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EFFICIENT MANUFACTURING
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NETWORKED PRODUCTION SYSTEMS
FOCUS Die & Mould
EM - Interview Aroop Zutshi, Global President & Managing Partner Forst & Sullivan
(p. 28)
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SPECIAL FEATURE Warehousing & Inventory
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DIFFICULT MATERIALS MADE EASY
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E D I TO R I A L
Demonstrating the radical shift! The trade shows like EMO provide live demos of the numerous new technological developments in machines, systems, tools and machine components. At the same time, they demonstrate the radical shift towards advanced manufacturing technologies, aimed at traditional goals such as trackable production processes, optimised resource utilisation, higher flexibility and increased productivity. In this context, we are happy to bring you the technology report on the EMO 2017 show in the Cover Story of this issue (although little late, but worth reading), presenting innovations designed to network the world of metalworking and progress its technological optimisation. I am sure you would love to know what trends and issues are the major focuses of production technology today, in this report. The die and mould sector is a good barometer of global manufacturing health, as it serves multiple industrial markets. The sector, which covers everything from compression moulds through to press tooling and fixturing, is a key supplier to practically all segments of industry, from automotive and aerospace, through to electronics and food & beverage. The Industry Focus in this issue is die & mould, where the articles talk on automated mould making and composite tooling. The DieMould India show, organised by TAGMA, has grown to become a unique trade fair in India for the die & mould industry, which presents innovative products and solutions covering the entire supply chain to the tooling industry. Have a look at the event preview to know more about this upcoming show. The Technology Focus features high-speed machining and titanium machining – the hot technologies in the machining area today. The Events section features reports on IMTEX 2018 – the metal forming show from IMTMA and Fritz Studer’s Motion Meeting conference. Happy reading!
“The trade shows demonstrate the radical shift towards advanced manufacturing technologies, aimed at traditional goals such as trackable production processes, optimised resource utilisation, higher flexibility and increased productivity”
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net EDITORIAL ADVISORY BOARD Raghavendra Rao Senior Vice President Manufacturing & Process Consulting Frost & Sullivan
Dr N Ravichandran Former Executive Director Lucas-TVS Chief Mentor, UCAL Fuel Systems
Satish Godbole Vice President, Motion Control Div Siemens Ltd
Vineet Seth Managing Director Mastercam India
N K Dhand CMD, Micromatic Grinding Technologies
Dr K Subramanian President, STIMS Institute, USA Training Advisor, IMTMA
Dr P N Rao Professor of Manufacturing Technology, Department of Technology, University of Northern Iowa, USA
Sonali Kulkarni President & CEO Fanuc India
Dr Wilfried Aulbur Managing Partner Roland Berger Pvt Ltd Dr Ravi M Damodaran President Technology & Strategy Varroc
Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
EM | Mar 2018
7
CONTENTS
Market
Management
12 NEWS
INTERVIEW 28
16
“Laser cutting machines will drive the future of cutting machine business”
Interview with Shreyansh B Hippargi, Managing Director, QVI India
30
“Never too late to start!”
Jack Ma, Founder & Executive Chairman, Alibaba Group
Tooling methods for composite tooling
The feature discusses direct and indirect tooling methods for composite tooling along with overviewing possible materials that can be used for tools and master moulds
LEADERSHIP INSIGHTS 20
“Growth will continue in the next fiscal”
DIE & MOULD
“The future looks promising!”
Aroop Zutshi, Global President & Managing Partner, Frost & Sullivan
Interview with Mani M, Managing Director, Messer Cutting Systems India 17
Focus
34
Reliability for automated mould making
The article talks on laser measurement systems for CNC machine tools that are used for non-contact tool measurement and tool monitoring
EVENT PREVIEW 50
Scaling the tooling industry A preview of the upcoming DIEMOULD India 2018 to be held at Mumbai
COVER STORY EVENT REPORT 54
Fabricating the future
A report on the recently held IMTEX Forming 2018 at Bengaluru 58
Continuous quest of innovation
A report on the recently held Fritz Studer Motion Meeting 2018 at Switzerland
22
Networked production systems
EMO Hannover 2017 presented innovations designed to network the world of metalworking and progress its technological optimisation under the motto of ‘Connecting systems for intelligent production’. The story analyses the major trends witnessed during the show by highlighting the digitalisation and networked production systems.
EM – the only industrial magazine in India that offers a three-dimensional perspective on technology, market and management aspects of manufacturing
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CONTENTS
Technology
Cover image courtesy: EMO-Hannover 2017
HIGH SPEED MACHINING 38
Accelerating production capabilities
SPECIAL FEATURE 44
An insight into how distribution centres can use lean principles and mobile power to improve operational efficiency
A read on the usage of high speed machining centres by an aircraft parts manufacturer to enhance efficiency and overall quality TITANIUM MACHINING 42
A guide to titanium machining
The article highlights the advantages of using titanium and the three methods of machining the material
EM | Mar 2018
Receiving best practices
VIEWPOINT 18
Union Budget 2018-19
The column explores the host of measures announced in the Union Budget along with opinions from industry leaders on its impact in their respective industry verticals
New Products 61 5-axis grinding centre; CNC controllers; Industrial troubleshooting kit with IR; Bearing housing retrofit 63 Global full-liner for Additive Manufacturing; Cylindrical grinder
Columns 07 Editorial 08 Contents 10 Guest Editorial 64 Highlights – Next issue 64 Company index
9
Sanjeev Baitmangalkar
STRATEGY & LEAN MANAGEMENT CONSULTANT STRATMANN CONSULTING
Indian manufacturing organisations should aspire to build the brand tag ‘Made in India’ as a value offering. This will mean building core competence values like reliability, safety, value for money, dependability, and appeal; and this is possible by building the business processes aligned to lean thinking and lean principles. Lean manufacturing companies work using the principle of PULL. Others work on PUSH. Unfortunately, we have more PUSH companies than PULL. The principle of PULL makes companies better and healthier. The government has tried to push for quality and competitiveness through its schemes, such as the cluster programme. Irrespective of how it is reported, these programmes have missed the essence of lean and at best have become attempts to reduce defects and give instructions on a few lean tools. Tools, when used properly, may provide change, but that does not guarantee continuity of improvements, consistency and impact on the balance sheet. Most claimants to lean are not lean. However, if lean is culturally embedded properly, 10
COMMENTS & COMMENTARY
GUEST | EDITORIAL
excellence will walk to its door step and so will customers, markets, share and profits.
Can those losing jobs rise to new expectations? Look at the tech industry vacancies. They are finding it hard to recruit college grads for new tech areas. So, these are going to be two different domains altogether – the domain where jobs are lost and the domain where jobs are created with a huge knowledge gap.
The cows are yet to come home on whether technologies in the digital space such as Artificial Intelligence, Machine Learning, IoT, 3D printing, etc. will reduce or increase jobs! We need to pay attention to the growth of jobs. Imagine if all cars are driven autonomous, what will happen to millions of drivers around the world? If batteries or hydrogen cells replace IC engines, what will happen to all those workers in auto component industries and those upstream to them? When automation replaces jobs of any kind, the question that needs to be answered is what’s the next job opportunity for those displaced? While the argument will rage that there will be creation of new jobs that will replace the old ones, these new jobs will demand entirely new levels of learning, skills and competence.
To overcome this potential social problem, there needs to be more ‘Job Creating Innovations’ and at different levels of education and opportunities led by innovators, manufacturing organisations and investors who invest in job creating innovations rather than in efficiency innovations. Investors and investment companies must consider to invest from profits made by their investments in efficiency innovation businesses into job-creating innovations so that growth and stability in jobs and economy can be maintained. There is much of sustaining innovation happening through substitute products, but such innovations only replace the old, they don’t add to overall jobs and economy. I hope the industry champions will selflessly lead the solutions.
JOB-CREATING INNOVATION
EM | Mar 2018
MARKET | NEWS
Altair & DesignTech to set up Centre of Excellence
DesignTech Systems and US-based Altair Engineering recently announced a collaborative effort with Science and Technology Park, which is an institute supported by the Dept. of Science and Technology (DST), Government of India. This partnership has been initiated to support the advancement of the ‘Skill India’ programme. The agreement to establish an Engineering Centre of Excellence (CoE) for research, innovation and skill building, is therefore, expected to benefit a large community of students, academic institutes and the overall industry. Speaking on this technical collaboration, Vikas Khanvelkar, Chairman & Managing Director, DesignTech Systems, said, "This collaboration intends to propose the Altair Centre of excellence for research, innovation & skill building and it can also extend engineering consultancy to small and medium scale manufacturing industries." The CoE is geared to encompass the following labs—Product Design Lab, Additive Manufacturing Lab, Design Validation Lab, Manufacturing Assessment Lab, Flow and Thermal Lab, Communication lab for loT, Signal Processing and Communication lab for loT and Control Systems and Mechatronics lab for loT. Also adding further insight was Dr Rajendra Jagdale, Director General & CEO, Science and Tech Park, who observed, "The park is collaborating with prominent education institutions in Maharashtra and other parts of India to set up these centres jointly, such as the Rayat Shikshan Sanstha, Vidya Pratishthan Baramati, Deogiri education institutes in Aurangabad, Chhatrapati Shahu in Pune and other similar institutes.”
Series of conferences on Virtual & Augmented Reality aims to bridge gap VRTech is a series of events, recently announced by Focussed Events, which will explore the benefits that Virtual Reality and Augmented Reality have for various industry verticals. The first, in this series, is the VRTech conference, to be held on April 18, 2018, in Pune and will focus on applications of Virtual and Augmented Reality in the field of design and manufacturing. The later editions will address and assess VR & AR’s potential in healthcare, defense, crime detection and disaster management. The theme of the current edition is ‘Helping industry go from drawing boards to immersive virtual product experiences and it aims to bring all related stakeholders on a single platform, so as to inspire attendees to see various available systems and how they could enhance workflow and set new standards in quality and cost savings. Globally, Virtual Reality and Augmented Reality is playing a vital role and being adopted as an engineer’s communication ‘language’ to help cross-functional teams digitally see and interact with their designs, as well as troubleshoot potential issues in pre-production. It is a visual expression of how it is going to be and is being used across the concept—development—build—assemble—maintenance framework in several sectors. Though this technology is being adopted in the Indian industry and is being used for the visualisation of product development and associated manufacturing processes, the intended users are still struggling to understand concepts and are not fully conversant with the various differentiating factors. The VRTech series of conferences aims to wipe out this gap and help educate and explain capabilities and influence potential users from mentioned industries to take appropriate decisions.
12
EM | Mar 2018
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MARKET | NEWS
India has potential to become digital factory of the world: CII CII recently held a conference in Gurgaon on hi-tech manufacturing and robotics, which witnessed the presence of many experts and leading companies from industrial automation, robotics and the automobile sector across the country. Addressing this summit, Ramesh C Jain, Past Chairman, CII Regional Committee on manufacturing technology and competitiveness & Director, Hi-Tech Group, stressed that the global manufacturing landscape is being transformed by digital technologies. Also speaking at the session was PV Sivaram, Non-Executive Chairman, B&R Industrial Automation, who said that speed, quality, service, flexibility and global focus are being identified as the essential elements for successful manufacturing for the next decade and manufacturers will be measured by their ability to respond quickly to sudden, often unpredictable changes in customer needs and wants. Next, Anuj Kapuria, Co–Chairman, CII NR Committee on Hi-Tech Manufacturing & Robotics and Founder & CEO, The Hi-Tech Robotic Systemz, spoke about the role of IoT and AI in manufacturing. He said that by 2020, there will be 30 billion connected devices on earth. “This information generated by the increase of connected devices represents a significant opportunity. Determining how to best identify, capture and interpret this increased volume of data can help organisations understand their market and customers better, as well as gain market share,” he said. Shifting gears to the MSME sector, Sivakumar Natarajan, Global Practice Head – Digital for Manufacturing Industries, Wipro, said that there are three broad areas where MSMEs need to look at as part of their IoT & broader digital transformation initiatives. “First is the Connected Plant, which requires improving the operational efficiency of physical plant assets, workers and associated processes resulting in improved asset utilisation, reduced operating and maintenance costs, while improving uptime and production. The Connected Enterprise is the second aspect, which requires improving the operational efficiency of an enterprise resulting in higher productivity of employees, lower cost of IT infrastructure and optimised supply chain performance. The Connected Customer is the third factor, which requires improving the effectiveness of marketing, sales and support of products and creation of new business models to increase revenue,” he stressed. The summit was attended by over 150 corporates from across the country and witnessed speakers from various organisations.
CGTech celebrates its 30-year milestone CGTech, the developer of VERICUT® software, recently celebrated three decades of innovation and consistent growth. Headquartered in California, with 10 wholly-owned subsidiaries and an extensive network of resellers to support customers worldwide, the company is releasing new CNC simulation and optimisation technologies. Speaking on this, Jon Prun, President, CGTech, said, “VERICUT development is driven by our customers’ needs and we always encourage input from users and partners. We host nearly 50 free VERICUT user group meetings worldwide each year so as to gather valuable customer feedback.” The company has been on a hiring spree in recent years to keep up with the demands of its customers, which consists of companies in the manufacturing industry.
