Modern Machine Tools - June 2011

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Editorial

June 2011 - MODERN MACHINE TOOLS 25

Grinding is coming of age and how! From the conventional to super abrasive, and from automotive to aerospace, it has evolved significantly

to meet the ever-growing complex needs of user industries. Also, in the race to achieve better finish quality, grinding plays the role of a high value-add differentiator. Ultra high precision machines and special grinding equipment come handy in attaining the much sought-after superior accuracy. At the same time, it is imperative to explore more economical ways in order to improve grinding productivity, part quality and production cost.

Going forward, the specific type of manufacturing practices will primarily determine the prospects of grinding wheels. Cases in point are the wheels made of new forms of synthetic abrasives such as seeded gel aluminium oxide and Cubic Boron Nitride (CBN). As the demand for grinding lighter yet stronger concept grows, the use of advanced materials such as polycrystalline super abrasive materials or CBN and aluminium oxide holds the potential to make the grinding wheel a viable option for shaping hard materials.

From the viewpoint of India, with a rise in outsourcing of high-end engineering jobs, especially involving advanced materials such as Inox, aluminium alloys, temperature resistant materials, to name a few, there should be a positive ripple-effect on high-end grinding

applications. For more such latest advancements related to grinding, turn to ‘Sector Watch’.

Now, let us look at another area that is experiencing some of the mega trends as well. The material handling segment has evolved from wooden planks in cluttered shop-floors to the latest breed of swift forklifts and electric stackers, and from bulky control panels to state-of-the-art & sleek ones. In fact, with the advent of compact designs & small turning radius, multi-directional forklifts and other material handling equipment facilitate better space utilisation. Another significant trend sweeping this sector is the demand for more environment-friendly equipment with less fuel consumption and reduced emissions.

However, the material handling segment still depends on import to a sizeable extent and is challenged by high import duties on sourcing of spare parts for the imported equipment. Till this sector attains critical mass in the country and the domestic production base expands significantly, it may remain a concern area. The ‘Industry Update’ offers a detailed perspective. Take a look.

M Lokeswara RaoPresident, IMTMA & MD, Lokesh Machines Ltd

Vikram SirurVice President, IMTMA & Executive Vice Chairman, Miven Machine Tools Ltd

N K DhandPast President, IMTMA & CMD, Micromatic Grinding Technologies Ltd

R SrinivasanPast President, IMTMA & MD, RAS Transformation Technologies

Gautam DoshiAdvisor, IMTMA & Consultant, Productivity & Quality Improvement Services

S N MishraPast President, IMTMA & Vice Chairman, Bharat Fritz Werner Ltd

On a ‘finer’ note

Editorial

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Manas R [email protected]

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Contents

MODERN MACHINE TOOLS - June 201126

Highlights of Next Edition

Sector Watch: Cutting Systems Industry Update: Machining Centres

Cover photo courtesy: Pferd India

Regular Sections

Rajesh Khanna, Chief Executive Officer, WENDT (India) Ltd.................... 70

Leaders Speak

Editorial...................................... 25

National News ........................... 28

World News............................... 38

Tech Updates............................. 47

Events .......................................118

Book Shelf ............................... 125

Product Update ...................... 126

International Products ............ 148

Product Index.......................... 152

Advertisers’ List ...................... 158

Sector Watch

Details on page 140

Grinding: Turning the wheels of fortune .............................. 50

Case StudyRoll grinding: Creating new benchmarks ............................................. 57

Market InsightsIndian crane industry: Scaling new heights .................................................... 67

Facility VisitMicromatic Grinding Technologies Ltd: Paving the path towards precision ............................ 78

Policy WatchIndian offset policies: Smoothening the runway for future growth ............. 85

ViewpointK S V Raghav, MD, Raghav Aerospace Manufacturing Technologies Pvt Ltd ......................... 92

Manufacturing ExcellenceSustainable manufacturing: Green design without compromise .......................... 96

Future FootprintsWomen in manufacturing: A whole new world of possibilities ............................ 100

Factory Fundamentals

� Cell works the night shift .................................. 105

� HMCs, turn/mills aid diversification strategy ............ 108

� Long-lasting insert turns around tough Inconel job ..... 112

Industry Update Material handling equipment: NextGen mechanisation ....................................... 62

Fritz Korradi, Managing Director - Metal Precision Business and Member of Executive Board, Tyrolit Group.............................. 74

National News


Yamazaki Mazak opens new state-of-the-art facility in Pune The Indian subsidiary of leading machine tool manufacturer Yamazaki Mazak recently inaugurated its new technology centre in Pune. The one-of-its-kind facility saw a grand opening in the presence of dignitaries from leading companies in the machine tool & allied industries apart from dealers, customers and the dynamic team of Yamazaki Mazak India Pvt Ltd.

The event was graced by Tomohisa Yamazaki, President, Yamazaki Mazak Corporation; M Lokeswara Rao, President, Indian Machine Tool Manufacturers’ Association (IMTMA); Vivek Sharma, MD, Yamazaki Mazak Singapore; and Prayashvin Patel, CMD, Elecon Group Company – the first Indian customer of Yamazaki Mazak.

While lauding the exemplary efforts of Yamazaki Mazak and initiatives taken for meeting the demands of customers satisfactorily, Patel said, “We have been using machines made by Mazak since last 30 years, and these have helped us reap better returns on investment. Apart from technology, the sales service

provided distinguishes it from others. The new centre will help the company provide better sales service and training to local customers.”

With the opening of this new -technology centre, the machine tool major has reinforced its commitment

to the customers in the Indian market. Elaborating about the key attributes of the facility, Takashi Yamazaki, Senior Managing Director, Sales and Marketing, Yamazaki Mazak Corporation, said, “The Indian economy is growing at 8.6 per cent per year, which is a positive sign for the industry. The new facility is four times bigger being equipped with spindle repair facility; training & seminar rooms and solution gallery

that have been designed with a specific focus on customer requirements during pre- and post-sales. With this facility Yamazaki Mazak will be able to provide a perfect end-to-end turnkey solution for machine, process and line integration.” The centre also offers various customer

support services such as special facilities for undertaking customer training by highly skilled employees of Yamazaki Mazak, besides boasting of an auditorium and conference rooms for organising technical seminars.

Further, the technology centre has 13 well-advanced machines including multi-tasking machines, horizontal & vertical machining

centres, CNC lathes and laser cutting machines, which will enhance the company’s customer support services. Currently, Yamazaki Mazak has three technical centres in India – Chennai, Delhi and Bengaluru – along with a strong sales and service network across the country, with offices in Ahmedabad, Coimbatore, Hyderabad, Indore, Jamshedpur, Kolhapur, Kolkata, Mumbai and Rajkot.

The new facility promises world-class service and support

Guhring India inaugurates service centre in GurgaonThe manufacturer of precision rotary cutting tools and allied tooling for automotive, general engineering, heavy engineering and other precision machining industries recently

inaugurated its 5000 sq ft state-of-the-art service centre at Sector 8, IMT Manesar, Gurgaon. The service centre has two main functions, ie reconditioning of used cutting tools and sales support for the northern zone. The company also has plans to extend this service centre as an Original Equipment Manufacturer (OEM) support centre by

adding capacity to provide technical services to the OEMs, which would be mainly directed towards the machine tool manufacturers. The company has deployed skilled manpower that includes operators and the sales team at this service centre.

Speaking at the occasion, Recai Kipik, Managing Director, Guhring India Pvt Ltd said, “After the economic recovery, the industry has become price conscious and is preplanning spending patterns by optimising resources. Our service centres will exactly support that initiative; we will help the customers reduce their tool inventories by turning around reground tools in a shorter time.”

second edition of ‘Seco News’ in May 2011. ‘Seco News’ is a modernised approach to bring out the latest cutting-edge technology to the market. It contains a launch magazine called ‘EDGE’, a machining navigator catalogue that contains all new products, concertina folders for all new products and a DVD that contains all information in electronic form. ‘Seco News’ was first launched in 2010 with the objective to provide improved quality information using modern ways of technology.

Seco Tools India releases second ‘Seco News’The manufacturer of high performance metal cutting tools launched the

National News


Tata Power Company to invest in wind & solar energyThe company will invest ` 1,300 crore in FY12 to add 185 MW generation capacities from wind and solar energy.

S Ramakrishnan, Executive Director, TATA Power Company informed that the company is targeting to add 35 MW from solar power in FY 12 by investing ` 550 crore. The capacity addition

will come from a 25-MW project at Gujarat’s Mithapur slated for commission in December 2011 and the rest is equally divided between expanding at Mulshi, Maharashtra where the company set up 3 MW solar power plant last month and installed capacities on rooftops of buildings. The ramp-up on both solar and wind energy is partly necessitated by regulatory environment, which requires a power distribution company to source a certain percentage from cleaner sources, Ramakrishnan said.

Timken accelerates capacity expansion at Chennai plantTimken India Manufacturing Pvt Ltd plans to invest around ` 200 crore towards capacity expansion at its

Chennai facility, which is currently manufacturing 8 to 12 inch bearings.

In the second phase of expansion, slated to begin in the first quarter of 2012, the company will manufacture zero to eight inch bearings for

automotive sector and in the final stage it plans to manufacture bearings of 12 to 18 inch, which are used in the heavy power transmission equipment industry. The company plans to invest around ` 80 crore in each of these expansions.

James W Griffith, President and Chief Executive Officer, Timken said, “We are driving productivity, capacity improvements and new product introductions to serve growing demand from our customers around the world.”

IMTMA organises workshop on workholding and fixturingIndian Machine Tool Manufacturers’ Association (IMTMA), the apex body for machine tool manufacturers in the country recently organised a two-day workshop on workholding and fixturing techniques for productivity improvement on CNC machines at SKF college campus in Pune. The workshop discussed about the challenges and opportunities in workholding and fixturing techniques. The interactive workshop was conducted by Gautam Doshi, Advisor to IMTMA and S K Gupta, retired Assistant General Manager -

Design & Business Development, TATA Motors. It was attended by managers, engineers and middle management personnel from various manufacturing companies where CNC machine is used. Prasad Pendse, Senior Executive Officer, IMTMA, said, “Workshop on workholding and fixturing is held once in every six months. Since it is attended by industry professionals, more case studies and practical examples are discussed to make the workshop interesting and beneficial.“

Hyundai launches new model of Verna in IndiaWith the new version of the Verna subcompact sedan, the company plans to sell 45,000 units this year, as it seeks to boost profitability with higher-margin vehicles amid slowing volume growth. The Verna is expected to help Hyundai achieve sales of more than 400,000 units in India this year.

The company executives have said the carmaker will tackle the challenge of easing volume growth by boosting sales of mid- and large-sized cars. The company believes that although overall market growth is poised to cool from last year’s 31 per cent as rising prices and interest rates discourage demand, Hyundai’s Indian unit sales will rise 15-17 per cent in 2011.

Areva T&D bags contract job from L&T Power Areva T&D India has bagged a contract worth ` 120 crore from L&T Power. Under the contract, the company would supply and install electrical balance of plant solutions for two 600-MW thermal power plants at Malwa in Madhya Pradesh, the company said in a filing to Bombay Stock Exchange (BSE).

Rathin Basu , Country President & Managing Director, Areva T&D India said, “This new contract underlines Areva T&D’s expertise in electrical balance of plant solutions.” As part of the project, the company would manufacture and install a substation as well as distribution and power transformers, he added.

Gautam Doshi addressing the delegates

National News


Lockheed Martin eyeing vast Indian defence marketThe company remains committed to its relationship with the Indian Air Force despite losing out on India’s multi-billion dollar combat fighter deal.

A Lockheed spokesman said, “We understand that the US Government is working on a response to the letter from the Indian Government. Lockheed Martin remains committed to our relationship with the Indian Air Force, Ministry of Defence and the other services.”

It is robust on the Indian defence market, as New Delhi goes on a massive buying spree in the coming years to modernise its armed forces.

“The US Government has informed Lockheed Martin that they have received a letter from the Indian Ministry of Defence concerning the M-Medium Multi-Role Aircraft (MRCA) competition,” the spokesman added.

GE to introduce 660, 800 MW steam turbines in IndiaWith India targeting a capacity addition of 1,00,000 MW in the 12th Five-Year Plan (2012-17), the demand for various power equipment including high-efficiency turbines is expected to be significant. To strengthen its presence in this fast-growing power sector, General Electric will introduce 660 and 800 MW supercritical steam turbines in India this year.

Kishore Jayaraman, President and CEO, GE Energy India, said “The recent focus on using higher efficiency thermal products in India, allows GE to introduce its latest generation 660 and 800 MW supercritical steam turbine technology here (in India).”

He also stated that GE’s steam turbine technology is highly flexible and can be customised with a variety of boiler conditions.

“We are open to associating with leading independent boiler Original Equipment Manufacturers (OEMs), consultants and Engineering Procurement and Construction (EPC)

contractors to develop the most optimal solution to the plant owners,” he added.

The steam turbine generator market in the country is expected to be around 10-12 GW per annum over next 10 years.

Beiqi Foton Motor to set up plant near PuneChina’s largest commercial vehicle-maker will set up a manufacturing facility in Khed district near Pune at an investment of about ` 1,676 crore spread over five years. In the first phase of production, which is likely to start by early 2013, light, medium and heavy commercial tucks would be manufactured.

The Maharashtra Government has signed a Memorandum of

Understanding (MoU) with Beiqi Foton to facilitate the investment in the State. Khed district is home to many Indian auto majors and auto ancillary units. A senior Maharashtra

government official stated that the company would get a waiver on VAT and other taxes. After this the company may consider similar units near Aurangabad and Kesurdi in Satara district. R Shankar, Executive Vice President (India Operations), Beiqi Foton said, “The range of products to be offered in the Indian market is yet to be finalised.”

The company could consider supplying vehicles from India to neighbouring countries such as Sri Lanka and Bangladesh.

Blum-Novotest opens new subsidiary in IndiaBlum-Novotest, a leading German manufacturer of innovative and high-quality measuring and testing technology, has established a new subsidiary office in India. The Indian subsidiary named Blum-Novotest Measuring and Testing Technology Pvt Ltd is headquartered in Bengaluru. B V Shyam and A Venkatesh have been appointed as the directors of the new joint venture.

Alexander Blum, President, Blum-Novotest GmbH, said, “The new subsidiary in Bengaluru will serve as a sales and service hub, supporting the other local sales and service offices in New Delhi, Pune and Chennai, while coordinating the setup of other future sales and service offices. Through this local presence Blum-Novotest GmbH is able to provide the best combination of excellent service and customer-specific problem solving capabilities for its customers.”

L-R: Alexander Blum, A Venkatesh, B V Shyam

National News


Siemens PLM hosts Teamcenter event at BengaluruThe event held at Bengaluru was to appraise the company’s existing customers about the lastest in the PLM technologies. The event was attended not only by the existing Siemens

customers but also by prospective customers from various industries.

At the event, Siemens announced some of the latest products offered by the

company including the Teamcentre, which will now be available on mobile devices like iPad. “As a part of overall PLM solutions offered by us, we offer solutions for CAD/CAM/CAE, digital product development, digital life cycle management and digital manufacturing. The Indian market, right from big to small size industries, is extremely mature in terms of using CAD systems as a part of their designing process and the market is ever growing,” said Vivek Marwaha, Director Marketing, Siemens PLM India. He further added, “There is a lot of research and development happening in the sector to utilise the CAD/CAM/CAE systems to a greater extent.”

General Electric India Industrial Systems in technical alliance with InnospinTo tap the emerging opportunity offered by mega thermal power project, General Electric India (GEI) has announced an alliance with

Innospin of Switzerland to locally manufacture and supply air-cooled steam condensers. The tie-up will help GEI to penetrate into air cooled

steam condensers for 600 MW and above power generation segment.

C E Fernandes, Chairman and Managing Director, GEI said, “Technology transfer and design support provided by Innospin will not only enable GEI to expand its marketshare and make foray into the global market but also target better topline and bottomline growth.” The products that will be manufactured in GEI’s manufacturing facility in Bhopal will make it the only Indian company equipped to locally manufacture and supply air-cooled condensers to new and upcoming super critical thermal power stations.

V C S Velumani appointed CEO of Shanthi Gears V C S Velumani who was earlier the Executive Director of Winergy Drive Systems India Pvt Ltd has been appointed as the CEO of Shanthi Gears Ltd. Talking about the future plans Velumani said, “We are looking at exponentially growing the company, targeting self-reliance in gear technology with focus on high-end gear boxes and big gears. Focus segments for growth include power, wind energy and standard products.”

The company currently has four manufacturing plants, three located at Singanallur and one at Muthugoundenputhur and is planning to launch a new range of standard industrial gear boxes and air compressors of various capacities within the next six months. However, the company will continue to focus on its core strength, ie supply of non-standard gear boxes and big size gears.

Deere to invest $ 100 million for raising tractor output in IndiaThe US based company plans to invest $ 100 million to expand its

plant at Pune and build a new plant in Punjab, thereby increasing capacity for producing tractors and harvesters in

India. According to Shailendra Jagtap, Director, John Deere India Pvt Ltd, the company will introduce a 60-hp tractor customised for the Indian market, and intends to start production at the new plant by 2013. Mukul Varshney, Senior General Manager - Sales and Marketing, added, “With government taking initiative to increase the minimum support prices for crops the credit flow has increased in the farm sector. These are key drivers for mechanisation to grow at a rapid pace.”

BMW superbikes to source gearboxes from IndiaHero Motors has been awarded a contract to supply gearboxes for BMW’s motorcycles for both domestic and global markets. Pankaj Munjal, Managing Director, Hero Motors, said, “We have d e v e l o p e d the gearbox o u r s e l v e s . U s u a l l y , c o m p o n e n t s such as engines and transmissions are made by the company itself, as they involve advanced technology. We have achieved the necessary expertise. BMW Motorrad will source gearboxes from us for products it sells globally.”

Hero Motors provides end-to-end engineering solutions. Its customers include Maruti Suzuki, Toyota, BMW, Hero Honda and Rotax. It has two plants in Ghaziabad where it produces transmissions, sheet metals and gear boxes, and one at Manesar.

Vivek Marwaha

World News


Sodick restructures its EDM businesses The newly expanded EDM solutions provider, Sodick Europe Ltd will now cover all aspects of distributor and dealer support, including sales

of replacement machine parts, EDM consumables and machine servicing for the whole of Europe, Russia, South Africa and the Middle East. Earlier, Sodick

distributors and dealers were supported by two separate companies - Sodick Europe, which handled machine sales, and Sodick Hightech Europe, which focussed on consumables sales and service support.

Peter Capp, CEO, Sodick Europe said, “This £ 1 million re-organisation has been designed to provide every customer across Europe with one ‘window’ for all their Sodick requirements, from the latest high technology EDM machines, to a single reel of EDM brass wire to the provision of in-depth technical support. In the UK, Sodick machine and consumables sales and support continues to be through sole Sodick distributor, Sodi-Tech EDM, which is growing both its sales and support activities and expects to recruit additional technical staff during the coming year.”

Gildemeister collaborates with Asian partners in ChinaGildemeister, Japanese machine tool builder Mori Seiki Co Ltd, and Chinese machine tool builder Shen Yang Machine Tool (Group) Co Ltd (SYMG) have together moved towards an international cooperation. The collaboration happened during the China International Machine Tool Show (CIMT) reflecting on the growing importance of China as the largest global sales market for machine tools.

Gildemeister, Mori Seiki and SYMG intend that all the partners in

the cooperation will be on an equal footing in China. The partnership will focus on the production of a machine series designed primarily

for the Chinese market at Shenyang, northeast China. Through this venture, Gildemeister is underlining China’s increasing significance as a machine tool market with a good likelihood of continuing to exhibit a strong rate of growth into the future.

Renishaw acquires UK-based additive manufacturing companyThe global engineering technologies company Renishaw Plc has acquired UK-based MTT Investments Ltd and its subsidiary, MTT Technologies Ltd,

which designs, develops and manufactures a d d i t i v e manufacturing and rapid p r o t o t y p i n g s y s t e m s . Sir David M c M u r t r y ,

Chairman and Chief Executive, Renishaw Plc said on the agreement, “MTT has a range of interesting technologies, including Selective Laser Melting (SLM) equipment, which currently has its main markets in aerospace and medical devices, but also has potential for use in other sectors. All its products are complementary to Renishaw’s existing

technologies and business, and we look forward to developing an exciting new business together.”

MTT Technologies has its subsidiaries in the US and Italy and a branch office in France. Its operations will be incorporated within Renishaw as a new product division and will continue to be based in Staffordshire. Speaking about the acquisition, Simon Scott, CEO, MTT, said, “We are confident that Renishaw will be able to provide us with the ability to fully unlock the potential of SLM, allowing us to compete with our peers and aim for a market leadership position.”

Haas opens first technical education centre in Finland Haas Automation Europe has started its first Haas Technical Education Centre (HTEC) in Finland. The educational centre is located at the North Karelia College of Technology and Culture in Joensuu, Finland.

At HTEC, the students will be instructed on three Haas CNC machine tools—a TL-1 toolroom lathe, a TM-1 toolroom mill and an SL-20 CNC turning centre—and a range of state-of-the-art production equipment supplied by HTEC industry partners. Haas established the new centre in partnership with the Finnish Haas Factory Outlet, a division of Oy Grönblom AB. Bert Maes, HTEC Coordinator, Haas Automation Europe, observed that the Organisation of Economic Cooperation and Development has called Finland one of the world’s strongest nations in manufacturing and the quality of its education. “We are delighted to support the next phase of excellence building long-term collaboration between technical schools and CNC firms,” he added.

L-R: Guan Xiyou, Chairman of the Board, Shenyang Machine Tool Co Ltd; Dr Rüdiger

Kapitza, Chairman, GILDEMEISTER and Dr Masahiko Mori, President, Mori Seiki Co Ltd

Sir David McMurtry

Peter Capp

World News


EMO Hannover 2011 to showcase new aerospace technologies

For the eleventh time, the Institute of Production E n g i n e e r i n g and Machine Tools (IFW), Leibniz Hannover University will host a two day c o n f e r e n c e entitled ‘New

Production Technologies in the Aerospace Industry’. The conference will be held from September 22 to 23 in Hanover. Professor Berend Denkena, Director, IFW, said, “It makes us very proud to know that our conference this year will be part of the world’s biggest trade fair for the metalworking sector.” He added “We will be offering visitors to the EMO from the aerospace industry a top-class forum for acquiring new information and exchanging news and views about the status of research work on an international level.”

Besides the metallic materials (particularly titanium and aluminium), fibre-reinforced plastics and material combinations will be a major focus. The conference will also focus on lightweight construction materials and their combinations in aircraft construction, the trend towards new, lightweight, high-strength materials and material combination. The market is demanding tool concepts for drilling and milling high-temperature-resistant metals and composite materials, new machine tool concepts for cost-efficient machining of titanium, and strategies for 5-axis machining. With these requirements, the aviation sector is evolving into a crucial driver for technological developments covering the whole gamut of metal-cutting processes.

Sandvik announces new President for materials technologyJonas Gustavsson has been appointed as the new President of materials

technology replacing Peter Gossas, who retired on May 31, 2011 after a nine year tenure. Gustavsson also becomes a member of Sandvik’s group executive management. He was earlier the President of the Wire and Heating Technology product area within Sandvik Materials Technology. Materials Technology occupies a position within the group equivalent to that of Sandvik Coromant, the cutting-tools division.

Olof Faxander, President and CEO, Sandvik AB, said, “With his broad background and proven ability to

successfully drive change, Jonas Gustavsson has the right profile to lead Sandvik M a t e r i a l s Technology. He brings with him experience from two different

product areas within the business area and has made an exceptional contribution to the development of Wire and Heating Technology over the past two years.” Faxander also acknowledged the achievements of Gossas, noting that the outgoing president could take credit for moving the product programme increasingly toward high-value-added products, improving manufacturing processes and stepping up product development.

