders from Germany, shows a strong dependence on German automotive manufacturers and their suppliers. Over 30% of orders are delivered to China.” With 75% of Studer universal external cylindrical grinding machines equipped with at least one internal grinding spindle, the company has now become an absolute specialist in pure internal grinding. As far as incoming orders are concerned, Studer and Schaudt Mikrosa have shown very different business development in incoming orders, last year. While Studer lagged behind the very highly set budget figures relatively early on, Schaudt Mikrosa achieved 55% over the value of 2014, with Asia & Germany being the main buyer markets.
Technology innovations The conference witnessed an array of technology projects, which are being implemented by Studer. The projects are listed below:
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Energy efficiency: Studer recognised this necessity early on and is now able to reappraise any machine with the respective production process and to define appropriate saving measures. The most important factor in the BluePlus approach is that a complete assessment is made. Sustainability is a vital consideration here and customer trials have shown optimisations of up to 20% of the current energy consumption. Cooling lubricants: Studer is also implementing studies on innovative new cooling lubricant methods in the area of liquid tools. Today, thanks to UGG’s in-house 3D print facility at IRPD, new processes can be developed even more efficiently. STUDER-WireDress®: This has made a name for itself during the past year. Here, unimagined geometries can be produced incredibly efficiently and with very high cutting ability. Customers are enthusiastic and are already seeing new applications. Coordinate grinding: Coordinate grinding is a technical challenge on cylindrical grinding machines. Studer offers highly efficient solutions for machining eccentric bores. Speaking on the new radius internal cylindrical grinding machines launched, Gaegauf announced that they will replace the CT700 and CT900 models. “The new S121, S131 and S141 radius grinding machines are majorly into the manufacture of dies. In the past, this range of parts was successfully covered by Studer’s universal internal cylindrical grinding machines CT750 & CT960. With its market entry, the new S121 radius grinding machine will now take over the range of applications of the CT750, while S131 has been designed for the previous component range of the CT960. Replacing the CT models has
EM | Mar 2016
REPORT | EVENT
The press representatives were taken for a tour of the new moving line at Thun, Switzerland
generated customer benefits—a higher level of technology has been achieved with the new radius grinding machines. This is evident in the machine bed, which now comprises of Granitan® and, thus, offers higher dampening levels, thermal stability and guidance accuracy,” he explained. To showcase the comparison of the new S131 with CT960, the company executives organised a fun-presentation to display how, in a similar fashion, they preserved the important parts of CT960 in developing S131, which presents a higher level of technology.
Applications in the field of transmissions As a partner to the automotive industry and its suppliers, SCHAUDT MIKROSA offers efficient machining solutions for many applications in the field of transmissions. The SCHAUDT ShaftGrind series, which is based on the proven camshaft grinding platform CamGrind, is perfectly designed for grinding input, output or intermediate shafts. From concepts with one grinding wheel to fully flexible solutions with up to four grinding wheels, any machine configuration is possible with the ShaftGrind series. Also, the multiwheel transmission shaft technology has been developed specifically for highly productive gear shaft applications. It allows synchronous machining of all bearing positions and spline diameters in a single plunge. A grinding tool with several wheels has been developed, which isolates spline machining from diameter machining in terms of vibrations. “Combined with our technology & experience, machining times of just 15 seconds can be achieved. If plane surfaces and flat shoulders are also machined, the machines’ wheelhead can be extended by a swivel-in spindle in accordance with the performance criteria. The concept is, thus, perfectly designed for maximising productivity in gear shaft machining,” added Gerd König, Managing Director, Fritz Studer AG.
EM | Mar 2016
Centerless machining for precision parts In addition to the various gear shafts, there are many other precision workpieces in the transmission which are ideal for centerless machining. Planetary gear pins, which are found in large quantities and different sizes in every automatic transmission, and needles for needle bearings are ideally suited for through grinding, for example. However, these parts must not only be produced precisely, but also quickly and cost-effectively. Needles with an allowance of 0.1 mm, a workpiece diameter of 5 and a length of 16 mm, are ground on a KRONOS M 400, for instance, at a speed of up to 16 meters per minute. This gives roughly 1000 finished parts per minute. The machines are real endurance runners.