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EM | Mar 2018
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MARKET | INTERVIEW
“Laser cutting machines will drive the future of cutting machine business” Mani N, Managing Director, Messer Cutting Systems India, highlights the growth of laser cutting machines, gradual transformation of plasma into laser and IoT-enabled products, in an interaction with Megha Roy. Excerpts… How has been the overall performance of your company in India? The performance of our company has been positive. In 2017, we have grown by 17% as planned. Going forward, we have the same expectation this year, and we hope to meet the target this year too. Overall, the thermal cutting industry is expected to gain momentum this year. Also, the cutting tools and machine tools industry, in general, is expected to perform well. As witnessed at IMTEX, many of our customers are planning to increase their capacity and put in more investments for the upcoming years. We plan to increase our capacity too. What are the upcoming trends that you foresee in your business sector? Over the past few years, we have witnessed a strong growth in terms of the laser cutting machines. Earlier, the number of laser cutting machine exhibitors used to be in single digit in IMTEX and ESSEN. However, in IMTEX 2018, there are more than 25 laser-cutting machines exhibited. So, it is clear that the laser cutting machine market is growing fast in India like what we have seen in China. Though the demand for laser cutting machines is growing fast, we have seen cases of laser users converting themselves into plasma cutting machines as well due to the innovation happening in plasma technology. We already have a factory for thermal cutting machine manufacturing in Coimbatore and soon we will be having a facility exclusively for standard and large format laser cutting machines. Since the market is maturing on plasma and laser cutting application, we also expect that the market will soon emerge for plasma-laser combination cutting machines. We had already launched a laser-plasma combination machine at IMTEX 2014 itself, but realised that the market was not ready for such a change at that time! What would be your outlook on the industry performance in this year?
16
The overall industry performance looks promising. Oxyfuel cutting has its own niche market for higher thickness materials, hence, it is expected to grow continuously. In addition, I do not expect the plasma market to go down because of the boom in the laser market. In fact, the plasma market will continue to grow stronger with better and highdefinition plasma machines. We expect that the entire outlook of plasma cutting machines will undergo a transformation. A section of the plasma cutting machine market will be taken over by laser machines and simultaneously, the improved plasma cutting machines will also take over a part of the present laser cutting market. What were the new products & technologies launched during IMTEX this year? We launched the plate processing machine at IMTEX this year. Apart from straight cutting, this machine performed straight and contour beveling, drilling, counter drilling, counter boring, tapping, thread milling and milling —all operations in one machine. How is your company coping up with the rapid pace of digitalisation and Industry 4.0 in the manufacturing sector? We have a dedicated team in our company working for Industry 4.0 and the IoT business. All our future products will certainly focus on the needs of Industry 4.0-enabled products, and we are ready to clasp this change. We have already released our product profile in terms of our capabilities in the IoT world. Therefore, we will be acting according to the market demand. How do you strategise post-IMTEX to get the maximum out of the exhibition? Post-IMTEX, we track the enquiry with the help of a lead management solution for the sales and marketing team. The QR scanner in it enables us to input data as required, and can be used for the entire period till we close the deal with a customer. ☐
EM | Mar 2018
INTERVIEW | MARKET
“Growth will continue in the next fiscal” Shreyansh B Hippargi, Managing Director, QVI India, in this interview with Suchi Adhikari, discusses the trends in the vision measuring systems market and the significance of this year’s IMTEX exhibition for their company. Excerpts… How has been the overall performance of your company in India? QVI India has been present in the market since 2008. We have been having a steady growth in the market. However, as an organisation, we want to grow & have better market share in our product line. We want to give our customers the updated technologies with advanced software. Thus, as a company, we are looking ahead in this direction. Keeping in mind the developments in the Indian manufacturing sector lately, in terms of advanced technology adoption, volatile market conditions and changing customer requirements, what would be your outlook on the industry performance this year? There has been an initial setback that the Indian manufacturing sector has faced after the implementation of GST. However, we have also witnessed the recovery from this initial setback and the market has shown steady growth. This growth has been steady and continuous, bringing in good numbers. Going by this trend, we anticipate further growth in the next fiscal. What were the new products and technologies that you launched during IMTEX this year? What are the upcoming trends that you foresee in your business sector? In this year’s IMTEX exhibition, which specialises on metal forming technologies, we are showcasing our company’s SNAP, 1-shot vision measuring systems, which are very good for inspection of huge number of small sheet metal components. These are the 1-shot machines and these systems give part dimensions, within seconds. With this specialty, we are sure that the product will find a good market in this metal
EM | Mar 2018
forming exhibition. Speaking of upcoming trends in our vision measuring market, the customer is looking at user-friendly software and that is where the challenge comes. We are well-equipped with strength in this context and our software is very user-friendly, especially the snap 1-shot vision measuring systems, which we had showcased at this IMTEX exhibition. The software auto-detects the feature and gives the results within seconds. These are the kinds of software which we are continuing to develop so that our users and customers can get the best of these systems. IMTEX provides a good platform for networking with customers and vendors. How do you strategise post IMTEX 2018 to get the maximum out of the exhibition? There is no denying that the IMTEX exhibition is a very good platform for networking, both with the customers and vendors. For us, it is also a platform where we educate and bring awareness to our customers about the latest technologies offered by our company, whether it is in terms of our vision measuring systems, the optics that we put into the systems and how good they are and the advantages that our software products bring to our customers and clients globally. Thus, this exhibition is a great platform for direct interaction with existing and future customers in this regard. Secondly, we are also looking for some channel partners in key geographies, with whom we would like to work with, to promote our products & technologies. So, this is an ideal platform where we can develop the business through customers and channel partners. ☐
17
VIEWPOINT | MARKET
Union Budget 2018-19: Enabling manufacturing growth
The Union Budget 2018-19, presented by Finance Minister Arun Jaitley, has been welcomed by the industrial sector. The measures announced in the Union Budget provide the much needed thrust to the economy and have been deemed inclusive. The industry expressed its approval for the focus on development of rural economy, manufacturing, infrastructure, education, ease of doing business, attracting investments and encouraging innovation and digitisation. Major budget highlights included import duty on select auto components, which has been enhanced to 15% and reduction in corporate tax for MSMEs to 25%. This viewpoint section further explores this year’s budget, keeping in mind the growing Indian manufacturing sector. Excerpts…
₹ ₹ ₹ ₹ ₹ ₹ ₹ Suchi Adhikari Sub-editor & Correspondent suchi.adhikari@publish-industry.net
“Momentum from the last quarter will sustain through 2018”
T
Dr Jairam Varadaraj, Managing Director ELGi Equipments
18
he budget has introduced some interesting schemes towards agriculture and rural development. They continue to support investments in infrastructure, which will support our portable compressor range. Many of our suppliers will benefit from the MSME tax reduction and perhaps the tax reduction will encourage capital expenditure, which could in turn support our industrial compressor range. Overall, while there are no explicit manufacturing boosters, we hope that the momentum from the last quarter will sustain through 2018.
EM | Mar 2018
MARKET | VIEWPOINT
“Budget is inclusive and pro-manufacturing”
T
Nirmal Minda, President ACMA
he Budget unveiled by Hon’ble Finance Minister is indeed inclusive and promanufacturing. The component sector is delighted that the duty on select items such as engine & transmission parts, brakes and parts thereof, suspension and parts thereof, gear boxes and parts thereof, airbags etc, have been enhanced from 7.5-10% to 15%. These items account for more than 50% of USD 43.5 billion domestic component industry’s turnover and over 30% of its USD 11 billion exports. The industry is extremely competitive in these areas and this measure will not only encourage investments but also encourage technology development in these areas. Further, reduction in corporate tax to 25% for SMEs with turnover of up to Rs 250 crore is yet another welcome step as over 80% of the companies engaged in the auto component manufacturing are SMEs. This measure, as also enhanced budgetary allocation of Rs 3,794 crore for credit support, capital and interest subsidy, will have a benign impact on the smaller enterprises. Simplification of procedure for credit availability through online-system for SMEs is also a welcome step. The thrust given to the development of rural economy, infrastructure, particularly roads, augurs well towards creating a vibrant automotive market in the country, which in turn, will fuel growth and development of the domestic auto component industry.
“Union Budget paves way for transforming India’s manufacturing landscape”
I
V Anbu, Director General & CEO IMTMA
EM | Mar 2018
ndia’s commitment to long-term macro-economic stability and prudent fiscal management has been reaffirmed with the Union Budget 2018, tabled by Hon’ble Finance Minister and Minister for Corporate Affairs, Arun Jaitley in the Parliament recently. The budget offers stability and opportunities for India’s manufacturing sector as well as its machine tool industry. The reduction in corporate tax for entities with turnover of up to Rs 250 cr to 25% is a positive step towards development of MSME sector and enhancing their production capacities. The Indian machine tool industry has around 1000 units engaged in the production of machine tools, accessories/attachments, subsystems and parts. Of these, around 25 companies in the large sector account for about 70% of the turnover and the rest are in the MSME sector and this sector stands to benefit a lot from this budget. The ministry’s move, therefore, is expected to give an uptick for the machine tool industry business, which has a significant number of MSMEs. The budget has taken measures to promote job creation in several sectors such as auto components, electronic goods, textiles, mobile phone manufacturing, and so on. An allocation of Rs 1.48 trillion for track doubling, gauge conversion, line works and redevelopment of stations will spur manufacturing. We foresee demand rising for a wide range of machine tools required by railways. Further, the sanctioning of Rs 120 crores for Scheme for Enhancement of Competitiveness in Indian capital goods sector including Advanced Manufacturing Technology Development Centre and Tumakuru Machine Tool Park is a continuation of the initiative taken by the Department of Heavy Industry to spur the development of advanced technologies in machine tools. Also, the capital expenditure outlay of Rs 80 crores towards trade infrastructure for export schemes for setting up of trade promotion centres will give a boost to export trade. It is a matter of satisfaction that the government has extended concessional custom duty on critical imports to all categories of CNC metalworking machine tools.
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LEADERSHIP INSIGHTS
Never too late to start! Jack Yun Ma
FOUNDER & EXECUTIVE CHAIRMAN ALIBABA GROUP
Founder of the E-commerce giant Alibaba, Jack Ma, has undoubtedly been one of the most enlightened entrepreneurs till date for thinking beyond the tangible gains of business imperatives. In spite of a number of failures during his early days of education and career, Ma has always been an epitome of believing in oneself, being persistent in the face of adversities and treating rejections & failures as opportunities to propel oneself ahead. Upon his failures, the tycoon started a translation service business, and on his first visit to the US in 1995 as a translator, Ma became aware of the internet and was stunned to learn that there were no representatives from China online. Immediately seeing the potential business opportunities of the internet and how it could facilitate Chinese enterprises to do business, the risk-taker along with his friends, decided to launch the Chinapage that listed Chinese businesses and their products. However, after the failure of this endeavour, he tried his hand at another internet-based business venture and gathered a group of potential investors at his home and sold them on his dream to 20
NEVER GIVE UP. TODAY IS HARD, TOMORROW WILL BE WORSE, BUT THE DAY AFTER TOMORROW WILL BE SUNSHINE launch Alibaba with the goal of facilitating international trade for small & medium ventures based in China. Ma’s vision for Alibaba is to make it survive for 102 years. As such, he has always made his purpose to create a clear, lengthy and purposeful vision. He entrails to have an obsessive focus on customer, not revenue or share price and encourages people to learn the tactics and skills from others, but not change one’s dream. His success mantras amalgamate the importance of team work in the attitude and passion of the people, rather than theoretical business skills. He also envisions the concept of acceptance and believes that changing one’s approach shall be the key to the success of his greatness. Instead of including all targets under the vision of one person, he collects
the entire common goal that everyone has in common—“Vision is more important than leadership skills!”. On developing and mentoring a team, Ma believes that a leader is only successful with a rightful team. “Focusing on the skills of employees, and employing people who can perform anything according to your vision is the cornerstone of a company’s success!” Also, he believes that this role is extended to a company’s culture wherein it’s the company’s responsibility to train an employee better. In addition to the foresight, Ma considers that a good leader should be extremely stubborn so as to know exactly what he wants to achieve. Currently, Alibaba has created jobs for around 30 million people globally and has an ambition of creating another 100 million jobs, thus, reaching the 2 billion mark. ☐
Megha Roy ASSISTANT EDITOR EM | Mar 2018
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FUTURE OF MANUFACTURING Networked production systems
Exhibitions like the EMO Hannover are the world’s most important international meeting points for production technology specialists from across all segments globally. The recently held EMO Hannover 2017 presented innovations designed to network the world of metalworking and progress its technological optimisation under the motto of ‘Connecting systems for intelligent production’. The feature, to be carried in two parts, focuses on the major trends witnessed during the show, and the first part discusses the digitalisation and networked production systems. A read on…
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Dipl-Ing Johann Kiesner, Institute of Production Engineering and Machine Tools, Leibniz University in Hanover, kiesner@ifw.uni-hannover.de
Maximilian Metzger, Institute for Machining Technology, Dortmund University of Applied Science, metzger@isf.de
EM | Mar 2018
TECHNOLOGY
C O V E R S TO R Y
Industry 4.0 robotic applications could seem like a far off future for manufacturers but IIoT capabilities may be closer than you think
At EMO Hannover 2017, there was a particular focus on cloud- and offline-based solutions for networking machines, tools, handling aids and production sequences, in order to achieve the intelligent production operations of tomorrow. Networked machines, whose operating states can be acquired and statistically evaluated at any time, plus intelligent tools in conjunction with intelligent tool management systems, constitute only one aspect of tomorrow’s manufacturing operations. Improved service structures at the customer’s facility thanks to smartglasses, comprehension-enhancing projections of complex tools using augmented reality, increase the customer benefits involved. But solutions for security-driven management of the data generated were also presented.