GM declared Automotive Innovation Leader Automotive giant, General Motors (GM) has been ranked No 1 innovator of 182 companies in its quarterly automotive and transportation industry scorecard by the Patent Board. The organisation analyses intellectual property performance across 17 industries and determines the leader in each sector based on measurements that include the number of patents, impact on the industry, technology and science strength. GM was also ranked first in

the automotive/transportation sector in the previous scorecard, published in January.

Alan Taub, Vice President - R&D, GM, said, “We focus on inventions that make our vehicles more sustainable. Our engineers are developing a d v a n c e d t e c h n o l o g i e s that increase fuel efficiency and ensure safety while maintaining the excitement of personal mobility.” During the past 10 years, GM increased its patent filings six-fold. The Patent Board announcement follows recent news that GM received more clean-energy patents last year than any other organisation, according to the Clean Energy Patent Growth Index of US patents. GM also received 940 US patents in 2010, which placed it in the top 25 of all companies.

ABB acquires Mincom Power and automation specialist ABB has acquired Brisbane-based Mincom from its current owners, private equity group Francisco Partners, for an undisclosed sum.

Mincom provides enterprise asset management software and services for asset intensive industries such as mining operations and mobile workforce management. Mincom has around 1,000 employees and annual revenues of approximately $ 200 million. The company has a distribution network in 19 countries. Joe Hogan, Chief Executive, ABB said, “The acquisition of Mincom is part of our strategy to continuously broaden our software offering, which helps us to increase the depth of our enterprise asset management, building our position as a leader in the key growth sectors of natural resources and energy.”

Jonas Gustavsson

Professor Berend Denkena

Joe Hogan

World News


Chinese steel producer ties up with Siemens for supply Siemens has agreed to supply drive, electrical and automation equipment for a continuous annealing line and a double-stand cold reduction mill to a Chinese steel producer, Shougang Jingtang United Iron & Steel Co, Ltd. The lines are designed to process tinned plate, and will be constructed in the company’s plant on the Caofeidian Peninsula in Hebei Province. The commissioning is scheduled for August 2013.

Siemens will supply the complete drive system, the basic automation, including the technological control systems for the continuous annealing line and the cold rolling mill, as well as the instrumentation and control system for the strip cleaning and after treatment in the two new lines in

Shougang Jingtang. The project also includes process automation, control desks and human-machine interface equipment with user-friendly process and plant diagnostic functions. The fast technological control systems in the rolling stand section will be based on the Simatic TDC control system and the programming will use standardised application modules. The process automation system and the operator control and monitoring system of the almost fully automated production lines will be equipped with standard server components.

STROTHMANN expands manufacturing siteSTROTHMANN expands its planning and manufacturing capacities at the German headquarters in Schloss Holte-Stukenbrock. In the initial construction phase, a storey has been added to the administrative building and the existent assembly site has been extended by 1,500 m² floor space. The space for the welding shop and for

more manufacturing capacities has been created. This would help storage, material preparation, manufacturing, assembly and electrical installation sections to be located in one site. “On this basis, we implement a linear material flow and a close integration of all manufacturing segments. In view of the growing demand, in the next stage of construction, we will build an additional office building, which will house our construction department

and project management,” said Derek Clark, CEO, STROTHMANN.

Founded in 1976, STROTHMANN has been a force of innovation in transport and handling facilities and has decades of experience in press shop automation. The company supplies complete handling solutions for press lines and sophisticated centering stations to highly dynamic stacking and destacking feeders.

SCHUNK CEO receives prestigious Robotics award Heinz-Dieter Schunk, CEO, SCHUNK Gmbh, recently received the Engelberger Robotics Award at the 41st International Robotics Symposium. The Engelberger Award is considered to be the most prestigious award in the

field of robotics. It honours individuals, who have provided o u t s t a n d i n g c o n t r i b u t i o n s in the areas of technology d e v e l o p m e n t ,

application, education and leadership. The award is named after Joseph F Engelberger, the founder of industrial robotics and father of the modern

robot industry and the prize has been awarded since 1977 by the Robotic Industries Association (RIA) trade organisation in North Amercia.

Heinz-Dieter Schunk is a pioneer in the field of gripping technology. He was one of the first engineers to develop standardised gripping modules. Today, SCHUNK is considered to be the worldwide competence leader in clamping technology and gripping systems. The SCHUNK programe has more than 10,000 standard components. Among the many benefits, operators profit from the worldwide largest gripper programme, the largest mechatronic gripper spectrum and from the 30-year functional warranty on multi-tooth guided gripping modules, which is second to none.

Navistar up for expansion US-based Navistar International is planning to expand its engine components business, PurePOWER Technologies, adding new jobs to the Indianapolis community. The company will recall 150 workers by June 2011 and plans to hire 100 additional workers by 2014 at the Indianapolis

foundry, one of the few remaining facilities in the US to make cylinder blocks and heads.

The company assured that the Indianapolis facility is capable to serve the needs of any manufacturer in the diesel engine arena. Eric Tech, President, Navistar Engine Group said, “The Indianapolis foundry is a vital part of the company’s efforts to maintain manufacturing capabilities and technical skills in the US. As a result of our investment to make the Indianapolis foundry a state-of-the-art facility, we will make the company more competitive to meet the global demands of the diesel engine industry.”

Heinz-Dieter Schunk

World News


Delcam announces agreement with AICON Delcam recently announced an agreement with AICON 3D Systems GmbH, the developer of the MoveInspect HR optical measuring system, at the Control exhibition held in Stuttgart. Under the agreement, AICON will supply Delcam’s PowerINSPECT inspection software with its metrology system.

AICON is one of the world’s leading providers of optical camera-based 3D-measurement systems. The company, which was founded in 1990 by Dr-Ing Carl-Thomas Schneider and Dr-Ing Werner Bösemann, was a spin-off of the Braunschweig Technical University and the VW Group’s R&D unit. Today, it has 60 employees and a customer base that includes renowned automotive manufacturers and suppliers, plus companies from the aerospace, shipbuilding and renewable-energy industries.

Dr-Ing Carl-Thomas Schneider, Managing Director, AICON explained, “For our users, it is essential that the analysis of metrology data can be completed quickly and easily. We are certain that our customers will benefit from the new interface to PowerINSPECT. We expect a lot of positive feedback from our customers for PowerINSPECT.”

Dr Lang appointed as the new MAG Global President MAG, a leading provider of manufacturing system solutions has appointed Dr Christian Lang, as the new Global President of the Industrial Equipment business. Along with his responsibilities as a member of the

board of MAG IAS GmbH, he also joins the company’s global executive m a n a g e m e n t team. Dr Lang now heads c o r p o r a t e activities in the area of metal-cutting solutions for industrial manufacturers. His previous responsibility as Managing Director for European and Asian sales at MAG will be taken over by Alexander Attenberger. Dr Lang has held that post since June 2010.

“As a full-scale provider of metal-cutting solutions and services, we partner with medium-sized manufacturers and tier suppliers to enhance their productivity,” explained the new head of Industrial Equipment for MAG. “With our unique portfolio of technologies and application expertise, we cover virtually all manufacturing needs in this segment, whether it is about turning, milling, gear manufacturing or combinations of these. In 2011, we will present an unprecedented amount of new developments and innovative products. We will introduce new 5-axis and multitasking solutions to cover even further areas, such as die and mould applications,” added Dr Lang.

Panasonic to expand production in China To boost its capacity, Panasonic Corp plans to expand it existing Chinese facility by adding a lithium-ion battery plant. Panasonic, the world’s biggest supplier for lithium-ion batteries used in consumer electronics, will build the

new factory in the eastern Chinese city of Suzhou. The company will also add facilities at subsidiary Sanyo Electric Co’s existing plant in Beijing. Production of lithium-ion batteries at Sanyo’s Japanese plant in Hyogo

Prefecture, in western Japan, will be moved to the new Chinese facilities. Panasonic turned majority-owned Sanyo into a wholly owned unit on April 1, 2011 and is realigning production to benefit from the integration.

Panasonic’s Chinese production plans come as Japan earthquake and subsequent disruption to Japan’s supply chain is causing some Japanese manufacturers to review their production systems and consider shifting production overseas permanently. China will start taking up a much larger portion of Panasonic’s output in a few years, as the company expects a 50 per cent rise in the group’s capacity for lithium-ion batteries for consumer electronics by 2015, the spokesperson said.

Areva inks deal in BulgariaFrance’s nuclear engineering company Areva and Bulgaria have entered into an agreement on future nuclear and renewable energy projects. Anne Lauvergeon, CEO, Areva said, “The company will provide nuclear safety

expertise for Bulgaria’s nuclear facilities.”

Bulgaria has two 1,000-megawatt reactors at its only nuclear plant in Kozlodui. In 2008, it struck a deal with Russia’s Atomstroyexport for a second plant at Belene, but the project has been delayed over financial terms.

Areva, which is a subcontractor to the construction of the future plant, said it would implement the highest safety standards. This memorandum of understanding also envisages some joint renewable energy projects like offshore wind turbines in the Black Sea.

Dr Christian Lang

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Tech Updates


Your gateway to the latest trends and technologies worldwide

Grinding machine provides high precisionThe WENDT CNC rotary surface grinder WRS series is a 3 axis-grinding machine and is equipped with Siemens 810DE/840DE/802D SL controls. The WRS series of machines WRS 300H/V and WRS 600H/V are available in both horizontal and vertical spindle arrangement. The machine is especially used for the grinding of precision parts for the automobile and engineering industry. These machines are manufactured

with and without electromagnetic chuck. The components such as piston ring, rocker arm, connecting rod, valve plate, and compressor plate, ceramic parts, tools and dies can be ground on this machine.

The special feature of the machine is the massive, multi-piece gray cast iron column, housing all the assembly units with the exception of the hydraulic and coolant lubricant system and the switch cabinet. The solid construction of all assembly units provides rigidity for the entire structure during grinding. The main assembly units of the machine are the circular table, cross slide, vertical slide in which the horizontally/vertically arranged grinding spindle is supported. It is mounted with electromagnetic circular chuck for the clamping of workpiece. The machine is provided with a separate lubrication unit that exclusively feeds the oil for the lubrication of guide ways for the cross slide axis.

Design software reduces lead time significantly Geometric Ltd has introduced the new version of DFMPro 3.0 which is a revolutionary technology framework for designers and facilitates upstream manufacturability validation & identification of areas of a design that

are difficult and expensive to machine. It is equipped with new ‘Assembly Analysis’ feature for Creo Elements/Pro, and now supports clearance analysis of assemblies. Designers working with assemblies have to repeatedly check clearances between sets of components, which can be extremely difficult and time consuming. A lot of time is spent in performing such clearance checks and again in reviews to reduce possibilities of human errors. It reduces lead-time significantly by reducing backtracking and design iterations.

The new release of DFMPro helps to define the clearance requirements as rules, which can be easily specified for individual as well as a set of components. Checking of complex assemblies becomes easy with new version of DFMPro. It provides the flexiblity to export and share the analysis results with other users. This drastically reduces checking time from days to hours and ensures adherence to nominal clearance specifications. In electronic designs, DFMPro helps to easily specify clearance requirements around capacitors, between heat sinks and casings, from harnesses to nearby components and many such applications.

Circular saw provides speed, power and durabilityPower tools manufacturer Skil has introduced its 3.9 kg circular saw 5500 with a 184 mm cutting blade in India. The new machine is powered by a 1500-watt motor for faster cutting speed and also boasts of the highest power to weight ratio in the circular saw category. It is perfect for both standard and heavy duty applications and can be used to cut a wide range of materials.

The new SKIL 5500 has a two-point view of the cutting line, which allows users to follow the line from both sides of the saw blade. The left side also features a cutting window that provides the user with a clear line of sight.

Tailored for optimum comfort, ease of use and safety, the SKIL 5500 has a die – cast aluminium body along with strong guard, stainless steel foot plate, enhanced carbon brush, bevel and depth setting mechanism and end cap design. The circular saw’s upper and lower metal guards have a thickness of 2.5 mm, well above the industry standard of 1.2 - 1.5 mm. The stamped metal foot plate of this circular saw is similarly designed with rough cutting applications to provide extra stability and durability to the tool.

Tech Updates


Grinding system increases productivity The new CC-GRIND from PFERD is a new generation of discs for surface grinding. It helps to provide aggressive grinding, achieve maximum stock removal and increase tool life on large surfaces. The new grinding disc version combined with the matching backing pad ensures maximum machining

capacity in a very short time. Unlike reinforced grinding discs, CC-GRIND discs are very flexible, allowing score-free machining, especially on convex and concave surfaces.

CC-GRIND has a patented quick-clamping and cooling system. When combined with the high-performance abrasives, it reduces 30 per cent workpiece temperature, increases machining capacity by 40 per cent and substantially decreases tool wear. The company offers it in two versions – ‘STEEL’ for use on steel, and ‘INOX’ for the machining of stainless steel (INOX). Both versions are available in 115 and 125 mm diameter. The cooling slot geometry ensures a high throughput of air, thus significantly reducing thermal loads on the abrasive and the workpieces. It is equipped with patented backing pads, and with the use of these backing pads, GG-GRIND grinding disc can be used on standard angle grinders. Special design of the backing pad increases grinding performance significantly depending on the material to be processed. It is equipped with keyless clamping system, which reduces tool-changing times significantly.

Bearings for caster application The Timken Company has recently introduced a revolutionary new line of easy-to-install, high-capacity bearings especially for the metal industry’s most demanding continuous caster applications. The new ADAPT™ bearings feature a unique design that provide optimal ease of installation, reliability and performance. For metal-industry, this translates into reduced downtime associated with maintenance intervals. The ADAPT™ bearing is used in the float position in strand roll support segments. Timken’s new ADAPT™ bearing is easy to install, offers extended bearing life and improves performance. The innovative design of ADAPT™ provides durability and flexibility to keep casters operating at optimal levels.

Each Timken ADAPT™ bearing consists of a cylindrical inner ring, an outer ring with a proprietary outer race profile and a roller/retainer assembly that features specially profiled rollers with a snap-in retainer. The inner ring has a cylindrical raceway, allowing the shaft to move (float) left or right relative to the outer ring. Both the inner and outer rings of this bearing can be fitted separately for easier handling and improved installation flexibility. The bearing’s component design simplifies inspection & removal and allows operators to independently change parts as needed during maintenance, saving time and costs.

Thread mill for wide range of applications The recently expanded range of TMSD multi-flute, single point thread mills from VARDEX extends the potential for the production of deep hole threads at highly productive and economical rates. It utilises the VARGUS cost-effective ‘U’, ‘A’ and the new Mini-L (for small bores from M14 x 0.5) single-point inserts (for large and small pitches, respectively). TMSD covers a wide range of applications.

TMSD is available in up to four cutting edge end mills and now supplied in cutting diameters from 13 to 36.5 mm, and in pitches from 0.5 to 8 mm. With weldon or cylindrical (carbide or steel) shanks - the latter can be shortened, when appropriate, to reduce the possibility of chatter - the tool is characterised by long, adjustable overhang (up to 144 mm) for optimal stability, which is also engendered by its ‘reinforced’ tool body. The carbide cylindrical shanks

allow the production of extra long threads with relatively small diameters. TMSD shell mill tools are also available in an equally comprehensive choice of styles, and in cutting diameters up to 98 mm and maximum thread length of 200 mm. TMSD features through-tool cooling for fast chip evacuation and cool cutting essential for deep hole applications.

Sector Watch

50 MODERN MACHINE TOOLS - June 2011

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An integral aspect of the manufacturing process, grinding has evolved from conventional to super abrasive – one that involves the use of sophisticated technologies to meet the growing complexities of challenging areas like aerospace, automotive and cement industries. In many applications, manufacturing sector cannot achieve the productivity goals with conventional grinding wheels. Here’s an insight into the related developments, role of software and future of grinding.

Nishant Kashyap & Swapnil Pillai

Sector Watch


Core industries in India are witnessing significant growth compared to that in the last few years. Various innovative and effective

techniques are being implemented by manufacturers to cut cost and stay competitive, while ensuring quality and excellent finish of products at the same time. It is here where grinding industry plays an important role. Grinding, which is a finishing operation on components involving high precision, has become a key area of interest for the metalworking industry because of its high value-addition to achieve quality finished goods. Ultra high precision machines and special grinding equipment are required for attaining accuracy. Coupled with state-of-the-art techniques, availability of skilled manpower and capability to deliver effectively, the manufacturers in Asia now hold the key to grab potential tooling business from around the world.

Propelling growthToday, customers have become more demanding. They expect high precision products at low cost, which has forced manufacturers to constantly improve the performance of machines. Adopting the most advanced technology for grinding is essential for staying competitive in the market.

The economic growth of China and India has induced demand for grinding machine manufacturers. Talking about India’s position in global market, Rajesh Khanna, Chief Executive Officer, WENDT (India) Ltd, says, “There are many companies in India that have a good standing in the global market and we also have a big role to play in the global market because of the size, competent labour, good technology, and raw material availability in India.”

As China has the fastest growing steel industries globally and India is moving towards becoming the second-largest steel producer in next five years, these

factors indicate a positive sign for roll grinding and cut-off machines in the Asian market in near future. According to Mathew Jacob K, Chief Technical Officer, Pferd India, “Functionally and aesthetically, grinding plays a crucial role in manufacturing, and particularly in today’s world, where things revolve around lighter yet stronger concept, good grinding is even more significant.” India has many steel projects and capacity expansion projects, which provide a great opportunity for grinder manufacturers to grow in the field of metalworking. Grinding machine manufacturers are looking at exploring the huge market potential at this point. Witnessing the boom in the manufacturing sector, grinding machine manufacturing is the right place to be in.

Talking about the current demand for grinding, Santosh Prabhu, MD, Tool Grinding Technologies, says, “Indian market for grinding is mainly driven by automotive industry followed by engineering, defence, etc. Auto industry is high volume-based and price sensitive, whereas engineering and defence are special application-based. Indian industry still imports grinding machines for high-end applications. Majority of crankshaft, cam shaft, fuel injectors, nozzles in common rail, etc, are the applications where Indian industry depends on imported machines.” Consequently,

India is emerging as one of the best global investment options and as long as industrial investments continue to be made, the demand for capital goods such as industrial grinders will grow.

Role of grinding wheelManufacturing industries have a growing interest in finding economical ways to improve grinding productivity, part quality and production cost. Grinding wheels are the most common and important types of grinding elements used in this industry, so having a good understanding of the type of grinding wheel and its proper application becomes important.

Grinding wheels come in many different sizes, shapes and abrasives. Their function is to remove material from the workpiece to smoothen, sharpen or polish it. This happens by the abrasive action of the wheel. Each grain of the wheel acts as a cutting tool. The abrasive grains are the actual cutting tools of a grinding wheel. Each cutting grain is sharp and irregular, and they chip off tiny thin flakes of the material while cutting. Abrasive type, abrasive grit size, hardness grade, grain structure and bond type affect wheel performance. By varying the other parameters like work speed, traverse, feed, etc, an operator can make a wheel act one grade softer or harder.

According to V S Goindi, Chairman, Goindi Group, “Grinding, as applicable to the metal cutting industry, is generally a finishing operation on components especially in industries like automotive, aerospace, white goods, etc, which calls for high precision. Accuracies sometimes reach sub-micron levels that

Grinding, as applicable to the metal cutting industry, is generally a finishing operation on components especially in industries like automotive, aerospace, white goods, etc, which calls for high precision.

V S Goindi, Chairman, Goindi Group

Key factors in selecting the right grinding wheel

� Material to be ground and its hardness� Amount of stock removal and finish required� Grinding machine power� Wheel speed� Area of grinding contact� Grinding fluid

Sector Watch


require ultra high precision machines and special grinding equipment like Cubic Boron Nitride (CBN) wheels, rotary diamond dressers, fine filtration equipment for coolants with controlled temperature, etc. To achieve high accuracies, in-process gaging, dynamic balancing of grinding wheels, among others, are commonly used.”

High-performance grinding wheels are used for the grinding of auto engine, auto gearbox, auto chassis and auto steering. They also find applications in the aerospace industry for turbine blades, root & tip profiles,

and so on. The prospects of grinding wheels depend upon the type of manufacturing practices that will be adopted in the future. Wheels made of new forms of synthetic abrasives such as the seeded gel aluminium oxide and CBN are also being used. Further, the use of advanced materials such as ceramics and composites will increase demands for new types of grinding wheels. Research and development in making cutting tools out of polycrystalline super abrasive materials or CBN and aluminium oxide will make the

grinding wheel a viable option for shaping hard materials.

Simulation in grinding Grinding is one of the most important machining methods for finishing, which is performed by using a large number of abrasive grains with irregular shapes and random distribution. While this feature enables accurate and high quality machining, it makes it difficult to analyse the grinding process. In order to solve this problem, several computer simulations have been developed, which help users to statistically calculate geometric interference between a grain and a workpiece. It gives user flexibility to visualise the result as an animated image using a three-dimensional graphics technique.

Prabhu says, “New generation CNC control system uses software and 3D simulation to work out the programs offline, which increases the productivity. Acoustic sensors reduce the idle time while dressing and approaching for the part, thereby increasing productivity. Most of the grinding process works on closed loop measurement system and this helps in high rate of consistent production.” The simulation makes it easy to understand the microscopic grinding phenomena, and makes it possible to analyse the surface generation process quantitatively. It can be used as a practical tool for predicting the grinding results such as surface roughness, and for optimising grinding parameters such as infeed rate. The key advantage to tool grinding simulation software is that users can design and perfect a complete tool grinding process off-line and prior to actual production. Khanna says, “There are new products coming up in the market, which use exotic materials. There are super alloys, hard-to-grind materials, composite materials and these materials can only be dealt with grinding. So there is a growing demand in this segment.”

New product designs are focussed on high precision at high material removal rate. Rigidity of the machine and thermal stability are the design features, which increase the consistency of grinding quality and wheel life.

Santosh Prabhu, MD, Tool Grinding Technologies

We expect the grinding for high-end applications to grow at a higher rate, since the awareness level for safer and specialised performance tools are catching up fast in the industry.

Mathew Jacob K, Chief Technical Officer, Pferd India

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Grinding wheels constitute the most important grinding elements

Sector Watch


Manufacturing then and now The manufacturing industry across the world is influenced by globalisation, changing economic environment and ever-changing lifestyle choices. Customers worldwide have more choices than ever before, putting pressure on grinding system manufacturers to deliver quality products as efficiently as possible. This has induced manufacturers to do away with old production systems and adopt new methods of production.

The automation used in industries have increased the productivity and reduced human error and time. The new technological developments have reduced the need for human presence, therefore increasing accuracy and efficiency to meet the ever-growing demand from customers. “New product designs are focussed on high precision in high material removal rate. Rigidity of the machine and thermal stability are the design features, which

increase the consistency of grinding quality and wheel life,” says Prabhu.

The Indian manufacturing industry is successfully competing in the global marketplace and registering high growth every year, but large sections of the sector still suffers from the technology gap and poor infrastructure. Goindi observes, “Regarding the requirement of Indian industries, it is becoming more dependent on the local suppliers as against imports, as was the case earlier. However, there is still a gap in technology levels in many areas of critical applications when compared to countries like Switzerland, Germany Japan, etc.”

He further adds, “There is a great need for higher R&D investments in this vital segment of machine tools as has been done by China. This is particularly important, keeping in view the strategic needs of defence and aerospace industries. It is important that a national policy for

development in this sector is formed soon – with partial financial help from the government.”

