modern machine tools - july 2012
DESCRIPTION
‘MODERN MACHINE TOOLS’, India’s numero uno magazine for the metalworking & allied industries, is brought out in association with Indian Machine Tool Manufacturers’ Association (IMTMA). This magazine brings forth the latest market trends & emerging technologies, highly useful features on machine tool and cutting tool applications, business strategies, success stories, views & visions of industry leaders, etc. Moreover, it serves as an active business-to-business platform for the manufacturing industry in India and across the world.TRANSCRIPT
Mod
ern
Mac
hine
Too
ls (J
uly-
12) -
Pg
5
Modern M
achine Tools (July-12) -Pg6
Mod
ern
Mac
hine
Too
ls (J
uly-
12) F
ront
-Pg
7
Modern M
achine Tools (July-12) -back - Pg8
Mod
ern
Mac
hine
Too
ls (J
uly-
12) F
ront
-Pg
9
Modern M
achine Tools (July-12) -back - Pg10
Mod
ern
Mac
hine
Too
ls (J
uly-
12) F
ront
-Pg
11
Modern M
achine Tools (July-12) -back - Pg12
Editorial
July 2012 - MODERN MACHINE TOOLS 13
T
Solid State of Fluids
o a quirky question on doubting the relevance of ‘almost dedicating’ an edition on seemingly smooth operating metalworking fluids, our answer is precisely that!! ‘Smooth Operations’ is what it ensures and hence, the attention. Another reason is the all important factor, ‘cost’—which has become the anthem of survival.
Traditionally, metalworking fluids have been widely used in machining operations to increase cooling and lubricity, and, as a result, enhance the tool life, reduce process variability, etc. In short, assist and ensure smooth operations. However, over the last decade, it has become apparent that fluid-related decisions have all too frequently been based upon industrial folklore rather than knowledge-based quantitative evidence. But lately, there has been a change in this thought process…a change which could be attributed to the fact that costs associated with fluid use often constitutes between 7% and 17% of total production costs, as compared to 4% for tooling costs.
Fluid-related expenses include the cost of installing a fluid supply system, fluid purchase and system maintenance, and discarded fluid (waste) treatment. Fluid-related costs are large because high production manufacturing plants frequently utilise several cutting fluid reservoirs—each containing thousands of gallons of cutting fluid. Often, an entire reservoir is flushed to clean the system when quality issues arise. Certainly, reducing the amount of fluid employed can result in significant cost and waste savings.
Given the critical role it plays in smooth operations as well as cost optimisation, this monsoon, MMT is all drenched with key stats and facts about the demand that the metalworking fluids industry can expect, going forward. According to a report, the metalworking fluids market in North America, Asia and Europe is projected to grow at about 3% per annum, from 2.1 million metric tonne in 2010, to nearly 2.5 million tonne by 2015. Asia is the fastest growing market with 5% annual growth from 2010 to 2015. Over those five years, the projection says that the North American metalworking fluids market will grow at 2% and Europe’s by 1%, annually. The report focussed on North America (the US, Canada and Mexico), Asia and Europe, whose estimated metalworking fluid consumption totalled 2.1 million tonne, valued at $6.9 billion, in 2010. Since 2007, Asia’s metalworking fluid demand grew 3.3% annually, while Europe’s slipped 1.8% and North Americas’ fell 7.8%, per year.
With so much happening in this segment, the metalworking fluids industry has responded to the market demands by offering newer and wider variety of cutting fluids. Many new coolants have been developed to meet the needs of new materials, new cutting tools, and new coatings on cutting tools. All this, while keeping the goal of machining operations intact, which is to improve productivity and reduce costs. And this is accomplished by machining at the highest practical speed, while maintaining practical tool life, reducing scrap, and producing parts with the desired surface quality. In short, the key lies in proper selection and use of cutting fluids to achieve all of these goals.
Here’s to slick operations and flowing solutions!
EditorialAdvisory Board
Vikram SirurPresident, IMTMA & Executive Chairman,
Miven Machine Tools Ltd
L KrishnanVice President, IMTMA &
Managing Director, TaeguTec India P Ltd
Shailesh ShethMedia Chairman, IMTMA &
Past President, IMTMA
M Lokeswara RaoPast President, IMTMA & MD, Lokesh Machines 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 LtdArchana [email protected]
July 2012 - MODERN MACHINE TOOLS 15
NEXT EDITION HIGHLIGHTSSpecial Focus: Rapid Prototyping Insights & Outlook: Railway & Equipment Machining
Insights & Outlook Industry Snapshot ...............................................................
Construction Equipment Machining .................................
Machining Solutions ..........................................................
Compact Rebar Shop ..........................................................
Manufacturing Modules ....................................................
96
98
Contents
Special FocusIndustry Snapshot ...............................................................
MWF Projection ................................................................
Advances in MWFs ...........................................................
Occupational Hazards ........................................................
Mist Control .......................................................................
6C—Metalworking Fluid Management ............................
Cutting Fluid Costs ............................................................
One Q Many Views ...........................................................
Biodegradable Fluids ..........................................................
Maintenance & Filtration .................................................
MWF Additives .................................................................
Tips & Tricks .....................................................................
50
52
In Conversation With
Terrence Miranda
MD, HAAS Automation India Pvt Ltd .... 42
Editorial ...................................................................... 13
Sarathi Sutras .............................................................. 19
News, Views & Analysis .............................................. 20
Technology & Innovation ............................................ 40
Event List .................................................................. 120
Products .................................................................... 124
List of Products .........................................................170
List of Advertisers .....................................................178
Regular Sections
56
95
Cover illustration: Hemant Lambe
49
64
66
68
70
76
78
82
86
Geography WatchChennai ............................................................................. 32
SMEs@GlanceGrowth Enablers .................................................................. 38
Facility VisitHittco Tools Ltd ................................................................... 88
Energy ManagementUsing Energy Efficiently Can Boost Profitability ............... 108
Event ReportACMEE-2012 .................................................................... 116
Event PreviewAMTEX 2012 .................................................................... 118
Special Focus Metalworking Fluids
54
100
104
106
Looking For A Specific Product?Searching and sourcing products were never so easy.