Initiative for networked production The VDW (German Machine Tool Builders’ Association) has launched a sectoral initiative for networked production. Its aims are development and software-based implementation of a standard for linking a whole array of highly disparate machine control systems at a shared interface. The initial phase of the project involves a core team comprising not only of VDW, but also major companies like DMG Mori, Emag, Grob, Heller, Liebherr-Verzahntechnik, United Grinding and Trumpf. With this collaboration, which is unique in its form, between firms from the machine tool industry and the VDW, machine tools are to be prepared for the digital future, and an urgently necessary foundation for “Industry 4.0” is to be created. The planned standard is tasked with making it possible to interchange data between machines with different control systems of many generations and forward them to manufacturing execution systems and/or to the cloud, in order to evaluate the data and utilise them for optimisation tasks. The goal of the initiative, thus, lies in harmonised networking of the production operation based on secure interfacing with EDP systems and clouds.
EM | Mar 2018
Integrated sensor technology The Swedish tool manufacturer, Sandvik Coromant from Sandviken exhibited a series of tools as part of its Industry 4.0 initiative. Here, under the roof of Coroplus, integrated sensor technology in tools and tool-holders during machining was spotlighted. For vibration-damped drilling rods, the silent tools and the final machining steps in elaborate components can be monitored using app-based systems. The customer can see whether the tool has engaged and what the thermal stress in the drilling rod is like. The manufacturing process for expensive and complex components is thus monitored. In addition, intelligent tool-holders forward data on running time, loading and battery status to an app and thus incorporate the idea of predictive maintenance. Fine-drilling heads can be precisely adjusted by means of an app for manufacturing accurate borehole diameters. A comparable solution is also offered by BIG Kaiser from the Swiss town of Rümlang. This means that the tool does not have to be manually adjusted in the tool presetting device, but can, for example, be extended and retracted for different diameters directly in the machine using an app on the tablet. This shortens process chains and reduces nonproductive times during tool adjustment.
Intelligent countersink tools The high-precision tool manufacturer, Hermann Bilz from the Swabian town of Esslingen has, for many years now, been producing countersink tools. These are used where the surface to be machined can be reached only through a borehole, e.g. in closed housings. A reversal of the sense of rotation causes the tool’s blade to be extended. In order to remove the tool from the borehole after machining, it is essential to retract the blade. Under the aegis of a joint project with O. Bilz and EWS, Hermann Bilz has developed a countersink tool that monitors
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C O V E R S TO R Y
TECHNOLOGY
Many machine tool builders and accessory builders are equipping their products with Industry 4.0 compatibility in anticipation of its implementation by customer shops
The key topic at the EMO in Hannover is the “Path of Digitisation” from DMG MORI, with which the company smooths the way to the future of the “Digital Factory” for its customers worldwide
retraction of the tool blade. The data is transferred to the machine’s control system using a communication protocol developed specifically for this purpose, and prevent a tool crash with the component if the blade is retracted incorrectly.
accessories. Systems of this kind offer far more than merely an orderly and tidy tool management concept. The customer can precisely determine the tool costs per component, arrange for tools to be made available quickly and promptly, and avoid incorrect tool selection. In addition, intelligent systems feature a link to the machine tool, and receive information on a tool fracture, trigger a new purchase order at the tool vendor, and provide the machine’s operator with a constructionally identical tool. Systems of this kind render clearer and more transparent tool flows within the manufacturing operation.
New interface with cyber-physical modules In particular, the Industry 4.0 Special Show offered exciting insights into tomorrow’s networked future for production technology. The academic community was represented at this special show by a large number of universities. One highlight was indubitably the government-subsidised BazMod research project, aimed at developing a manufacturer-independent standardised interface for exchanging media, data and energy between the machine tool and cyber-physical add-on modules. This enables an innovative functional expansion of machine tools to be achieved using sensor/actuator-based cyber-physical systems (CPSs), which had previously been integrated into the machine tool, depending on the manufacturer involved. Standardised contacts at the face expand the established hollowshaft-cone holder and thus make possible an intelligent interface for supplying data and energy to intelligent tools. The signal transmission feature integrated into the spindle provides a link to the machine, thus rendering superfluous complex signal receivers that had hitherto been installed in the machining space at the tool-holder, and expanding the technical duty options for actuator-based tools.
Holistic tool management systems At the EMO Hannover, in the context of Industry 4.0, holistic tool management systems were a major focus. Many manufacturers of high-precision tools – such as the Iscar, Gühring and Sandvik companies – but also metrological specialists like Zoller GmbH from Pleidelsheim, supplied intelligent storage solutions for tools, components and
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With digitalisation initiatives to the digital factory The machine tool manufacturer, DMG Mori showcased numerous innovations. One highlight announced was the open IIoT platform (Industrial Internet of Things) Adamos, which began operation on October 1, 2017 with 200 experts. It originated from the alliance between DMG Mori, Dürr, Software AG and Zeiss ASM PT, and is tasked with offering solutions for digitally networked production. In addition, DMG Mori uses Open Connectivity for access to its Celos-Ecosystem, so as to make possible a consistently harmonised digital data flow even with third-party makes or manual workplaces, thus taking one step further towards its vision of a digital factory. Besides innovative software solutions for networking, several new machine models were showcased: these included the even sturdier NHX 6300 horizontal machining centre for titanium machining, the high-dynamic-response DMU 200/340 gantry for machining large components, and the Multisprint 25/36 multi-spindle automatic lathes, which promise more productivity when machining long turned parts.
First collection, then networking Systems can be networked on different levels. The question here arises for machine tool users as to whether all data must be
EM | Mar 2018
TECHNOLOGY
C O V E R S TO R Y
TECHNOLOGY
C O V E R S TO R Y
sent to the cloud immediately. The answer to this is no, as far as Bosch Rexroth from Lohr am Main is concerned. The presentday internet would certainly not be able to provide the capacity that would be necessary in order to transfer the huge quantities of sensor information to the cloud that machine tools are nowadays already able to make available. For this reason, Bosch Rexroth unveiled the Data Analytics Server on a machine from the machine tool manufacturer, Pfiffner. What’s involved here is additional local computing power installed in the machine tool’s control cabinet, enabling machine and process data to be collected, stored and analysed. The aim is to process data beforehand, so as to admit to the cloud only the really essential compressed quantity of data, and in this way, avoid overloading the data lines. It remains to be seen, though, what data it is expedient to send. They can, however, be determined by the users themselves using appropriate analytical tools and configuration programs that can be operated with minimal previous knowledge.
Connected Machining – networking without the cloud Dr Johannes Heidenhain GmbH from Traunreut demonstrated its Connected Machining function package, enabling consistently digitalised job management to be provided: transparent processes, time-saving work sequences and facilitated use of the data involved. The Remote Desktop Manager from Heidenhain premiered at the fair, for example, enables the customer to access the PCs located in the network and the software installed on them directly in the control system at the touch of a button. In the demonstration, Heidenhain did not restrict themselves to their own stand, but networked no fewer than 22 machines, which were distributed over the entire grounds of the fair. In order to check the status of the machines, there was no need to take a long walk over the huge exhibition grounds, since with the aid of the new StateMonitor software package, a glance at the screen sufficed in order to find out the machine’s current state using RAG status displays. Further functions, such as displaying the current machining program or using filters so as to display only machines in a particular operating state, simplify the work of machine operators. Heidenhain wants to deploy the Connected Machining solutions in small and mid-tier companies with 10 to 15 machines. For this reason, they deliberately rejected the idea of a cloud solution and the concomitant risks, with regards to data security, for example. Instead, networking takes place on local servers.
Digitalisation of the value added chain Siemens AG has demonstrated its Internet of Things (IoT)
EM | Mar 2018
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TECHNOLOGY
Ecosystem MindSphere as a digitalisation platform for all industrial sectors. The application concerned involves digitalisation of the entire value added chain, as exemplified by an injection-moulded component for a drone. Machine tool manufacturers and operators were able, with the aid of such specific practical examples, to bring themselves up to speed on the advantages that the merging of the real and virtual worlds offer them. For this purpose, Siemens, for the EMO, connected more than 200 machines to MindSphere via the Manage MyMachine app. This enabled visitors to retrieve live information from a computer on the machining code being executed and the current operating state of machines from all over the world. Openness of this kind, of course, necessitates appropriate solutions with a view to data security. Identify3D is a security solution of this nature, which assures the traceability of digital manufacturing processes for protecting intellectual property while enabling the design and production data available to be used for components with technically precise specifications only for a limited quantity.
Industry 4.0 platform for gear-cutting The family firm, Klingelnberg presented its Industry 4.0 solution approach tailored to the gear-cutting industry, which is based on an IT platform. The key idea here is rigorous networking and holistic provision of process information along the entire process chain involved in gearwheel production. The GearEngine IT platform from Klingelnberg constitutes the backbone of the cyber-physical closed loop production system. As a central link between the machine tools and other services (like the company’s own SmartTooling tool identification system), it manages toothing data, production equipment, and the part history in three databases. For this purpose, the machines involved report to the platform individual data, e.g. about the tools and clamping devices used in machining the current gearwheel. This enables the entire production process for an individual gearwheel to be reconstructed. In addition, it is possible to intervene directly in the production operation, e.g. by improving the machining parameters between machining two gearwheels.
Expanded service with smartglasses Index-Werke GmbH & Co KG Hahn & Tessky from the
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Swabian town of Esslingen showcased various innovative solutions for the digital era within the context of its iX4.0 initiative. Besides a cloud-based IoT platform for receiving and editing machine and process data, the new service structure with smartglasses is particularly noteworthy. By using smartglasses with a real-time capability, the customer can repair his machine himself in the event of failures. A service technician from Esslingen offers visual support for this. The information and instructions are transmitted to the customer via the glasses onto this machine. This saves time and reduces standstills.
Integrated sensor technology for avoiding rejects In the field of high-precision technology, Renishaw from New Mills, UK, showcased its portfolio of systems for metrological applications and generative manufacturing. In the context of connectivity, the company showcased an integrated metrological capability. In the shape of the EquatorTM flexible test instrument, the company offers an intelligent process control system that enables tool corrections in the CNC production process to be updated fully automatically. Thanks to direct embedding in the production operation, correction data are transferred from the measuring instrument to the machine, and taken into due account when manufacturing subsequent components. Waste can, thus, be simply avoided by continual re-adjustment.
Radical shift towards digitalisation The EMO Hannover 2017 showed that the radical shift towards digitalisation is being well received in the metalworking industry. Numerous IoT platforms like Adamos, Grob-Net 4 Industry or MindSphere were presented, which are progressing the advance of digitalisation. In line with this trend, manufacturers showcased numerous tools and other equipment that – fitted with sensors and digital communication interfaces – serve as suppliers of data to the digitally networked production systems. The up-to-the-future technologies nonetheless pursue traditional goals, such as trackable production processes, optimised resource utilisation, higher flexibility and increased productivity. ☐ The second part of the article will be carried in the next issue of EM Courtesy:VDW
EM | Mar 2018
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MANAGEMENT INTERVIEW
“The future looks promising!” …says Aroop Zutshi, Global President & Managing Partner, Frost & Sullivan, who has been working with Fortune 500 companies in designing their growth strategies and evaluating new opportunities for growth. Excerpts from his interview with Shekhar Jitkar…
How do you see the role of technology changing over the years, when it comes to growth strategies in the manufacturing sector? The future will see a greater proliferation of automation, including greater adoption of Artificial Intelligence and robotics, which will lead to advanced human interfaces. Technologies will keep pushing consumer aspirations and features, while the spread of automation will enhance productivity and guarantee quality (consistency). As evolution unfolds, one will see a convergence of technological advances and enhanced automation with the powerful potential of the Internet. With innovations such as the 3D printers and dronebased applications, we will see renewed purpose and excitement among consumers. The Teslas, the Googles and the Amazons have pushed expectations into a whole new frontier! The future looks very promising.