Facility with Flow-Assembly+ A highlight of the event was the tour of the new moving assembly line, which went into operation on October 15, 2015 at Thun. Flow-Assembly+ has been designed for Studer’s entire product portfolio. Design modifications such as special in-process gauging systems or customer-specific clamping systems are integrated in the lineflow. “Today, we do everything in one line, everything in flow”, is how König explained it. While explaining the whereabouts of the assembly line, Ted Neckel, United Grinding, North America, shared, “The USP of the line is that the laser measurement & grinding are done in a single motion. Automation concepts like KANBAN, six sigma and lean management are practiced here. As far as latest technologies are concerned, wire dress, a real dressing system that uses latest technology is practiced.” With a workforce of around of 800, the factory performs laser machining and grinding at the assembly line. On an average, with a lead time of 8 days, a standard machine is ready with the customer,” he concluded. ☐
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TECHNOLOGY | NEWS
Oil-free compressor
Gear hobbing machines
BOGE has developed the new whisper-quiet and ultra-low vibration compressors of the EO series that is compact enough to install near to work station. The compressors feature integrated compressed air treatment and supply Class 0 oil-free compressed air. A modular concept with one to four air ends systematically matches compressor use to demand and also offers maximum versatility - no matter whether it used on receivers, with refrigeration dryers, as a duplex unit or with a cyclone separator. The core component of EO-compressors (EO EO series stands for Eccentric Oil-free) consists of one or more scroll compressors. Each of these operates with two spirals, one of which is fixed, while the other rotates eccentrically. The two spirals intertwine without touching. The intake air is continuously compressed into the increasingly narrower interior space, thereby producing pulsation-free compressed air, which is absolutely oil-free. The use of a two-stage after cooler additionally boosts efficiency. Up to four compressors can be accommodated in a housing.
EMAG offers KOEPFER gear hobbing machine, type 160, that are perfectly synchronised for non-circular machining. Non-circular gears are making headway in many areas of application—in machines, engines, and pumps where they ensure perfectly tuned irregular power transmission. As their popularity increases, the search for an efficient way of manufacturing K 160 non-circular gears is being stepped up. Currently, the complex geometric shapes are often still manufactured by EDM, sintering, or shaping. However, this incurs relatively high costs, especially at small and medium unit volumes—due to the need for new tools, for example. Users are looking for solutions that make it possible to respond quickly to changing requirements in gear production—from circular gears to non-circular gears and back again. The K 160 gear hobbing machine carries out machining process with perfectly synchronised and dynamic machine axes. The hob follows the exact contour around the component. The procedure ensures that the teeth are cut in precisely the shape required.
BOGE India | Chennai Email: fc.jayakaran@boge.com | Tel: +91-44-4359-3454
EMAG India | Bengaluru Email: HAshwini@emag.com | Tel: +91-80-4254-4400
5-axis machining solution
Gear shaping machine
Haas Automation offers a highly cost-effective solution that brings 5-axis machining within the reach of shops that perhaps wouldn’t normally have the necessary budget. The combination of a Haas DT-1 drill/tap centre and TRT-100 dual-axis rotary/tilting table can deliver both 3+2 and full 5-axis machining at a very affordable price. The DT-1 is a compact, high-speed drill and tap machine featuring a generous 508 x 406 x 394 mm work cube yet maintaining a very small footprint. The powerful BT-30 taper spindle spins to 15,000 rpm, and allows rigid tapping to 5000 rpm. The machine provides cutting feed rates to 30.5 m/min for high speed milling, and the machine’s DT-1 drill/tap centre 20+1 side-mount tool changer swaps tools quickly to reduce non-cutting time. Furthermore, high speed 61 m/min rapids combine with high acceleration rates to shorten cycle times and increase throughput. Adding the Haas TRT100 dual-axis rotary table to the DT-1 provides high speed, accurate, 3+2 positioning and full 5-axis machining of small, complex parts.