Promising business The image of India as a manufacturing hub has created huge opportunities for Indian industry. Since grinding is a widely used method of precision machining, India seems to be the preferred destination for grinding machine and equipment manufacturers. Driven by domestic demand and the cost efficiency advantage of India, the business outlook for industry in the country is expected to grow considerably. Mathew avers, “We expect the grinding for high-end applications to grow at a higher rate, since the awareness level for safer and specialised performance tools are catching up fast in the industry.” The rise of automobile, heavy engineering and cement industry in the country has positively affected the grinding machine segment and this is expected to continue in coming years. “More advanced, aggressive yet stable grinding grits will become the future when it comes to demanding grinding applications. As more high-end engineering jobs are being outsourced to India, especially involving advanced materials like Inox, aluminium alloys, temperature resistant materials, etc, we expect significant increase in high-end grinding applications,” notes Mathew.

The challenge for grinding industry is to meet the international standards and yet stay competitive. This can be achieved by more investments in R&D, absorption of technology, research activities with academia, etc. Over a period of time, as the market becomes more mature with increasing volumes, co-operation between industries will increase, which will help grinding equipment manufacturers understand the industry requirements and provide customised solutions, promising a robust future for grinding.

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Grinding is one of the most essential machining methods for finishing and shaping

There are new products coming up in the market, which use exotic materials. There are super alloys, hard-to-grind materials, composite materials and these materials can only be dealt with grinding. So, there is a growing demand in this segment.

Rajesh Khanna, Chief Executive Officer, WENDT (India) Ltd

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Case Study


Numerous new developments in the area of work- and back-up roll materials have ushered in a sea-change in rolling mills during the last few years. More wear resistant rolls with higher mechanical strengths place new demands on grinding tools and machines. With SECUR ROLL STAR, Tyrolit is setting new standards for the efficient grinding of rolls in cold and hot rolling mills.

The grinding operation, the so-called repair grinding, is subdivided into roughing, which requires high material removal in the shortest time,

profile grinding and sparking out, in order to achieve the desired surface quality. All three operations have to be managed with the same grinding wheel without dressing in between.

Creating new benchmarks

ROLL GRINDING

Gebhard Melchior, Dr Gernot Kaltenhauser

Case Study


The main requirements from the tool include lifetime, the surface quality of the roll and the grinding time. As many roll grinding machines are fully automatic, great importance is attached to consistent quality, ie, the reproducibility of the grinding tools.

Initial situation: Quality assuranceAll raw materials used at Tyrolit are subject to strict and exact quality standards, which naturally undergo inspection at the stage of ‘incoming goods’. Resin-bonded grinding tools are subject to grade variations, which influence the stock removal rate and wheel lifetime (G-ratio). Certain specifications are manufactured with

a variation. The reasons for these deviations are quality variations in the raw materials and the production process of the grinding wheels. In most cases, the technical specification is defined together with the individual suppliers and matched to our needs.

In the past years, the tolerances for the individual quality characteristics have been narrowed down as far as it is meaningful and able to be executed according to the present state-of-the-art. This means that those variations of our products on account of raw materials have been reduced dramatically. To be able to examine the stability of the product quality more closely, the production process has to be more exactly analysed.

At considerable expense, an examination was made of the extent to which the raw materials or production processes influenced the variations. At the same time, the critical production steps for the product quality control were defined. Manufacturers of resin-bonded grinding tools have to accurately inspect every individual production step, in order to guarantee maximum reproduction. However, positive findings are also to be gained from the achieved result:� The exact definition and inspection

of the production sequence constitutes know-how & decisively influences the product quality

� A quantification of the variations makes the specification finding easier

� In future, bonds will be developed, which react even more robustly against raw material variations, production variations and environmental influences

SolutionThe already mentioned knowledge has served as the basis for the development work in the area of roll grinding wheels. Two projects were carried out in 2004 namely ‘Technical application support with roll grinding’; and ‘New systems – conventional resin’. The former was started in order to establish the reproduction of the mechanical strength. Figure 1 shows the reproducibility of two specifications by repeated production lots. The mechanical strength serves as inspection dimension for the quantification, which correlates well with the G-ratio.

In order to be able to carry out the follow-up tests, it is helpful to know the mechanical strength of the samples. The new inspection method will not only be used with sample wheels but carried out accompanying production so that product quality is guaranteed. The characterisation of the bond systems and their reproducibility can be well-

Figure 1: Mechanical strength of 2 specifications with repeated production

Trend of mechanical strength over 10 batches

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New grinding solutions by Tyrolit making way for change in the industry

Case Study


implemented with these new methods.

In the course of the second project, the attempt was to develop an even more constant bond system, which compared with standard bonds should show the following characteristics:� Improvement of

reproduction� Improved free cutting

capability with the same G-ratio

� Higher G-ratio with the same free cutting capability

The solution for the new system has been selected in such a way that the bond has to react in a stable manner with regard to external influences and variations with the individual production steps. In addition, it is possible to produce specifications with open structures in a reproducible way. These goals were realised through the use of special additives and the conscientious optimisation of each individual production step.

Characteristics of the SECUR ROLL STAR product lineBased on the characteristics of the standard bonds (good bonding of the grain, coolant resistant and free cutting), the new bond system has been developed with the designation B01. The following results were achieved:� More consistent product� Higher G-ratios with constant

stock removals� Higher stock removals with

constant G-ratios� High porosity wheels possible� Insensitive to coolant/lubricant

type and temperature

In a nutshellThe positive trial results have already been confirmed with subsequent production orders. Some of the highlights include:

Innovation: Grinding active additives produce a mild grinding behaviour and make good workpiece surfaces possible. The bond can be made harder because of this, through which a higher G-ratio can be achieved by unchanged free cutting ability. Colour coding of the different specifications makes classification for application easier.Characteristics: These include improved reproduction, excellent damping ability, minimum strength deterioration when used in wet grinding, and excellent bonding of the grain. Moreover, this product is

insensitive to coolant/lubricant type & temperature, and has good after roughing surface finish. In addition, very free cutting specifications are available.Quality: This aspect can be controlled by using newly developed inspection methods and documentation of the quality inspection data in newly developed databank.

To sum up, the newly developed system constitutes a real innovation in the area of resin-bonded, conventional grinding wheels.

Gebhard Melchior is the Head of Marketing - Metal Fabrication at Tyrolit Schleifmittel-werke Swarovski KG. He specialises in cut off wheels, roll grinding wheels and HP wheels for the steel industry. Email: [email protected]

Dr Gernot Kaltenhauser is the Head of R&D - Metal Precision at Tyrolit Schleifmittelwerke Swarovski KG since 1999. He specialises in resinoid conventional grinding wheels. Email: [email protected]

Grinding of an HSS work roll – 750 x 2500 mm, machine with 110 kWRoughing parameters:vc = 45 m/s nRoll = 49 min-1

Infeed 0.04 mmTraverse feed rate 0.1 mm/minTraverse speed 3000 mm/minTotal stock removal 1 mmCustomer requirement:G-ratio > 2.3 cm³/cm³Stock removal rate when roughing > 40 cm³/minResult:

G-ratio [cm³/cm³]

Stock removal rate [cm³/min]

Tyrolit standard 1.5 45-53

Strongest competitor*

2.3 51-56

SECUR ROLL STAR 2.7 50-56

* Higher sintered aluminium oxide content

Practical example 1 Practical example 2

The most remarkable efficiencyincrease compared with the presentstandard programme has beenachieved in a steel mill in Northern Europe: Grinding of an IC-working roll in a hot-rolling mill; machine power 90 kW Roughing parameters:vc = 42 m/s N Roll = 46 min-1Infeed 0.05 mmTraverse feed rate 0.15 mm/minTraverse speed 4000 mm/minTotal stock removal 1.2 mmCustomer requirement:Increase of the G-ratio and the stock removal rate compared with the standard specifications.Result:

G-ratio [cm³/cm³]

Stock removal rate [cm³/min]

Tyrolit standard 1.97 28

SECUR ROLL STAR 4.81 60

Industry Update


With the manufacturing sector charting an uninterrupted growth path and every industry fast donning a more modernised avatar, it is possibly the best time for the material handling equipment sector to explore new avenues. A couple of decades back, this industry had started with the most basic equipment, but now it is all set to experiment and go beyond the conventional.

It is not unusual to see labourers loading and unloading heavy merchandise manually. The country is still in a major way dependent on the labour

force. But the picture is changing slowly. Taking cue from the global trend towards adoption of state-of-the-art automation, the

Indian manufacturers are also looking at having swanky shop-floors, with the latest material handling equipment adorning their facilities.

Back on trackAfter witnessing a major setback from the global recession, the material handling systems industry has come

NextGen mechanisation MATERIAL HANDLING EQUIPMENT

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back on track. Most experts in the industry feel that after the dip in production, the industry is up for a significant growth in the near future. “The first quarter of 2008 was good, but from the second quarter up till early 2010, the industry was in a recession mode. Material handling equipment come under capital goods, and most capital goods purchases were in a suspension mode in most industries. The business started recovering slowly in 2010 and registered a growth of 20 per cent. The growth of the industry is certainly poised in the right direction,” says an elated S A Mohan, CEO, Maini Material Movement.

Changing milestonesManufacturers spanning various sectors, including aerospace and automotive, are looking to implement automation solutions at their shop-floor. While dock lifters and scissor lifts are fast replacing wooden planks and scores of labour force, the material handling equipment presently coming into the market is complete with high level of automation. There is a huge shift in the technological aspect as well. From the initial equipment categories with huge bulky control panels, it has now evolved to become more sophisticated and sleek.

According to industry experts, at present over 80 per cent of the manufacturers are in the unorganised sector. And this is where the industry envisages a change. Various material handling equipment manufacturers have come up with some of the latest technologies in the Indian market. An array of electric and semi-electric stackers throng the market with compact designs & small turning radius, which facilitates the use of material handling equipment with the least possible space requirement. The Indian market also offers a gamut of lift tables with the capacity to hold weight of up to 5,000 kg and more. Multi-directional forklifts are now entering the market,

which allows companies to utilise space better and not worry about turning radius.

“The cost of real estate is going up, which makes optimal use of space a necessity. Moreover, the trends are changing in every area, for instance the construction of warehouses. Earlier, warehouses were around 6 metre high. Today, warehouses over 16 metre high are built. This calls for appropriate material handling equipment, which can store and retrieve materials kept so high. The aisle space is also reduced so that more number of racks can be placed in the available space. We have come up with equipment, which has small turning radius, so that it can move around the narrow aisle space with ease,” notes Mohan. According to D S Sekhar, Managing Director, SFS Equipments Pvt Ltd, productivity can be enhanced by selecting the right equipment and there are many innovations in the market today.

Trendsetters Even as most industries are moving towards modernisation, material handling equipment is finding its way across all sectors. The Indian market is also trying to be in sync with the global market. While tow tractors are catching up with the

trend in the automotive industry, the same are also widely becoming popular in airports, railways and various other places. Apart from the regular industries, material handling equipment is also paving towards new sectors like wind energy parks, paper manufacturing, among others. Also, as the shop-floors of most industries are dramatically seeing a change, the material handling machinery manufacturers are working with the customers to provide customised solutions as per the shop-floor requirements.

There is an upcoming trend in the area of equipment used for loading and unloading of heavy materials from ships wherein such activity can be done accurately in minimum possible time, without causing much damage. With the advancements in machines, operator comfort is also being given high importance, and innovations such as joysticks in forklifts replacing steering wheels are some of the latest product offerings.

“The material handling equipment industry is growing because materials are getting heavier. For example, coils are much bigger than it used to be earlier. For customers, it is important to rationalise material handling during the manufacturing process. They want equipment, which would

It is a matter of education so that people start adopting such material handling equipment, and we feel that in the next three to five years, things will significantly change. In India, the trend has been more inclined towards adapting to new technologies. And as that happens, the material handling system industry will also have its share of growth.

S A Mohan, CEO, Maini Material Movement

India is a growing market and it is a good option to do business in this region. We cannot deliver ‘off-the-peg’ products to this market, but devices specially designed for individual fields of operation.

Nicole Moraru, General Manager, WIMO Hebetechnik GmbH, Germany

Industry Update


make the shifting process quicker and ensure no damage to the transported materials,” observes Nicole Moraru, General Manager, WIMO Hebetechnik GmbH, Germany.

Hurdles facedAs the material handling equipment industry is still in a nascent stage, the initial challenge faced by the industry is to create a demand for the high-end products available in the market. Even as quite a number of organisations are revamping their shop-floors to accommodate the latest material handling equipment, this sector has a long way to go. “It is a matter of education so that people start adopting such equipment, and we feel that in the next three to five years, things will significantly change. In India, the trend has been more inclined towards adapting to new technologies. And as

that happens, the material handling system industry will also have its share of growth,” believes Mohan.

Besides the fact that most industries still depend on the unorganised sector, thereby posing a problem for material handling equipment industry, this sector also faces the challenge of sourcing spare parts for imported equipment at lower cost due to high import duties.

But things are changing fast, and companies in India are working towards improving efficiency & productivity rather than being labour-intensive in their operations. In the logistics industry, where speed and efficiency are the key, it is imperative to have material handling equipment. While such equipment is seen as a cost-adding activity, it is essential that there is an emphasis on speed when it comes to delivery of products in the market. “From a manufacturing and

logistics operation scenario, material handling equipment is becoming unavoidable these days, irrespective of the cost of labour and it is seen as a value-addition rather than a pure cost. The material handling equipment industry is set to boom in the Indian market in the coming five years, with a projection of 20,000 new equipment requirements annually from the current figure of 4,000,” points out Sekhar.

Tapping global shoresWhile the material handling system industry is still trying to tap the domestic market, a global reach is a long way to go. “In the Western world, the market is organised, so the size of the industry is also huge, whereas, in case of China, the economics is different. There is huge amount of local consumption and export as well. So the combined demand is high. In India, we are mostly manufacturing it for the domestic consumption, and therefore the demand is still low and the industry size per se, in terms of volumes, is small. For example, in India, we manufacture 5,000 forklifts a year; whereas in Western countries, it is around 200,000-300,000. In China, the figure comes to over 200,000,” states Mohan.

But the industry is optimistic about the growth in this sector. “India is a growing market and it is a good option to do business in this region. The steel and automobile industries are witnessing growth. I think it is important to deliver high quality products. We cannot deliver ‘off-the-peg’ products to this market, but devices specially designed for individual fields of operation. In almost all cases, we collaborate with our customers in order to elaborate the best possible solution for the task required,” feels Moraru.

Green solutions Making green movement a part of the industry is a constant effort. There has been a significant demand for making material handling equipment more eco-friendly. There is a preference for electric-driven instruments, which would save fuel, reduce emissions and produce less noise. The industry is conducting indepth research to come up with new technology and pave way for more environment-friendly equipment in the future. “The industry needs to make more efforts towards going green with the use of battery operated equipment,” concludes Sekhar.

From a manufacturing and logistics operation scenario, material handling equipment is becoming unavoidable these days, irrespective of the cost of labour and it is seen as a value-addition rather than a pure cost.

D S Sekhar, Managing Director, SFS Equipments Pvt Ltd

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Market Insights


Having started as simple machines used to carry up and bring down materials, cranes and hoists have come a long way. These have become more sophisticated with time, and simplified various processes in manufacturing. Material handling equipment have greatly reduced human efforts and also brought down the process timing, thereby increasing the output.

With India pulling out all the stops in building world-class infrastructure, crane manufacturers are looking at exploiting the

emerging market potential this presents. Witnessing the boom in the manufacturing sector, crane manufacturing offers huge opportunities. Thus, this segment is treding on the growth trajectory.

The Indian marketThe Indian crane industry is split along the lines of organised sector and unorganised sector. Further, it is divided geographically. Hence, there are only a handful of players

in the organised sector who are really active on a pan-India basis. There are around 200 crane manufacturers in India and the industry is all set to grow at 30 per cent annually.

The industrial cranes market in India is highly fragmented. The organised sector accounts for almost 30 per cent of the total marketshare, while small crane companies (almost 150) constitute the rest. Interestingly, almost 30 per cent of the crane manufacturers fall under the government-owned companies and the remaining 70 per cent under the private sector. The latter is the most vibrant part of the Indian economy, which is growing at a high pace and willing to adopt new technologies.

Scaling new heights

INDIAN CRANE INDUSTRY

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Western India contributes 50-55 per cent of the total requirement; southern India follows with 20-25 per cent; northern India with 15-20 per cent; and eastern India with 5-10 per cent.

Growth drivers The industrial crane sector has a strong positive correlation with basic economic indicators. Any fluctuations in the economic indicators reflect immediately on the sector. Keeping in mind the current movements, India has a few key factors in its favour that will ensure the continuing growth of this segment. The resumption of a steady inflow of investments from foreign multinationals, increase in domestic spending on infrastructure construction & power projects, robust domestic growth rates, strong internal fundamentals and a healthy banking system make India an attractive destination for companies that are facing shrinking sales in other economies.

Consequently, India is emerging as one of the best global investment options. And as long as industrial investments continue, the demand for capital goods such as industrial cranes will grow. The key driver of the industrial cranes industry currently is the infrastructure industry, closely followed by steel and automobile industries. The Indian infrastructure is under–developed and there is huge potential for improvement. Within the infrastructure industry, construction and power projects are the main drivers. In the next fiscal, the demand for construction equipment will rise as a result of several projects in the areas of road construction, irrigation and power, among others. Demand for industrial cranes would be high, led by ongoing massive investments in industrial and SEZ projects. It would also get a boost from greenfield and brownfield expansion of refinery projects.

While the Indian market provides a plethora of opportunities to crane manufacturers, the challenges in this sector cannot be overlooked. Manufacturers face bottlenecks while

undertaking business development in terms of making the users understand the application and utility of the machinery. Skilled manpower development is yet another issue, which needs to be addressed appropriately to allow optimum utilisation of the equipment.

Customer-focussed approach The Indian industrial cranes industry is getting more customer-oriented, as the Indian customers are ever-evolving. From being exposed to low quality equipment a decade back, today they have an array of high quality equipment. Hence, the demands of the customers are also growing. Initially, the customer used to have a single line focus, ie only on the pricing aspect, without bothering a lot about the technical comparisons among different offerings. However, now the customer goes through the complete technical specifications and ensures that the end-product encompasses all the functional features as well as other aspects like reliability, safety, ease of maintenance, etc.

Another remarkable trend in this sector is that with several international tie-ups happening, the industry has started to have considerable global influence in terms of quality and use of better technology. As far as availability of high-end solution goes, the Indian materials handling equipment sector is at par with the global industry when it comes to industrial cranes. Today, the latest and best technology is available in India and Indian industrialists are embracing these products with open arms. Cost-efficiency is definitely important, but the competitive advantage of cranes lies in technological superiority. India is following the international trend of consolidation in the industry; most Indian manufacturers are associating

with international majors on the technology front.

Potential for foreign investors For international firms looking to enter the Indian market, the time is right with investments soaring in each of the construction segments. Foreign investors can enter the domestic market by setting up marketing companies. This allows them to establish a brand and also, at a later stage, to establish their own manufacturing units. Players with technological know-how can succeed, as technology is the major entry barrier.

A foreign investor or manufacturer can have a joint venture with an Indian partner through technology transfer. Any product with better installed technology has greater demand compared to its competition. Potential customers have to be made aware of technological advancements. A foreign investor can also associate with an Indian manufacturer whose processes are good by providing monetary support to establish more manufacturing units.

Future scopeIndia has a vast technical talent base, an established component vendor base and low labour rates, all of which lend it the distinct advantage of becoming an export hub for the Middle East and South-east Asian markets in the area of material handling equipment. India can also be regarded as a future R&D hub for international giants because of low R&D manpower costs. Manufacturers should provide customised solutions by providing additional accessories and specifications geared towards maximising the customers’ productivity.

To sum it up, India is an exciting market, and is expected to offer huge opportunities in the material handling equipment segment over the next 20 years.

Tushar Mehendale is the Managing Director of ElectroMech Material Handling Systems (India) Pvt Ltd, one of India’s largest manufacturers of industrial cranes by volume. He is a Mechanical Engineer and has to his credit an MS degree in Manufacturing Systems from USA. Email: [email protected]


Leaders Speak

…believes Rajesh Khanna, Chief Executive

Officer, WENDT (India) Ltd, one of the

fastest growing diversified companies in the

grinding segment. Today, the company has

made a mark in the Indian industry with

its Super Abrasive Grinding technology. It

provides its grinding excellence to a range

of industries including automobile, cutting

tools, engineering, refractory, ceramics,

glass, steel, power, defence and aerospace.

In a tête-à-tête with Debarati Basu, he

charts out the growth path that the grinding

industry is heading towards.

India is the second-largest steel producing country in the world. In what direction is the grinding industry advancing to be in sync with the growth? India is witnessing a growth phase, with several global players in various sectors including steel coming to India. Grinding is a crucial part of almost every industry, be it aerospace or automobile. Unlike earlier times, high-speed wire rod steel mills have become order of the day. It in turn calls for using precision grinding tools to improve production. Similarly, other industries have been experiencing intense competition to produce components that are lighter, more exacting, while being harder and tougher. Industries now prefer harder and exotic alloy materials, which are tough-to-grind, necessitating the usage of high performance grinding tools. This is where the grinding industry plays an important role. Moreover, the developed nations are looking at developing countries like India to serve as their manufacturing hub. As a result of which the precision components are getting shifted to Brazil, Russia, India and China. In India, we have seen a healthy growth in excess of three times the country’s Gross Domestic Product (GDP) in the grinding industry.

Tell us about the market in India as you envisage it five years down the line. As mentioned above, we have seen a healthy growth in the grinding industry last year. For instance, we have grown by


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46 per cent over the last year with the Super Abrasive business growing by 32 per cent and Non-super Abrasive by 138 per cent. We are optimistic of this positive trend continuing over the next five years.

Though India is gaining momentum in the field of technology and research, sophisticated machinery are still being imported. What is the reason behind this and the role of WENDT in changing this trend?There is a big dearth of high-end precision grinding machines in the country, which are traditionally being imported. The Indian psyche is against paying higher price for machines. Customers rather tend to choose low-priced machines than going for a quality precision machine due to price factor. Now with many MNCs coming into India with their pressing demand on quality and precision, the Indian manufacturers have no choice. The

customers are now ready to invest in the precision machines to address their demand and are also willing to pay for the differential. This is where we are trying to bridge the gap. At WENDT, we are now manufacturing high-precision CNC surface grinders, cylindrical grinders, precision profile grinders that would address this growing need. We are using state-of-the-art German technology weaving the price requirement of the Indian industries and offering machines in line with their expectations.

What advantages does the Indian market provide to the customers vis-à-vis global competitors?India still has the labour advantage, which is available at lower cost. China too is considered to have an edge when it comes to cheap labour, but I believe the workforce there is now becoming expensive. In India, however, we have committed, hard working populace coupled with relatively cheaper man-

hours and a workforce having good knowledge of English, which is globally accepted. The other competitive edge we have is the high level of IT literacy and computer programming skills. All these put together makes India an upcoming hub for CNC machines. This makes us more versatile and competitive in the global market.

What is the demand pattern in the market? As the industry is going for more tough-to-grind materials for components, the demand for super abrasive grinding tools is continuously on its uptrend, and with various global companies looking at the Indian market, the growth in demand is likely to continue. We do not really have a demand-supply gap as we work on the philosophy of building capability, while also ensuring adequate capacity to address spurts in demand. We are capable of producing and supplying as per the customer requirements in terms of both quality and quantity.

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Which latest advancements the industry would see in the near future? Grinding industry has come a long way. From the conventional abrasive grinding with abrasives like aluminium oxide and silicon carbide, users have graduated to harder super abrasives like diamond and cubic boron nitride in resin, metal, vitrified and electroplated bonded system. The latest trend is towards special bonding system like permanent bonded system or the brazed products where abrasives are chemically bonded to make them more aggressive and long lasting. With super abrasive being expensive, the industry is now looking at faster processes like laser-assisted machining, high performance fine grinding water jet cutting & wire sawing, etc.

What are the major challenges that the industry faces currently and what is being done to overcome these? The major challenge is that unlike other industries, here one has to be a local regional player. One cannot have a centralised plant at a particular place and conduct business across the world. One needs to be nearer to the customer since it is a service-oriented and technology-driven industry.