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What do you think about the growth strategies in the Indian manufacturing industry (big & SMEs) in terms of adapting to advanced technologies? Indian companies will adapt to technologies that will enhance customer experience and reduce possibility of errors. This could still be restricted to visionary thinkers who have the financial muscle to patiently wait for the break-even. SMEs will wait and watch; depending on their financial muscle, they could either totally adopt the technology or look for stripped-down versions, which can do the task at hand albeit at a lower cost. This is where the multitude of Indian institutes (IITs, NITs, and IISCs) could play a role. There should be greater interaction between academia and industry. Reverse engineering on the higher end may just find its way to India. While SMEs would look to adopt tech, the compulsions of India would drive them to use cheaper labour, which of course, will need upskilling. How automation can help India become a global manufacturing hub on the basis of SWOT analysis? Automation will definitely help India in productivity, quality consistency and also push it a few levels up the technology ladder, besides making the workplace safer. However, whether or not it would make India a global manufacturing hub depends on a host of other factors, such as favourable government policies, global sized investment tickets, and a more favourable perception of Indian manufacturing. Should India indeed become a global manufacturing hub, based on outsourcing of semi-skilled jobs to a “low cost” manufacturing economy, it would incentivise and support a devalued Indian rupee. This could eventually create macroeconomic challenges; hence, the government has to be clear and vocal about its long-term vision and expectations from the manufacturing fraternity.
EM | Mar 2018
INTERVIEW MANAGEMENT
“As the Global President & Managing Partner of Frost & Sullivan and with over 30 years of experience, Zutshi is responsible for developing the growth strategy besides driving globalisation and expansion of business”
Strength: India has access to skilled manpower that can use What do you think would be the future of manufacturing and and operate sophisticated shopfloor automation products product development? and solutions. Adoption of automation will catapult Indian IoT, Artificial Intelligence and more and more integration manufacturing to the next level as more and more global of everything that is to be interconnected, could very well companies adopt the Industry 4.0 framework. India has well define the future mantra. As in the past, we expect core developed manufacturing facilities in all sectors across the cross innovation and related early manufacturing (of new products section of industries. Cost of technology is dropping significantly and technologies) to happen in the parent companies (and and therefore adoption is far more easy countries). However, over a period of and convenient. Many of the automation time, with increasing volumes and to products are now manufactured and maintain focus on continual innovation, developed in India including sensors, older products could be systematically AUTOMATION WILL ALLOW INDIA systems, PLCs, etc. outsourced to other global regions, Weakness: Adoption of automation TO OPERATE IN THE ECOSYSTEM, which could be closer to mass markets WHICH IS RAPIDLY MOVING means disruption in process and and deliver the cost advantage. TOWARDS AUTOMATION potential changes in employment conditions of workers. While large and What are your views on the implications TRIGGERED BY THE FOURTH some medium sized enterprises have of Digital Transformation in India vs REVOLUTION OF the necessary training and skills to both other emerging markets? INDUSTRIALISATION invest and deploy automation solutions, Digital Transformation in India is a many find automation products very must, simply because it will reduce expensive and are often times unable to the complexity and variance in justify investments. For small scale enterprises there is a lack transactions that are performed in an economy as huge of understanding of automation products and hence there is and vast as India. To quote a parallel example, the world’s poor implementation. A vast majority of manufacturing in cheapest car was designed to be manufactured in one of the India still remains in the hands of small enterprises. They world’s state-of-the-art plants in India, simply because the operate with limited resources and limited access to capital. volumes were expected to be so large that there was a need Threats: Automation has two levels of impact. It will certainly to “automate” the process of car manufacturing, to make result in performance improvements across the manufacturing them not only fast, but also consistent in quality. There enterprise. At the same time, it will also most likely displace was no room for car-to-car variation on any count. Digital certain positions that will no longer be needed with automation. Transformation (DT) of India is akin to “automation” This fear of losing jobs has often times made it difficult for of all the mass transaction processes (and this includes manufacturers to implement automation solutions. manufacturing as well). Opportunities: Automation will make India ready for the next India will require a huge infusion of funds and technology century. It will give India the competitive advantage and make to be able to pull this off. A savvy Central Government it a bigger and stronger player in the global arena. Automation committed to DT will need to be complimented by equally will allow India to operate in the ecosystem which is rapidly savvy State Governments and administrators; otherwise the moving towards automation triggered by the fourth revolution usual, very-developed-yet-underdeveloped scenario will of industrialisation. continue in India. ☐
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EM | Mar 2018
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DIE & MOULD FOCUS
Tooling methods for composite tooling The feature focusses on two main types of tools—direct and indirect tools for tooling composites, along with overviewing possible materials that can be used for tools and master models and their properties. A read on… The design of a tool or mould starts during the design phase of the part. The designer will need information about the part, such as, how will it be made, using which production process, which fibres and resin will be used, does the part have undercuts, how many parts need to be made and in what time period, will it be a prototype—small or large series, what are the part tolerances and what surface finish is required. Dependent on the answers to these questions, the result will be a single or a double tool, a tool with inserts, the materials used for the tools, the number of tools, specifications for a heating system, the number of in- and outlets and their position, specifications for a clamping system, specifications for a demoulding system and specifications for an alignment system.
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Types of tooling methods Tools can be divided into two categories—direct and indirect tooling. They each have advantages and disadvantages. The preferred type will depend on quality, quantity, cost, lead time, expertise, etc. Direct tooling method: The direct tooling method deals with moulds that are directly machined from a block of solid material. The materials used for this method range from blocks of polymer to tooling foams, metals and machinable ceramics. Moulds made by Additive Manufacturing would also be classed under the direct tooling method. Indirect tooling method: The indirect tooling method
EM | Mar 2018
FOCUS DIE & MOULD
starts with a master model. This master model can be machined or it can be an existing product. Once the master is prepared, the mould is cast or laminated onto it. These moulds are mostly made from GFRP (glass fibre-reinforced polymer) and CFRP (carbon fibre-reinforced polymer), but castable polymers, ceramics, concrete or nickel electroforms are also possible.
Materials for master models and moulds Selecting materials is really a matter of selecting properties. The list of relevant properties can be grouped into five categories. Physical properties: • Density • Coefficient of thermal expansion • Thermal conductivity • Specific heat capacity • Porosity • Maximum use temperature
Mechanical properties: • Strength • Stiffness • Hardness • Brittleness Chemical properties: • Compatibility with resins and their curing agents • Compatibility with the solvents and release agents to be used • Tendency to corrode in the production environment Manufacturing properties: • Ease of machining • Achievable tolerances • Surface finish • Ease of integration with presses, ejectors and injections • Acquisition time • Cure or thermal shrinkages or other dimension changes • Maximum size • Minimum and maximum gauge limitations Advt
METAL WORKING FLUIDS
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DIE & MOULD FOCUS
• Availability of suitable suppliers • Their workload and competitive positions Use properties: • Longevity • Maintainability • Reparability • Ease of modification It is important to realise that the materials chosen for making the master model and mould will determine how the mould will behave during production, the number of parts that can be made from it, how much the final product will cost, etc. The selection affects the whole production chain. As such, a thoughtful choice made with the advice of experts will save time and money in the end. The most commonly used materials for master models and moulds are: • Unfilled and filled polymers: Precast blocks or other shapes of polymers such as PTFE, nylons - or mass cast systems such as filled epoxies, polyesters or syntactic foams - fall into this group. Filled and unfilled polymers can be used for moulds for relatively small parts of low to moderate complexity, where closure and injection pressures are limited and temperatures are low to moderate. • Tooling blocks: Light and stable material are intended for manufacturing master models or, occasionally, for use in direct tooling. Tooling foam is likely to be used for prototyping activities and for very short runs – for example, for master models. • Fibreboards: Fibreboards such as MDF (medium density fibreboard) and HDF (high density fibreboard) can be used for making master models and moulds. Fibreboards are similar in weight to tooling foams and both filled and unfilled polymers, but are sensitive to moisture. Fibreboards have often been used in the past. Nowadays, tooling foams and (un)filled polymers are more often preferred because they are more homogeneous and less moisture-sensitive. The main disadvantage of fibreboards is the limited layer thickness and their soft cores or hard skins. • Glass fibre reinforced polymer (GRP): Commonly used for manufacturing tools, often in combination with core materials. Electric heater mats or heater pipes can be integrated for controlling the tool temperature. GRP tools are widely used for low-to-moderate production volumes (up to 2,000 pieces). The great advantage of GRP tools is that all the knowledge for making and repairing the tool is normally present at the
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composite processing company. However, tight radii are very difficult to obtain and tolerance build-up can be problematic. • Carbon fibre-reinforced polymer (CFRP): Tools made with CFRP are generally manufactured with prepregs via autoclave rather than by hand-lamination. CFRP tools are commonly used. However, as with GRP tools, tight radii are very difficult to achieve and tolerance build-up can be problematic. • Nickel electroforms: As with GRP and CFRP, nickel electroform tools are made with a master model. Nickel is electrodeposited on the master model, forming a thin metallic surface without the need for machining. The metallic skin is reinforced by a steel or composite structure. Nickel electroform tools give a relatively lightweight tool face that gives good long-term performance. However, other materials should be used for large or complex moulds. • Ceramics: Ceramics are a large group of materials, ranging from plaster and concrete to special blends of different types of materials. As with the previous mould technologies, a master model is also needed for ceramic materials. Ceramic moulds can be cost effective for small quantities or for prototypes. They however, are susceptible to wear and are difficult to repair. • Aluminium: Moulds in aluminium can be manufactured by milling, starting from block material or near-net shapes. The material properties can vary significantly. Aluminium can be used for moulds but is better suited for moderate part quantities (up to about 5,000 parts). Special care is needed during demoulding as aluminium is scratch-sensitive. • Steel: As with aluminium, steel moulds can be milled from block material or near-net shapes. Steel moulds are the most robust and high gloss surfaces can be achieved. They have the longest service life, but require a high investment cost and special care is needed to avoid corrosion.
Making the final decision... It should be clear that the final decision always will be a compromise between different candidate materials, and that the importance of each criterion is case dependent. Decision-making techniques such as multi-criteria decision making (MCDA), Consensus and Promethee can be useful. ☐ Courtesy: ©Sirris For more details, visit: www.sirris.be
EM | Mar 2018
DIE & MOULD FOCUS
Reliability for automated mould making The article talks on laser measurement systems for CNC machine tools that are used for non-contact tool measurement and tool monitoring, while highlighting how it helped Playmobil to set-up automated production lines at its in-house mould shop As the company approaches its 40th anniversary, some 2.6 billion Playmobil figures currently populate the earth. Many new figures are released every year, placing high demands on the in-house mould shop. To achieve maximum efficiency in unmanned, automated operation, Playmobil’s numerous machining centres have been using LaserControl measuring systems of Blum-Novotest already for 15 years. “For Playmobil figures, hundredths of a millimetre count,” says Attila Britting, Head of Playmobil’s in-house mould shop in Zirndorf near Nuremberg. “The aim in building the injection moulds is to produce finished plastic items that require virtually no rework – which is vital in view of a daily production of
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approximately 10 million individual parts and over 100 million figures a year. Consequently, the mould separation must also be a high-precision operation, so that there are not any burrs on the individual parts or the finished figure.”
Need for automated production The moulds are specified for extremely high volumes, and production runs of 200,000 to 300,000 pieces from one mould are no rarity. The required productivity can only be achieved by partially automated production alongside the normal two-shift operation. So, an array of machines work overnight on prepared
EM | Mar 2018
ELECTROCHEMICAL DRILLING – MAKE QUICK WORK! SIMPLER
MORE STABLE
FASTER
MORE VARIABLE
LOWER COST
ELECTROCHEMICAL DRILLING PRODUCES ABSOLUTELY NO BURR OR DRILLING CAPS
HIGHLIGHTS +
Drilling produces no burr or drilling caps. This means no deburring – a crucial advantage for machining components which are difficult to access.
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The material is not heated by the ECM process which means no negative effects on its microstructure and no micro-cracks.
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A lot of ECM boreholes (20 or more) can be drilled at the same time; short cycle times and lean processes are a matter of fact. The feed rate can be up to 5 mm/min.
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The process is suitable for hard and soft machining. The material hardness does not affect the feed rate.
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The service life of the drilling cathodes is very long, even for hard materials. The tools suffer almost no wear.