Liebherr has developed new tooth-trace modification options using the electronic helical guide function on the LSE 200-500. The requirement of gear system design engineers to undertake load-dependent tooth-trace modifications on these gear teeth has increased steadily over the last few years. To date tooth-trace modifications, such as helix crowning cß, tooth trace angles fhß or conicity and end relief could only be undertaken on shaped gear teeth using a specially designed back-off cam (B4-axis). Where taper angles are greater, the so-called taper shaping process can only be actioned by tilting the entire machine base LSE 500 with CNC axes (B5-axis). Given the two-flank shaping process, the mentioned modifications on both tooth flanks are symmetrical. This does not permit any degree of optimisation in relation to differing demands on drive and coast flanks. Both symmetrical and asymmetrical tooth-trace modifications can be undertaken by using the LSE 500 gear-shaping machine’s electronic helical guide function in combination with single-flank shaping. The machine has a mechanical capping head with electronic diagonal control.
Haas Automation India | Navi Mumbai Email: tmiranda@haascnc.com | Tel: +91-8080902412
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Liebherr Machine Tools India | Bengaluru Email: info.mti@liebherr.com | Tel: +91-80-4117-8591
EM | Mar 2016
NEWS | TECHNOLOGY
Scanning probes
Quick jaw change system
Renishaw has introduced the RSP3-6 extended reach scanning probe for use with the REVO 5-axis measurement system on co-ordinate measuring machines (CMMs). The RSP3-6 probe provides enhanced capability for accessing and inspecting features deep within bores by combining long extensions of up to 800 mm with REVO’s 5-axis movements. RSP3-6 is ideal for inspecting large parts, such as engine blocks and components for heavy machinery used in the construction, mining, automotive and defence industries. The RSP3-6 system consists of a probe and a range of stylus holders, for applications requiring straight and cranked extensions. The RSP3-6 RSP3-6 probe is automatically interchangeable with all other probe options available for REVO. This flexibility means that the optimum tool can be selected to inspect a wide range of features, all on one CMM platform. The RSP3-6’s straight stylus holders offer extensions up to 800 mm from REVO’s A-axis centre of rotation, and its cranked stylus holders offer extensions up to 600 mm from the same reference point.
SCHUNK offers new quick jaw change system, SCHUNK PRONTO that is a real set-up time killer for conventional lathe chucks with screw connected chuck jaws. It lowers set-up time of a complete jaw set to 30 seconds, which is about 95% faster than conventional solutions. SCHUNK PRONTO combines fine-serrated supporting jaws (1/16" x 90° or PRONTO application 1.5 mm x 60°) with special quick-change inserts, and extends the clamping diameter up to 45 mm in seconds. This is eight times more than with conventional lathe chucks. To achieve a fast and highly repeatable jaw change the locking of the changing inserts are loosened with an Allen key, the insert is removed and replaced with another one. This prevents an incorrect positioning. In locked condition, a six-sided form-fit clamping ensures maximum process stability, and provides high force and torque transmission. This system is suitable for clamping raw and machined parts. Different supporting jaw variants for small, medium, and large clamping ranges are also available.
Renishaw Metrology Systems | Pune
Schunk Intec India | Bengaluru
Email: samina.khalid@renishaw.com | Tel: +91-20-66746772
Email: rakhi.singh@in.schunk.com | Tel: +91-80-40538999
Taper-face toolholders
Cylindrical grinding machine
Seco Tools has added a new range of taper-face toolholders to meet machinists’ increasing needs for higher production and process reliability. These new options provide two surfaces of contact to offer increased rigidity and consistency compared with standard holders when machining complex parts at high cutting parameters. The new taperface toolholders are designed for use with dual-contact spindle systems. EPB BT-TF They use plastic deformation of the machine spindle to achieve simultaneous fit of both the taper and the flange face from the holder to create a highly rigid connection and prevent the toolholder from being pulled into the machine spindle. This results in higher run-out precision and better machining accuracy. It also makes it possible for machinists to use higher machining parameters for substantial increases in productivity. They are available for spindle connections BT30 TF, BT40 TF, BT50 TF, CAT40 TF and CAT50 TF in both metric and inch programs. In addition to complex part machining, the taper-face toolholders excel in situations that magnify cutting forces.