Just type MMT (space) Product Name
and send it to 51818eg. MMT EDM and send it to 51818
Se
e
Insights & Outlook Construction Equipment
Turn to Page 122 for
Latest TENDER Updates
July 2012 - MODERN MACHINE TOOLS 17
FOUNDER & EDITOR, NETWORK 18Raghav Bahl
PRESIDENT & EDITORIAL DIRECTOR, TV 18Senthil Chengalvarayan
EXECUTIVE EDITORArchana Tiwari-NayuduEDITORIAL TEAM
Debarati Basu (Bengaluru), Nishant Kashyap, Kimberley D’Mello, Tarun Tampi, Prateek Sur, Archana Singh
PRODUCT DESKPaskaline Sebastian, Hemantraj Ratnakumar, Ninad Ahire
ASSISTANT ART DIRECTORVaruna Naik
DESIGNHemant Lambe
CHIEF PHOTOGRAPHERMexy Xavier
PHOTOGRAPHYNeha Mithbawkar, Joshua NavalkarBUSINESS CONTROLLERS
Akshata Rane, Lovey Fernandes, Deepak Bhatia, Ashish Kukreti, Shwetha ME, Jayashree N, Sugandha Kulkarni, Shefali Mahant
PRINTINGEXECUTIVE VICE PRESIDENT
Ananth R IyerASSISTANT GENERAL MANAGER - PPC
Shekhar Khot
PRODUCTION TEAMDnyaneshwar Goythale, Surekha Karmarkar
Ravikumar Potdar, Ravi Salian, Sanjay Shelar
OVERSEAS CONTACTRingier Trade Media Ltd CHINA
1001 Tower 3, Donghai Plaza, 1486 Nanjing Road, West, Shanghai 200040, China Tel: +86-21 6289 – 5533 Ext. 368, Fax: +86-21 6247 – 4855
(Craig Shibinsky) Email: [email protected] Trade Media Ltd HONG KONG
9/F, Cheong Sun Tower, 118 Wing Lok Street, Sheung Wan, Hong Kong Tel: +852 2369 – 8788 Ext. 21, Fax: +852 2869 – 5919
(Octavia Au-Yeung) Email: [email protected] Trade Media Ltd TAIWAN
Room 3, Fl. 12, No. 303, Chung Ming S. Rd., Taichung, TaiwanTel: +886-4 2329 – 7318 Ext. 16, Fax: +886-4 2310 – 7167
(Sydney La) Email: [email protected] Trade Media Ltd GERMANY, AUSTRIA, SWITZERLAND
Tel: +41-44 734 0472, Fax: +41 44 734 0680Email: [email protected]
USA Tel: (513) 527-8800 Fax: (513) 527-8801
Email: [email protected]
USA Alfredo Domador, 6505 Blue Lagoon Drive, Suite 430 Miami, FL. 33126, USA
Tel: (305) 448-6875, Fax: (305) 448-9942
GROUP CEO, NETWORK 18B Sai Kumar
CEO-PUBLISHING, INFOMEDIA 18Sandeep Khosla
EVP-HUMAN RESOURCESSanjeev Kumar Singh
ASSOCIATE VICE PRESIDENTSudhanva Jategaonkar
ADVERTISING SALESShashin Bhagat (Ahmedabad)[email protected] B (Bengaluru)[email protected] Hara Subramaniam (Chennai)[email protected] N (Coimbatore)[email protected] Kalyan Chakravarthy (Hyderabad)[email protected] Gokhale (Indore)[email protected] Bidawat (Jaipur)[email protected] Abhik Ghosal (Kolkata)[email protected] Dhingra (Ludhiana)[email protected] Yadav (New Delhi)[email protected] Dass (Pune)[email protected] Pathak (Vadodara)[email protected]
MARKETING TEAMGanesh Mahale, Prachi Mutha, Varsha Nawathe, Abhay Borkar
NEWSSTAND AND SUBSCRIPTIONSDISTRIBUTION HEADSunil Nair
DEPUTY GENERAL MANAGERManoj Palsay
SENIOR MANAGER - SUBSCRIPTIONSSheetal Kotawdekar
CO-ORDINATORSRahul Mankar, Anant Shirke, Sarita Quadros,Chaitali Parkar, Kamlesh Mathkar, Vaibhav Ghavale
SERVICESSUBSCRIPTION SERVICES For subscription queries, write [email protected] or call +91 22 30034631-34 or toll free 1800 200 1021PERMISSIONS For subscription to copy or reuse material from MODERN MACHINE TOOLS,Write to [email protected]
• Monthly Issue Price: ` 100 • Annual Subscription: ` 799
Views and opinions expressed in this magazine are not necessarily those of Infomedia 18 Ltd, its publisher and/or editors. We at Infomedia 18 Ltd do our best to verify the information published but do not take any responsibility for the absolute accuracy of the information. Infomedia 18 Ltd does not accept the responsibility for any investment or other decision taken by readers on the basis of information provided herein. Infomedia 18 Ltd does not take responsibility for returning unsolicited material sent without due postal stamps for return postage. No part of this magazine can be reproduced without the prior written permission of the publisher. Infomedia 18 Ltd reserves the right to use the information published herein in any manner whatsoever.
Infomedia 18 Ltd is the publishing arm of Network 18.