This is not all. There are several unorganised players in the market who are small time players and may adopt short-term practices for their sustenance, which poses continued nuisance for the organised sector.

Further, there is a good market for diamond tools in industries such as stone, gems polishing and diamond jewellery & lapidary, which is mostly dominated by the owner-driven companies. If the

government comes up with a clear policy for development of these industries and make them more organised & globally competent, it would give a boost to the grinding industry as well.

How does India fare in the global market? There are a few companies including our parent company M/s Carborundum Universal Ltd in India that have a good standing in the global arena. With CUMI and WENDT GmbH as joint venture partners for technology, WENDT (India) has a big role to play in the global grinding market. The Indian products are technologically competitive and fare very well in the global market in terms of price-performance ratio.

Tell us about your innovative products. Last year, we have formally launched a practice called ‘Innovation@Wendt’ to develop innovative products for the industry taking into consideration the present and latent needs of customer. This year, we plan to introduce two new innovative products to address the price-sensitive segment. Focus is on having sizeable percentage of innovative products, thereby adding to our product basket. We are also into making special purpose machines, tailor-made to customer requirement by incorporating innovative features.

What are the technological advancements in the area of diamond grinding that would take the diamond industry to the next level? Irrespective of the fact that there are small unorganised players, we strive hard

to make products, which can still provide a competitive edge to our customers.

The diamond processing industry is big in India. A majority of diamonds are being processed in India, China and other developing countries. In India, this industry is using imported products and low-cost tools sourced from countries like China. We are trying to provide these products with the technological edge, which can help the industry in processing the diamonds faster and cheaper, thus at an affordable price.

Today, most of the businesses are incorporating green policies as part of their business plan. What initiatives have been taken by WENDT to be environment-friendly?All activities and practices at WENDT are focussed towards being environment-friendly. We have a unique effluent treatment plant with zero discharge. We have used the natural topographical gradient so that the pumping of water and consumption of power is bare minimum. We also monitor issues, which might possibly cause harm to the ozone layer and have banned the use of items & chemicals like carbon tetra chloride, tri-chloro ethylene, etc, in our plant altogether. Also, while taking up any new process or project, we first check on any impact that it might have on the ecology.

Expansion plans of your company… After a modest start with a small unit way back in 1983, we have added facilities over the years. From being a small insignificant player , today we are the most preferred supplier of super abrasive tooling to the industry.

A few years back, we started our subsidiary WGTL in Thailand and subsequently added WENDT Middle East in Sharjah. In order to strengthen the regional presence in South East Asia, we are prospecting to set up a subsidiary in Indonesia and service centres in India.

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We do not really have a demand-supply gap as we work on the philosophy of building our capability, while also ensuring adequate capacity to address spurts in demand. We are capable of producing and supplying as per the customer requirements in terms of quality and quantity.

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Leaders Speak


…avers Fritz Korradi, Managing Director-Metal

Precision Business and Member of Executive Board,

Tyrolit Group – a leading supplier of innovative

solutions in grinding, cutting, drilling, honing, dressing

and polishing. Tyrolit Group is the market leader in

the abrasives industry and a leading manufacturer

of bonded abrasives, offering its target groups with

economical and innovative grinding solutions. In

conversation with Debarati Basu, Korradi touches upon

a range of topics on the growth of grinding industry in

India and Tyrolit’s plans for entering into the Indian

market to emerge as one of the major partners for

grinding applications.

With considerable growth in the manufacturing sector, India is an important market for us

Q What is the current business and investment opportunities in India and what will be the future pattern?India is an important market with considerable growth taking place in the manufacturing sector. Thus, this sector is showing a huge potential for

further growth. In this situation, it is advantageous for customers to use machining solutions that

will help them to produce more number of parts in less time.

This will reduce the investments required for future expansion of facilities. We at Tyrolit saw this increasing demand

for quality product as an opportunity, and thus invested in building our own organisation in India.

How do you perceive the grinding market in the country in terms of potential and growth opportunities?The growth in the grinding market is in line with that of the manufacturing sector. Customers

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Leaders Speak


are looking at opportunities to accelerate the grinding operations as well as reduce overall cost in the grinding processes.

New investments have been made in high-quality machines, which will yield better return on investment to customer, along with high-productivity grinding solutions.

Currently, the industry is facing a shortage of skilled labour. What initiatives are in place to retain skilled workforce in the company? What policies or initiatives need to be taken to correct the situation? As our office is relatively new in India, we have not yet faced this problem. However, we are confident that recruiting the right people for the right job, maintaining a good working environment, providing essential training to employees, etc should help in retaining the skilled workforce.

With the economy experiencing an upswing, what have been the major changes in your product portfolio to cater to this dynamic market?With this improving trend, the focus now is on how to accelerate production and, at the same time, be more economical. Our company is focussed on introducing new products for the benefit of our valued customers. We have more than 100 personnel working in the Research and Development (R&D) department who continuously strive to bring out innovative products to help users reduce product manufacturing costs.

Most manufacturers are of the view that a public-private partnership will boost the manufacturing capacity of India. What are your views on the same? Also, if such a partnership will be beneficial, then what should be the percentage of involvement?We believe that the public-private partnership will boost the manufacturing capacity in India. With this approach, the emphasis is on infrastructure development. With good infrastructure, the country will attract more investments in the manufacturing sector. This can either be in the form of better roads for transportation of goods or well set infrastructure for starting facilities such as that in Special Economic Zones (SEZs).

What are the best practices/technologies adopted by the company on the shop-floor? Also, elaborate on the R&D effort of the company.At Tyrolit, we follow the most stringent quality norms, a practice that enables us to consistently provide our customers with quality products. This is essential for ensuring that all manufacturers rely on us.

Our R&D department constantly works to develop new, customer-focussed and environment-friendly technologies. We continuously work towards bringing up innovative solutions and production technologies that are in line with market trends. We are also striving for constant improvement in our existing products and further development of bonding systems.

In co-operation with the Original Equipment Manufacturers (OEMs) as well as our valued customers, we try to arrive at new solutions to simplify the existing grinding methods. The evolution of the ‘Viper System’ for grinding of turbine blades in the aerospace industry is an example of such activities.

Elaborate on the technologies offered by the company.Tyrolit offers solutions for all grinding applications, from the processing of semi-finished products in the steel production industry, to precision grinding of engine components in the automotive industry. We also work closely with the OEMs to decide on optimum grinding processes for specific components. Our products and services are spread across steel mills and automotive, bearing, gearing, tooling industries, etc.

In a nutshell, no matter how varied the demands made by the most diverse of industries, we have the right product to meet every need of the customer. Right from the cut-off wheel, with a diameter of 2,000 mm, to diamond tools for polishing silicon wafers in the electronics industry, we have them all.

Future plans for expansion in India...Two years ago, we had begun setting up our own Tyrolit sales organisation, with the target to include some of the most important industrial areas. Our aim is to offer our clients the best service and application support in the grinding industry. In order to grow our business to occupy a significant market share, we believe that our next step must be to start local production to keep lead times low. Overall, we will continue focussing on the Indian market and work to emerge as one of the major partners for grinding applications.

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With good infrastructure, the country will attract more investments in the manufacturing sector. This can either be in the form of better roads for transportation of goods or well set infrastructure for starting facilities such as that in Special Economic Zones (SEZs).

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Surging towards high-precision grinding solutions, Micromatic Grinding Technologies Ltd is aiming to become the global leader in world-class high-technology grinding machines. With various other industries witnessing significant growth, Micromatic too is headed towards providing quality and reliability. Bringing in the latest technology and innovation, the company is on its way to provide products and services beyond precision.

Way back in 1973, Micromatic Grinding Technologies Ltd (MGT) had started its unit in Ghaziabad

and manufactured its first cylindrical grinding machine under the company name Micromatic Machines. Almost four decades later, the company has not only expanded but also made a mark in the grinding industry.

Apart from the three units in Ghaziabad, the company, two years ago, established a sprawling facility in Bengaluru to cater to the growing demand in the southern region. Spread across an area of 4,500 sq ft, the unit provides its expertise to every possible sector, including automotive & pumping industry, railways and aerospace.

Paving the path towards precision

MICROMATIC GRINDING TECHNOLOGIES LTD

Debarati Basu

Facility Visit


With all four facilities in Ghaziabad and Bengaluru spanning a total area of 1,50,000 sq ft, and 400 trained workforce, over 200 machines are rolled out every year under the banner. The Bengaluru unit alone has a capacity of manufacturing 120 machines per annum and is on its way towards expansion in the near future.

Manufacturing milestones Over the years, the company has been consistently adding some of the most innovative products to its product catalogue. Right from stroke and length match grinding machines with which it started off, it has added new technologies, keeping pace with time and customer demand. With machines such as heavy duty cylindrical grinding machine, piston ring profile grinding machine, CNC heavy duty cylindrical grinder and compact CNC grinder model, the company has made a mark in its own way.

Some of the most recent products rolled out by the company in the market include the Rhino – the 7-axes CNC crank pin grinder, iGrind 50 CNC internal

grinder, eGrind 200 hydraulic cylindrical grinder for tool room applications, universal grinder B-axis machine, crankshaft main journals grinder and heavy duty cylindrical grinding. Catering to smaller industries and making technology more affordable for them, MGT has come up with a simple Grind 50 CNC cylindrical grinder. The latest addition to the company’s product line is Stallion SH 63 STAT CNC grinder equipped with hydrostatic guide ways.

MGT also specialises in a unique process called scraping. To add value to its available technology, it has employed human resources who have received special training in the up scraping and down scraping process from Switzerland.

“Every year at MGT, we push our boundaries, innovate and come up with something new. We have successfully created a technology that allows us to completely automate the grinding of ceramic components in our grinding machines,” avers Sidhartha Dhand, Director, Micromatic Grinding Technologies Ltd.

Stepping into the global market Recently, MGT added its first European branch in Grenchen, Switzerland. With this office, the company aims to make an impact in the European market and head towards its mission to become a global player.

Among its numerous other undertakings, a joint venture with JTEKT Corporation, Japan, is a feather in the cap for the company. The collaboration took place in 2008 under the name Toyoda Micromatic Machinery India Ltd, and since then, with their expertise in CAM grinding technology, they have jointly come up with four new machines, including a new cost-effective small cam lobe grinding machine, which adds greater value to the existing product line.

The company exports to Europe, Middle East, Australia, the US and South East Asia, besides providing services to almost all major automotive companies in India. MGT exports three to four per cent of its production every year to the global market.

“Grinding is all about super finish and accuracy. It is a surface finishing operation. We give great importance to transparency in pricing and machine building activities. This is the way we try and add value to our services,” says Narayan Muramatti, CEO, Micromatic Grinding Technologies Ltd.

Innovation and research Unique products are the result of in-depth research and knowledge of customer need. MGT is heavily engaged in Research and Development (R&D) programmes to bring out new and competitive products for the market. The R&D centre at the company is recognised by the Government of India, and it is constantly engaged in developing new technologies to improve existing machines and create new ones.

In 2010, the centre witnessed a breakthrough in its R&D. For easy setup change and reducing setup change time, the company has come

Work in progress on heavy-duty grinding machines at MGT

Precision is the quality of exactness. And at Micromatic Grinding Technologies, we try to understand, create and deliver precision that is more economical.

Sidhartha DhandDirector

Facility Visit


up with a customised screen. This screen uses an interactive method that allows the system to be operated in accordance with messages displayed on the CNC display. The technology is easy to understand and operate, making it easy for beginners to readily create and edit programs and run the production.

Last year, the company set up its Information Technology (IT) infrastructure to be able to meet all business needs, even before they arise. The company has 23 servers, with VMware (Virtualisation) as the driver of its IT technologies. The deployment will be completed this year, making the infrastructure at MGT more reliable and future-ready than before.

“Precision is the quality of exactness. And at MGT, we try to understand, create and deliver precision that is more economical,” avers Dhand.

Employee-friendly campus Great care is taken to ensure employee satisfaction at MGT. While numerous activities are conducted at the facility to keep the employees’ spirits high, care is taken about their safety. Most machines used in the unit come with full enclosure and mist collectors to keep a check on possible health hazards to operators of the machines.

Apart from safety, the company offers equal opportunity to its employees to express their views and

ideas across all grades of workers, thus making them feel that they are an important part of the entire process.

“We have not just built a skilled labour force in our company, but also integrate collaborative thinking across all levels sans hierarchy, and this helps us to innovate better. So, for most of the new products, we have ideas coming in from every quarter of the company,” ascertains Dhand.

Recently, the company was featured as one of the three Indian companies in the book series Humanism in Business by a Switzerland based international organisation ‘Humanistic Network’. This book is a collection of business case studies from all corners of the globe. What unites this group of businesses is that all of them are highly successful market actors in a competitive environment and yet they consider their ultimate aim as the generation of societal benefit rather than maximum profit.

“At MGT, we encourage every individual to communicate freely and openly, as this is an effective way of

showing respect to individuals. In addition, it avoids all difficulties related to inevitable loss of communication down the line, which often results in distorting the facts and unfortunate interpretations at all levels,” affirms Dhand.

Environment consciousness The company also gives high consideration to being environment friendly.

As part of its eco-friendly efforts, the company uses re-usable pallets for transportation from its Ghaziabad to the Bengaluru factory, thus saving on a large number of trees on an annual basis. The company has also deployed a Vapour Absorption Machine (VAM) since 1997 at the Ghaziabad unit, for Chlorofluorocarbon (CFC) free air conditioning. Here, powder coating technology is being used in place of spray painting to reduce air pollution.

“Every company exists in the context of its ecosystem and while most of the effort is directed towards business goals, it is important that the ecosystem of the company is protected and enhanced over the years. The negative impact of mindless resource utilisation, with no efforts at environmental enhancement, has given rise to huge global problems. We, on our part, always seek to enhance the environment in a multitude of ways,” reflects Dhand.

Future plans With this high rate of growth in the industry, MGT has achieved a turnaround of ̀ 56 crore. The company further aims to reach its target of ` 100 crore this year. “We are in the process of adding more machines and manpower to our facility in order to increase productivity. We are currently producing 120 machines per year and have a target to roll out over 300 machines at the Bengaluru unit, with the expansion in place. And while we are trying to understand the need of our customers, we are simultaneously strengthening our vendor base, as most of our business happens through the vendors,” concludes Muramatti.

Micromatic engineers engrossed at a highly skilled process called ‘Scraping’

Grinding is all about super finish and accuracy. It is a surface finishing operation.

Narayan MuramattiCEO

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Policy Watch


Ranked as the second largest aviation industry in the world, India is flying high with a robust economic growth. The burgeoning Indian middle class coupled with an increasing number of air travellers will further strengthen the country’s aviation industry. Also, the rising need to enhance/modify existing fleet and include new ones has resulted in increasing opportunities and potential for national as well as international companies.

The growing Indian defence quota has initiated a fierce competition among the defence suppliers from US, Russia and Europe.

The country’s soaring aerospace industry has created opportunities for manufacturers and Global Service Providers (GSP) in India. The rising demand from the defence and civil aviation sector combined with the State’s procurement offset policy has resulted in participation and

alliances. The offset policy drafted by the State, which is related to defence procurements has been extended to buy state-owned carriers also such as Air India.

Background of India’s defence offset policyThe growth of the country’s defence industry has been sporadic since independence. It did not follow any definite plan though emphasis was laid on enhancing indigenous defence

Smoothening the runway for future growth

INDIAN OFFSET POLICIES

Hema Yadav

Policy Watch


production capability. An attempt to change this was made during the 1962 India-China war. However, this did not derive the desired result due to several factors such as:

The Soviet friendship: A major factor in the incapability of India designing a strong military industry was the easy access to defence equipment from the former Soviet Union. Sophisticated defence equipment were transferred to India under the rupee-rouble arrangement and a few license production facilities were also established in India, for example for the MiG-21 aircraft. The prevalent Cold War ensured continuous supply of military equipment to India, alienating it from Western superpowers like the US.

However, with the collapse of the Soviet Union, India lost easy access to sophisticated defence equipment at cheap prices. The issue was compounded by the absence of an alternative source of modern defence equipment. The situation became worse with the almost complete disruption in the supply of services and spare parts necessary to maintain the predominantly Soviet-equipped Indian armed forces. The navy was particularly affected, as it was dependent on Soviet designs and equipment for some of the ships that were under construction in India. This led to incurring huge expenses and time overruns in the construction programme of naval vessels. This compelled India to seek alternative channels to develop a certain level of indigenous capability.

Closed economy: Prior to the liberalisation policy of 1990s, India

obtained technical knowledge for the repairs and local production of a few critical spare parts. These efforts were mostly case-specific and were not components of any systematic strategy for the comprehensive development of a defence industry. They were also service-driven in the absence of any coherent strategy to achieve self-reliance. However, the liberalisation of the Indian economy that almost coincided with the collapse of Soviet Union harnessed India’s productive capabilities, providing impetus to the goal of developing a domestic military industrial complex.

Defence procurement procedureThe year 2005 witnessed the formulation of the country’s first ever defence offset policy to assist in developing the country’s defence industry. The policies were incorporated in the Defence Procurement Procedure (DPP) 2005. The initial policy introduced a 30 per cent offset in contracts valued above ` 3 billion under ‘buy’ and ‘buy and make’ categories. Under the policy, foreign vendors had the liberty to discharge their obligations either through the execution of defence exports of Indian items and services or through investments in India’s defence infrastructure. They also had the option of selecting Indian firms in consultation with an industry associate of their choice to implement their offset obligations. These offsets were non-mandatory, leaving the Services Capital Acquisition Plan Categorisation Committee (SACPCC) to recommend the incorporation

of offset obligation in acquisition proposals.

On the flip side, the policies lacked clarity and were not assigned to any designated agency in the Ministry of Defence (MoD) for guiding, overseeing, executing and monitoring the implementation. The prevailing confusion resulted in failure of the policies, which did not yield any dividend or benefit. Building on the disaster of DPP 2005 the Government of India made significant changes in DPP 2006.

Indian aviation industryIndia is carving a niche for itself as a manufacturing hub due to its technical expertise and cost-efficient environment. The manufacturing segment is projected to be another main beneficiary of the State’s offset policy, and is likely to result in deals cut across the 30 per cent offset limit. A report published by market research firm RNCOS, titled ‘Global Aerospace Market Forecast (2006-2009)’ described Indian aerospace industry witnessing three main trends – fast growth in civil aviation, development in manufacturing (especially in the private sector) and emergence of India as an aerospace technology-sourcing centre.

Global aerospace players have a preference for services of GSPs from India like Infosys, HCL, Wipro and TCS, where their Global Delivery System (GDS) have been valued on international scale, making it easier for them to meet the current offset requirement of 30 per cent.

DPP 2011From January this year, a new DPP is in place. However, the more liberal offset policy compared to its predecessors will not be applicable to the country’s largest defence procurement, the Medium Multi-Role Combat Aircraft (MMRCA), thus quashing the hopes of many vendors. Programme offsets require foreign vendors to provide work for Indian

Highlights of DPP 2006

� Offset was made mandatory in defence contracts of the size and nature as prescribed in the 2005 policy

� Overseas companies were allowed the flexibility of forming joint ventures with the ones in India

� A new organisation called the Defence Offset Facilitation Agency (DOFA) was established comprising representatives of all stakeholders - the Services, Defence Public Sector Undertaking (DPSU), Defence and Research Organisation (DRDO), etc

Policy Watch


industry up to a certain percentage of the programme’s value. The $ 11 billion MMRCA project was viewed as a potential major boost to India’s still-maturing defence industry. Highlights of the sixteen point document include:

Preference will be given to indigenous design, development and manufacture of defence equipment. Therefore, wherever the required arms, ammunition and equipment are possible to be made by the Indian industry within the timelines required

by the Services, procurement will be made from indigenous sources. Whenever the Indian industry is not in a position to make and deliver the equipment as per the Service Quality Regimes (SQRs) in the requisite time frame, procurement from foreign sources would be resorted to, in accordance with the DPP. While examining procurement cases, the time taken in the procurement and delivery from foreign sources vis-à-vis the time required for making it in the country, along with the urgency and criticality of the requirement will be examined as per the DPP before deciding to proceed with procurements from foreign sources.

Based on the approved Long Term Integrated Perspective Plan (LTIPP), equipment/weapon systems/platforms required 10 years and further down the line will by and large be developed/integrated/made within the country. Sub-systems/equipment/components that are not economically viable or practical to be made within the country may be imported, ensuring their availability at all times. However, as far as possible, the design and integration of the platform/system will be undertaken within the country.

The government will endeavour to build up a robust indigenous defence industrial base by proactively encouraging larger involvement of the Indian private sector in design, development and manufacture of defence equipment. Towards this end, efforts would be made in progressively identifying and addressing any issue which impacts; or has the potential of impacting the competitiveness of the Indian defence industry in comparison to foreign companies.

To synergise and enhance the national competence in producing state-of-the-art defence equipment/weapon systems/platforms within the price lines and timelines that are globally competitive, all viable approaches such as formation of consortia, joint ventures and public private partnerships etc within the

List of products eligible for offsets banking

� Defence equipment-small arms, mortars, cannons, guns, howitzers, anti-tank weapons and their ammunition

� Bombs, torpedoes, rockets, missiles, other explosive devices and charges, related equipment and accessories specially designed for military use

� Equipment specially designed for handling, control, operation, jamming and detection. Energetic materials, explosives, propellants and pyrotechnics.

� Tracked and wheeled armoured vehicles� Vehicles with ballistic protection designed for military applications, armoured

or protective equipment � Vessels of war, special naval system, equipment and accessories� Aircraft, unmanned airborne vehicles, aero engines and aircraft equipment,

related equipment specially designed or modified for military use, parachutes and related equipment

� Electronics and communication equipment specially designed for military use � Specialised equipment for military training or for simulating military

scenarios� Forgings, castings and other unfinished products that are specially designed

for products for military applications and troop comfort equipment� Environmental test facilities and equipment for the certification, qualification,

testing or production of the above products. Software designed or modified for the development, production or use of above items. This includes software specially designed for modelling, simulation or evaluation of military weapon systems, modelling or simulating military operation scenarios and Command, Communications, Control, Computer and Intelligence (C&I) applications. High velocity kinetic energy weapon systems and related equipment. Direct energy weapon systems, related or countermeasure equipment, super conductive equipment and specially designed for components and accessories.

� Internal security equipment: Arms and their ammunition including all types of close quarter weapons

� Protective equipment for security personnel including body armour and helmets. Vehicles for internal security purposes including armoured vehicles, bulletproof vehicles and mine protected vehicles. Riot control equipment and protective as well as riot control vehicles.

� Specialised equipment for surveillance including hand held devices and unmanned aerial vehicles. Equipment and devices for night fighting capability including night vision devices. Navigational and communications equipment including for secure communications. Specialised counter terrorism equipment and gear, assault platforms, detection devices, breaching gear.

� Training aids including simulators and simulation equipment� Civil aeronautics: All types of fixed wing as well as rotary aircraft including their

airframes, aero engines, aircraft components and avionics. Aircraft design and engineering services, technical publications, raw material and semi-finished goods, flying training institutions and technical training institutions (excluding civil infrastructure).

Policy Watch


government approved framework will be undertaken. The Academia, Research and Development Institutions as well as technical and scientific organisations of repute will be involved for achieving this objective.

The government will further simplify the procedures under the ‘MAKE’ category of the DPP in such a manner that it enables the indigenous design and development of the required equipment/weapon systems/platforms by both public and private industry in a faster timeframe.

Service Headquarters (SHQs), while laying down the qualitative requirements for defence equipment/weapon systems/platforms to be developed/integrated/made, will exercise due diligence at all times to keep in view feasibility and practicability of the QRs. It will be ensured that the systems/platforms designed/developed/integrated in the country provide a competitive edge to our services vis-à-vis our potential adversaries.