STUDER is now advancing work on the S141, which has been successfully launched on the market, to produce its S131 and S151 machines and thus introduce an entire series. The S131 is much smaller and more compact than the S141 - with a swing diameter over the table of Ø 250 mm (9.8") and a maximum grinding length of 175 mm (6.9") for internal and 125 mm (4.9") for external grinding. It is available for workpieces with a maximum S151 length of 300 mm (11.8"). The S151 is a somewhat larger than the S141 - it has a swing diameter over the table of Ø 550 (21.6") mm and a maximum grinding length of 400 mm (15.7") for internal and 150 mm (5.9") for external grinding. It is available for workpieces with a maximum length of 700 mm (27.5"). Naturally, the S131 and S151 machines are designed using the same fully developed technology as the S141. In the design of the S141 particular focus was placed on ergonomics.
Seco Tools India | Pune Email: Bharati.Sawant@secotools.com | Tel: +91-2137667406
EM | Mar 2016
United Grinding India | Bengaluru Email: prabhakar@grinding.ch | Tel: +91-99-8013-8897
85
TECHNOLOGY | NEWS
Modular system for profile machining
Precision metalworking tools
SUHNER has developed new modular system that enables the creation of special machines for various applications of profile machining. The illustrated machine produces precision rail guides and was designed and built by the company’s division for special machines. The rapid transfer of the pieces was as important as the precise and rapid loading, unloading and fixture. The geometry of the fixture device allows Modular system simultaneous drilling, in steps of the holes in tool steel. The high pressure internal cooling of the carbide tools allows an excellent drilling performance. The installation consists in 2 spindles that operate in less than 3 min 140 drilling operations, loading and unloading included. The positioning of the spindle and the actual drilling operation takes place in about 2 seconds. The automatic loading and unloading allows predictable autonomy. Stacks and checking the position and the feeding of bulky work pieces must be adapted individually to the workpieces. Assembly profiles are often cut for further cost optimisation from bar stock.
From the esteemed IMC (International Metalworking Companies) stable arrives the youngest member yet – Duracarb, which is a full-length tool supplier with D-Mill, D-Drill, D-Turn and D-Cut, in addition to the solid carbide range, to cater to every application in the shopfloor. Duracarb tools are engineered to meet the modern cutting tool needs of customers from various industries, across a spectrum of applications that include turning, milling, drilling, holemaking, grooving etc. Apart from product and process excellence, the company is Duracarb cutting tools looking to offer the most customer friendly experience in the market. Bringing together the pedigreed quality assurance as an IMC brand, and a unique price point competitiveness to the industry, Duracarb is fast proving to be the smart Indian choice for the indigenous manufacturing scenario, according to the company. Manufactured in IMC facilities around the world, Duracarb products and production systems incorporate automatic quality control procedures and are certified by internationally recognised standards like AS 9100 / ISO 9001, ISO 14001 and OHSAS 18001, to name a few.
SUHNER India | Bengaluru Email: automation.in@suhner.com | Tel: +91-80-2783-1108
Duracarb | Chennai Email: sales@duracarb-india.com | Tel: +91-044-4904-8328
Cassette sealing solutions Trelleborg Sealing Solutions has revolutionised cassette seal design with their new CSL 1500. CSL 1500 is a unique innovative seal that incorporates opposing sprung lips and a stacked design to reduce friction and wear, extending seal life while improving contaminant exclusion and static sealing ability. Originally designed for agricultural and construction equipment, the CSL 1500 has been vigorously tested in the laboratory and field to prove reliability. The CSL 1500 seal has completed 3,000 hours of slurry and hot oil testing as well as over a year of gruelling field service without leakage. Now being utilised in other application areas, the CSL 1500 applies innovative seal design to give greatly improved performance. A stacked design gives more room to add components and permits a larger volume of grease, which serves as a barrier to contamination, while a new oil seal lip provides the superior sealing capabilities expected from the company’s product. In addition, a new bonding method leaves a fine finish on the riding surfaces. Trelleborg Sealing Solutions | Bengaluru Email: rohit.nair@trelleborg.com | Tel: +91-80-33729355
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Statement about ownership & other particulars about EM, as required to be published in the first issue every year after the last day of February FORM IV (See Rule 8) 1. Place of Publication: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 2. Periodicity of Publication: Monthly 3. Printer’s Name: Shekhar Jitkar Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 4. Publisher’s Name: Shekhar Jitkar Nationality: Indian Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 5. Editor’s Name: Shekhar Jitkar Nationality: Indian Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 6. Names & addresses of individuals who own EM and partners or shareholders holding more than 1% of the total capital in publish-industry India Pvt Ltd: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 Details of the shareholders of publish-industry India Pvt Ltd who are holding more than 1% of the paid up equity share capital of the company as on 10-03-2015: a) publish-industry Verlag GmbH, NymphenburgerStrasse 86, 80636 Munich, Germany b) Kilian Mueller, NymphenburgerStrasse 86, 80636 Munich, Germany I, Shekhar Jitkar, hereby declare that all the particulars given above are true to the best of my knowledge and belief. Dated: March 08, 2016 Sd/SHEKHAR JITKAR Signature of the Publisher
EM | Mar 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 - Apr 2016 IMPRINT Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Features Writer Megha Roy megha.roy@publish-industry.net
» Casting & forging Despite radical reforms in manufacturing processes, casting as a production technique still adopted heavily to build complex products. Basic technologies in casting & forging have not undergone much change, but the emphasis has changed. The world has become more environmentally conscious and technologies have to conform to more and more stringent environment norms. The next issue will highlight some of the trends in the casting & forging sector.