Printed by Mohan Gajria and published by Lakshmi Narasimhan on behalf of Infomedia 18 Ltd.Executive Editor: Archana Tiwari-NayuduPrinted at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Infomedia 18 Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai - 400 028. MODERN MACHINE TOOLS is registered with the Registrar of Newspapers of India under No. MAHENG / 2008 / 24347. Infomedia 18 Ltd does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition.
July 2012 - MODERN MACHINE TOOLS 19
What do Stuttgart in Germany, Shanghai in China,
Bilbao in Spain, Osaka in Japan and Taichung
in Taiwan, all have in common? Each one is
an industry paradigm, clusters that have been meticulously
fostered and developed by nations that have led the world in
the manufacture of machine tools. These clusters have evolved
as global hubs, concentrating in a cohesive geographical space,
the resources, institutions, knowledge, and capital required to
build the “mother machines that build all other machines”.
These concentrations symbolise a key, but often ignored,
‘sutra’ of this mother industry, the development of a machine
tool eco-system encompassing the
entire value chain.
Industrial clusters are a must for
manufacturing in any developing
nation, doubly so for a vertically
integrated and technology-driven
industry like machine tools. In
a global market, clusters offer
competitive advantages conducive
to growth, such as flexibility,
efficient logistics, information
exchange, and reduced transaction
costs. To illustrate these
advantages, Taiwan, the small
island nation that incredibly
ranks 6th in production and 4th in
exports, globally, has 72% of its
machine tool industry focussed in
Taichung! Over 490 enterprises
are clustered within a city that in a
few decades of planning and rapid
progress, has rightfully earned the tag, the world’s
first ‘Machine Tool Village’.
Such clusters are, essentially, little ecosystems
that bring together all the elements necessary for
the development of a sustainable machine tool
industry. In India, where 50% of the industry’s
output comes from clusters in the south, Bengaluru
is the best example of an evolved eco-system,
albeit leaps and bounds behind Taichung. Industrial clusters
develop in stages, from initiation to quantity expansion to
quality improvement to eruption. Each stage involves the
incorporation of key developmental elements as shown in
the figure. In order to achieve, by 2020, a 67% market share
for domestic manufacturers, a rise in exports to 20% and a
ranking within the top 10 machine tool producers globally,
every element of a machine tool ecosystem must be developed
in Bengaluru, Pune, Rajkot and Ludhiana. The integration
of large players in the industry with the hordes of smaller
manufacturers and ancillaries must be supported by visionary
government policies, investment in setting up of bridging
institutions such as machine
tool parks, common facility
centres, business and market
development support, and
technology institutes. Looking
at the Indian machine tool eco-
system, R&D development and
innovation seem to be elements
where Indian manufacturers
have particularly fallen behind,
in terms of initiative, access
and investment. Clusters
like Taichung have proved
how heavy investment in
R&D goes a long way in
ensuring the sustainability and
competitiveness of a machine tool
industry. Besides strengthening
CMTI and widening its
presence, manufacturers need to
indigenously develop high-class
products, and academia should be deeply entwined
with the industry, right from training to cutting-edge
innovation.
On the whole, it is pertinent that the machine tool
sector is perceived, not in isolation, but intrinsically
nurtured in an ecosystem. For Indian industry cluster,
the sutra is to muster strength to usher in an era of a
‘New Deal’, the need for which is greater now than
ever before.
Merchant of DreamsBy Shailesh Sheth
Shailesh Sheth, an eminent authority, shrewd analyser of trends, brilliant strategist and considered by the industry as a “Guru”, to us, he manifests as ‘Sarathi’, accomplishing his timely purpose in the ever evolving world.
The Machine Tool Eco-system
Machine Tool Manufacturers
Jobwork Companies
Consultants
IT Support Service
Providers
Trade Association
R&D + Academic
Institutions
Skill Development
& Training Institutes
Financial Institutions
Components Manufacturers
(Vendors)
Part Suppliers
MODERN MACHINE TOOLS - July 201220
News, Views & Analysis
Hypertherm Introduces Powermax105
Rittal bags innovation award
Hypertherm, a manufacturer of
advanced cutting products,
launched Powermax105 in
Asia at the 17th Beijing Essen Welding
& Cutting Fair, 2012. Powermax105
is a new 105-A air plasma system used
for hand-held and automated cutting
and gouging. The system is designed to
comfortably cut metals into 32-mm thick
pieces and sever metals by up to 50 mm.
The new system delivers faster cut speed,
improved cut quality and industry-leading
consumable life for better performance at
a lower operating cost.
Rittal India has won the best
innovation award for Liquid
Cooling Package (LCP). Rittal
RimatriX5 solves the problem of climate
control for high heat losses per rack with
LCP. Extremely high heat loads are
dissipated from the rack via the LCP air/
water heat exchanger. The system also
allows temperature-neutral expansion of
the data centre with pay as you grow
concept, in terms of scalability and
modularity.
The Indian subsidiary of
leading control system and
robot manufacturer, FANUC
Corporation, recently inaugurated its new
technology centre at 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 FANUC India
Pvt Ltd.
The event was graced by Sonali
Kulkarni, President & CEO, FANUC
India Pvt Ltd; Kazuhisa Otsuka,
Executive VP, FANUC India Pvt Ltd;
Katsuo Kohari, Manager, FA Overseas
Sales Joint Department Sales Division,
FANUC Corporation; and Nirmal
Bhogilal, Chairman & MD, Batliboi Ltd.
The facility has been designed in
such a way that no electricity is required
for lighting during day time, thereby
saving valuable energy. To make it more
environment friendly, the facility does
not use glass that prevent heat generation
inside the building, thus reducing the
energy consumption.
With the opening of this new
technology centre, the machine tool major
has reinforced its commitment to the
customers in the Indian market. It is being
equipped with training & seminar rooms
and solution gallery that are designed with
specific focus on customer requirements
during pre- and post-sales. Currently,
FANUC India has its Head Office at
Bengaluru and branch offices at Pune
and Delhi, along with a strong sales and
service network spread across the country.