The government also recognises that development of complex systems is generally a stage process with incremental changes progressing from Mk-I and Mk-II and so on. The stage process will be

followed. However, at every review of such developmental projects by the Defence Production Board or Defence R&D Board as the case may be, it will be ensured that our equipment, weapons systems and platforms are such that they provide an edge to our forces over our potential adversaries. In case of delays in the realisation of the projects, the corresponding proposal will be processed as per the DPP and the option of ‘Buy’ shall be followed for the necessary numbers till indigenous production capability is established where after indigenous systems shall be procured.

Policies will be put in place to encourage the OFB, DPSUs and the private sector to strengthen their research and development wings so that constant upgradation and improvement in systems under manufacture is possible.

The government will set up a separate fund to provide necessary resources to public/private sector including Small and Medium Enterprises (SMEs) as well as academic and scientific institutions to support research and development of defence equipment/systems enhancing cutting edge technology.

In all cases of transfer of technology, DDP along with DRDO, HQIDS and SHQs will be involved in identification and evaluation of requisite technology, and subsequently would be responsible to ensure that appropriate absorption of technology takes place in the Indian industry. Thereafter, successive generations of the weapon systems/platforms will be developed in the country.

Upgrades will be carried out by the Indian industry as far as possible. DRDO, HQIDS, SHQs, OFB, DPSUs and the private sector will work in close co-ordination for continuous upgradation in systems.

The committees set up under the DPP will process the acquisition proposals in accordance with the above policy guidelines.

Through the current DPP, the Ministry of Defence is encouraging participation of the Indian industry and supporting them to become self-reliant. The crucial question is how effectively the government will work with the private sector to develop indigenous platforms and systems, given the limitations of time and technology that may be available in the country. The DPP 2011 is aimed at speedy indigenisation and to substantially reduce dependence on foreign suppliers. Under the current policy international companies winning defence contracts in India will no longer be required to invest in direct defence equipment to fulfill offset obligations. However, the government has allowed itself the right to bypass the bidding process if ‘strategic considerations’ dictate.

The new DPP for 2011 has broadened the scope of the offset policy to include civil aerospace, internal security and training within the ambit of eligible products for the discharge of offset obligations. The changes brought in by the current DPP will provide a wide range of offset opportunities to defence vendors and encourage building up of indigenous manufacturing capability in crucial areas.

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Towards a brighter future: Indian aerospace sector is witnessing tremendous growth both in defence and commercial aircraft

Viewpoint


Essential parts and equipment for aerospace machiningAerospace machining is a high-profile industry in machining and manufacturing of precision components/parts, which are critical and high precision in nature, with close geometrical tolerances from bar stocks, billets, forgings and castings required for building aircraft, helicopters, rockets, missiles, spacecrafts, launch vehicles, satellites, etc that operate in space or outer space.

It involves extensive deployment of CNC machinery such as CNC machining centres, CNC milling and CNC turning centres supported by grinding, jig-boring, honing, broaching and other conventional machines. Non-traditional machining processes can be carried out on CNC wire EDM, chemical milling and waterjet & laser-cutting machines.

There has been a major shift in the usage of conventional to CNC machine tools, with simultaneous multi-axes machining capabilities for machining complex & 3D contouring parts, as they have close geometrical dimensional tolerances and stringent quality checks. These adapt high-speed machining technologies, high-end graphics, Computer Aided Design and Manufacturing (CAD/CAM) software/workstations for generating shop floor drawings, process sheets, 3D solid

and surface modelling of complex contoured components.

These are suitable for Numeric Control (NC) tool path simulation & verification, generating NC codes, specially coated cutting tools for hard & dry machining, special cutting fluids for maximising productivity, advancements in workholding systems, for high-precision metrology instruments/equipment such as 3D CNC Coordinate Measuring Machines (CMM). Further, these latest technologies call for high investments.

Business outlookThe government’s new defence procurement & offset policy regime is undergoing a paradigm shift and is being credited to open business opportunities to the tune of $ 100 billion in the next few years. The Indian aerospace component manufacturers would be the main beneficiaries of this. Also, with Hindustan Aeronautics Ltd (HAL) and Indian Space Research Organisation (ISRO) stepping up their roles in global aerospace businesses and being aggressive in exports business, offset trade policy initiated by the government and Maintenance Repair Overhaul (MRO) facilities in India, growth is likely to be on a rapid pace.

K S V Raghav

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Aerospace machining market is growing at a reasonable rate, which is expected to continue for next 10-15 years

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With the government looking for MRO investments in counter agreements with giant foreign aerospace industry players, there are a lot of opportunities for the aerospace machining industry in the country, especially if we can quickly adapt the latest trends in machining technologies, strictly adhere to the quality systems, maintain delivery schedules and of course by being cost-competitive.

India’s growing financial & technological strength, ongoing modernisation plans and enormous new opportunities in the aerospace sector have opened innumerable new avenues. Further, owing to the success of India’s first scientific mission to the moon Chandrayan, the world now acknowledges our superior technologies.

Issues in aerospace machining segmentSome of the challenges, especially in small and medium enterprises include:� Initial financial investments towards

margin money� Convincing the bankers for sanction

of term loans for procurement of plant & machinery; sanction of bank guarantee limits and working capital requirements

� Availing approvals from various government agencies

� Inducting skilled & technically competent personnel and retaining them

� Inducing confidence in customers about technical capabilities, maintaining consistency in quality, schedules, financial stability, restricting employee turnover, etc

� Manufacturing process involves long cycle time and more gestation periods for realisation of payments

Trends and demandsAerospace-machined components require 100 per cent quality checks of all features of a component and of the whole lot. All stages of various processes and activities need to be

properly documented. The current trends in the Indian aerospace machining industry are on par with the ones elsewhere in the world, in terms of experience gained and knowledge-base of the related technologies, access to procurement of aerospace grade raw materials, establishing & proving the processes, availability of good quality machine tools, metrology equipment, and technically skilled & experienced manpower at low costs. These factors have enabled the global aerospace giants in setting up their offices in India, and outsource components from its aerospace machining industry for their needs.

The advent of global aerospace giants and their setting up of offices in India for outsourcing aerospace-machined components for their needs has brought in awareness and improvements in the aerospace machining industry in the country, in terms of advancements in machining, process standardisation, applications of precision metrology, usage of computers, high-end CAD/CAM systems, among others. Several companies are working towards AS9100C Quality Management System Certification established by International Aerospace Quality Group (IAQG), as it is now mandatory for exports.

Future of the Indian aerospace industryAerospace machining market is growing at a reasonable rate and the projections for the next 10-15 years looks positive, which is a good news for the Indian machine tool building industry that was earlier focussing on general engineering, automotive, tool, die, mould, capital goods, consumer durables and intermediate goods

sectors. These sectors are known to give a major push of growth to the machine tool industry. These sectors need high-production and low-cost machine tools. These machine tools are produced and sold in significantly big volume with good profitability.

However, the needs of aerospace market are different, as it requires high-precision machine tools. These machine tools are produced in low volumes but fetch high profit margin. In recent times, the machine tool industry in India is successful in the aerospace segment too. Since the demand of the aerospace segment varies from other segments, the machine tool building

industry has responded positively to this requirement and found it viable to make additional investments to carry out R&D for this sector.

Earlier, we were not permitted to import high-precision multi-axes and multi-tasking machine tools due to various sanctions and restrictions. We are glad that now the machine tool industry in the country is technically advanced and is competing with global machine tool suppliers. This leads to a healthy competition and the money stays within the country itself.

To capture the aerospace market, the machine tool industry has to carry out more R&D activities, attract additional investments, recruit technical & highly skilled manpower dedicated to this segment, constantly interact with the aerospace machining industry, give additional & adequate training to their workforce, generate innovative ideas within the organisation, bring in awareness among the workforce about the aerospace requirements & quality issues and sustain market competition.

With the government looking for MRO investments in counter agreements with giant foreign aerospace industry players,

there are a lot of opportunities for the aerospace machining industry in the country.

Manufacturing Excellence


Companies can gain a sustainable competitive advantage and be environmental stewards – through robust design and optimisation.

If most companies have considered environmental regulations as a major obstacle to successful business, the leading organisations are now seeing the opportunities

and competitive advantages standing behind this apparent constraint. This trend has been recently quantified by a BCG / MIT Sloan survey published in January 2011.

Environment-friendly designs are expected to consume less energy and to be less demanding for raw materials. Those could quickly translate into cost reduction, either

operating cost or manufacturing cost, as well as a product price increase to value the green flavour of the product. But this will not succeed if the integrity of the environment-friendly solution is not demonstrated.

Designing a sustainable product cost-effectively and quickly does not compromise with product robustness and performance looks like an impossible challenge with traditional technology. Best-in-class companies changed these threats into major opportunities by switching design to the virtual world. Using engineering simulation, they are virtually designing, manufacturing and testing new solutions much faster and more thoroughly than ever before. A much larger number of prototypes are investigated opening the door to green design without compromise with cost, robustness, performance and safety.

The need for sustainability Throughout much of the world, people expect that life will become better, easier and more comfortable for succeeding generations. Over the past century, privileges once limited to the wealthy have become commonplace; indeed, many are now considered a necessity. Owning a car, flying around the world, accessing a computer, connecting to the Internet

Green design without compromise

SUSTAINABLE MANUFACTURING

Engineering for sustainability includes designing more efficient ways to treat waste, such as studying settling in a wastewater treatment tank

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from anywhere, and using a cell phone are routine activities, even in emerging countries. However, the world cannot sustain such exponential growth forever. The planet has received a wake-up call about addressing overconsumption. Many scientists state emphatically that we are putting our planet, and the human species, in danger.

The population is rapidly draining the world’s fossil energy sources; at the same time, emissions from these fuels are negatively impacting the environment and its natural evolution. Huge amounts of waste material are being stored with the hope that the Earth can cope with it. Most people are aware that the globe cannot sustain these practices forever. While a growing number of people are urging the world’s population to do something about it, many individuals are unwilling to sacrifice their comfortable lifestyle.

Reluctance to sacrifice current standardsWithout a doubt, cars could be more environment-friendly, but if you surveyed the planet, would you find people willing to pay more to achieve this objective? Most would

be reluctant to accept significant reductions in performance, speed or acceleration. Green building is a common aspiration, but will the occupants tolerate being a bit less warm in winter, and a bit more warm in summer? Renewable energy is a ‘must do’ only if the resulting power is less expensive and at least as stable. An admirable goal: Can we reach it without personal compromise? Common sense dictates that we cannot meet such expectations using traditional approaches and technologies. Real breakthroughs may be necessary to achieve sustainability goals in these areas: � Better energy management:

Fossil fuels remain an important energy source, but they could be used more effectively and selectively. Sources of renewable energies should be exploited. Transportation, construction and manufacturing must become more energy efficient.

� Pollution reduction: Twenty-first century lifestyles result in the release of huge quantities of various materials into the environment, making absorption and recycling of these substances

difficult without a direct impact on the planet.

� Product lifecycle: After a lifetime of use, products quickly become waste material. Shortened product life increases the amount of waste. processing recycled materials into new products in a cost-effective manner can benefit greatly from modern simulation technology.

Virtual experimentation, virtual testing, virtual prototypingIf sustainable products and processes today are merely ‘nice to have’, it is likely green design will become mandatory in the future, legislated and forced by market pressures to develop better solutions. Pioneers and leading companies are already preparing for this evolution by designing sustainable solutions, but the challenge is daunting. Environmental friendly products may require major innovations that could impact both cost and robustness. Innovation usually requires intense experimentation and optimisation. Real breakthrough solutions need systematic testing to ensure that new designs behave properly throughout the entire lifecycle. Experimentation and testing processes are typically time intensive, costly and difficult to manage in a highly competitive world. Best-in-class companies are addressing this issue by switching to the virtual world.

Numerous reports and industry studies, suggest that an order of magnitude more experimentation can be done virtually for a smaller cost. Engineering teams can vary numerous parameters to identify the best combination of sustainable design, minimal cost and maximal performance. Leading companies are systematically testing their virtual product prototypes against conditions that would be experienced throughout the lifecycle to ensure that product behaviour will satisfy end users. Continually

Engineering simulation can help organisations meet regulations and standards. This study was used to assess the impact of fume cupboard discharges on surrounding buildings and the environment

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increasing computational power combined with high-efficiency solvers can contribute to the effort: they might enable the number or complexity of virtual tests to double

every 18 months without impact on cost or time to market.

Robust design and optimisationSustainability adds a new dimension that is difficult to handle with standard technology. Designing smart, green products to a high level of product integrity requires investigating a growing number of parameters – such as dimension, materials and operating conditions – to provide designers with enough freedom to meet numerous constraints. Robust design includes identification of influential parameters and evaluation of design sensitivity based on performing variations.

The combination of parametric studies and sensitivity analysis for a

large number of parameters using advanced tools (robust design and optimisation) opens the door to a new era of design.

Engineering simulation: A profitable green technologyEngineering simulation has proven its cost-effectiveness in developing innovative products. This same technology can be used to design greener products and processes. Pioneering companies are already creating a cleaner and more profitable future by changing their design processes and widely adopting simulation to transform the green challenge into a major business opportunity.

Designing smart green products to a high level of product integrity requires advanced tools that investigate a growing number of parameters

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Thierry Marchal holds the dual role of Industry Director as well as Marketing Director for Thought Leadership at ANSYS. He specialises in providing engineering simulation solutions across different industry verticals like biomedical, construction, consumer products etc. Email: [email protected]

Future Footprints


After lying low for a few years, the manufacturing sector is witnessing a comeback. Although it holds a knowledgable and talented workforce, the contribution of women in the core industrial field is minimal as compared to that of men. The coming decade will see this equation change significantly for the better.

It might be passe to say that behind every successful man there is a woman. In today’s world, women have been achieving new feats in every

industry like men. In the near future, one should not be surprised to find women at par with men, be it any field or industry. Unfortunately, the manufacturing sector does not

highlight any prominent female achievers. The entire workforce comprises mostly of males and rarely one can see the ratio tilting the other way. The manufacturing sector is growing at a rapid pace in the country and allied fields are also doing well. At such times, this field should be viewed as one with opportunities by males and females alike. However, due

Aafreen Shaikh

DFSDFSD

A whole new world of possibilities

WOMEN IN MANUFACTURING

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Future Footprints


to lack of sufficient encouragement or prominent names, the demand to pursue a career in this field is lukewarm.

The need and growth of this sector is based on large orders from the automobile, defence, aerospace and engineering segments. Thus, opportunities are visible in every sector.

Globally, tooling industry seems to be wide and large scale, with 100 per cent contribution of manpower focussed to bring the sector to another level. However, in this regard men continue to outnumber women. But in the near future, can we predict a change in this statistics significantly?

Lack of women in manufacturingKnowledge of Science, Technology, Engineering, and Mathematics (STEM) is widely regarded as critical to be competitive in the current global economy. Due to the unequal ratio of males and females working in this sector, there is a huge disparity in their earnings too. These ratios lead to a less liking for the field in general. In a 2009 survey, only 5 per cent of the girls said they were interested in an engineering career. It should be noted that attracting and retaining more women in the manufacturing workforce will maximise innovation, creativity and competitiveness.

Because of our psychological belief that women lack the aptitude to succeed in STEM fields, women in manufacturing careers are considered inappropriate. The idea that girls are

not good at science is simply floating in the air that we breathe. These false ideas prevent girls and women from pursuing engineering. Such implicit beliefs directly influence parents’ decisions to encourage or discourage their daughters from pursuing science and engineering careers. Hearing or sensing such thoughts and misconceptions in the immediate environment is affecting individual career choices. It simply breaks down a girl’s self-confidence in her abilities. Also, there is lack of female role models in the field of engineering that young females can get inspired from.

ReformsSpecific solutions and ways must be implemented to increase the number of women in the tooling industry:� To develop training programmes for

girls to focus on machines, technical aspects of programming, and not merely on broader applications

� Develop opportunities for women in various departments in tooling industries

� Exhibitions or conferences should be held where female employees interact with other engineers

Generating interestAlthough technology has become more pervasive in the lives of young people, technology as a carrer is

not what they want to pursue when they grow up. According to a recent survey held in the UK, 90 per cent of girls between the ages of 11 and 16 thought computers and cutting edge gadgets are cool, but only 28 per cent of those girls seriously considered careers in the technology industry.

Women’s contribution in technology is often taken for granted, merely rolled up as a part of the great tidal wave of innovation surrounding the computer age. The marketing side of technology and services has the potential to become increasingly important in the future. To connect innovative technologies with consumer usages, women will be naturally positioned to be project managers on technology ventures because of experience in other departments and disciplines. Today, if we realise this, we may consider making technology or innovations with a female eye for detail, which would definitely help the society in the long run.

While Indian women are making great strides in the field of advertisement, media, education, healthcare, hospitality, etc, surprisingly, until date no Indian woman is at the forefront in the manufacturing sector. Considering that India is emerging as a global manufacturing hub, the issue of skilled manpower needs to be addressed. Hence, courses developed for women will improve the employment potential for women engineers in sectors such as automobile, auto components manufacturing, aerospace, die mould and other industries, thus providing the much required skilled workforce. Women are the real architects of society and the fastest way to change society is to mobilise women of the world. As author Diane Mariechild aptly put, “A woman is the full circle. Within her is the power to create, nurture and transform.”

Aafreen Shaikh is the Assistant Manager - Operation at DIJET Industrial Co Ltd. The company is a worldwide supplier of precision metal cutting tooling and high impact custom cemented carbide. Email: [email protected]

Women making a mark in the tooling industry

� Klara Kaczkowska has worked as a CNC machine tool engineer with Abplanalp Consulting, a highly successful Haas Factory Outlet (HFO) in Warszawa, Poland

� Melanie Cattaruzza has been working at Switzerland’s Haas Factory Outlet� Jo Ann Mitchell is working as a Machine Investment Support Specialist for

world-leading tooling company and Haas Technical Education Centre (HTEC) partner, Sandvik Cormorant

� Kristin Alexanderson has been working as a CNC machine tool sales engineer for Haas Factory Outlet (HFO) in Jonkoping, Sweden

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At this aerospace and medical component manufacturer, a Doosan HMC paired with a flexible pallet magazine and cell controller from Fastems has increased production and part quality while eliminating variation throughout the production chain.

Every night at 12:30 am, the shift manager at Westwood Precision flips off the optional stop toggle on the Doosan cell, makes sure

everyone’s gone, turns out the lights and locks the doors. John Landau, production manager at the Everett, Washington-based contract shop, admits it was a bit unsettling at first to leave the Doosan HMC and integrated Fastems pallet magazine running unattended all night. A year and a half after installation, however, he says he’s “amazed” at what the system has done for machine utilisation, which is

now close to 94 per cent on a 24-hour clock. In addition to improving productivity, running unattended nearly 24/7 has reduced the time, cost and stress associated with setups while eliminating variation throughout the production chain.

T h e 3 5 - p e r s o n shop special ises in close-tolerance machining of complex aerospace and medical components in small-to-medium lot sizes.

Gordon Nisbet, Company President, attributes the company’s success since its 1982 founding to its commitment to continuous improvement. The decision to purchase the cell – the company’s single most expensive capital investment – last summer in the midst of the recent recession is a testament to that commitment, Nisbet says. “Economic conditions posed a threat, but the slowdown also gave us the time we needed to adapt our company to make it more competitive, more productive, more efficient, more predictable and just all-around better,” he recalls.

Operational EfficiencyThe company determined that the next step towards meeting those goals was automation. Like those in many other shops, Westwood operators had a long list of steps to check off before hitting the cycle start on any given job. Tearing down the previous setup; switching out the fixtures and subplate; loading and unloading tools; uploading the next program; touching off the first tool; and other, smaller steps in between consumed significant amounts of production

Cell works the night shift

The Doosan HP 4000 HMC offers sufficient rigidity to make heavy cuts at high feeds and speeds

It has been our persistent effort to provide incremental value to our readers with ‘cutting-edge’ information. As a part of this endeavour, we have this feature - ‘From Modern Machine Shop’, in an exclusive arrangement with the premier metalworking and machine tool publication in North America. Modern Machine Shop (MMS), published by Gardner Publications, US, offers exceptionally high editorial features and circulation standards that have become a hallmark of its operating philosophy and worldwide reputation. We strongly believe that the information provided in this feature will keep our readers updated about the latest global developments in business strategies & technological innovations, the quintessential ingredients for competitive manufacturing.



time. Downtime and associated costs were even greater when accounting for shift changes, breaks and the fact that shutting machines down every night essentially amounted to an entire shift of lost production.

Work lots, types and sizes all dictated certain basic machine tool and work storage specifications for any new equipment. The targeted work consisted of close-tolerance, prismatic aluminum parts requiring simultaneous X-, Y- and Z-axes movements with anywhere between 20 and 100 tools. Lot sizes ranged from 1 part to 250 or more, but typically between 25 and 100. Typical tolerances were measured in tenths, and surface finish requirements were stringent. Due to the unpredictable nature of its aerospace work, the shop also wanted to be able to set up 30 or more jobs in advance and run any one at a moment’s notice.

Finding the right fitEvaluating these and other requirements led the shop to conclude that it would require a rigid HMC capable of repeating within tenths at heavy cutting depths and high feeds and speeds. That machine would be outfitted with an automated, computer-controlled pallet system. That system would have to be expandable – that is, the shop would

need the ability to add to the pallet pool when necessary and incorporate new control functionality when available. After careful consideration, the company settled on an HP 4000 HMC from Doosan Infracore (West Caldwell, New Jersey) and an FPM750 Flexible Pallet Magazine (FPM) and cell controller from Fastems (West Chester, Ohio).

With a 14,000-rpm spindle, a top feed rate of 1,181 ipm and rapid traverse of 2,362 ipm, the four-axis HMC’s mechanical attributes fit the bill for the shop’s job requirements. On the control side, its Fanuc 31i CNC with AICC Nano Type II high speed software provides 200-block advance position calculation to maintain these high speeds and feeds during simultaneous multi-axis movements. Additionally, the machine’s 30-hp spindle enables it to handle the required roughing chip loads, while its 262-tool ATC has sufficient capacity to minimise tool changes between jobs.

The machine was integrated with the three-level, 48-pallet FPM via the combined efforts of engineers from Fastems, Doosan and CNC Machine Service, the local Doosan distributor. The FPM includes a setup station for loading parts and a stacker crane to transport pallets to and from the container. The cell controller offers tool monitoring capability and

stores job packs containing setup sheets, blueprints and other turnkey data for use by employees with password permission.

Setup technician Jason Vise was busy prepping jobs for the system long before it arrived. All were alumineum parts because material inconsistencies in ferrous metals could cause problems during lights-out operation, he says. Chosen jobs also consisted of repeat parts with unpredictable schedules. Preparing these parts in advance would enable their quick completion without jeopardising other work.

The new cell’s benefits became apparent shortly after production began. Vise says one significant time-saver is the cell controller’s ability to prioritise job scheduling based on key variables, including required delivery, programmed tool life and tool availability. “All of this scheduling is going on in the controller, automatically, based on our entering key variables for each job,” he says.

The flexibility that comes with automatic rescheduling based on a complicated set of conditions has reduced inventory and improved cash flow, Landau says. He cites one example in which the control recommended skipping the next job in favour of two different, more urgent jobs. “Based on three job sizes, cycle times and delivery requirements, it determined that we could complete and ship two smaller jobs and still have enough time to run the originally scheduled job without any delay in the required delivery.”