» Industrial robotics There are new factory robotic trends emerging every day, like the addition of vision and sensors to make robots easier and safer to work with in a human-populated environment. The next issue of EM will discuss these advanced technologies incorporated in robotics. » Geometric Dimensioning and Tolerancing The proper use of Geometric Dimensioning and Tolerancing (GD&T) within a welldefined product development effort can identify a bad design before it results in a lot of needlessly expensive parts. EM will feature the articles on importance of GD&T in manufacturing
» Green machining practices The demand for sustainability is growing stronger every day, and manufacturers are looking for ways to comply to reduce their impact on the environment and increase profitability. The concept of green manufacturing aims at design and implementation of processes that will eliminate waste and reduce environmental impact in work pratices and plant operations. The special feature in the next issue will talk on this concept in detail.
Features Writer Maria Jerin maria.jerin@publish-industry.net Advertising Sales Sagar Tamhane (Regional Head - North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net Dhiraj Bhalerao (Regional Head - West & South) Contact: +91 9820211816 dhiraj.bhalerao@publish-industry.net Prabhugouda Patil Bengaluru Contact: +91 9980432663 prabhu.patil@publish-industry.net Advertising Sales (Germany) Caroline Häfner (+49 - 89 - 500 383 - 53) Doreen Haugk (+49 - 89 - 500 383 - 27) sales@publish-industry.net Overseas Partner Ringier Trade Media Ltd China, Taiwan & South-East Asia Tel: +852 2369 - 8788 mchhay@ringier.com.hk Design & Layout Jogindar J Dumde (Graphics Designer) jogindar.dumde@publish-industry.net Editorial & Business Office publish-industry India Pvt Ltd 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Tel: + 91 - 20 - 6451 5752
COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . .Page Ace Micromatic Group . . . . . . . . . . . . . 37 Ace Micromatic MIT . . . . . . . . . . . . . . . 32 Autocam Technology Co . . . . . . . . . . . . 71 BFW . . . . . . . . . . . . . . . . . . . . . . . . . 12 BIEMH . . . . . . . . . . . . . . . . . . . . . . . . 47 Blaser Swisslube . . . . . . . . . . . . Cover, 27 Blum Novotest India. . . . . . . . . . . . . 29, 54 BOGE . . . . . . . . . . . . . . . . . . . . . . . . . 84 Robert Bosch Engg & Business Solutions . 32 CD-Adapco . . . . . . . . . . . . . . . . . . . . . 74 CG Tech . . . . . . . . . . . . . . . . . . . . . . . 53 CII . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Comsol Multiphysics . . . . . . . . . . . . . . . 25 Cooper Corporation . . . . . . . . . . . . . . . 16 Delcam Ltd . . . . . . . . . . . . . . . . . . . . . 18 EMAG . . . . . . . . . . . . . . . . . . . . . 49, 84 Ervin Junker Maschinenfabrik . . . . . . 10, 59 Espirit . . . . . . . . . . . . . . . . . . . . . . . . . 61 Everising Machine Co . . . . . . . . . . . . . . 67 Forbes & Company . . . . . . . . . . . . . . . 15 Frost & Sullivan . . . . . . . . . . . . 10, 32, 73