Even amidst
e c o n o m i c
u n c e r t a i n t i e s
in India, Freudenberg
Group, a family-owned
German company,
expanded its reach
in the Indian market
through a new plant
at Mysore. Chem-
Trend Chemicals Co
Pvt Ltd and Klüber
Lubrication India Pvt
Ltd, headquartered
at Mysore, will
manufacture specialty
lubricants, release agents and maintenance
products. By 2016, Freudenberg expects
to invest around Rs 130 crore in the
new production plant, which is spread
across 40,000 m2. The two companies
supply to a wide range of customers
including the automotive, energy and
wind energy sectors.
“India is not just a low-cost
production centre for us. Almost 60% of
its GDP comprises local consumption
compared to only 40% in China. We
are here to serve the local market and
not to export. When we were facing
crisis in other parts of the world, we
showed 20% growth in India,” said Dr
Jörg Matthias Grossmann, Regional
Representative, Freudenberg India, and
Executive VP & CFO, Freudenberg
Chemical Specialties.
Apart from this, the Group, under
the brand, EagleBurgmann Pvt Ltd, is
expanding its R&D centre at Pune. It
will be a fully automated, computerised
state-of-the-art test centre for testing
seals for refineries, petrochemicals and
chemical plants. The facility will become
functional by the end of 2012.
FANUC Opens New State-of-the-art Facility in Pune
Freudenberg Expands Operations in Mysore and Pune
� Dr Jörg Matthias Grossmann (centre), Regional Representative, Freudenberg
Group, India, along with other Freudenberg off icials, addresses the press on
the Group’s major Indian investments.
FANUC’s Pune Centre� Will be used as a new training
centre
� Will help in providing total engineering solutions
� Will be treated as a live technical centre
� Will help to serve Pithampur, Rajkot and Mumbai regions, apart from Pune.
MM
T Ju
ly-2
012
A
d N
ame:
Big
Dai
show
P
g N
o. 2
1
MM
T July-2012 Ad N
ame: Precihole Pg N
o. 22
MM
T Ju
ly-2
012
A
d N
ame:
Mitu
toyo
Pg
No.
23
MM
T July-2012 Ad N
ame: Fullton Pg N
o. 24
MODERN MACHINE TOOLS - July 201226
News, Views & Analysis
Timken has awarded ‘2011
Foundation of Quality
Excellence’ Award to its bearing
plant at Chennai, India, during its
Asian Quality Conference in May 2012.
The awards are presented each year in
recognition of top quality performance
amongst its more than 50 plants around
the world, and the Chennai plant is one
of the two Asian plants recognised. The
facility produces single- and double-row
case-carburised tapered roller bearings,
including cups, cones and assemblies,
of 8 inches and above outside diameter.
Timken Chennai Wins ‘Foundation of Quality Excellence’ Award
IMTMA Seminar Calendar: July 2012Date Topic Venue
July 11, 2012 Seminar on Idle Time Reduction in Metal Cutting through Quick Changeover Techniques
Technology Centre, BIEC, Bengaluru
July 11, 2012 Seminar on Welding Technology in Auto Industry
Pune
July 12–13, 2012
Workshop on Process Capability—The Quality Route to Sustained Growth in Manufacturing
Technology Centre, BIEC, Bengaluru
July 13, 2012 Seminar on Servo Technology for Industrial Motion Control
SKF College Campus, SKF India Ltd, Chinchwad, Pune
July 17–18, 2012
Training Programme on New Product Development on CNC Turning Centres
Technology Centre, BIEC, Bengaluru
July, 17–18, 2012
Seminar on New Manufacturing Strategies using Multi-Tasking and 5-axis CNC Machines
Pune
July 20, 2012 Seminar on Lasers in Metalworking Technology Centre, BIEC, Bengaluru
July 20–21, 2012
Workshop on Measurement Systems Analysis Gurgaon
July 23–24, 2012
Seminar on Heat Treatment Process in Metalworking
Technology Centre, BIEC, Bengaluru
July 24, 2012 Seminar on Design of Hydraulics, Pneumatics Coolant and Lubrication System
Gurgaon
July 24–25, 2012
Workshop on Workholding and Fixturing Techniques for Productivity Improvement on CNC Machines
SKF College Campus, SKF India Ltd, Chinchwad, Pune
July 25, 2012 Seminar on Right Selection of Linear Motion Guideways, Ball Screws & Servo Drives for Industrial Machinery
Gurgaon
July 27, 2012 Workshop on Calibration of CNC Machine Tools
SKF College Campus, SKF India Ltd, Chinchwad, Pune
CAPA, VIC to Promote Aerospace City in Bengaluru
Centre for Asia Pacific Aviation
(CAPA) India and Vittal
Innovation City (VIC) will
co-promote CAPA-VIC Aerospace City
in Bengaluru. The aerospace park will be
one of the industry clusters at VIC and
will spread over an area of 750 acre. VIC is
India’s first green technology & IPR safety
zone focussing on aerospace, defence &
electronics. CAPA, the region’s leading
specialist advisory, research & knowledge
practice, will bring together international
aerospace operators and manufacturers.
Nicolás Correa Received Orders of the Order of €5.5 million at the BIEMH
Nicolás Correa—the Spanish
company—received orders worth
multi-million pounds during the
27th edition of BIEMH (May 28–June 02,
2012, Bibao, Spain):
� One order was from Italy for a gantry
milling machine, with a mobile
sleeper, with X–Y–Z–W runs of
11,800 × 6,800 × 1,500 and 1,650,
respectively, for a total value of
€2 million. It will be used to machine
large components for the nuclear
sector.