Efficient manufacturingThe Doosan HMC offers its own benefits. Landau says the machine’s rigidity facilitates heavier cuts at faster speeds and higher feeds. He recalls one particular job involving close-tolerance housing components that the shop moved from a different machine to the new HMC shortly after it was installed. With the feed-rate override set at

Landau, shown here at the cell controller while Jason Vise works at a setup station, says one of the cell controller’s advantages is remote management. This enables both the company and the three key system suppliers (Doosan, Fastems and the local machine distributor) to upload programs, debug alarms or monitor operations via the Internet



150 per cent, the new machine completed each part in 3 minutes and 45 seconds – 50 per cent less time than the previous machine. Additionally, the ability to run the parts at the higher feeds and speeds recommended for that particular combination of tool and material improved surface finish quality by nearly 50 per cent. Overall cleaner cutting eliminated most of the hand deburring, reducing total cycle time for that secondary operation from more than seven minutes to less than one minute per part.

With the previous machine, the shop had to reduce the feed rate to meet tolerances on parts mounted at the top of the tombstone fixture or farthest away from the pallet table. “The cutter was working far enough out from the bearing surface to act like a long lever,” Landau explains. “We had been getting too much deflection between the pallet table and the coupling. On the Doosan, running at a 50 per cent faster feed rate, there was still no deflection.”

These gains were particularly notable because the part’s surface included a 3D radius that blends into a straight wall, he says. This required simultaneous X-, Y- and Z-axes movements. Much of the cycle time savings were achieved during these moves, which involved toolpath calculations that many CNCs could not handle. In that scenario, he says, the CNC typically suppresses the programmed feed rate. That was a non-issue for the Fanuc CNC and its 200-block look-ahead capability.

In addition to improving productivity and part quality, the cell has redefined the company’s notion of what setups should entail, Vise says. Running virtually 24/7 has reduced interruptions and downtime previously associated with change-overs. Landau adds that production control is easier and more effectively executed. “We have eliminated variation at many points in the production chain. We do not see the spikes in production like we used to. We see higher, straighter-line charts, and that is a very good thing.” he concludes

The company sets up multiple jobs in advance for storage in the container of the Fastems FPM



This company had expanded its facility, implemented lean practices and taken other steps to improve efficiency, but breaking into new sectors such as wind energy would require new technology. Two turn/mill machines and two HMCs from Mazak enabled the company to take on new jobs and win suppliers’ confidence for more opportunities in the future.

From the moment of its founding, R&M Mfg has strived to achieve growth through diversification in terms of both services it

provides and industries it supplies. Rather than adopting a more conservative posture when revenues dipped in 2009, the company made investments to pursue new business even more aggressively, specifically targeting tough wind energy and aerospace work. Lean implementation, a facility expansion and other such efforts brought the company a long

way towards reaching its goals, but the true difference-maker was an investment in two turn/mill machines and two large HMCs from Mazak (Florence, Kentucky).

The initiativeBased in Milton, Wisconsin, R&M was founded in 2004 when Mark Merk received word that the automated assembly equipment manufacturer where he had worked for 25 years would soon close. Similarly to R&M’s later efforts to invest amid a dire recession, Merk saw opportunity in a situation that would likely cause others to despair. “At age 50, I did not want to have to move my family in pursuit of a job, and I knew that a lot of other people affected by the plant closure felt the same way,” he recalls.

Enter R&M, a provider of precision machining, engineered assembly and fabrication services. To start the business, Merk purchased a facility with 20,000 sq ft of floor space and 2,000 sq ft of office space, along with much of the equipment used in the former plant. The company’s first 10 employees were handpicked from the most talented and experienced of those who had recently been laid off from his former employer.

Two years later, that initial workforce had doubled amid a steadily increasing revenue and customer base. In 2008, the company

HMCs, turn/mills aid diversifi cation strategy

R&M was founded by Mark Merk (left) after his previous employer closed its doors. Merk shifted his focus to sales once the company was bought by David Underwood (right) in 2008



was purchased by a customer, David Underwood, and Merk shifted to the role of Vise President of sales. Thanks in part to an increased emphasis on sales, the company ended that year with $ 11 million in revenue, compared to $ 2 million when it started four years earlier.

Embracing challengesDespite this success, 2009 would bring substantial challenges to further growth. Seeking to offset reduced order quantities resulting from the economic recession, R&M recognised opportunities for new business in wind energy and aerospace. However, breaking into those sectors would be difficult because many of those jobs are shifting toward exotic materials with tight tolerances and complex geometries. Additionally, it seemed customers were moving to shorter and shorter turnaround times. “We used to have seven to ten days to provide a quote, and then the customer would want delivery in eight weeks. Now, they want a quote within two days and delivery in two to three weeks,” Merk recalls.

In response, the company expanded the facility to 45,000 sq ft - more than double its original size - obtained new ISO certification, and implemented a 5S project and other lean initiatives to reorganise and streamline operations. Despite these efforts, it soon recognised that it would need new machining technology to set itself apart from similar operations by pursuing tough energy and aerospace work. Specifically, the company determined that it required a pair of HMCs to replace outdated models. It would also need a pair of turning centers with milling capabilities that could meet stringent tolerance requirements and combine multiple operations on one platform. All of these machines would need the capacity to handle large parts.

In December 2009, the company took delivery of a Mazak Quick-Turn Nexus (QTN) 350 MY turning center. The next month, that machine was followed by a QTN 450 MY turning center and an HCN 6800 HMC with a Palletech automation system. An HCN 10800 HMC completed the quartet in March 2010.

Technological edge In addition to high precision, Merk says the turning machines’ greatest benefits are their Y axes and live tooling, which enable combining multiple operations on a single platform. The horizontals, which replaced older models at R&M, feature heat compensation features, software packages and other technologies not available even a decade ago. Merk says the machines’ integrated Palletech pallet systems are especially useful for saving time. “One can stage 24 different jobs, hit the cycle start button and walk away,” he notes.

Merk cites one project for the Department of Defense as an example for the sort of work the shop has been able to pursue since investing in these machines. The job involves parts made of a special grade of steel that require tolerances ranging to ± 0.0003 inch and 30-Ra surface finishes. In the past, these complex components would have required operations across a series of machines. Now, the company can machine the parts complete with only two: the HCN 6800 and QTN 350 MY. “A lot of that is due to the live tooling and Y-axis capabilities on the QTN 350 MY, which eliminate a substantial amount of set-up time,” Merk explains.

As for the company’s foray into wind energy work, Merk cites a family of large bearing sleeves that fit to the main shaft of a system’s generator. The 4140 steel components can be as heavy as 1,500 lbs and as large as 6 feet in length and 15 inches in diameter. Each part’s Inner Diameter (ID) and Outer Diameter (OD) must be machined to within ± 0.0005 inch, and they require 20-Ra surface finishes. The sleeves were previously produced by another manufacturer, which would machine the parts to within 0.01 inch before sending them out for finish grinding to meet stringent OD and ID requirements. “We analysed the cost of these parts and realised that about 50 per cent of it stemmed from the outsourced grinding. If we

Merk says the QTN 350 MY’s Y axis and live tooling enables the company to combine multiple machining operations, including milling, drilling, boring, tapping and more, on a single platform



could eliminate that we could provide enormous savings to the customer,” Merk recalls.

Viable option The company found that in addition to meeting the tolerance and surface finish demands, which eliminated the need for grinding, the QTN 350 MY could machine each bearing sleeve in a single operation. Demonstrating

this achievement to the wind-systems producer not only won the job, but also started a relationship that continues to pay dividends, Merk says, “We drove a lot of savings to that particular customer, so they took a harder look at us. Since then, the opportunities have not stopped.”

Although the new machines were chosen primarily based on the technical capabilities necessary for the jobs R&M wanted to pursue that was not the only reason the company chose Mazak over other builders. “They have made a clear commitment to our success, and that adds a whole other layer to the benefits we receive from the technology,” says Underwood. More specifically, he notes that the builder quickly responds to service calls and works to maintain a relationship with the company.

He further adds, “There are a lot of days when I will come in and a Mazak rep will be on the floor. I will go down to see if there was an issue he was

responding to, but it will turn out that he just had some free time and wanted to stop by and do some continuing training with our operators.”

The builder’s training services, which R&M has leveraged to cross-train much of its workforce, are especially valuable, he adds. As a result of this training, every shopfloor employee can run at least two different types of machines, and 75 per cent of the workforce can operate any machine. Broadening employee expertise improves flexibility and makes the company more likely to succeed in machining challenging parts than similar smaller operations, establishing a strong position as the economy continues to recover. “We are in an arena where we are playing with the big boys. There are not too many shops like ours that can quickly and accurately machine extremely high-tolerance parts. Mazak helps us participate in that market,” Underwood concludes.

The Mazak HMCs are employed to machine parts such as this generator rotor for a wind power turbine



By changing to a hex-shaped turning insert with a 45-degree lead angle, this shop saved thousands of dollars on a difficult Inconel turning application.

When inserts rupture in Inconel, the typical reaction is to “take the load off” the

insert by lightening the cut, says Jim Whitley of cutting tool manufacturer Ingersoll (Rockford, Illinois). However, this reaction may be ill-advised. Shops tend to forget that rupture often begins with an edge going dull, which, in turn, overloads the insert to the point of breaking down. “This can happen within a few seconds, so it is easy to miss wear as the root cause,” he explains. “Assuming that adequate machine horsepower is available, the better answer is to go to a stronger insert with a gentle lead angle and make fewer, deeper passes.”

Following Whitley’s advice paid dividends at Scot Forge, which saved $ 2,400 per part on one tough Inconel turning application after retooling to Ingersoll’s Hex-Turn inserts and adjusting machining parameters accordingly. Based on its success with that job, the company has standardised on Hex-Turn and those same parameters for rough turning a growing variety of Inconel parts.

Scot Forge is a diversified, employee-owned forging company that has been in business for more than 100 years. It has plants in Clinton, Wisconsin as well as Franklin Park and Spring Grove, Illinois. By customer preference, most of the company’s output is delivered in the forged and rough-machined condition.

Quest for the best practiceHoward Dempsey is supervisor of the machine and saw shop at the Clinton plant, a site that runs 24 hours a day, five days a week and houses 200 employees, 50 of whom are machinists. He says the part that prompted the company’s switch to Hex-Turn is just one of a growing number of jobs involving high-temperature alloys, which management has identified as a trend. “We get about six reorders a year for that part, and orders for other Inconel and titanium forgings are rising,” he notes. “So, we decided it was time to develop the best practice for machining them.”

Taking orders on Inconel, titanium and other high-temperature alloys provides a competitive advantage

Long-lasting insert turns around tough Inconel job

Thanks to a 45-degree lead angle and top-face chipbreaker, the Hex-Turn inserts outlast their predecessors by 69 to 1 while reducing cycle time on the Inconel forging by 15 hours



and a source of pride, since these exotic materials are abrasive to tools and impose high cutting forces. Additionally, they tend to generate hot, stringy chips that can stick to the cutting edge and overheat the tool. As a result, such work can create bottlenecks, tie up machines and increase tooling costs.

That was the case with Scot Forge’s problem component, a huge Inconel No 7718 hub used in nuclear turbomachinery. This part requires rough turning and facing to remove about 0.8 inch of material across its entire diameter, primarily for truing up. As forged, it measures 98 inches in diameter, with a step-down to a 93-inch diameter on one end.

Previously, machining took 105 hours and 40 passes at a feed rate of 0.02 ipr, a cutting depth of 0.075 inch and a speed of 38 sfm. The turning and facing operations required different inserts, and the job typically ate through 69 inserts per part. In fact, tool failure was so prevalent that inserts required indexing every half inch, and the job had to be run 100-percent attended. Moreover, the main failure mode was edge rupture, which renders the insert useless even if some edges go unused. All the while, the operation tied up a large vertical lathe from MAG Giddings & Lewis (Fond du Lac, Wisconsin) that the company needed for other work.

Future prospectsWith an eye toward a better standard practice for turning this class of alloy, Dempsey asked all his tooling vendors for their best ideas and began testing different solutions. Most tools the company tested produced minor improvements at best. The exception was the Hex-Turn, which features a 45-degree lead angle presentation and top-face chipbreakers. Tests showed these inserts could significantly improve cycle time and tool life compared to the square, flat-topped, zero-lead models the shop had been using.

The company standardised parameters for the new tool at an 0.015-ipr feed rate (slightly less than the previous rate), an 0.15-inch cutting depth (double the previous setting) and a speed of 60 sfm (60 per cent higher than the previous setting). Despite more than doubling the cutting rate, each insert lasted through the whole part. Cycle time dropped 15 per cent. “We would have been happy with just the tool life improvement,” says Dempsey. “The throughput gain was an unexpected bonus.”

Cutting deeper reduces the number of required passes, which, in turn, reduces the insert’s exposure to the hot, abrasive environment at the cutting edge. However, as Whitley explains, an insert’s ability to withstand a deeper cut depends on its strength. That’s why—true to its name—the Hex-Turn features a hexagonal geometry, a shape that is second only to round inserts in strength, he says.

Ingersoll product manager Raymon Avery adds that the other difference-maker is the 45-degree lead angle, which is made intrinsically possible by the insert’s hex shape and chipbreaker top face. This lead angle provides a gentler entry into the work that reduces cutting forces and protects the insert. Meanwhile, the contoured top face breaks up the long, hot, gummy chips characteristic of Inconel alloys and deflects them away from the insert to reduce heat.

In all, the drop-in retooling saved $ 1,500 in cycle time and $ 900 in tooling costs—per part. Cost savings aside, having a secure process for such difficult material enables Scot Forge to bid more confidently on Inconel jobs and to compete more effectively in a high-tech niche. “This improvement enables us to maintain competitive costs for machining Inconel,” says Dempsey. “Otherwise, we would have been forced to raise prices to cover the excessive cost of tooling and the resulting sub-par productivity.”

Scot Forge’s Brandon James indexes a Hex-Turn insert, which will last reliably through the entire machining process on the big Inconel forging. The shop’s previous, square inserts typically failed after just one inch of feed

The large Inconel hub requires rough turning and facing to remove about 0.8 inch of material across its entire diameter. As forged, it measures 98 inches in diameter, with a step-down to a 93-inch diameter on one end

Ingersoll’s Raymon Avery and Scot Forge’s Howard Dempsey stand amid finished Inconel hubs while discussing how to tackle the next tooling issue. Avery or his colleague Jim Whitley meet regularly with Scot Forge representatives to stay ahead of the curve in production planning

Events - National


InterMachinery IndiaThe 5th edition of InterMachinery India will be showcasing machinery & equipment, which will be attended by a large number of international exhibitors; June 9-11, 2011; at Bombay Exhibition Centre, Mumbai

For details contact:Worldex India Exhibition & Promotion Pvt Ltd, 309, Parvati PremisesSun Mill Complex, Lower Parel, Mumbai Tel: 022 4037 6700Fax: 022 2496 2297Email: [email protected]: www.intermachineryindia.com

Automotive Engineering Show International exhibition on technologies for automotive manufacturing; June 10-12, 2011; at Chennai Trade Centre, Chennai

For details contact:

Focussed Event Management Pvt LtdPlot No. F/11 & F/12, Camlin Fine,WICEL, Andheri (E), Mumbai Tel: 022 3201 9137Fax: 022 2832 4404Email: [email protected]: www.focussedevents.com

IndiaMART Process Engineering Expo 2011An exhibition for showcasing hardware, instrumentation, controls and other

hardware tools & equipment; September 1-3, 2011; at HITEX Exhibition Centre, Hyderabad.

For details contact: Hyderabad International Trade Expositions Ltd First Floor, Trade Fair Office BuildingHitex Exhibition CentreIzzat NagarHyderabad Tel: 4023 112121/2311 2122/2311 2123Fax: 4023 112124Email: [email protected]: www.hitex.co.in

MetEx India 2011International exhibition on metal, metallurgical technologies, equipment and service; September 22-24, 2011; Bangalore International Exhibition Centre, Bengaluru

For details contact:Koelnmesse YA Tradefair Pvt LtdB 501/502, KEMP Plaza, Mind Space,Chincholi Bunder, Malad (W), MumbaiTel: 022 42107804Fax: 022 40034433Email: [email protected] Web: www.metex-india.com

IA IndiaInternational trade fair for process & production, automation and industrial building automation; December

6-9, 2011; Bangalore International Exhibition Centre, Bengaluru

For details contact:Hannover Milano Fairs India Pvt LtdB-303, Dynasty Business ParkAndheri- Kurla Road, ChakalaAndhrei East Tel: 022 40050681 Fax: 022 40050683Email: [email protected]: www.ia-india.com

CeMAT IndiaInternation trade fair for material handling and logistics; December 6-9, 2011; Bangalore International Exhibition Centre, Bengaluru

For details contact:Hannover Milano Fairs India Pvt LtdB-303, Andhrei (E), Mumbai Tel: 022 40050681Email: [email protected]: www.cemat-india.com

IMTEX Forming 2012 & Tooltech 2012International exhibition focussing on the exhaustive range of forming technologies in all engineering applications. The concurrent event – Tooltech 2012 is dedicated to cutting tools, tooling systems, machine tool accessories, metrology and CAD/CAM; January 19-24, 2012; at Bangalore International Exhibition Centre (BIEC), Bengaluru

For details contact:Indian Machine Tool Manufacturers’ AssociationBangalore International Exhibition Centre, 10th Mile, Tumkur Road Madavara Post, Bengaluru Tel: 080 6624 6600 Fax: 080 6624 6661Email: [email protected]: www.imtex.in

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

& Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.

For details

Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028.

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

PUNEMaharastra

Nov 18-21, 2011Auto Cluster Exhibition

Centre, Pimpri-Chinchwad

INDOREMadhya Pradesh

Jan 6-9, 2012Poddar Plaza, Nr Gandhi Hall

CHENNAITamil Nadu

Dec 8-11, 2011Chennai Trade Centre,

Nandambakkam

AHMEDABADGujarat

Oct 14-17, 2011Gujarat University

Exhibition Hall

RUDRAPURUttarakhand

Sept 23-26, 2011Gandhi Park

AURANGABADMaharashtra

Feb 17-20, 2012Garware Stadium

Chikkalthana

Events - International


BlechexpoInternational trade fair for sheetmetal processing; June 6-9, 2011; Stuttgart, Germany

For details contact: P E Schall GmbH & Co KGMesseunternehmenGustav-Werner-Straße 6D-72636 FrickenhausenTel: +49 7025 92060Fax: +49 7025 9206620Email: [email protected]: www.blechexpo-messe.de

Atlantic Design & ManufacturingThe international event will showcase advanced design & manufacturing; June 7-9, 2011; at Jacob K Javits Convention Center, USA

For details contact:Canon Communications11444 W Olympic BlvdLos Angeles, CA 90064Tel: +310 445 4200Fax: +310 445 4299Email: [email protected]: www.ubmcanon.com

Machine Tool & Manufacturing Indonesia – Surabaya 2011The international exhibition will showcase products from machine tool, metalworking, welding, manufacturing machinery and equipment industry; June 8-11, 2011; at Surabaya Convention Hall, Indonesia.

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

Mechanical Engineering Metal Working, Kazan 2011International exhibition of technologies, equipment, instruments, materials for mechanical engineering and metalworking industries; June 15 - 17, 2011; at Kazanskaya Yarmarka Exhibition Centre, Russia

For details contact: Kazanskaya Yarmarka OJSC8, Orenburgsky TraktKazan, 420059, RussiaTel: +7 843 570 51 09 Fax: +7 843 570 51 09 Email: [email protected]: www.expokazan.ru/eng

Queensland Manufacturing Show 2011Manufacturing fair for engineering, machine tools, instrumentation & control, computer-based processes, systems & services, automation & robotics, welding, heat-treating, joining, logistics, warehousing & materials handling, hydraulics & pneumatics; June 21-23, 2011; at Brisbane Convention & Exhibition Centre, Australia

For details contact: AEC (Australian Exhibitions & Conferences Pty Ltd)Level 2, 267 Collins StreetMelbourne Vic 3000, AustraliaTel: +613 9654 7773 Fax: +613 9654 5596 Email: [email protected]: www.aec.net.au

AsiaMold 2011The 5th edition of the event will showcase the latest in press tools and machine tools, and industrial dies & moulds from around the globe; September 21-23, 2011; at Poly World Trade Centre, China

For details contact:DEMAT GmbH

Carl-von-Noorden-Platz 560596 Frankfurt / MainGermanyTel: + 49 6927 4003 0Email: [email protected]: www.asiamold.de

AfriMold 2011The 2nd edition of the event includes a tradeshow floor, technical conference and networking opportunities all dedicated to advancing business and technology in tooling, mould-making, design and development; September 27-29, 2011; at Sandton Convention Centre, Johannesburg

For details contact:AfriMoldPO Box 7266Primrose Hill, South AfricaPhone: +27 7235 36699Fax No: +27 8651 62975Email: [email protected]: www.afrimold.de

Machine Tools Vietnam 201120th Vietnam International Industrial fair will showcase a variety of machine tools; October 19-23, 2011; at Vietnam Exhibition and Fair Centre, Vietnam

For details contact:Vietnam Exhibition Fair Centre (VEFAC)148 Giangvo Road, HanoiVietnamTel: +844 3834 5655Fax: +844 3831 1228Email: [email protected] Web: www.vietnamindustrialfair.com

The information published in this section is as per the details furnished by the respective organisers.

In any case, it does not represent the views of

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Book Shelf


Gear cutting tools: Fundamentals of design and computation

The book provides a novel and practical mathematical method for designing gear cutting tools with optimal parameters. The author offers a scientific classification of kinematics scheme of gear machining before discussing the best possible tool design. This book also facilitates development of scientific predictions, and in most cases it provides optimal designs and solutions in analytical and graphical form. The author explains both the scientific basics and practical aspects of gear machining advances. The book offers an excellent context for exploring the pervasive ties between the geometry of gear cutting tools and kinematics of gear machining process.

Author: Stephen P RadzevichPrice: ` 8,800

Permanent magnet synchronous and brushless DC motor drives

The book provides a comprehensive overview of power electronic convertors for permanent magnet synchronous machines and control strategies for variable speed operation. This book is suitable for both industrial and academic audiences. This book also covers the simulation and communication torque ripple of Permanent Magnet (PM) brushless DC motor drives. It is divided into three parts – fundamentals of PM synchronous and brushless DC machines, power devices and inverters; PM synchronous motor drives; and brushless DC motor drive.

Author: R KrishnanPrice: ` 8,500

Available at:Wisdom Book Distributors, Hornby Building, 1st fl oor, 174, D N Road, Mumbai 400 001 • Tel: 022-2207 4484/6631 8958 • Telefax: 022-2203 4058 • Email: [email protected]

Product Update


This section gives information about the national and international productsavailable in the market

Turret milling machine Shiv Machine Tools offers turret milling machine manufactured by Ninja, which is in compliance with European standards (CE) with its superior quality and features. The machine is made of extra ribbed heavy-duty construction, which is made of meehanite casting, and provides excellent structural rigidity. Powered by a 3 HP motor it offers 16 variable speeds. The machine is currently offered in 3 models of 2KH(V), 4KH(V) and 5KH(V),

which has a table size of 1067 x 230 mm, 1270 x 254 mm and 1370 x 254 mm, respectively. Options include variable speed motor, power feed for X/Y/Z axis and boring heads.

Shiv Machine ToolsChennai - Tamil NaduTel: 044-2522 3473, Fax: 044-2522 7954Email: [email protected]

CNC turret punch pressWeldor Engineering offers CNC turret punch press `WELPRO-255’. The machine has the punching capacity of 20-25 T and can punch up to 4-6 mm thick MS sheet. The machine has been designed and developed through structural analysis technique. The main aim

of this machine is accurate and high speed productivity with minimal end cost. The machine is useful in automobile industry, white goods industry for stainless steel cabinet of refrigerator, SS panel of electrical equipment manufacturers, etc.