EMAG India Private Limited I “Technology Centre” I No. 17/G/46-3 · Industrial Suburb I 2nd Stage · Yeshwanthpur I Bangalore · 560022 I Karnataka · India Phone: +91 80500 50163 I Fax: +91 80500 50165 I E-mail: sales.india@emag.com I Website: www.emag.com
DIE & MOULD FOCUS
In the manufacture of highly complex injection-moulded tools, hundredths of a millimetre count: All single parts are precisely matched to each other
Playmobil is a line of toys produced by the Brandstätter Group, headquartered in Zirndorf, Germany
jobs. To execute these jobs, several of the machining centres are equipped with pallet changers and tool magazines with the capacity to hold as many as 120 tools. The machines even keep running unmanned over the weekend. The Blum-Novotest systems are installed in the machining area of the automated DMG five-axis machining centres. After every tool change, the laser automatically measures the length and radius of the tool prior to machining, and after machining, checks for breakage and wear. Thus, our skilled workers no longer have to pre-set the tool in the pre-setting device. A new tool is simply shrink-fitted into the holder and measured at machining speed after fitting. This ensures that the tool data in the machine is correct, numerical errors or data reading mistakes can no longer occur. Further features include high-speed automatic compensation for the thermal expansion of the entire machine and for spindle displacement. Incorrect tool data can have costly consequences such as defective tools, rejects, or machine stoppage. A spindle damaged by a crash will cost at least 18,000 Euros to replace.
it shows the least wear during the large volume production. It does cause considerable tool wear during cutting, however. That is why it is very important to keep an eye on the running times of the individual tools. The BLUM laser measuring systems do this very well. High-precision measurement in a dirty environment poses a major challenge, and cooling is essential to the production process. To protect the optical system from being soiled, the measuring system is mechanically sealed off from the coolant by a pneumatically operated shutter piston during machining. The rotating tool is also cleaned with compressed air prior to measuring in order to ensure that the measurement is not impaired by swarf, dirt or cooling lubricants. During measurement, a stream of barrier air provides protection against soiling.
Laser measurement systems Without a monitoring system to detect worn or broken tools, automated production is hardly possible. The LaserControl system’s breakage monitor ensures that broken tool detection runs immediately after every machining step. Depending on the programming, the machining centre can then either exchange the tool for a twin or notify the on-call service staff, who can log in to the machine over the internet and monitor the workshop through a webcam. At Playmobil, as many as four of the key tools are held in the tool changer, which means that the automated overnight jobs run very reliably. We mostly use steel with high chromium content because
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Accuracy and repeatability The LaserControl systems have truly been their money’s worth at Playmobil. The systems are practically maintenance free; and, after more than 10 years in continuous operation, the seals look like new. Above all, however, the experts have never been let down by the laser systems and have experienced nothing but good things in terms of service, too. “We have had only good experience with BLUM lasers – and we save working time because there is no need for pre-setting,” Marco Mendl, Team leader-CAD/CAM/NC, summarises. “The accuracy of the LaserControl systems is astounding, as well. Based on our experience, its repeatability is within less than two thousandths of a millimetre. And for us, one thing is for certain: Without the BLUM laser systems, this degree of automation would not be possible.” ☐ Courtesy: Blum Novotest
EM | Mar 2018
HIGH-SPEED MACHINING | TECHNOLOGY
Accelerating production capabilities An application story on the usage of high-speed machining centres from Datron Dynamics by Aero-Tec Industries that enhances efficiency and overall quality of the entire product line In 2005, Aero-Tec President, Charles Harbert set out to find a CNC machine capable of batch machining illuminated displays for aircraft communications gear from cast acrylic. But these were to be no ordinary displays and to produce them to exacting specifications, the company needed to find an extraordinary piece of equipment. According to Harbert, “Encapsulated within the part are two sealed 5 volt lamp modules — one provides backlighting for UHF and the other (at the top) illuminates the display that sits behind a clear window. The lamp modules are filtered in order to be compatible with night-vision goggles worn by military pilots and the lettering at the bottom is nonilluminated.” The parts shown here include a completed part (minus the two wires that come out of the recessed terminals on the back) and the two other parts show the innards and illustrate the complicated steps required for manufacturing this part.
Enhancing productivity levels When Aero-Tec came across Datron Dynamics, Inc, (Milford, NH) on the internet, Harbert’s hope for superior technology was
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bolstered by a website that showed vanguard high-speed machining centres and perhaps more importantly, a smorgasbord of integrated features that smacked of a real turn-key solution. “In particular”, said Harbert, “I was interested in how Datron’s high speed technology and integrated vacuum table could impact our efficiency and the overall quality of our entire product line.” In fact, Datron’s VacuMate™ workholding ultimately had as much to do with Aero-Tec’s success with this particular aerospace part as the 60,000 RPM machining technology itself. VacuMate is designed to swiftly and efficiently secure flat workpieces to the bed of a machining system. Thin stock, which could be secured only with great difficulties before, can be secured literally within seconds. This includes plastic foils as thin as 0.001” or aluminium sheets up to 0.250” thick. The vacuum table features airflow-optimised ports, with recessed chambers, to provide superior vacuum distribution. A low cost, gas-permeable substrate serves as a sacrificial vacuum diffuser, allowing the cutter to machine through the workpiece, without cutting into the table. When placing a single 18”x12” VacuMate segment (or up to 4 connected
EM | Mar 2018
HIGH-SPEED MACHINING | TECHNOLOGY
Blanks milled from sheet of militarygrade cast acrylic
Black and white layers of paint are milled away on the top wall of the window opening
segments for a total of 24” x 36”) on the machine bed, the same position is maintained every time. That’s because the VacuMates are keyed using a beveled boss-in-cavity system to insure location repeatability.
Workholding benefits According to Bill King, President, Datron Dynamics, “Most CNC manufacturers just don’t get involved in workholding. They sell you their machine and let you find a way to hold your parts once it arrives. Well, Datron takes a more holistic approach and considers workholding as a part of the overall solution.” It was this integration that convinced Aero-Tec to procure the Datron machining system complete with 3D probing and VacuMate — and Harbert and the R&D group went right to work on perfecting the process. The first step was to batch machine or “cookie cut” a 24” x 36” sheet of military grade cast acrylic to create the back side of the part. Using a QuadraMate™ (4 connected VacuMate segments), material is secured. The probe scans the surface of the material to validate the position of the blank while at the same time feeding any irregularities into the Microsoft® Windows®-based controller. Any surface irregularities are compensated for dynamically in the machining parameters — without operator intervention and before the machining even begins. This ensures that despite variances in thickness, the depth of the cut will stay the same. This is critical for this aerospace part and for Aero-Tec since they machine into the acrylic within four thousandths, shy of breaking through the material. After cutting the basic ‘blanks’, the individual parts are re-secured on the vacuum chuck for the milling of clearance cuts to accommodate the electrical terminals on the face side. The parts are removed from the machine bed and two special terminals are installed from the face side and potted in place with catalysed polyester. The excess potting material is wet sanded away to leave the face smooth. Next, the lamp assemblies and the associated wiring are installed with special care being paid to its position so that the electronics are not severed during subsequent phases of production performed on the Datron high-speed
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machining center. Then these components get potted again with polyester to secure them in place. The parts are then placed back on the Datron machine and secured with the vacuum fixture so that all of the detailed features that appear on the back can be machined — the rectangular window is cut down to the step. Then, the operator flips the part over and places it in a dedicated fixture on a separate station within the Datron machine’s working envelope. Here, the window through cut is finished and a bevel around the opening is machined and the shoulder is cut using a ballnose end mill. An additional clamp is placed in the through hole (window) to hold the part while the periphery is cut—freeing the part from the block of military acrylic. The individual displays then go through a painting process — black over white. After paint, lettering is applied with a diodepumped laser system that ablates the black paint to expose the white underneath. The Datron machining centre was used to fabricate the registration fixture required for the laser system. The parts are returned to the machine where the black and white layers of paint are milled away on the top wall of the window opening on the back side. This allows NVG secure light to spill onto the display that will be installed behind the window. Finally, the window itself (also machined from cast acrylic on the Datron) is glued in and the wires are soldered in and potted. The Aero-Tec design allowed for the wires to go in last so that the Datron machine operators don’t have to struggle with them during the various machining processes.
Conclusion Harbert praises Datron’s durability by saying, “I really cannot attest to the quality of the Datron service department because a year and a half into this project, the machine hasn’t hic-cupped once — so we haven’t needed any service, which is exceptional.” Further, he explains, “It’s amazing how much work goes into a finished military part. But, if that’s what keeps us all safe then it’s worth the effort — and if the quality of this part is critical to that safety, then Datron is literally a lifesaver.” ☐ Courtesy: www.datron.com
EM | Mar 2018
TNC 620 Tailor-made for compact milling machines The TNC 620 offers you a broad spectrum of applications for the economical manufacture of your products—from the simplest to the most complex parts. It supports you with well proven cycles, efficient options, and soon a new and innovative operational design. The new HEIDENHAIN TNC 620’s touch screen reacts to your gestures while the context-sensitive user interface always displays exactly those elements that you may need for the situation. This not only facilitates operation, it also saves you space. So the new TNC 620 is the tailor-made control for compact milling machines: simple in operation, reliable in use, and graceful in appearance.
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T I TA N I U M M A C H I N I N G | T E C H N O L O G Y
A guide to titanium machining Titanium is fast becoming a favoured material in the manufacturing industry. This article highlights the advantages of using this material and the three methods of machining the material. A read on… Titanium is a versatile high-strength material with low density, high melting temperatures and high reactivity with cutting tool materials. It’s low thermal conductivity increases the temperatures at the cutting edge and causes rapid wear and plastic deformation. Further, due to the high reactivity, it also results in chemical interactions with the cutting tool, which is responsible for crater wear during machining. Titanium also gets strain hard during machining, which causes notch wear at the depth of cut and at the same time, low modulus of elasticity apart from high strength at elevated temperatures, which make it unique for being used for high temperature applications like aeroplane parts. With its exceptionally high strength-to-weight ratio with good corrosive resistance, the metal has high hot hardness and wear-resistance. Compared to steel, it is just as strong but only
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Vipin Rajput Regional Application Expert— Aerospace—Asia Pacific Seco Tools
40 per cent of its weight ratio compares to steel, which is twice as strong as aluminium but only 60 per cent more in weight compared to aluminium. Additionally, there are some other types of titanium materials like Ti-5-5-5-3, which is also known as the Russian titanium and it is 30 per cent stronger than Ti-6Al-4V and its machinability is 50 per cent compared to the normal Ti-6Al-4V, which makes it more challenging when compared to the normal titanium. Another version of the metal, which is the Ti-407, is the new material, which is 20 times easier to machine than Ti-6Al-4V.
Recommendations of machine for titanium machining It is very important to use the right and strong machines
EM | Mar 2018
T E C H N O L O G Y | T I TA N I U M M A C H I N I N G
for titanium. Some of the recommendations for good milling machines for titanium include very high torque in machines, which is required and may go as high as 300–1500 Nm. Further, low RPM and in most cases, 3000 RPM is enough because carbide cutting tool is being used with a low cutting speed of 45 -100 m/min. Internal coolant is also a must; the higher it is, the better.
Machining methods in titanium The tool life plays a critical role during the machining of titanium, so there are some good machining methods, which should be used specially during roughing so as to get higher productivity and better tool life. Some of the machining strategies for titanium machining include: Dynamic turning: It is important to understand while doing turning of Ti Alloys to use the right strategy and dynamic turning is one of them, which gives higher productivity and safe process during rough turning .One needs to pick the right software for this. For example, the short version is that we will avoid full engagement (Ae 100%) and pursue a constant engagement angle (<30°) and thus constant temperature and chip average. This will give the optimum control over tool pressure, tool wear and chip control. Dynamic milling: This is an effective milling method for roughing with solid carbide tools and with indexable tools with higher cutting length. There is a strong tendency towards advanced roughing/dynamic milling optimised strategies based on algorithms. This has to be split into two main algorithm calculation directions. The first has to be the constant Vf constant arc of contact when entering concave convex area by adapting step over. The second has to be the variable Vf in order to maintain average chip thickness when entering concave convex area (arc of contact changes). The key behind this is to use maximum depth of cut, which can be used according to application and smaller side step (Ae) so that one can achieve the highest metal removal rate (MRR). We also have the same time on the cutting edge where we use small depth of cut or higher. Further, it is very good once one has low torque in machines. Helical milling: Helical milling is one of the best methods to scoop out material during roughing of titanium material especially when you have stronger machines, because it needs high torque. Seco Tools pioneers in the machining of titanium material and is developing new technology of cutting tools, which are a cost-effective solution for such kind of materials. â&#x2DC;?
EM | Mar 2018
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I M AGE C OURT ES Y: Shutterstock
S P E C I A L F E AT U R E | W A R E H O U S I N G & I N V E N T O R Y M A N A G E M E N T
Receiving best practices In today’s world of increasing customer expectations and delivery requirements, a distribution centre’s overall velocity can impact how well they survive in their local markets. The article offers insight into how DCs can use lean principles and mobile power to increase velocity, improve processes and reduce labour costs. Velocity, a buzz word in today’s supply chain world, means many things to many people. To some, it means increased cost and negative P&L performance to meet customer demand and respond to the “Amazon Effect”. To others, it’s a thoughtful intentionality to move not only what needs to be moved and when it needs to be moved, but to move it more frequently in smaller batches. In the world of distribution, smaller batches almost immediately equate to higher costs, as pick waves are sub-optimised, unless we think about our distribution strategies altogether differently. Typical facility designs, work area designs and wave release
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schedules are built for large batches to a degree. We’ve witnessed many facilities plagued with the problem where the first shift crew waits on work and second shift work waits on crew. Sorters and diverters get clogged up with peak volume coming through in large batches, and operators are sent out with a day’s worth of work, only to come back at the end of the day with unfinished tickets and complaints about the order being “dirty”.