Th e company provides milling solutions for:
� Equipment manufacturing
� Die and large mould
manufacturing
� Monolithic elements for
the aerospace, railway, and
energy, including turbines,
wind milss and general
mechanical sectors
� Another order, worth €1.5 million, was
from Chinese client Beyang Hanfen for
FPV-W 75 gantry milling machine, with
a mobile sleeper, with X–Y–Z–W runs
of 7,500 × 4800 × 1,500, and 1,650,
respectively.
� German client Zeisier bought a mobile
column floor-type machine from the Axia
family for €675,000.
� The company also sold fixed bench
machines in the UK and France to clients
CMS Cepcor and Robatel, respectively,
for a total sum of €650,000.
MODERN MACHINE TOOLS - July 201228
Leaders’ Views
Impact of Economic Slowdown on Machine Tools Industry
The current economic situation that the country is facing has definitely resulted in
a slowdown in capital investment. This does not augur well for the machine tool
industry. Coupled with this, the rising petroleum costs and the high inflation rate have
resulted in the overall slowdown of the manufacturing industry. Consequently, our customers
are deferring investments. We have to definitely look at the ways in which the input costs can
be reduced in areas such as the cost of the raw materials, labour, etc. In addition to this, the
government also has to look into the cost of imports in the import duty.
- N Gopinath, VP – Marketing, MMC Hardmetal India Pvt Ltd
The Indian machine tool industry is facing stiff competition from all over the world.
We, therefore, have to constantly innovate in terms of technology and processes
as well as value engineering. The missing links in the Indian industry are in the
areas of machine reliability and faster delivery. To achieve this, we need to create a strong
vendor base. However, this aspect of the industry is not very strong. We still do not have
reliable suppliers of auxiliary systems and critical machine components. The industry needs
to concentrate on strengthening the vendor base.
- Mohini Kelkar, MD, Grind Master Machines Pvt Ltd
Even as the Indian economy is rendered rudderless, with political leadership unable
to rise to the occasion, we are happy to note that our industry is full of optimism,
despite a weakened rupee, high interest rates and rising costs. All our customers are
geared to achieve 30% growth in 2012–13 amidst these major external handicaps.
- Sonali Kulkarni, President & CEO, FANUC India Pvt Ltd
The Indian machine tool industry has no option but to grow exponentially over the
next decade. Robust consumer-driven demand will accelerate progress in India
like never before, as it rises to become a powerful contributor to the international
supply chain. The current economic situation is probably not as exciting as we would like
it to be; however, it should hardly be interpreted as a situation that merits a critical or
desperate attitude. If we were to modestly forecast an average growth of 7.5% in GDP over
the next 5 years, we can arithmetically translate that, at the minimum, to a healthy 15%
growth per year in the machine tool industry.
- Satish Sadasivan, MD, SCHUNK Intec India Pvt Ltd
MODERN MACHINE TOOLS - July 201230
News, Views & Analysis
With the demand
slump in the
a u t o m o t i v e
industry, component
manufacturers are also
trimming down their output
to prevent inventory pile up.
The automakers this year
have seen a steep reduction
in demand pattern, which
led to downsizing the
production.
As vehicle sales dwindle
due to high interest rates
and petrol prices, many
automobile manufacturers in
India have planned to shut
down their plants temporarily
to reduce inventories. This
has directly affected the
component manufacturers
across the country. As
per Auto Component
Manufacturers Association
(ACMA) reports, the
components industry saw
a turnover of around $40
billion in 2010–11 and is
estimated to touch $66.3
billion in 2015–16. India’s
exports from the sector
stood at about $5.2 billion in
2010–11, expected to reach
$12.3 billion 2015–16.
Car sales in India grew
at the slowest pace in seven
months during May with
just 2.78% rise as high
interest rates, which are
hovering around 11-13%,
and petrol prices hit the
market.
JCB India,
the country’s
l a r g e s t
manufac tu re r
of construction
e q u i p m e n t
has launched
‘The All New
3DX’ Backhoe
Loader. With
the launch
of this new
equipment, the
company aims
to strengthen
its share of the
backhoe loader
market in India.
Speaking about the launch,
Vipin Sondhi, MD & CEO,
JCB India, said “We are
extremely delighted with the
launch of this
all new JCB
3DX Backhoe
Loader. The
benefits that
t h i s n e w
g e n e r a t i o n -
e q u i p m e n t
provides to its
customers are
immense. It
ensures 20%
lower fuel
consumpt ion
in excavation,
which wil l
result in fuel
savings worth `2.25 lakhs
per year at current diesel
prices. It is the best engine in
the construction and the
equipment industry.”
Component Firms Cut Output as Automakers Trim Production
JCB launches New 3DX Backhoe Loader in India
Advantages of 3DX Backhoe Loader� Will result in 20% lower fuel
consumption in excavation
� Will create 20% more cabin space
� Has twin ram steering facility for easy steering
� Has been provided with new brake linkage to ease the braking effort
� Has been fixed with new bonnet for easy maintenance
� Offers the best return on investment.
MODERN MACHINE TOOLS - July 201232
GEOGRAPHY WATCHChennai
Chennai’s automotive industry is moving forward at full throttle, and with this, the city encompasses in itself a cauldron of business opportunities for the machine tool builders of India. Debarati Basu throws light on the various lucrative options that Chennai offers...
The huge conglomerate of
automobile manufacturing
industry based in and around
Chennai has created a
thriving industrial ecosystem
for business to pour in. From the very
inception of the automotive industry
in the country, Tamil Nadu has been
providing the right environment to
optimise on the emerging opportunities.