Weldor Engineering Pvt LtdRajkot - GujaratTel: 0281-236 0242, Fax: 0281-236 0466Email: [email protected]

Cylindrical grinding machineHi-Life Machine Tools offers cylindrical grinding machine. It is equipped with 802 D CNC system – 2 axes & 1 spindle. The digital AC servo motors are for X & Z axes. The linear motion guide ways are provided for cross slide for the better response. The universal work head is with CNC controlled Constant Surface Speed (CSS) of work piece. The CNC dressing system provided is of various types of profiles, which can be generated through programming. The straight/angular wheel configuration is available. The CNC control permits multi diameter external grinding in plunge or traverse, taper, radius and profile grinding. This machine is equipped with a colour monitor for graphic simulation and an air-conditioning unit is available for control panel.

Hi-Life Machine Tools (P) LtdAhmedabad - GujaratTel: 079-2282 1615, Fax: 079-2282 2800Email: [email protected]

Universal grinder machineHitesh Engineering Works offers universal grinder machine. This heavy duty machine is for high precision grinding of gauges, dies & punches for tool room application with an accuracy of diameter 0.002 micron. The machine body is made from closed grain casting with maximum grinding length of 300 mm and height centre of 130 mm.The centrally motorised lubrication unit, the grinding wheel spindle is made from EN-24 material case, which is hardened and has a super finish. This runs in the white metal bush for smooth running of grinding wheel. The grinding wheel size is of 300 x 25 x 127 mm. The head swiveles with a 45 degree movement through rack & pinion work.

Hitesh Engineering WorksWadhwan - GujaratTel: 02752-241 926, Fax: 02752-241 036Email: [email protected]

Timing belt drive Kwedos Belt Drives offers timing belt drives, designed and manufactured with matching pulleys as per the international standards. Timing belt drives operate in applications requiring

positive and non-slip power transmission. The precision moulded belt teeth are designed to enter and leave the matting grooves on the pulleys in a smooth manner with low friction. Timing belt drives provide exceptional versatility and reliability. Small and lightweight drive packages can be used

in a wide variety of applications. These belt drives also offer efficient operations over a wide range of loads and speeds. These are available from 0.01 to 250 kW for any complicated or high-torque requirement.

Kwedos Belt Drives Pvt LtdAhmedabad - GujaratTel: 079-2550 7367, Fax: 079-2687 0311Email: [email protected]

Product Update


Tube straightening machineITL Industries offers Tube Straightening Machine (TSM) in 6, 10 and 14 rolls. The accuracies are 1 in 1,000, 1 in 2,000 & 1 in 3,000, respectively. TSM plays a vital role in improving

the quality of ERW and SS tubes that are produced on tube mills and draw benches, respectively. Tube straighteners are available in single speed, dual speed and with stepless

speed variation. High speed of 120 m per minute is easily achievable. Straightening is done without any marking on inside and outside of the tube, giving it a good finish, thus imparting skin hardness to the tube. The TSM is fully stress relived with fabricated frame. Work rolls are made of HCHCR steel and hardened for longer life. Rolls mounted on antifriction spherical roller bearing and the entire roller mechanism is independent of all other components. Easy-to-read dial type indicators with simple initial machine setting are few of the unique features of this machine.

ITL Industries LtdIndore - Madhya PradeshTel: 0731-304 4400, Fax: 0731-272 1110Email: [email protected]

Product Update


Tunnel mucking system Electromech Material Handling Systems offers tunnel mucking system. It is a unique and cost-effective bulk material handling system for extraction and disposal of overburden generated

during construction of tunnels. This system can efficiently remove overburden generated during construction of deep shafts as well as the overburden generated during the tunnelling operation itself. This system consists a

high lift winch, a support structure complete with columns, gantry girder and rails. It is also equipped with motorised trolley, the gantry girder, a lower block, a heavy-duty side dumping rectangular or square cross section bucket, a self-dumping section and all the associated electrical parts. This configuration offers a higher degree of flexibility as one more motion (long travel) is available and such a system can be used for mucking parallel shafts. The overhang portion of the crane facilitates travel of the crab outside the legs and dumps the overburden in dumpers.

Electromech Material Handling Systems (India) Pvt LtdPune - MaharashtraTel: 020-2292 2222, Fax: 020-2292 3300Email: [email protected]

Product Update


Waterjet cutting machineAnjani Technoplast offers Nanojet series of waterjet cutting machine with drill head option and titling jet arrangement. This machine with a tilting jet (±45o) integrated with drill head gives an edge over normal waterjet cutting machines. The Nanojet drill head allows reliable piercing on laminates as well as composites before waterjet cutting. The drill head is mounted to the X-axis carriage. The drill option has the capability of accurately piercing small diameter holes in laminates and composite material. There is also a unique feature of tilting jet, which is capable of achieving zero taper in most of the materials. Advantages and benefits of waterjet cutting machines include: precision or near neat shape cutting, waterjet’s ability to cut almost any material in a thickness range from thin foils up to 150 mm and even more.

Anjani Technoplast LtdGreater Noida - Uttar PradeshTel: 0120-478 9000Email: [email protected]

Product Update


Super-rigid press Kawa Press Systems offers super-rigid press in the capacity rating of 10, 16, 25, 40, 63, 80, 100, 125, 200 and 250 ton. The machine incorporates features such as variable speed drive, manual or motorised slide adjustment, pneumatic clutch, pneumatic counter balance, slide tool die holder, stroke counter, electropneumatic safety control, manual or automatic centralised lubrication systems, hydraulic overload safety device, pneumatic die cushion die lifters, hydraulic die clamping etc. Applications include sheet metal components for automotive/furniture/electronic and wide range of consumer goods industries.

Kawa Press Systems Pvt LtdRajkot - GujaratTel: 0281-246 1102, Fax: 0281-246 1665Mob: 098253 89169Email: [email protected]

Product Update


Combi flap brushes and wheelValgro Engineers offers Fynex combi/interleaved flap wheels. These are manufactured from closely packed strips of Valgro material, with an additional flap of coated a b r a s i v e between each layer. The i n t e r l e a v e d flaps are then radially bonded to a resin core, and mounted on a spindle. Interleaved flap brushes are designed for electric hand tools and small bench grinders. The Valgro material between the layers of coated abrasives provides a resilient backing that eliminates the possibility of the ‘layover’ effect encountered with conventional abrasive flap wheels. Interleaved flap wheels generate a deep uniformed scratch pattern, which is significantly more aggressive than the non-interleaved wheels.

Valgro Engineers Pvt LtdAhmedabad - GujaratTel: 079-2297 2603, Fax: 079-2297 2606Mob: 093740 83443Email: [email protected]

An invite that rewards as well...

Dear Reader,

‘MODERN MACHINE TOOLS’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the machine industry.

You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 3000 words, while that of a product write-up should not exceed 200 words.

The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format.

The final decision regarding the selection and publication of the articles shall rest solely with ‘MODERN MACHINE TOOLS’. Authors whose articles are published will receive a complimentary copy of that particular issue and an honorarium cheque.

Published by Infomedia 18 Ltd, ‘MODERN MACHINE TOOLS’ is the leading monthly magazine exclusively meant for manufacturer and user fraternities of the machine trade. Well supported by a national readership of over 1.25 lakh and strong network of 25 branch offices across India, this magazine reaches out to key decision makers among the Indian manufacturers of machine products, machinery and allied sectors. Also, by virtue of tie-ups with global

media majors, it ensures that advertisers are able to promote their products and services across the globe at no extra cost.

So get going and rush your articles, write-ups, etc…

Thanking you,

Yours sincerely,

Manas R BastiaEditor

Infomedia 18 Limited

‘A’ Wing, Ruby House,J K Sawant Marg, Dadar (W)Mumbai 400 028India

T +91 22 3024 5000F +91 22 3003 4499E [email protected] www.infomedia18.in

D +91 22 3003 4669

Product Update


Tools trolley Basic Engineers offers a wide range of tool trolleys for various types of application and usage. The range includes:

tool-trolley for VMC-HMC, CNC machines, automobile workshop trolley, wiring trolley and many other. The company also offers customised systems for specific requirements; specified tools cabinet to serve as cassette type tools cabinets for safely storing of press brake tools. Unique, user friendly and safe designs set their products apart from others. Salient features of

these products: spacious storage facility with an ease in mobility; innovative designs that fits customers every single need; easy access for machine solutions; adjustable drawer as per customer need; superior quality at less price; and user friendly.

Basic EngineersAhmedabad - GujaratTel: 079-2583 1575, Fax: 079-2583 1575Mob: 098253 44527Email: [email protected]

Product Update


Roll-forming machineGodson Bending Systems offers r o l l - f o r m i n g m a c h i n e . It provides roll forming solutions for simple to critical jobs. Features include: machine built from prime material, the body and structure stress relieved, robust design of heavy duty steel plate body, heat treated alloy rolls, easy replacement of parts, easy to operate & highly adaptable, economical, greater efficiency and longer life. Applications are in industries such as electrical & electronics, fabrication & construction, steel furniture and automobile.

Godson Bending Systems Pvt LtdRajkot - GujaratTel: 0281-236 1467Fax: 0281-236 1873 Mob: 098790 79267Email: [email protected]

Product Update


Hydraulic pressDowel Engineering Works offers hydraulic press. This press ranges from 15 tonnes to 150 tonnes capacity in mild steel robust construction. The Crown column and bottom are solid without bend and welded. The table is vertically operated by worm winch gearbox and rest on load pins placed in the holes in column at desired height. Rollers are provided with the bed for easy handling of heavy jobs. The cylinder is made from honed tube and hard chrome

plated ram is made from mild steel, operated by single acting cylinder. Good quality seals assure long working life. The ram is provided with replaceable socket to facilitate attachment of dies and tools. The double plunger pump, give quick ram travel by low pressure plunger and low speed develops with high pressure plunger.

Dowel Engineering WorksRajkot - GujaratTel: 0281-236 2465, Fax: 0281-236 2465Mob: 098242 31975Email: [email protected]

Product Update


CAD/CAM software Heta Services offers CAD/CAM software from Metalix, Israel. This software is for CNC laser, punch press, plasma & water jet-cutting machines. It is equipped with all the features starting from the very basic CAD for sheet metal

to the advance unfolding of sheet metal components. It has a unique & successful feature of cost estimation of the product after punching, cutting, bending & after process of welding & assembly. Its unique tool, which can be plugged & played, is portable with the machines available in the market. It finds its application in the industries in CNC fabrication, air-conditioning manufacturing and furniture manufacturing industry.

Heta ServicesMumbai - MaharashtraMob: 093223 99599, 099300 04026Email: [email protected]

Product Update


Radial drilling machineArsun engineers offers AR series of radial drilling machine, which are designed to offer rigidity, precision and ease in operation. The model AR50 has a drilling capacity of 50-mm in steel and 60-mm in cast iron. Its drilling motor power is 3.7 kw (5HP) and arm lifting motor power is 1.1 kw (2HP). The machines have robust structure with generously provided ribs and appropriate wall thickness for base-plate, arm, inner column & column sleeve and are rigidly built to withstand static as well as severe dynamic loads. The drill-head comprises of a gearbox and a feedbox fitted with hardened gears on spline shafts running on antifriction bearings in an oil bath, offers 8-speeds and 5-auto feeds. Auto feed disengages automatically when reaching preset drilling depth or against too high drilling pressure, thus prevents breakages or damages to the internal moving parts. Its double column design, wide clamping area of base plate along with ample rigidity of the machine makes is suitable for drilling, tapping, reaming and boring operations. These machines find application in engineering workshops, fabrication shops, die, mould & machinery manufacturing, automobile & shipbuilding industries, railways, defense industry.

Arsun EngineersBhavnagar - GujaratTel: 0278-251 4076, Fax: 0278-242 0132 Mob: 094268 16961Email: [email protected]

Photoelectric gap sensor Lubi Electronics offers ‘Sunx’ RT-610 series photoelectric gap sensor. It is ideal for gap sensing, mark sensing and address reading. In this sensor, the beam axis alignment is not required as the emitter and receiver are integrated in a single body. It has a sensing range of 10 mm, 20 mm and 50 mm. The models with a sensing range of 10 mm and 20 mm are available in red LED type and green LED type for mark sensing. This sensor provides high reliability as the housing material is made of die-cast aluminum. It can be used effectively in typical applications such as packaging, pharma and machine tool industries.

Lubi ElectronicsAhmedabad - GujaratTel: 079-2220 5471, Fax: 079-2220 0660Mob: 093274 97006Email: [email protected]

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Product Update


The information published in this section is as per the details furnished by the respective manufacturer/

distributor. In any case, it does not represent the views of

CNC milling machineDMG India offers DMU 50 eco five-axis CNC universal milling machine. This machine stands out for high precision and reliability, and sets standards in the workshop, in training and in the laboratory, as well as in tool, fixture and mould construction. With its sturdy cross slide construction and large, easily accessible machining compartment, the DMU 50 eco offers the ideal basis for both one-off production and efficient five-axis manufacture of small series.

DMG India Pvt LtdBengaluru - KarnatakaTel: 080-4113 1281, Fax: 080-4113 1285Email: [email protected]

International Products


Circular saw machineEverising Machine Co offers circular saw machine. This new classic type is equipped with high capacity and efficiency

for the metal cutting market, developed to meet high efficiency and accuracy demands, and it also reduces the buyer’s cost. The efficiency of this machine is three times that of major band saw cutting machines presently available in

the market. The blade and bar feed is equipped with servo motor and ball screw. The automatic chip conveyor is of chain type. The machine along with the table weighs 2470 kgs.

Everising Machine CoTaichung - TaiwanTel: +886-4-2359 3178, Fax: +886-4-2350 5420Email: [email protected]

Super open type vise HerBert Enterprise Co offers super open type vise. The whole swivel base is made by stainless steel with harden treatment; it is durable and is equipped with high accuracy. It has an oil-free

powerful mechanical boost system, which gives greater clamping and never collapsing pressure. The chip cover, which is adopted, prevents chips from falling

that may cause bad motion. It can easily clamp the work piece for a longer period. The jaw is deeper than those of same grade vise. The standard accessories that come along with this machine is handle set, guide key, screw- M6x10Lx2pcs, chip cover and vise locked block-4 pieces.

HerBert Enterprise Co Ltd Taichung Hsien - TaiwanTel: +886-4-2627 5073, Fax: +886-4-2627 1395Email: [email protected]

Rotary sawing machine JIH-I Machinery Co offers rotary sawing machine with JIH-20 series. This is applied for angular cutting such as ±45 ‘±22.5’± 30‘ 90 degree or any other angle requirement. The prompt angle setting is done with the manual positioning. The machine range starts from 16”20”24”30”and 36” to choose from. In this machine, the automatic rotary and automatic feed system is required. This machine is combined with angular and 90 degree machine to function as one machine, which saves cost and space. The machine is constructed with high quality pneumatic part & electric part to ensure that the machine is always in a high productive situation.

JIH-I Machinery Co LtdTaichung Hsien - TaiwanTel: +886-4-2532 8325, Fax: +886-4-2532 1325Email: [email protected]

Boring and milling machine You Ji Machine Industrial Co offers boring and milling machine in HFB series. The frame component parts are stiff single piece casting structures, and the machine base uses a box section design, combined with extensive structural ribbing in a single piece. All the structural components have been heat treated and stress relieved thereby enhancing the stability, rigidity and movement precision

of the machine. The Y axis uses a twin servo system design that incorporates two ball screws, each with optical scales

and also has a balancing compensation system to maintain horizontal accuracy that addresses the impact of the natural gravity effects and potential leveling issues from horizontal movement of W and Y axes. So when the ram expands and contracts during machining, this does not impact the accuracy of the machine. Cutting power is delivered by a spindle motor coupled with a two step German ZF gearbox for incredible cutting power. This machine finds its application in industries such as windmill, mould and other heavy industries.

You Ji Machine Industrial Company Ltd Kaohsiung Hsien - TaiwanTel: +886-7-698 3068, Fax: +886-7-698 3071Email: [email protected]

Vertical turning centreDanobat offers vertical turning centres for applications in car industry, aerospace, subcontracting, power generation, etc. These machines are developed by means of a close co-operation with the customers, in order to propose them the right solutions, taking in consideration the increase of the productivity and the cost reduction. The modular design enables a wide range of specifications to be configured in a short time and to be produced efficiently and cost effectively. The vertical turning centre can machine components up to 6.000 mm in diameter and a height of 4.500 mm.

DanobatElgoibar - SpainTel: +34-943-748 044, Fax: +34-943-743 138Email: [email protected]

International Products


The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any

case, it does not represent the views of

Five-axis machining centreLANG GmbH & Co KG offers a five-axis simultaneous machining centre – Milling Cube-MC 500. The advantage of this machine is the shorter production time of the workpieces. The result is a reduction of the number of converting processes, reduced amount of manual rework, paired with high machine availability. In addition to hard machining, this machine allows complete production of the workpiece, drilling and threading without the use of other machines. The machine is equipped with a granite base, which is stress-free and offers better thermal & vibration stability. This feature allows high precision with high-speed manufacturing. This compact machine has large working area and optimal chip removal. This is enabled by the horizontal arrangement of the milling spindle. Chip removal from the machine can be done by using a chip tray or a chip conveyor. The machine is equipped with sliding doors, which allow loading and unloading by crane or other devices from two sides. This machining centre allows workpieces with maximum dimension of 350 x 350 x 300 mm and maximum load capacity of the table is 300 kg.

LANG GmbH & Co KGHüttenberg - GermanyTel: +49-6403/7009-0, Fax: +49-6403/7009-40Email: [email protected]

Clamping systemRolleri offers clamping systems for press brake machines. ROL1, a quick clamping system for Promecam/Amada connection standard, allows the vertical connection of the tools to the press brake machine and at the same time, the tools are correctly aligned in vertical direction. The range of ROL1 products includes the ROL1 PN system and ROL1 HYD system, an oil-pressure locking system. The company also offers ROL2, a system for quick clamping of the lower tools composed by a special clamp (L = 500 mm) that can be activated by a lever inserted in the middle of the system.

Rolleri SpAVigolzone (PC) - ItalyTel: +39-05238 70905, Fax: +39-05238 79030Email: [email protected]