Idea of velocity In a world where customers are beginning to demand order-
EM | Mar 2018
How noisy is this gearbox design?
Visualization of the noise pressure level outside the gearbox and vibrationinduced von Mises stress in its housing. Building quieter transmission systems starts with designing quieter gearboxes. Noise, vibration, and harshness (NVH) testing is an important part of the process, but you are not limited to conducting physical experiments. To improve gearbox designs well before the production stage, you can perform vibroacoustic analyses using simulation software. The COMSOL MultiphysicsÂŽ software is used for simulating designs, devices, and processes in all fields of engineering, manufacturing, and scientific research. See how you can apply it to modeling gearbox vibration and noise. comsol.blog/NVH-simulation
S P E C I A L F E AT U R E | W A R E H O U S I N G & I N V E N T O R Y M A N A G E M E N T
It is better to avoid walking to PC to look up orders in order to utilise time
to-ship lead times in terms of hours, we have to think differently about the design of our facility and the way we release work to the floor. A facility designed for higher velocity activity can be more cost-effective as we alleviate bottlenecks, keep operators busy at all times and have a higher frequency of accountability checks on per¬formance. These high velocity facilities are forced to look at the waste embedded in long walk paths to and from printers or to and from fast-moving product. These high velocity facilities are forced to examine the role of automation in core areas of their business, and synchronise the work in each of the areas so that it flows smoothly from shift start to shift end. The idea of velocity in a distribution environment can be a scary one if we’re not ready for it. The problem we have today is that the market is now forcing it upon us, whether we are ready or not. So, let’s think differently about the concept and lean into it rather than running from it. This means that we need to be more aggressive with our process improvements and labour utilisation.
Minimising the waste Process improvements should be targeted at minimising the waste of the warehouse, namely, excess motion and transportation that occurs when workstations are not where they should be or materials are not stored or received as they should be. Frequent re-slotting or changing of pick routes can be beneficial for facilities to minimise the waste of walking or equipment motion. Many of these improvements have to be facilitated by outside parties that are not accustomed to the way we’ve always done it, but include the operators as they are the experts of the process. In many cases, we find that motion occurs because the
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facility layout is inflexible, so process improvements are largely hindered by immobile workstations. Our ability to flex up or down or move starting and finishing points for a process is severely limited, so we have to also think differently about the way we set up our workstations. When designing or transforming a receiving process, keep the following techniques in mind. Please note, when we say ‘PDCA’ we mean a regular process of ‘Planning’ work and targets, ‘Doing’ the work, and ‘Checking’ plan versus making ‘Adjustments’ or taking ‘Actions’ to drive improvement to the processes. 1. Inbound receiving schedule to level flow across the day, allowing for labour planning and regular PDCA on unload timing performance 2. Pre-receiving of qualified supplier-partner freight to direct putaway 3. Receiving processes located at or near docks or usage of mobile work-stations to minimise motion and improve dock to stock lead times 4. Quality sorts and audits only where necessary to protect customers and downstream processes 5. Visual performance management system with regular PDCA integrated into supervisor standard work
Mobile powered workstations Once process improvements have been made, allowing workers to become more mobile adds a whole new dimension to productivity. Mobile powered workstations simply take static devices used in the receiving process and make them mobile. Shippers across all industries are seeking ways to move receipts and shipments off their loading docks as quickly as
EM | Mar 2018
CAM? Decision made? Explore the benefits of hyperMILL and switch to the CAM solution for all of your 2.5D, 3D, 5-axis, mill-turn, HSC and HPC requirements.
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S P E C I A L F E AT U R E | W A R E H O U S I N G & I N V E N T O R Y M A N A G E M E N T
Scan, inspect, print and apply labels directly at the pallet
possible. World-class companies have a dock to stock time of 2 hours or better, but the industry average is more like eight hours (at best). Many companies have inventory sitting for days on their docks. That time frame may have worked during a time when companies established their own shipping schedules based on their individual capabilities, but it doesn’t fly in an era where customers want their orders in two days or less. Product waiting to be received is very costly as it impacts inventory turns, customer service and order cycle times. It also creates space issues and congestion in companies that can’t handle the volume. Spending eight hours or more moving products from the dock and into their respective places in the warehouse - or cross-docking the goods and getting them back out the door quickly - isn’t an efficient way to use one of logistics’ biggest expenses: human labour. Shippers have to be able to squeeze as much as they can out of every hour worked, however, if those workers are forced to walk back and forth to printers or wait around for orders or information to come from upstream departments, the wasted hours start to accumulate pretty quickly. For example, in an operation where thousands of cartons are coming into a facility on a daily basis, printing and retrieving labels for those cartons one pallet, or even one truckload - at a time generates hundreds or even thousands of extra steps. It also leads to the following problems: 1. Receiving docks get backed up, leaving trucks idling outside waiting for an open bay or material handler 2. Inventory needs to be handled multiple times to make room for new receipts and overflow
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3. Workers spend countless hours walking back and forth in their areas entering data and printing labels. They then need to marry the proper labels to the proper order. It’s the marrying process that causes errors in a lot of companies because workers are trying to do this in batches instead of one order at a time 4. Docks are underutilised due to the slow process of putting away incoming product (i.e. they could be freed up for shipping, etc.)
Improving workforce productivity By minimising unnecessary ‘touches’ and the number of steps that workers have to take on the warehouse floor, shippers can essentially double workforce productivity while also eliminating costly waste. It’s really simple math. If you cut your motion in half, you can double productivity. For example, people who walked four hours a day without any production, after converting to mobile power find that they have freed up almost half a shift of productivity they never knew existed. Finally, by eliminating paperwork and relying on mobile carts that are equipped with a portable power system used to power laptops, barcode printers or scanners, companies can effectively boost dock-to-stock cycle time, reduce labour by as much as $10,000 per worker, reduce the number of improperly labelled products and minimise inaccurate inventories. When you take paper out of the equation, and then factor in the many other advantages of using mobile carts for receiving, the benefits are remarkable. ☐ Courtesy: Newcastle Systems
EM | Mar 2018
EVENT | PREVIEW
Scaling the tooling industry As a step forward towards achieving manufacturing excellence in the tooling sector, TAGMA India will be organising the 11th biennial die & mould international exhibition on April 11-14, 2018, at Bombay Exhibition Centre, Goregaon, Mumbai. An event preview… Dies and mould are one of the typical capital goods as machine tools, and one of the tools necessary for modern industries to run mass-production. The advanced technology and globalisation has seen quality tools being made available for the manufacturers. However, the die and mould industry in India faces acute challenges of slow adoption of advanced technologies, lack of fineness in the finished products and a severe competition from the international market. To address this, the Indian industry needs to be internationally competitive so that it can reduce delivery times and achieve operational excellence in productivity and maintenance standards. Catering to such growth possibilities in the Indian market, DIEMOULD India 2018, the 11th biennial die & mould international exhibition, will be held on April 11-14, 2018, at Bombay Exhibition Centre, Goregaon,
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Mumbai. With a positive recovery trend in the overall economy and tremendous growth prospects possible with government’s focus on manufacturing growth, the Indian tooling industry is poised to meet the new growth challenges and achieve the past double digit growths achieved through capacity building and expansion.
Industry outlook The importance of tooling industry is universally recognised as a strategic component for driving industrialisation of a country. The rapid growth of industries such as automobiles and auto components, domestic appliances, consumer electronics and consumer durables – in the wake of the rising economic growth – ensures the expanding need and demand for dies, moulds, tools
EM | Mar 2018
EVENT | PREVIEW
The 11th edition of Die & Mould India is an excellent opportunity for all the businesses related to the tooling industry to display and market their products/services
and gauges. The ever-shortening life-cycle of products, resulting from intense competition in industries, also warrants the development of new tooling devices and designs. The Indian tooling industry can grow further with government initiatives. Major Original Equipment Manufacturers (OEMs) in India are working on a plan for indigenisation of components getting into their main assemblies as per government guidelines. This includes the auto & electronic sectors. Policy reforms by government to make the procurement of tooling from indigenous sources will ensure growth in domestic production. The dies, moulds and press tools manufacturing industry has substantial multiplier effect on the domestic economy, therefore, it must be nurtured to become self-reliant.
A trend setter exhibition The 9th Die & Mould India exhibition was inaugurated by Late Dr APJ Abdul Kalam, the 11th President of India, with his aptly chosen keynote address titled ‘A vibrant die and mould industry for an economically developed nation’. His Excellency highlighted the importance and necessity to grow this vital mother industry, which largely contributes to a successful manufacturing economy of a country. The 10th Die & Mould India exhibition held at Bangalore was highly successful with a growth of over 32% in number of exhibitors, 35% in exhibitor (toolmakers), 42% in exhibitor (MSME), and 19% in exhibition area. The event attracted exhibitors, visitors from over 19 countries worldwide. The 11th edition of Die Mould India is an excellent opportunity for all the businesses related to the tooling Industry to display and market their products/services. The highlights of DMI 2018 include:
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• Introduction of ‘3D metrology and printing pavilion’ • Country pavilion • B2B pavilion • Overseas delegation With regular participation since the inception of leading brands from India and abroad, exhibiting their latest proven technologies, incorporating features to improve productivity, quality and reduce costs, attract quality visitors like CEOs, consultants, decision makers to the exhibition. They expressed satisfaction finding solutions to their needs, seeing new innovative products and manufacturing process covering the entire supply chain to the tooling industry, providing a wide spectrum to choose from in meeting challenging and faster deliveries and quality demanded by customers of the highlycompetitive manufacturing sectors. The exhibition will focus on: • Providing insights to formulate strategy to meet the challenges faced by the tooling industry • Staying updated with the latest innovation in the global tooling industry • The capabilities and presence in the Indian Die Mould industry • The exposure of the industry workforce to the latest innovation across all tooling applications • Attracting new talent to the tooling industry The exhibition will display an array of products in die & moulds, press tools, die casting/moulding machine, rapid prototyping & modelling, CAD/CAM system related to dies & moulds, measuring machines, mould-base and standard parts of dies & moulds, hot runner systems, machine tools for making dies & moulds, CNC milling/machining centre and EDM machines. ☐ Compiled with inputs from TAGMA India
EM | Mar 2018
EVENT | REPORT
» • • • • • • • •
HIGHLIGHTS Total 504 exhibitors 292 Indian and 212 foreign exhibitors Business orders worth Rs 539 cr generated Business enquiries worth Rs 4819 cr obtained Participation from 23 countries including India 3 country group pavilions: Germany, China & Taiwan Footfall of 36,000 visitors Over 500 live machines
Fabricating the future Spread across 33,000 sq mts, IMTEX Forming 2018 witnessed about 504 exhibitors displaying over 500 ‘live’ machines from 23 countries. The six-day exhibition paved way for technological advancements, as well as exposed users and manufacturers to a range of value-added forming technologies under one roof. A post event report… Metal forming plays a major role in the production of diverse products starting with automobile industry to high precision components for the instrumentation and electronics industries, and everywhere in-between. To keep this key role of metal forming in manufacturing industry, a continuous development is necessary concerning the materials, development of new & innovative forming processes, tooling and manufacturing equipment, etc. Focusing around these trends, IMTEX Forming 2018, along with Tooltech 2018 was organised by Indian Machine Tool Manufacturers’ Association (IMTMA), at Bangalore International Exhibition Centre, Bengaluru, on January 25-30, 2018. With an international participation from Germany, Italy, Japan, Taiwan, UK and USA, the exhibition size, this year, grew by 18% and showcased future technologies that could be vital for enhancing
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productivity for the Indian manufacturing industry.
Highlights The exhibition was inaugurated by R V Deshpande, Hon’ble Minister for Large & Medium Scale Industries & Infrastructure Development, Government of Karnataka, along with AS Kiran Kumar, Former Chairman of ISRO; Nirmal K Minda, President—Automotive Component Manufacturers Association of India (ACMA); Jamshyd N Godrej, Chairman—Exhibitions, IMTMA; P Ramadas, President, IMTMA; V Anbu, Director General & CEO, IMTMA and Indradev Babu, Managing Director, UCAM and Vice President, IMTMA. Speaking about the significance of the show on SMEs, P Ramadas said, “Indian manufacturing landscape has a
EM | Mar 2018
REPORT | EVENT
‘Connect’, an awareness programme on imparting knowledge on the machine tool industry to young engineers, was held on January 26-29, 2018
significant number of SMEs. The exhibition was important for fulfilling their aspirations and goals. The SMEs were able to leverage opportunities which would enable them to rise a notch higher. The presence of decision-making authorities from original equipment manufacturers (OEM) resulted in securing well-qualified leads and accelerated the sales process at the show. The show generated overwhelming response from SMEs engaged in manufacturing of vices, presses, manufacture of parts such as wheels and castors, measuring, welding and material handling solutions, and so on.” Reflecting on the potential of the show, Anbu added, “IMTEX FORMING 2018 was the largest in the series in terms of exhibition area as well as exhibitors. There has been a significant increase in the number of business visitors which affirmed the immense potential of business opportunities that the exhibition had in store for the manufacturing industry. The show will further strengthen the bonds between machine tool manufacturers and customers and we hope the leads generated during the show will result in good business outcome.”