Starting from Ford Motors, which
ventured here in 1995, to Hyundai,
BMW, Mitsubishi, Nissan and the
leading Indian companies such as Ashok
Leyland, TVS Group and M&M, almost
all major automakers have made Chennai
their home. Chennai hosts around 35%
of India’s auto ancillary units, and has
thus rightly gained the sobriquet ‘Detroit
of Asia’.
Building BusinessHowever, even with one of the biggest
auto clusters in place, Chennai could
never promote its own machine tools
setup. It either imports or outsources
most of its machine tool requirements
from various Indian cities. It procures its
machine tool requirements mainly from
Bengaluru and Coimbatore, which have
established their manufacturing base for
machine tool requirements. Syed Amjed,
Sr VP - Global Marketing, Bharat Fritz
Werner Ltd, explains, “Though we agree
that Chennai is an auto hub, Bengaluru’s
business is divided into categories
like automotive, aerospace & general
engineering.”
A setup for manufacturing
machine tools would need established
requirements for castings apart from
suppliers and sub-suppliers. For
Chennai’s auto industry, importing
machine tools or outsourcing its
requirements from other Indian cities
is more feasible than putting in the
investment for manufacturing the same
in Chennai.
Rama Bhatathi, Head Sales, South,
Hyundai WIA Pvt Ltd, says, “Over
the last 20–30 years when Chennai was
strengthening its automotive industry,
Bengaluru was simultaneously building
up its machine tools segment. And
now, both these cities have their own
matured market with established players.
Today, any global machine tool builder
entering the Indian industry would look
at Bengaluru just like any global auto
company will come to Chennai. This is
the ecology that has been traditionally
been created.”
This has given rise to an opportunity
for the Indian machine tool builders to
extract business opportunities from this
auto cluster. “Metal forming and metal
cutting form almost 60% of the total
manufacturing process of automotive
industry. Hence, the machine tools
industry has a huge role to play.
Bengaluru alone provides 55–65% of
the total national domestic consumption
followed by other Indian machine tool
clusters including Ludhiana, Rajkot and
Coimbatore,” says TK Ramesh, CEO,
Micromatic Machine Tools Pvt Ltd.
Machine tools industry is a
manpower-intensive industry that
requires volumes to justify the
investment. While the national
requirement for machines is around
15,000–20,000 machines per annum,
Chennai’s requirement is roughly
around 2,000–3,000 machines per
annum. While Chennai has some key
machine tool builders providing for the
auto industry’s requirements, it can also
explore this segment of manufacturing
as well.
“As the auto industry grows, the
machine and tool industry will also see a
rise, even though it may not be as huge
an industry as the automotive. The state
does have a few machining companies
and although they are not large in
number, they certainly produce quality
machine tools,” says Dilip Kumbhat,
CEO, K-Lite Industries, and Chairman,
Chennai Auto Ancillary Industrial
Infrastructure Upgradation Co.
Paving the WayIndia today has positioned itself as one of
the fastest growing auto markets in the
world. According to a CII Survey, the
Indian automotive industry is expected
to grow at the rate of about 13% per
annum over the next decade to reach a
size of around $165–175 billion by 2022.
At the rate at which the automotive
cluster is gearing up for the global race,
the machine tool industry definitely has
a lot to draw from Chennai.
Mod
ern
Mac
hine
Too
ls (J
uly-
2012
) Fr
ont -
Pg
33
Mod
ern
Mac
hine
Too
ls (J
uly-
2012
) Fro
nt -P
g 34
Mod
ern
Mac
hine
Too
ls (J
uly-
2012
) - F
ront
-Pg
35
Modern M
achine Tools (July-2012) -Pg36
MODERN MACHINE TOOLS - July 201238
SMEs@GLANCEGrowth Enablers
At a time when the industry is on a full swing towards development, SMEs need to be strengthened to ensure consistent growth. However, while the big industries are growing even bigger, SMEs in India still have to fight for better benefits to explore its opportunities. Here is an insight into what SMEs really need. Debarati Basu reports…
The Small and Medium
Enterprises (SMEs) play
a vital role in the growth
of Indian economy. They
contribute over 45% of
industrial output, 40% of exports,
employ 60 million people, and more
importantly, have the potential to create
1.3 million jobs every year.
The contribution of the SMEs
towards the GDP in 2011-12 was
around 17% and studies predict that it
is likely to increase 22% by 2012-13.
According to a study, liberalisation and
deregulation in the industry would also
contribute to the sector’s growth. The
sector, which has grown at the rate of
35% in the last two years, is likely to
register 40% growth in the next five
years. However, with all the growth
projections, the Indian SMEs are still
grappling for support from government
and bigger companies alike.
Challenges EncounteredWith the potential that the Indian
SMEs possess, the segment can grow
manifold if given appropriate support
from all quarters. The growth of this
segment would result in the overall
growth in the production of the Indian
industry as well, and thereby the Indian
economy. However, the odds that
SMEs have to face have outweighed
their growth. This segment of the
industry is still grappling to own a
share of benefits from India’s growth
story. Here is a wish list of the Indian
SMEs and what they actually want:
� Availing easy finances: It goes
without saying that finance is a
major constraint that SMEs face.
The non-availability of credit
facilities and exorbitantly high
interest rates are some key issues
that all levels of the industry have
to grapple with. However, these
issues come down heavily, especially
on SMEs. Therefore, they need a
quicker and hassle-free procedure to
avail finances.
� Government aid: A helping attitude
of the Central Government and state
governments is the first requirement
of SMEs.
� Support to undertake R&D: SMEs
are the fountainhead of innovations
as they are the closest to the ground
realities of manufacturing. But, in a
desperate measure to cut down cost
to make profits, howsoever marginal,
the first thing that is usually struck
off from the list of expansion plans
is the investment in research and
development. Despite every effort,
most SMEs today have become
offloading units for mass production.
“Being an SME makes you a
puppet at the hands of the Original
Equipment Manufacturers (OEMs).