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Product Index


1 Adaptor ........................................................... 136

2 Adjustable adaptor.......................................................122

3 Aerosol multispray ......................................................... 59

4 Air-conditioner................................................................. 20

5 Airline fluid ........................................................................ 59

6 Aluminium processing system .................................. 77

7 Angle encoder.................................................................BIC

8 Angular bevel gear.......................................................127

9 APFC panel ........................................................................ 20

10 Appliance switch............................................................. 27

11 Assembly & high temperature grease .................... 59

12 Automatic drilling machine ......................................107

13 Automatic grinding machine ...................................111

14 Automatic tapping machine ....................................107

15 Automotive lubricant .................................................... 97

16 Automotive oil ...............................................................109

17 Balance system ............................................... 115

18 Bearing ................................................................................ 94

19 Bed type milling machine .........................................135

20 Belt grinder......................................................................149

21 Bench grinding machine............................................149

22 Bench type drilling machine ....................................131

23 Billet shearing machine ................................................ 84

24 Blade ..................................................................................145

25 Blanking line machine................................................... 77

26 Block...................................................................................130

27 Boring and milling machine .....................................148

28 Boring machine .............................................................135

29 Brine chiller......................................................................129

30 BTA/ejector counter boring ........................................ 24

31 BTA/ejector drilling ........................................................ 24

32 C frame power press ........................................ 84

33 Cable .................................................................................... 53

34 Cable & hose carrier....................................................... 99

35 Cable carrier ...................................................................... 94

36 Cable connector .............................................................. 94

37 CAD/CAM software ......................................................136

38 Cam follower...................................................................132

39 Cam grinding..................................................................143

40 CAMWorks software.....................................................127

41 Carbide..............................................................................136

42 Carbide end mill .............................................................. 65

43 Carbide endmill tool......................................................BC

44 Carbide rod........................................................................ 45

45 Carbide tool ..........................................................131, 136

46 Casting ...............................................................................FIC

47 CE marked CNC vertical machining centre..........FIC

48 CE marked milling machine.......................................FIC

49 Centre drill ......................................................................... 46

50 Centre drill .......................................................................136

51 Centreless grinder.........................................................143

52 Centreless grinding machine .......... 19, 71, 146, 150

53 Ceramic insert ................................................................169

54 Cermet...............................................................................169

55 Chain.................................................................................... 94

56 Chain oil.............................................................................. 59

57 Chuck.................................................................................136

58 Circular saw machine ..................................................148

59 Clamping series .............................................................134

60 Clamping tool...................................................................BC

61 Cleaner ................................................................................ 83

62 CNC.........................................................7, 15, 41, 167,124

63 CNC angular cylindrical grinding machine....71, 19

64 CNC cylindrical grinding machine............................ 71

65 CNC equipment ............................................................... 21

66 CNC grinding machine ...............................................111

67 CNC guillotine shear ...................................................... 66

68 CNC horizontal boring & milling machine ............ 17

69 CNC horizontal machining centre...........................FIC

70 CNC hydraulic press brake .......................................... 66

71 CNC laser cutting machine.......................................... 66

72 CNC lathe ....................................................................56, 93

73 CNC machine.......................... 8-9, 15, 41, 69, 170-171

74 CNC machine tool.........................................................123

75 CNC machining centre...........................................15, 41

76 CNC milling machine........................................... FIC,146

77 CNC precision lathe........................................................ 61

78 CNC punch press............................................................. 66

79 CNC tap chuck & tap adaptor ..................................122

80 CNC tap holder & pull stud.......................................122

81 CNC tooling....................................................131,136,145

82 CNC tools holder & pully stud .................................122

83 CNC turning centre ....................................... 15, 41, 124

84 CNC turning lathe.........................................................143

85 CNC turning mill.............................................................. 17

86 CNC turret punch press..................................... 126,150

87 CNC vertical lathe ........................................................... 17

88 CNC vertical machining centre...........................15, 41

89 CNC wheel turning machine ...................................... 17

90 CNC/VMC machine...................................................33-36

91 Collet..................................................................................136

92 Collet chuck............................................................. 61, 136

93 Collision monitoring ...................................................BGF

94 Combi flap brushes and wheel................................132

95 Command panel system ............................................172

96 Compressor oil ................................................................. 59

97 Conduit and connector system................................. 27

98 Connector ...................................................................49, 94

99 Console system..............................................................172

100 Control cabinet ................................................................ 49

101 Control panel.................................................................... 49

102 Control panel accessories............................................ 27

103 Control system................................................................. 49

104 Controlling machine tool............................................BIC

105 Conventional precision lathe ..................................... 56

106 Coolant....................................................................121, 137

107 Coromill ........................................................................... FGF

108 Corothread ..................................................................... FGF

109 Corrosion preventive mill ............................................ 83

110 Counters & power supply ............................................ 13

111 Countersink ......................................................... 10-11, 31

112 Crank pin grinding machine.....................................143

113 Crash control .................................................................BGF

114 Crush blade .....................................................................103

115 Cutter......................................................................... 81, 145

116 Cutting fluid...................................................................... 83

117 Cutting oil ............................................................... 121,137

118 Cutting tool ............................................................................

....... 29, 39, 45, 65, 79, 81, 103, 131, 138, 141, 142, 159

119 Cutting tools carbide metal working tool...........169

120 Cylindrical grinder ................................. 71,93, 146,150

121 Cylindrical grinding machine ...................................126

122 Deburring solution......................................... 157

123 Deep hole drilling machine .................................. 24,43

124 DFMPro tool....................................................................127

125 Diamond tool ..................................................... 10-11, 31

126 Didactic equipment ....................................................... 49

127 Die coater.........................................................................103

128 Die/mould machine ..................................................... coc

129 Distribution transformer .............................................. 20

130 Drawing & forming compound ................................. 83

131 Drill ....................................................................................... 65

132 Drill chuck arbor............................................................136

133 Drill mill.............................................................................136

134 Drill sleeve .......................................................................122

135 Drill tap centre ................................................................FIC

136 Drill tool ..............................................................................BC

137 Drilling head ...................................................................107

138 Drilling machine ............................... 131, 135, 170-171

139 Drilling tool .................................................. 10-11, 31, 39

140 Drive technology............................................................BIC

141 Dust collector .................................................................149

142 Edrawings publisher ...................................... 127

143 Electric motor lamination system............................. 77

144 Electro mechanical balancing .................................BGF

145 Element shrink disc ......................................................132

146 Enclosure cooling unit ................................................172

147 Enclosure system ..........................................................172

148 Encoder............................................................................... 13

149 End mill .................................................... 46, 89, 136, 138

150 Engineers files .................................................................. 46

151 Exhibition - engineering expo .................................140

152 Exposed linear encoder...............................................BIC

153 Fan & filter unit .............................................. 172

154 Feed unit ..........................................................................146

155 Files.....................................................................................131

156 Fine pitch bevel gear...................................................127

157 First contact detection...............................................BGF

158 Five axes CNC hob regrinder....................................147

159 Five axes CNC tool grinder........................................147

160 Five axes high speed machining centre .........15, 41

161 Five face machining centre..............................170-171


Product Index


162 Five faces double column milling machine...... COC

163 Floating holder ..............................................................122

164 Force feed lubricator ...................................................146

165 Forging press.................................................................... 84

166 Forging roll ......................................................................135

167 Freewheel-oneway-clutch .........................................132

168 Friction drop hammer................................................... 84

169 Friction screw press ....................................................... 84

170 Gang drill machine......................................... 131

171 Gas spring ...............................................................116-117

172 Gear cutting machine ................................................. coc

173 Gear grinding technology .........................................155

174 Gear milling.....................................................................157

175 Geared drill machine ...................................................131

176 General machinery .......................................................130

177 Geomcaliper....................................................................127

178 Glass ...................................................................................153

179 Grease........................................................................ 59, 109

180 Greases & speciality ....................................................... 97

181 Grinder ...................................................................... 71, 150

182 Grinding machine ................................................................

..............................71, 91, 111, 143, 149, 146, 150, 153

183 Grinding process control ..........................................BGF

184 Grinding process optimisation ...............................BGF

185 Grinding process visualisation................................BGF

186 Grinding tool .......................................................... 91, 153

187 Grooving & parting tool ............................................... 45

188 Ground spiral bevel......................................................127

189 Guillotine shear................................................................ 66

190 Gun drill ................................................................ 10-11, 31

191 Gun reaming..................................................................... 24

192 Gundrilling......................................................................... 24

193 H frame power press........................................ 84

194 Hammer.............................................................................. 84

195 Handling system module............................................. 49

196 Hard chrome plated bar.............................................134

197 Hard cut end mill ............................................................ 65

198 Helical bevel gear .........................................................127

199 High precision tool holder .......................................... 23

200 High speed drill .............................................................131

201 High-speed centreless grinding machine ............. 19

202 HMC....................................................................................124

203 Hold back device...........................................................132

204 Holemaking tool............................................................103

205 Hollow bar ......................................................................... 73

206 Horizontal boring mill ........................................18, COC

207 Horizontal CNC lathe ..............................................12, 22

208 Horizontal machining centre...............................12, 22

209 Horizontal milling machine..................................... COC

210 Horizontel machining centre ........................................7

211 Hydraulic & gear oil........................................................ 59

212 Hydraulic angle lock vise ...........................................136

213 Hydraulic centreless grinding machine ...............146

214 Hydraulic cylinder.........................................................146

215 Hydraulic cylindrical grinder.....................................146

216 Hydraulic cylindrical grinding machine ...............146

217 Hydraulic forging hammer........................................135

218 Hydraulic hand pump .................................................146

219 Hydraulic internal grinding machine ....................146

220 Hydraulic pallet pump ................................................146

221 Hydraulic press ..............................................................135

222 Hydraulic press ..............................................................135

223 Hydraulic press brake.................................................... 66

224 Hydraulic surface grinding machine .....................111

225 Hydraulic valve system ...............................................146

226 Hydro balancing softner ...........................................BGF

227 Hydroforming................................................................... 77

228 Hypoid bevel gear ........................................................127

229 Indexable tool................................................... 65

230 Inductive proximity switch.......................................... 27

231 Industrial cleaning ........................................................113

232 Industrial control & sensing device ......................... 13

233 Industrial cooling system...........................................129

234 Industrial lubricant ......................................................... 97

235 Industrial oil ....................................................................109

236 Industrial robot ..............................................................151

237 Inner & outer race grinding ......................................143

238 Interface electronic .......................................................BIC

239 Internal grinder..............................................................146

240 Internal grinding machine.......................... 19, 71, 146

241 Internal thread grinding.............................................143

242 Invertor/variable frequency drive............................. 13

243 Iron & steel part.............................................................103

244 Iron worker ........................................................................ 66

245 ISO & milling insert......................................................... 65

246 ISO turning insert............................................................ 65

247 Isolation transformer ..................................................... 20

248 Jack .................................................................. 146

249 Keyless transmisson element........................ 132

250 L-angle box ..................................................... 127

251 Large enclosure .............................................................172

252 Large size horizontal machining centre......170-171

253 Large size machining centre .................................... coc

254 Laser cutting machine .................................................. 66

255 Laser shaping ......................................................... 91, 153

256 Laser system...................................................................... 77

257 Lathe .......................................................................................7

258 Lathe .................................................................................... 16

259 LED........................................................................................ 27

260 Length gauge ..................................................................BIC

261 Lens mould......................................................................103

262 Level controller ................................................................ 13

263 Limit switch....................................................................... 27

264 Linear way vertical machining centre..................... 69

265 Load break switch........................................................... 27

266 Lube .......................................................................... 121,137

267 Machine centre ................................................. 17

268 Machine measurement tool.......................................BIC

269 Machine tool.........................................................104, 165

270 Machine tool accessories ...........................................122

271 Machined component.................................................130

272 Machining & grinding fluid......................................... 83

273 Magnetic modular encoder .......................................BIC

274 Manual feed drilling machine..................................107

275 Marine oil .........................................................................109

276 Masonry drill ..................................................................... 46

277 MCC & PCC enclosure .................................................172

278 Measured value acqusition and display................BIC

279 Measuring & monitoring relay for 1ph/3ph ......... 13

280 Mechanical shear ............................................................ 66

281 Metal cutting ..................................................................165

282 Metal cutting tool ........................................................... 55

283 Micron drill ......................................................................103

284 Miling tool........................................................................103

285 Milling......................................................................... 39, BIC

286 Milling centre.......................................................................7

287 Milling cutter ............................................... 10-11, 31, 45

288 Milling grade.................................................................. FGF

289 Milling head ...........................................................170-171

290 Milling machine.......................................... 135, 170-171

291 Milling machine & machining centre....................104

292 Milling tool ........................................................................BC

293 Mistubishi CNC wire EDM..........................................124

294 Modular tooling system ................................. 10-11, 31

295 Motion control ................................................................. 13

296 Motor ................................................................................... 53

297 Motor protection circuit breaker .............................. 27

298 Mould ................................................................................135

299 Mould component........................................................103

300 Multi-functional tool...................................................... 45

301 Multimedia union ................................................116-117

302 Multi-spindle drilling and tapping head..............107

303 Oil/coolant cooler........................................... 129

304 Online B2B marketplace...................................101, 152

305 Or-laser welding system.............................................124

306 Pallet pump..................................................... 146

307 Panel air-conditioner ...................................................129

308 PC enclosure ...................................................................172

309 PCB drill.............................................................................103

310 PCD & CBN tool .............................................................169

311 Photo electric sensor ..................................................... 13

312 Photoelectric gap sensor ...........................................138

313 Pillar drill machine........................................................131

314 Pilot light............................................................................ 27

315 Piston pump ...................................................................129

316 Plasma cutting machine............................................... 66

317 Plastic machined component ..................................130

318 Plates-sheet .....................................................................130

319 Plug and socket ............................................................... 27

320 Pneumatic automation...............................................119

321 Polishing machine ........................................................149

322 Polymat.............................................................................130

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Product Index


COMPLETE ENGINEERING UNDER ONE ROOF @www.engg-expo.com

323 Position display unit .....................................................BIC

324 Power chuck ...................................................................134

325 Power chucking cylinder.............................................. 93

326 Power distribution component...............................172

327 Power pack......................................................................146

328 Power pack unit.............................................................146

329 Power saver....................................................................... 20

330 Power sources .................................................................. 87

331 Precision bearing ..........................................................133

332 Precision gear cutting tool........................................ coc

333 Precision ground bar ...................................................134

334 Precision steel ........................................................ 91, 153

335 Precision switch............................................................... 27

336 Precision switch single & multiple ........................... 27

337 Precision universal cylindrical machine ...............146

338 Press ...................................................................................165

339 Press brake ........................................................................ 66

340 Process automation and control equipment....... 49

341 Process oil .......................................................................... 97

342 Programmable logic controller ................................. 13

343 Programmable terminal ............................................... 13

344 Proximity sensor.............................................................. 13

345 Pull stud............................................................................136

346 Punch press.....................................................................150

347 Push button ...................................................................... 27

348 Quick change tapping chuck......................... 122

349 Radial............................................................... 135

350 Radial drilling machine ...............................................138

351 Reamer ........................................10-11, 31, 46, 136, 159

352 Reaming & tapping ......................................................122

353 Reversible tapping attachment...............................122

354 RFID ...................................................................................... 13

355 Robot .................................................................................151

356 Rods ..................................................................................130

357 Roll-forming machine..................................................134

358 Rolling oil ........................................................................... 83

359 Rotary .....................................................................................7

360 Rotary cam switch .......................................................... 27

361 Rotary cylinder ...............................................................134

362 Rotary damper ......................................................116-117

363 Rotary encoder................................................................BIC

364 Rotary joint & union............................................116-117

365 Rotary sawing machine ..............................................148

366 Rotating union ......................................................116-117

367 Rust preventing oil ......................................................... 83

368 Safety light curtain .......................................... 13

369 Safety protection device .............................................. 27

370 Screw press......................................................................135

371 Sealed linear encoder...................................................BIC

372 Self adhesive tape.........................................................133

373 Self opening die-head.................................................122

374 Servo stabiliser (air cooled)......................................... 20

375 Servo stabiliser (oil cooled) ......................................... 20

376 Sheet metal forming...................................................... 77

377 Sheet metal machine ..................................................130

378 Shock absorber .....................................................116-117

379 Side lock adaptor ..........................................................136

380 Sinking EDM....................................................................169

381 Siphon system.......................................................116-117

382 Six axes CNC tool grinder ..........................................147

383 Small junction/distribution box ..............................172

384 Solenoid valve................................................................129

385 Solid carbide drill ............................................................ 55

386 Solid carbide drill with IC............................................. 55

387 Solid carbide mill ............................................................ 55

388 Solid carbide reamer ..................................................... 55

389 Solid carbide reamer with IC...................................... 55

390 Solid carbide rotary burr .............................................. 81

391 Solid carbide special drill ............................................. 55

392 Solid carbide special mill ............................................. 55

393 Solid carbide special reamer ...................................... 55

394 Spade drill .......................................................................... 81

395 Special induction hardening machine.................... 87

396 Special purpose machine ...........................................FIC

397 Special refrigeration equipment .............................129

398 Special tool......................................................................136

399 Spindle nose tooling ..................................................... 45

400 SPMS .................................................................................... 24

401 SSM nut.............................................................................122

402 Stacker pump .................................................................146

403 Standard chuck................................................................ 81

404 Standard induction hardening machine ............... 87

405 Stock shape .....................................................................130

406 Straight bevel gear.......................................................127

407 Super open type vise...................................................148

408 Super-rigid press ...........................................................131

409 Surface grinder ..............................................................111

410 Surface grinding machine .........................................111

411 Switching relay ................................................................ 13

412 Taegu turn-hex-turn ........................................ 81

413 Tap.................................................. 10-11, 31, 46, 81, 131

414 Tap adaptor.....................................................................122

415 Tapping head .................................................................107

416 Telecom .............................................................................. 20

417 Temperature controller ................................................ 13

418 Tensioner nut .................................................................132

419 Thread milling ................................................................157

420 Thread milling cutter..................................................... 14

421 Thread rolling system..................................................144

422 Thread turning ..............................................................157

423 Thread whirling tool ................................................... FGF

424 Threading solution .......................................................157

425 Threading tool..................................................................BC

426 Three axes high speed machining centre......15, 41

427 Timer.................................................................................... 13

428 Timing belt drive...........................................................126

429 Tool.....................................................................................136

430 Tool bit................................................................................ 46

431 Tools trolley.....................................................................133

432 Tooling system.................................................................BC

433 Toolroom machine ......................................................... 69

434 Touch probe ....................................................................BIC

435 Track roller .......................................................................132

436 Transformer oil................................................................. 97

437 Transparent gel................................................................ 59

438 Tube ...................................................................................130

439 Tube straightening machine ....................................127

440 Tubing accessories ......................................................... 49

441 Tunnel mucking system .............................................129

442 Turning....................................................................... 39, BIC

443 Turning centre ......................................................170-171

444 Turning holder ................................................................. 45

445 Turning tool ............................................................103, BC

446 Turnkey project (energy) ............................................. 20

447 Turret ................................................................................... 93

448 Turret milling machine ...............................................126

449 Turret punch press ............................................... 66, 150

450 Twin-spindle compound grinding machine......... 19

451 Twist drill ..........................................................................136

452 Twist drill (parallel & taper shank)............................ 46

453 Ultra high pressur apparatus ........................ 103

454 Universal cylindrical grinding machine.................. 19

455 Universal grinder machine ........................................126

456 Universal quick change chuck & adaptor

for drilling ........................................................................122

457 UPS ....................................................................................... 20

458 Used CNC turret punch press ..................................150

459 Valve .................................................................. 49

460 Valve terminal .................................................................. 49

461 Vane pump......................................................................129

462 Velocity & feed controller .................................116-117

463 Ventilator..........................................................................133

464 Vertical CNC lathe....................................................12, 22

465 Vertical grinder ..............................................................135

466 Vertical machining centre ......................... 7,12, 22, 93

467 Vertical turning centre ................................................148

468 Vision sensor..................................................................... 13

469 VM series ............................................................................ 16

470 VMC ....................................................................................143

471 VMX series ......................................................................... 16

472 V-tec double column VMC ........................................124

473 Water chiller.................................................... 129

474 Waterjet cutting machine..........................................130

475 Wear part............................................................................ 45

476 Wear resistant tool .......................................................103

477 White oil ............................................................................. 97

478 Winmax control software............................................. 16

479 Wire cut EDM..................................................................169

480 Wood working machine.............................................130

481 Workshop machine ......................................................130

482 Zero bevel gear .............................................. 127

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Amit Engg Co 130T: +91-22-22657006E: [email protected]: www.amitmachines.com

Apex Group 165T: +91-124-4017138E: [email protected]: www.apex-group.com

Autogrip Machinery Co Ltd 134T: +886-4-822-8719E: [email protected]: www.autogrip.com.tw

Autotech Machine Tools Sales & Services 8-9T: +91-20-27130091E: [email protected]: wwwautotechcnc.com

Bevel Gears India Pvt Ltd 127T: +91-80-28410239E: [email protected]: www.bevelgearsindia.com

Bharat Fritz Werner Ltd FICT: +91-80-28395745E: [email protected]: www.bfwindia.com

Big Daishowa Seiki Co. Ltd 23T: +81-729-828277W: www.big-daishowa.com

Blaser Swisslube India Pvt Ltd 121T: +91-124-4994000E: [email protected]: www.blaser.com

Camozzi India Pvt Ltd 119T: +91-120-4055252E: [email protected]: www.camozzi-india.com

Ceratizit India Pvt Ltd 45T: +91-33-24947146E: [email protected]: www.ceratizit.com

Devco Engineers 150T: +91-2752-243997E: [email protected]: www.liongrinders.com

Dijet Industrial Co Ltd 65T: +91-22-40121231E: [email protected]

W: www.dijet.co.jp

Durr Ecoclean 113

T: +91-20-30585001

E: [email protected]

W: www.durr-ecoclean.com

EFD Induction Ltd 87

T: +91-80-7820404

E: [email protected].

W: www.efd-induction.com

Electronica Hitech Machines Pvt Ltd 12, 18, 22

T: +91-20-30435400


W: www.electronicahitech.com

Emuge India Pvt Ltd 14

T: +91-20-39310000


W: www.emugeindia.com

Ermaksan Machine Ltd, Sti 66

T: +91-224-2947500


W: www.ermaksan.com.tr

Factory Automation Technology Co. L 17

T: +886-5-213-3166


W: www.femco.com.tw

Ferrocare International 129

T: 91-20-26830655


W: www. ferrocare.com

Festo Controls Ltd 49

T: +91-80-22894100


W: www.festo.com

Finechrome Shafts Pvt Ltd 134

T: +91-22-29203647


Forging Machinery Manufacturing Co 84

T: +91-161-5011755


W: www.nkhhammers.com

G W Precision Tools India Pvt Ltd 55

T: +91-80-40431252


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Gallus India 79

T: +91-124-4141434


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Geometric Ltd 127T: +91-22-67056880E: [email protected]: www.camworks.com

Greenleaf Corp 89T: +814-763-2915W: www.greenleafglobalsupport.com

GSK Cnc Equipment Co. Ltd 21T: +91-44-42152387E: [email protected]: www.gsk.com.cn

Guhring India Private Ltd 31T: +91-80-40322500E: [email protected] W: www.guhring.in

Haas Automation India Pvt Ltd 7T: +91-20-32935433E: [email protected]: www.HaasCNC.com

Havells India Ltd 53T: +1800-11-0303E: [email protected]: www.havells.com

Heidenhain Optics & Electronics (I) BICT: +91-9886835186E: [email protected]: www.heidenhain.in

HG Technology Co Ltd 138T: +886-4-7362-725 E: [email protected]: www.hgt.com.tw

HI - Life Machine Tools Pvt Ltd 71T: +91-79-22821615E: [email protected]: www.hilifegroup.com

Hong Ji Precision Machinery Ltd 43T: +886-4-2422-1095E: [email protected]: www.hong-ji.com.tw

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Hurco India Pvt Ltd 16T: +91-44-43108726E: [email protected]: www.hurco.com

Hyundai Kia Machine 123T: +91-9940653703E: [email protected]: www.hyundai-wia.com

Igus India Pvt Ltd 94T: +91-80-39127800E: [email protected]: www.igus.in

IMI Machine Tools Pvt Ltd 122T: +91-2764-233983E: [email protected]: www.imitoolsindia.com

IMT Exim (India) Pvt Ltd 124T: +91-44-45540442E: [email protected]: www.imtexindia.com

India Oil Corporation Ltd 109W: www.iocl.com

IndiaMART InterMESH Limited 101, 152T: +1800-200-4444E: [email protected]: www.indiamart.com

Indian Machine Tool Manucatures’ Association 160T: +91-80 -66246600E: [email protected]: www.imtma.in

Indian Tool Manufacturers 46T: +91-22-25852559E: [email protected]: www.indiantool.com

Indus 128T: +91-98453 63917E: [email protected]: www.induss.co.in

ISMT Limited 73T: +91-20-41434100E: [email protected]: www.ismt.com

Jin Year Precision Co Ltd 136T: +886-4-2523-2817E: [email protected]

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Jyoti Cnc Automation Pvt Ltd 15, 41

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Kabel Schlepp India Pvt Ltd 99

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KINOL 137

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Korber Schleifring GmbH 140

T: +91-8041554601


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Korea Association Of Machinery Industry 139

T: +82-2-369-7869


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Kuka Robotics India 151

T: +91-124-4635774


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Larsen & Toubro Ltd 141-142

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Liang Lih Machine Co Ltd 107

T: +886-4-2426-1151


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LMT India Pvt Ltd 144

T: +91-44-24405137


W: www.lmt-tools.co.in

Maco Corporation India Pvt Ltd 116-117

T: +91-33-24758371


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Metcut Toolings Private Ltd 159

T: +91-836-2333092


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Micromatic Machine Tools 93

T: +91-80-41492285


W: www.acemicromatic.com

Millitronics Cnc Machines 69

T: +98-45902876


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Mitsubishi Heavy Industries India Pvt ltd COC

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M’La Sales Corporation 81

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Nicolas Correa S.A. 104

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NMTG Mechtrans Techniques Pvt Ltd 132

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NN Combined Engineering Agencies Pvt Ltd BGF

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Omron Automation Pvt Ltd 13

T: +91-80-40726400


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Paragon Machinery Co Ltd 19

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Parishudh Machines Pvt Ltd 143

T: +91-120-3205167

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Reishauer Ag, Ch-Wallisellen 155

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Right Vision 135

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Rittal India Pvt Ltd 172

T: +91-80-23519792


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Robin Precision Products Pvt Ltd 136

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S&T Engineers 167

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Sah Petroleum Ltd 97

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Sandvik Coromant India FGF

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SBS Precetion 115

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Schuler India Pvt Ltd 77

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Seco Tools India Pvt Ltd 29

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Servomax India Ltd. 20T: +91-40-44436666E: [email protected]: www.servomax.net

Siddhapura Engineering Works 131T: +91-278-2428054E: [email protected]: www.siddhapuradrills.com

Siemens Ltd 75W: www.siemens.com/sinutrain

Sreelakshmi Traders 133T: +91-44-24343343E: [email protected]: www.sreelakshmitraders.com

Taegutec India Ltd BCT: +91-80-27839111E: [email protected]: www.taegutec-india.com

Takamatsu Machinery Co Ltd 61T: +81-76-2741403E: [email protected]: www.takamaz.co.jp

Techtronics India Ltd 170-171T: +91-124-2370555E: [email protected]: www.techtronics.in

Teknic 27T: +91-22-26592392 E: [email protected]: www.teknic.co.in

Tool Grinding Technologies Inc 147T: +91-80-41170352E: [email protected]: www.tgtindia.com

Tungaloy India Pvt Ltd 103T: +91-022-61248888E: [email protected]: www.tungaloy.co.jp.in

Tussor Machine Tools Ind P Ltd 56T: +91-422-3200183E: [email protected]: www.pinachoindia.com

Tyrolit India Superabrasive Pvt Ltd 91T: +91-80-40953259E: [email protected]

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Vardhaman Enterprise 131

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Vargus Ltd 157

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Vinit Performance Polymers 130

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Weldor Engineering Pvt Ltd 150

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Wendt India Ltd 153

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Werner Finley Pvt Ltd 129

T: +91-80-23289889


W: www.wernerfinley.com

Wexper India Ltd 169

T: +91-124-2210020


W: www.wexper.com

Yamazaki Mazak India Pvt Ltd 33-36

T: 91-2137-668800


W: www.mazak.com

YG Cutting Tools Corporation Pvt Ltd 10-11

T: +91-80-43543636


W: www.yg1.co.kr

Zen Wu Zheng Sun Tool Co Ltd 145

T: +886-7-352-5743


W: www.jsk-tools.com.tw

Zenith Hydromatic 146

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MODERN MACHINE TOOLSJu

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176

Reg No: MH / MR / WEST / 235 / 2009 – 2011 RNI No: MAHENG / 2008 / 24347 WPP Licence No: MR / Tech / WPP – 359 / West / 2009-2011

Licence to Post Without Pre-Payment at Mumbai Patrika Channel Sorting Office, Mumbai GPO., Mumbai 400 001

Date Of Posting 1ST & 2ND Of Every Month / English & Monthly.

Date Of Publication: 28th of Every Month

176

Reg No: MH / MR / WEST / 235 / 2009 – 2011 RNI No: MAHENG / 2008 / 24347 WPP Licence No: MR / Tech / WPP – 359 / West / 2009-2011

Licence to Post Without Pre-Payment at Mumbai Patrika Channel Sorting Office, Mumbai GPO., Mumbai 400 001

Date Of Posting 1ST & 2ND Of Every Month / English & Monthly.

Date Of Publication: 28th of Every Month

Modern Machine Tools - June 2011

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