Forming technology on the rise Forming technology is gaining momentum and importance in the industry. Technology in forming is moving rapidly, especially the automotive & composites, where focusing on the parts, right from the beginning has become important. Owing to the current technology development, it is expected that the forming technology will be gaining momentum in the upcoming years too. It was on these lines that IMTEX 2018 witnessed exhibitors displaying a wide range of high-end presses, laser cutting machines, and technologies related to bending and tube drawing. Advanced technologies such as Industry 4.0 and IoT,
EM | Mar 2018
along with automation, robotics, sensors, CAD/CAM and tools that were more related to support the metal forming user industries were also displayed. Delegations from public and private sectors representing user industries such as auto components, aerospace, defence, railways, electrical and electronics, plastic machinery, white and brown goods, medical engineering, and others took part in the show.
Parallel shows The International Seminar on Forming Technology was organised in conjunction with IMTEX Forming 2018. The seminar covered the more pertinent aspects of forming technology, its requirement in the manufacturing industry, and the technology gaps that can be bridged. It focused on processes, equipment & software, and materials & tools, to bring together the fraternity of forming technology on a common platform to discuss the latest developments in technology landscapes. The exhibition also witnessed the i2 (Industry-Institution) academia pavilion that featured R&D projects on manufacturing from 44 institutions representing from all over India. ‘Connect’, an awareness programme on imparting knowledge on the machine tool industry to young engineers, was held on January 26-29, 2018. A ‘Reverse International Buyer-Seller Meet’ was also held, where potential buyers from 10 countries visited the show to explore business opportunities. Overall, IMTEX Forming 2018 served to open up the way for development of Indian metal forming sector by acting as an enabler to forging long-term business relationships, which could lead to the growth of the country’s economy. The six-day exhibition that drew around 36,000 visitors with business enquiries worth Rs 4819 cr concluded on a positive note.
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EVENT | REPORT
“Incremental compliance factor drives demands”
Pradeep Patil, Managing Director, TRUMPF India Pvt Ltd
At IMTEX 2018, we showcased bending machine, new generation 2D laser cutting, Tru Laser Cell capable of laser cutting, welding and cladding and the latest TRUMATIC series combi machine that offers the best of punching and laser technology to manufacturers. As accessory, we also brought the ‘parts centre’ that is effective for busy manufacturers. We believe in the incremental compliance demands in the automotive sector, adoption of new technology in railways, construction and agri-equipment and investments in infrastructure like smart city projects, which are some of the underlying drivers of this impetus in the metal forming industry. We also witnessed an overwhelming turnout of customers and associates at this IMTEX. We look forward to being able to be at the fore front and help our customers solve their manufacturing demands and be their partners in their aspirations to serve their customers.
“Focusing on specific components of machines”
Vasant B Vibhute, Managing Director, GIVI Misure India
The overall metal forming industry is experiencing a growth-phase. To add on to the momentum, our team at GIVI Misure, is always eager to support its customers for all the precision measurements and low-cost automation requirements. Rather than focusing on the entire machine tool manufacturing, I believe, it’s time to focus on the manufacturing of specific components of the machines. Our company has witnessed a growth percentage of 15-25% in the metal forming industry in 2017. The major growth driver for this industry has been the automobile industry. Also, automation of various kinds has been a prominent decisive factor in this regard. As far as the current trends are concerned, the profound developments in the storage of batteries have been of vital importance. The research areas in this field have also increased manifold. As such, there is an inclination and a rapid growth in terms of electric vehicles lately.
“Unveiling the next generation plasma in India”
Yaseer Wahajet, Market Manager - India, Hypertherm India Thermal Cutting
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At IMTEX 2018, we showcased our entry-level and high-end plasma technologies. We unveiled our latest technology called X-definition plasma for the first time in India. This technology focuses not only on cut quality, but also helps to reduce cost, which is well-suited for a developing market like India. It can cut a wide range of materials, like mild steel, stainless steel, and aluminium. Moreover, it enables operators to use web servers to look into the error codes and monitor the operation remotely. In India, many end-users are still using older technologies, like oxy-fuel cutting, which is a comparatively slower process. Keeping this in mind, we demonstrated to our visitors the advantages of using plasma cutting technology. We also educated them on how to reduce the operational cost, how to improve cut quality and what a CNC machine and plasma can do together. We have received many positive leads and visitors came to us seeking knowledge and understanding of what they need, in terms of CNC plasma cutting technology. After IMTEX, we plan to conduct trainings and seminars in various cities and follow-up with the leads generate at the show together with our channel partners, who demonstrate how our technologies have been incorporated into their systems, thus providing end-users a better solution.
EM | Mar 2018
REPORT | EVENT
“Growth has exceeded our expectations this year”
MK Narasinga Rao, Managing Director, LVD-Strippit India
This year at IMTEX, we showcased our fibre laser technology, which is a 4 kW fibre laser machine that can cut 16 mm thickness. The piercing speed of this machine is quite high and it is a globally competitive product. In terms of industry performance, the last two years have not been positive. However, we are noticing a positive growth trend this year and it has exceeded our expectations. Government policies such as the GST implementation and investments in infrastructure have acted as a big positive and contributed to the growth trend in the Indian manufacturing sector. The response we have received during the show has been very good. We want to leverage this by putting as many installations as possible and cash in on as many orders as possible. Combining our previous prospects as well as networking with prospects from IMTEX, we have found that our customers belong mostly in the transportation, infrastructure and aerospace sectors.
“Focus on Industry 4.0 technologies”
AV Srinivasan, CEO, Meiban Engineering Technologies
We have been exhibiting the servo turret press every IMTEX since 1994.This year, too, we have displayed our 30 tonne servo punching machine and a servo press. Both the machines are ecofriendly and the running costs are low. We also highlighted that our machines are Industry 4.0 ready. We have noticed that in the automotive sector, many large companies have already adopted Industry 4.0 technologies. However, our customers, who are into the MSME sector, are not yet aware of this concept. So, we educated them on how data collection and segregation will be useful in increasing their machine uptime. We received a good response at the show this year.
“Industry growth reflected at IMTEX”
Renganathan Chellamraja, CEO, Chennai Metco
AT IMTEX 2018, we launched the precision cutter and displayed certain new products as well. These products cater to all the engineering segments. We also received a good response from the exhibition this year. IMTEX has always been a success for us. We participate in fairs across the globe and we find IMTEX to be more vibrant compared to other international fairs. This shows that the Indian economy is doing well and hence, in the coming years, more growth is expected. In the last few months, we witnessed growth in the industry and that was reflected in the fair as well.
Compiled by Team EM
EM | Mar 2018
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EVENT | REPORT
Continuous quest of innovation Themed under ‘Grinders United!’, this year’s edition of Motion Meeting showcased the recent additions in the company portfolio, along with highlighting the most extensive application knowledge, product portfolio and range of services in the market. A post-event report… Every year, United Grinding hosts the annual Motion Meeting with its sales partners and international press to showcase the latest innovations, sales trends, investment in production and the prospectus of the upcoming years. This year, with the theme ‘Grinders United!,’ the conference was organised to showcase its latest technology advancements at the United Grinding headquarters at Thun, Switzerland. The press conference at the event highlighted the system maintenance and overhaul department. With the maintenance contracts specifically tailored to the machine, Studer has a service that is used by more than 1,500 customers a year. According to Jens Bleher, CEO, Studer, Schaudt and Mikrosa, “We make our customers more successful. The cylindrical grinding professionals are able to do this, thanks to their flexibility in production and the constant pursuit of innovation.”
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Prabhugoud Patil Senior Manager prabhu.patil@publish-industry.net
New orders “We succeeded in clearly exceeding the plan in 2017,” added Bleher. As per the company officials, the start of the year was a success, the Spring Machine Tool Exhibitions were successful and the positive trend continued until the end of the year. As early as June, Studer received more orders than planned. More orders were received from almost every sector. The decline following the diesel scandal could be absorbed, and in the automotive industry, a substantial normalisation of investment activity was noticed. The distribution of orders received by Studer across geographic regions shows that Western Europe continues to be the largest sales market. The business in Germany increased again significantly. North America was also able to maintain its position. Additionally, China made the biggest jump due to the
EM | Mar 2018
REPORT | EVENT
rapid development of the market last year. Here, Studer received several major projects in the automotive industry. The development in the rest of Asia was restrained. Schaudt Mikrosa rose sharply after a weaker 2016. In spring, the order intake picked up and by the end of the year, a significant increase was achieved. Especially in the automotive sector, an increase in demand was noted. “The regular customers from Germany reported back impressively,” said Bleher. This is also reflected in the regional distribution. Schaudt Mikrosa received 50% of the orders from Germany, and 25% from China. Further potential can be seen in the rest of Europe and the USA.
Ensuring training & maintenance With record sales, customer care for the group underlined its strong position once again. The ongoing improvements of the organisation at Studer show success with all plan values exceeding in 2017. The increase in efficiency in service and further improvements in adherence to schedules for maintenance form the basis for further expansion of the business. “We invest a great deal in training and further education of our employees,” said Sandro Bottazzo, CSO, Studer, and further added, “have developed a development and career roadmap for our service technicians, among other things. With our service academy, we have also created the environment to optimally train and certify our employees and representatives in well-equipped facilities.” Bleher and Bottazzo also explained that Studer is committed to inspiring its customers. This only works with Studer-enthusiastic employees. Here, too, Studer wants to play a leading role as a modern employer and in the coming months will specifically set-up and implement projects relating to employer branding.
Clear emphasis in production “Being good is the worst enemy of becoming better,” shared Stephan Stoll, COO, Studer. To avoid this, Stoll defined three priorities for 2018: Solid foundation: The foundation is the offspring. 10% of Studer Schaudt and Mikrosa employees are apprentices. The dual education system in Switzerland and Germany is a guarantor for the positive development of the companies, and indeed of the economy. Highest precision: Precise grinding machines require precise components. That is why the cylindrical grinders are expanding their core competence in mechanical processing. This is achieved with the commissioning of a large 5-axis milling
EM | Mar 2018
centre; two more 5-axis centres with integrated turning function are planned for 2018. This is one of the biggest investments in this area. This system offers the ideal prerequisite for digitising the manufacturing according to the 4.0 standards. Benchmark efficiency: Efficiency is being driven forward by a range of projects, for example, with the development of the new universal grinding machine from Studer. Studer, Schaudt and Mikrosa are also implementing a number of projects within the Industry 4.0 initiative of the United Grinding Group. This is similar to the digital assembly instructions, which will be started as an App on a tablet. This will be introduced by the cylindrical group on a wide basis in 2018. The assembly becomes paperless.
Technology as a resource The resources that are tapped for the production include software, digitisation, sensors and coolants. • Agile software development: This involves having a smart development method that delivers a usable result every 30 days. The success is based on the close cooperation of the team and follows a well-defined procedure. It is a methodical approach that should not only be used in the field of software development, but will also be introduced in the electromechanical field this year. • Digitisation: The OPC-UA standard was successfully introduced. With the secure connection to the machine, process information is easily transferred to external systems. The customer can easily access a large selection of signals, integrate this into his application and is always the master of his confidential data. • Sensors: Intelligent sensors provide insights for the early failure detection of machine components. An important step is the direction of Predictable Maintenance. Specially developed sensors enable a process-reliable approach of the grinding wheel to the dresser and to the workpiece. Data analysis has posed a challenge for many years. Studer has accepted this challenge and with the development of the Studer Sensitron 4.0, it takes contact detection into a new dimension. The first stage of this technology is already in use on the S11 and on the new universal grinding machine. • Coolants: Together with IRPD AG, which is active in 3D printing technology, Studer is developing coolant nozzles with laminar flow characteristics. This allows the coolant to be precisely directed into the grinding gap, thus, achieving the optimum cooling effect at the desired point. This significantly improves the processing quality and process times.
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“We expect higher order volumes from India” …says Jens Bleher, CEO, Fritz Studer AG, in an interaction with EM, while discussing the application of the Swiss precision standards in the company products and highlighting the Indian market. Excerpts... How does United Grinding cater to enhance production process with a minimal use of resources? To enhance the production process, we initiated the PuLs® programme that stands for precision & passion and has become our corporate philosophy. Based on the spirit of this philosophy, we have developed a whole package of measures, which we implement in all company brands. These are integrated concepts, which result in smoother processes, and individual initiatives, helping to save energy in concrete production steps. How do you ensure the required quality and precision standards of your products, given precision standards of the Swiss manufacturing technology? It is a long chain—from a customer's initial contact with the United Grinding Group to the purchase of a machine and individual application customisation. This is followed by years of successful operation of the machine by the customer. Until the machine reaches the end of its life cycle decades later. Our group is constantly working to optimise each of these steps for the customer’s benefit. This is not just a question of the use of resources during the manufacture and operation of a machine.