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Name . . . . . . . . . . . . . . . . . . . . . . .Page Grind Master Machines . . . . . . . . . . . . . 38 Haas Automation . . . . . . . . . . . . . . . . . 84 Hannover Messe . . . . . . . . . . . . . . . . . 63 Heidenhain Optics & Electronics India . . . 45 Hong Ji Precision Machinery . . . . . . . . . 69 Hyundai WIA India . . . . . . Back Inside Cover igus . . . . . . . . . . . . . . . . . . . . . . . 14, 21 IMTMA . . . . . . . . . . . . . . . . . . 10, 20, 78 Jyoti CNC Automation . . . . . . . . . . . . 3, 18 Kaizen Institute Consulting Group . . . . . . 12 Korloy India . . . . . . . . . . . . . . . . . . . . . 13 Liebherr Machine Tools India . . . . . . . . . 84 Makino . . . . . . . . . . . . . . . . . . . . . . . 48 Marposs India . . . . . . . . . . . . . . . . . . . 17 Mitsubishi Heavy Industries . . . . . . . . . . . 2 MMC Hardmetal . . . . . . . . . . . . . . . . . . 19 MotulTech India . . . . . . . . . . . . . . . . . . 41 Nicolás Correa, S.A . . . . . . . . . . . . . . . 35 Omron Automation . . . . . . . . . . . . . . . . 11 PARI . . . . . . . . . . . . . . . . . . . . . . . . . 30
Name . . . . . . . . . . . . . . . . . . . . . . .Page PMT Machines . . . . . . . . . . . . . . . . . . . 51 Quaker Chemical Corporation . . . . . . . . . 42 Renishaw . . . . . . . . . . . . . . . . . . . 60, 85 Rollomatic India . . . . . . . . . . . . . . . . . . 65 S&T Engineers . . . . . . . . . . . . . . . . . 1, 55 Schunk Intec India . . . Front Inside Cover, 85 Seco Tools . . . . . . . . . . . . . . . . . . . . . 85 Siemens Ltd . . . . . . . . . . . . . . . . . 20, 22 Siemens PLM Software . . . . . . . . . . . . . 66 Strausak . . . . . . . . . . . . . . . . . . . . . . . 57 Suhner . . . . . . . . . . . . . . . . . . . . . . . . 86 TaeguTec India . . . . . . . . . 86, Back Cover TAGMA . . . . . . . . . . . . . . . . . . . . . 14, 77 TAL Manufacturing Solutions . . . . . . . . . 32 Trelleborg Sealing solutions . . . . . . . . . . 86 United Grinding India . . . . . . . . . 43, 81, 85 Vargus India . . . . . . . . . . . . . . . . . . . . . 6 Volvo India . . . . . . . . . . . . . . . . . . . . . 20 YG1 Cutting Tools . . . . . . . . . . . . . . . . 4,5 ZF India . . . . . . . . . . . . . . . . . . . . . . . 18
Board of Directors Kilian Müller (CEO - Worldwide) Hanno Hardt (Head - Marketing & Business Development) Frank Wiegand (COO - Worldwide) Shekhar Jitkar (Publisher / Chief Editor) Subscription Cover Price: `100 Annual Subscription Price: `1000 em.india@publish-industry.net Tel: +91-20-6451 5754 Printing Kala Jyothi Process Pvt Ltd, S.No: 185, Kondapur, R R District, AP 500 133, INDIA Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of editorial contributions is only allowed with express written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted. Internet http://www.efficientmanufacturing.in Digital edition http://issuu.com/publishi/docs
EM | Mar 2016
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F500D/600D • High-precision P4 Angular Contact Bearing main spindle • Dual Tables for high productivity • Latest Servo ATC for fastest tool exchange in the class • Latest SIEMENS 828D Controllers for various software support
HS Series
• Heavy Duty Motion Roller Guidways • Powerful Dual Wound Spindle Motor • Heaviest Maximum load in its Class • Big Plus Spindle (BBT)
HYUNDAI WIA India Office
#4/169, Rajiv Gandhi Salai, (OMR), Kandanchavadi, Chennai - 600 096, Tamilnadu, India Tel. +91 44 3290 1719 Mob: +91 9840999094 e-mail. sales@hyundai-wia.com, service@hyundai-wia.com