SMEs are usually trapped in the
cycle of scope, quality and schedule
and one of them is compromised
in the entire process. Although it
involves a lot of investment, every
SME should try to design its own
products and create a brand for
themselves in the market,” feels D
Ramamoorthy, Director, Applied
Engineering & Technologies Pvt
Ltd.
� Knowing the global requirements:
The world is growing at a rapid pace
and there is a dire need for SMEs
to keep themselves abreast with the
recent developments. The small
scale industries need to have a clear
understanding of what the global
customers need to manufacture
products that match the international
specifications. For this, the industry
needs to have a proper channel of
communication between the OEMs
and the entire gamut of SMEs.
Looking AheadGone are the days when SMEs
were synonymous with low-quality
manufacturing at less cost of production.
Today, they are trusted upon by OEMs
to produce quality-testified components
as per the standards of international
market. Various state governments have
started taking note of the potential that
SMEs hold and numerous industry
associations are also now coming
forward to help this segment. However,
SMEs still await a synergised effort
towards strengthening the backbone of
Indian machine tool industry.
Aiding small companies manufacture bigger wonders
MODERN MACHINE TOOLS - July 201240
High feed rates call for
powerful drive systems and
weights that are as low as
possible. On the other hand, a high
level of accuracy requires a high level of
rigidity, which also leads to large cross
sections, and hence, to large volumes
and weights where designs to cope with
force distribution are concerned.
Past reaction to the different
processing requirements relating to
rough and finishing machining was to
develop modular sub-assemblies. These
sub-assemblies were then combined
to adapt the machining level in the
best possible way. This meant that a
number of machines or process units
were necessary for complete machining
of the tool.
The concept of scissor dynamics
links the dynamics of a parallel structure
with the broad operational range
encompassed by scissor kinematics.
In contrast to other solutions, the
dynamic gain was deliberately set as
the limiting parameter because the
traversing movements of the serial axes
are accelerated within the range of the
required compensatory movements.
Through dynamic-oriented
utilisation of axial redundancy, it is
possible to achieve optimum adaptation
of the machine characteristics to the
relevant stage in the process. At the
same time, a considerable expansion of
the process scale is achieved because new
machining strategies are made possible
by the means of these improved and
controllable machine characteristics.
Potential for cost saving in crankshaft
manufacture and for enhancing the
quality of machining is offered by
the use of a high-precision dry machining
process instead of the previously used
machining process of grinding.
Consider, for instance, crankshaft
manufacture. Here, the precision turn
milling technology has the potential to
replace the grinding process. Grinding
process, as a machining process, requires the
use of cooling lubricants for geometrically
indeterminate cutting. The trend towards
machining using geometrically-determined
cuts and the subsequent achievement
of levels of precision of less than IT4
as well as form deviations smaller than
4 micrometers (previously achievable
exclusively by grinding) holds out the
promise of enormous potential for cost
saving, resulting not only from the use of
dry machining, but also from shortening
the process chain.
The p r e cond i t i on s f o r
economic and process-reliable
dry machining of the component
have been created by the development of
this new type of precision turn milling
machine, associated integrated studies of
the Work-Piece-Tool-Process-Machine
system, and new approaches to development
in respect of process, tool & coating and/or
lubricating principals.
To research thermal characteristics,
a rigid temperature management
is necessary to simulate various
operating conditions. One aim is to
determine the correlation between
temperature change and heat-dependent
shifts for the machine sub-assemblies,
which, to a major extent, determine the
working accuracy. Based on the knowledge
acquired relating to the heat sources and the
flow of heat, design measures can be derived
to reduce thermal deformations/shifts.
A further possibility is the correction
of the thermal shifts by direct/indirect
compensatory action. External thermal
influences are simulated by means of
conditioning the surrounding air and
base plate temperature for the thermo
cell to supplement conditions in practice.
Experimental tests may be carried out
during machine downtime, at idle
with the programme cycle and while
machining, in order to determine thermal
loads that have a disruptive effect on the
operational accuracy of the machine tool.
Over and above this, vertical or horizontal
temperature layers may be generated,
which may be used to render thermo-
neurological zones on the machine tool
identifiable by means of which workshop
conditions can be simulated.
Scissor Kinematics provides flexible machining strategies
Precision turn milling machine makes dry machining more efficient
Thermo cell simulates workshop conditions for machine analysis
Courtesy: Fraunhofer Institute for Machine Tool
and Forming Technology IWT
TECHNOLOGY & INNOVATION
42
IN CONVERSATION WITHTerrence Miranda
MODERN MACHINE TOOLS - July 2012
…and depreciation of the rupee and the situation in Europe is making overall business conditions uncertain. The industry wants the government to take certain policies and decisions much
faster,” says Terrence Miranda, MD, HAAS Automation India Pvt Ltd, a leading CNC
machine manufacturer, as he shares current trends and challenges that the industry is facing with Nishant Kashyap. Excerpts…
The machine tool companies in India are facing serious challenges…
Terrence Miranda
July 2012 - MODERN MACHINE TOOLS 43
How has the machine tool industry responded to the increasing demand from customers for high speed and better productivity? In recent years, machining tasks have
become more complex. This means that
the machine technology has to become
more complex to provide cutting-edge
machining. The demand for quicker and
better productivity has naturally gone up.
Customers now want to increase their
productivity dramatically. At the same
time, they do not want to compromise
with the cost. Hence, to be in the business,
machine tool builders have to manufacture
products that are cost effective as well as
provide value for money. The increasing
demand for better productivity, efficiency
and speed would mean that we would need
faster machine tools that can efficiently
deal with complex machining.