All other steps – such as customer service, order processing or logistics – have also been examined for optimisation potential. Many small and large individual measures produce a complex whole for increased customer benefit. The base of these measures is the PuLs® corporate philosophy, which determines the actions of all employees, as well as a toolkit for designing ‘lean’ processes, including optimisation programs like Six Sigma. What are your company’s upcoming plans for the Indian market? In the recent years, we established our own sales and services branch in Bengaluru, which is working in close relationship with the sales agent network in India to serve our customers. The organisation is prepared for higher order volumes, which we expect to be coming from the market. Out of all the brands of United Grinding Group, which brand has a better potential in India? We do not see remarkable differences to any other markets in product distribution in the Indian market, so the application landscape seems to be similar to other markets. What we still see, with shrinking tendencies, is that India is importing many used machines from our European customers. ☐
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EM | Mar 2018
TECHNOLOGY | NEWS
5-axis grinding centre
CNC controllers
EWAG offers PROFILE LINE 5-axis grinding centre that is a solution for efficient and flexible machining of indexable carbide inserts. The machine is built in close partnership with sister company Walter Maschinenbau GmbH and enhanced with EWAGâ&#x20AC;&#x2122;s tooling and software expertise. This partnership has produced an efficient grinding centre for advanced grinding of highly-complex interchangeable insert geometries, including interfaces. The innovative PROFILE LINE technology of the PROFILE LINE has set new standards of production efficiency for these applications. For example, an intelligently integrated 6-station changer for grinding wheel sets and coolant supply manifolds ensures optimum wheel selection, thereby, maximising the machining volume for sintered blanks. Another outstanding feature for autonomous multi-shift operation is the intelligently integrated, flexible automation with a 6-axis Fanuc robot. Customer-specific pallets can be accommodated in the user-friendly robot cell. A high-resolution CCD-HD vision system is available for loading grid pallets using magnetic grippers. Cleaning, re-clamping and centering stations can also be integrated and adapted to the customer-specific product range.
Heidenhain offers TNC controls that provide myriad functions for the quality and precision-oriented aerospace industry. The dynamic precision functions aim at the time-efficient production of precise workpieces with high surface quality, and effectively reduce dynamic errors. The economic efficiency is boosted without compromises on contour accuracy and surface quality, especially in heavy duty machining. The dynamic efficiency functions increase metal removal rates and process safety. At the same time, they can reduce the mechanical load on machines and tools. Machine tools equipped TNC controls with Heidenhain measurement and control technology provide many advantages for the demanding aerospace industry. They enable high-precision machining and complex compliance with standards and regulations within the framework of an efficient production process. A consistently high surface quality, the reliable compliance with tight tolerances, high machining speeds and the documentation and validation of complex processes accompanying production runs, all play a part in this. High-precision linear and angle encoders in a closed-loop control always measure perfectly accurately the actual axis position.
United Grinding | Bengaluru
Heidenhain India | Chennai Email: tripathi@heidenhain.in | Tel: +91-44-4023 4312
Email: Sudheendra.C.R@grinding.ch | Tel:+91-80-30257-606
Industrial troubleshooting kit with IR
Bearing housing retrofit
Extech Instruments, a FLIR Company, offers Extech TK430-IR industrial troubleshooting kit. The kit is ideal for electrical testing needs including installation and repair of electrical systems, HVAC equipment and large appliances. It includes the EX430: true RMS, auto ranging multimeter with 11 functions; MA200: 400 Amp clamp meter with basic AC current and 1mA resolution; 42510: infrared thermometer (-58 to 1000 degree Fahrenheit /-50 to 538 degree Celsius) with laser pointer and 40130: Non-contact voltage detector Extech TK430-IR (from 100 Volt to 600 Volt AC). TKG430-IR is complete with a set of test leads and Type K bead wire temperature probe. The kit is supplied in a heavy duty hard carrying case that provides protection and organisation for meters and accessories. Extech is one of the largest manufacturers and suppliers of innovative, quality handheld test, measurement and inspection tools in the world. The companyâ&#x20AC;&#x2122;s catalogue of handheld test equipment has offered an unsurpassed selection of test equipment (and accessories) for every application and budget.
igus offers lubrication-free igubal spherical balls made of high-performance plastic iglidur J to quickly replace metallic pillow blocks and flange bearings. The spherical balls made of iglidur J are not only cost-effective, but also have a very low coefficient of friction in dry operation. The material absorbs only little moisture, so that the use of the spherical balls is also suitable for outdoor use. Due to the chemical resistance of the highperformance plastic, the use of exchangeable spherical balls is also suitable for use in chemically igubal spherical balls demanding applications such as agricultural technology. iglidur J displays its advantages especially in soft shafts. The igubal spherical balls are currently available in six dimensions for housing number 204-210. On request, igus also manufactures spherical balls made of other iglidur materials. As an alternative to injection moulding, the company offers its customers the option of machining spherical balls from their desired material from the iglidur bar stock product range.
FLIR Systems | New Delhi Email: flirindia@flir.com.hk | Tel: +91-11-4560-3555
igus (India) | Bengaluru Email: ragesh@igus.in | Tel: +91-80-45127810
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EM | Mar 2018
NEWS | TECHNOLOGY
Global full-liner for Additive Manufacturing
Advt
DMG MORI is advancing its Additive Manufacturing product line with consistent development in both powder nozzle and powder bed techniques. The company offers the LASERTEC 3D and LASERTEC SLM series that constitute the cornerstone of the company’s strategic orientation in this future-oriented technology. While the LASERTEC 3D hybrid successfully combines laser deposition welding with a powder nozzle and 5-axis milling, the LASERTEC SLM series stands for selective laser melting in a powder bed. The powder bed process in particular is of great importance since the technology has a share of 80% in the market for the Additive Manufacturing of metallic LASERTEC 65 3D components. Based on the LASERTEC 65 3D hybrid, LASERTEC 65 3D has a 40% larger work area compared to the hybrid model despite its 45% smaller footprint. Other features such as different track widths, higher laser power up to 4 kW as well as the option of also processing reactive materials (e.g. aluminium or titanium) in sandwich structures expand the innovative aspects of the machine. DMG MORI India | Bengaluru Email: ankur.agarwal@dmgmori.com | Tel: +91-80-4089-6538
Cylindrical grinder EMAG offers HG 208 cylindrical grinder that is a customised grinding solution for transmission shafts with modular components. A solution for the precision machining of shafts in series production, with its modular design principle, these machines can be adapted to a wide variety of machining tasks and integrated into EMAG production lines. The component and grinding technology used may add additional technology HG 208 requirements such as in-process measuring devices; dressing units for CBN and corundum grinding wheels, automatic balancing units and more. It is these very different demands that characterise the development of the HG 208 horizontal cylindrical grinder. Another important factor for production planners in the automotive industry is the holistic approach from EMAG. The mechanical engineering company masters all processes for soft and hard machining and has extensive experience in the establishment of complete production solutions. The HG 208 has been on the market for around 15 years already, which states the customer’s benefit from a technology that is well established.
Statement about ownership & other particulars about EM, as required to be published in the first issue every year after the last day of February 1. Place of Publication: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 2. Periodicity of Publication: Bi-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 A&D 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 19-03-2018: a) publish-industry Verlag GmbH, Machtlfinger Strasse 7, 81379 Munich, Germany b) Kilian Mueller, Machtlfinger Strasse 7, 81379 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 19, 2018 Sd/SHEKHAR JITKAR Signature of the Publisher
EMAG India | Bengaluru Email: HAshwini@emag.com | Tel: +91-8050050163
EM | Mar 2018
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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 - April 2018 IMPRINT Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Assistant Editor Megha Roy megha.roy@publish-industry.net Senior Content Developer – Digital Maria Jerin maria.jerin@publish-industry.net
» Casting & Forging Despite radical reforms in manufacturing processes, casting as a production technique is 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 edition 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 humanpopulated environment. The upcoming issue will discuss these advanced technologies incorporated in robotics. » Laser/Plasma cutting The application of CNC technology in laser/ plasma cutting gives advantage of faster cutting speeds, ability to cut complicated shapes in wider varieties of materials, user friendliness, non-dependency on skilled operators and intelligent features to take care of cutting failures. The subsequent issue analyses these developments in terms of technical articles and offers insights into new age innovations.
» Green manufacturing 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 practices and plant operations. The special feature in the forthcoming issue will talk on these practices in detail.
Sub-editor & Correspondent Suchi Adhikari suchi.adhikari@publish-industry.net Advertising Sales & Marketing Sagar Tamhane (General Manager – North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net Dhiraj Bhalerao (General Manager – West & South) Contact: +91 9820211816 dhiraj.bhalerao@publish-industry.net Prabhugoud Patil (Senior Manager – 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 Tarun Kumar Pyne Senior Graphic Designer (Print & Web) 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 ACMA . . . . . . . . . . . . . . . . . . . . . . . . . .19 Alibaba Group . . . . . . . . . . . . . . . . . . . . .20 BIEMH . . . . . . . . . . . . . . . . . . . . . . . . .25 Blaser Swisslube . . . . . . . . Back Inside Cover Blum-Novotest . . . . . . . . . . . . . . . . . . 1, 34 Carl Zeiss . . . . . . . . . . . . . . . . . . . . . . .28 CGTech . . . . . . . . . . . . . . . . . . . . . . 14, 49 Comsol Multiphysics . . . . . . . . . . . . . . . .45 CII . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Chennai Metco . . . . . . . . . . . . . . . . . . . .57 DesignTech Systems . . . . . . . . . . . . . . . .12 Datron Dynamics . . . . . . . . . . . . . . . . . . .38 DMG Mori . . . . . . . . . . . . . . . . . . . . . . .63 EMAG India . . . . . . . . . . . . . . . . . . . 35, 63 Epicor Software Corporation . . . . . Back Cover Everising Machine Co . . . . . . . . . . . . . . . .43 Elgi Equipments . . . . . . . . . . . . . . . . . . .18 Fibro India . . . . . . . . . . . . . . . . . . . . . . .11
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Name . . . . . . . . . . . . . . . . . . . . . . .Page Flir Systems . . . . . . . . . . . . . . . . . . . 27, 62 Focussed Event Management . . . . . . . . . .61 Fritz Studer . . . . . . . . . . . . . . . . . . . . . .60 Givi Misure . . . . . . . . . . . . . . . . . . . . . . .56 Heidenhain Optics & Electronics India . . 41, 62 Hypertherm . . . . . . . . . . . . . . . . . . . . . .56 IMTMA . . . . . . . . . . . . . . . . . . . . . . 19, 54 Igus India . . . . . . . . . . . . . . . . . . . . . . 2, 62 Jyoti CNC Automation . . . . . . . . . . . . . . . .3 Kim Union Industrial Co . . . . . . . . . . . . . . .63 Lakshmi Machine Works . . . . . . . . . . . . . .13 LVD-Strippit India . . . . . . . . . . . . . . . . . .57 Marposs India . . . . . . . . . . . . . . . . . . . .15 Mastercam India . . . . . . . . Front Inside Cover Mitsubishi Electric . . . . . . . . . . . . . . . . . .51 MMC Hardmetal . . . . . . . . . . . . . . . . . . .33 MotulTech India . . . . . . . . . . . . . . . . . . . .31 Messer Cutting Systems . . . . . . . . . . . . . .16
Name . . . . . . . . . . . . . . . . . . . . . . .Page Meiben Engineering Technologies . . . . . . . .57 Newcastle Systems . . . . . . . . . . . . . . . . .44 Open Mind CADCAM Technologies India . . .47 Prompt Integrated Technology . . . . . . . . . . .6 QVI . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Sirris . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Stratmann Consulting . . . . . . . . . . . . . . . .10 Seco Tools . . . . . . . . . . . . . . . . . . . . . . .42 TAGMA . . . . . . . . . . . . . . . . . . . . . . 50, 53 Tectyl Oil & Chemicals . . . . . . . . . . . . . . .37 Trumpf India . . . . . . . . . . . . . . . . . . . . . .56 United Grinding . . . . . . . . . . . . . . . . . 58, 62 Vargus India . . . . . . . . . . . . . . . . . . . . . .21 VRTech . . . . . . . . . . . . . . . . . . . . . . . . .12 VDW . . . . . . . . . . . . . . . . . . . . . . . . . . .22 YG1 Cutting Tools . . . . . . . . . . . . . . . . . 4,5 Zavenir Daubert . . . . . . . . . . . . . . . . . . .39
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 the magazine contents is only allowed with 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 https://industr.com/en/ Digital edition http://issuu.com/publishi/docs
EM | Mar 2018
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