On the other hand, from the user
industry’s perspective, faster machining
of components would require highly
specific tools tailored to the machining
process to maximise process speed. At the
same time, for higher productivity, the
product needs to be handled properly for
setting up the tools. Naturally, all these
additions to handle complex machining
will increase the cost. Hence, the industry
is continuously going through a cost–
quality tussle.
What are the current market trends?Currently, I see three major trends in
the industry. First is the extensive use of
automation. Loading/unloading of parts
with the help of robots, automatic pallet
systems or bar feeding systems is a clear
trend that is being seen in India. In this
ever-growing world, it is not just enough
to have CNC machine tools; customers
want to automate the entire process. This
would reduce dependence on manual
operation and also increase productivity.
The second trend is the growing
demand for 5-axis machining centres. As
the accuracy standards are going up, the
necessity to machine a part in a single setup
(i.e., 4–5-axis machining) is also growing.
This trend is seen in every machine shop,
big and small players alike. Companies
Q
Q
Which personality inspires you and
why?
If I was asked to name one person who
inspires me, I would say John Roth who
is the present Director of Production
at HAAS. He has been my mentor
and guide since I started working for
HAAS as a dealer and then as the
Country Manager for HAAS India.
What do you consider as a turning
point in your career?
The challenges that we faced in the
difficult years from 1998 to 2002
to bring the HAAS name to India
were the turning point for me. I truly
believe in the adage that adversity can
very often bring out the best in people.
multi-tasking machines that are affordable
for the mass market. I believe that multi-
tasking is a trend for the future.
What are the emerging sectors for machine tool builders? The construction equipment industry is
one of the fastest growing sectors and
it is definitely creating a lot of demand
for machine tools. One more sector to
look for is that of the aerospace industry,
which is growing at a fast pace in India.
Apart from these, medical, defence,
telecommunication, and other such
industries are also generating demand for
machine tools. The automobile and auto
component industries remain the biggest
customers of machine tools. I believe that
in the next two years, these industries
will provide an impetus to machine
tool builders and will demand the latest
generation of CNC machine tools.
What are your projections for the industry? In 2011–12, the sales in the metal
forming and metal cutting industry of
India were around $2.5 billion. In the
market in which we compete (where we
deal with machining centres and vertical,
horizontal & turning centres), we estimate
that a little over 14,000 machines—both
local and imported—were sold in India
in 2011–12, of which our market share
would be around 5%. The year 2012–13
has started on a slow note due to the
Eurozone crisis and high inflation. So I
think this financial year will also see a
similar number of CNC machines being
sold. We do expect to see stronger growth
in the 3rd and 4th quarters of 2012–13. In
this situation, the major challenge for us
is to increase our market share.
How is the adoption rate of CNC machines in India?The machine tool industry in India has
shown a double-digit growth rate over
the last several years and this trend should
continue. As large and small companies
in a diverse range of industries move
from conventional to CNC machines to
upgrade their productivity and meet their
own customer or product requirements,
personalUP CLOSE &
Q
Q
Q
are forced to adopt 5-axis machining.
The immediate cost of adopting a 5-axis
machine may be high, but in the longer
term, it will ensure increase in productivity
and reduced costs in manufacturing.
Currently, many cost-effective 5-axis
machines are available that can perform
almost all 5-axis operations other than very
high-end processes. Transitioning from
3-axis CNC machine to 4- and 5-axis
machines was not as easy as it is now.
The third trend is the use of
multi-tasking machines. Multi-tasking
machines combine various processes,
such as milling and turning, in a single
machine. These machines are growing in
importance as customers look to reduce
part handling and increase machine
versatility. Manufacturers are now
trying to combine more processes in a
single machine. Adopting multi-tasking
machines would improve productivity of
the machine and work space, as there will
be one machine for all these operations
instead of 2–3 different machines for each
operation. However, the challenge that
machine tool builders face today is the
way it has increased the complexity in
manufacturing operations. Many machine
tool builders are focussing on developing
MODERN MACHINE TOOLS - July 2012
Terrence Miranda
44
the demand for CNC machine tools will continue to go up.
Where does India stand in terms of R&D activities in the machine tool industry? R&D in the Indian machine tool industry is in its nascent
stage. But, there are many Indian machine tool builders who
are introducing indigenous products that are suitable for both
the domestic and global markets. However, the industry has not
seen many path-breaking technologies yet. The Indian industry
has a lot of opportunities for growth. Many Indian machine tool
builders are now showing the potential to develop products that
are unique and patented worldwide. But in terms of technology,
they have a long way to go. Products from Japan, Germany and
the US are technologically highly advanced as compared to the
products that are made in India.
What are the challenges you see in the industry today? The machine tool companies in India are facing challenges
similar to what other industries are facing. The depreciation
of rupee against all major currencies like dollar, pound and
yen is a major challenge. The situation in Europe is making
overall business conditions uncertain. The industry wants the
government to take certain policies and decisions much faster.
The current situation is not making India’s condition any better
as it is affecting the market sentiment and it is definitely not
helping capital investment. The machine tool industry is a
capital-intensive industry and anything that hurts capital
investment will hurt the machine tool industry.
India’s poor infrastructure is also a big cause of concern,
even though the country is making rapid progress. While power
and infrastructure represent huge opportunity areas, they are
also a bottleneck. As demand for better infrastructure increases,
it will call for a lot of machine tools. Whether it is power
generation or infrastructure, the equipment used in these
industries would require CNC machines for their manufacture.
Thus, we have both potential and opportunity in these sectors,
but the machine tool industry needs to gear up to meet these
requirements. Another challenge for us is to build value in the
product. Companies that can combine the need for higher
productivity and cost effectiveness will be successful.
What are your strategies to deal with the current situation?We are neither a low-cost machine tool manufacturer nor
do we make high-end or highly specific CNC machines.
Our focus will be on enhancing the value proposition for our
customers. When you combine productivity and efficiency
with cost, it becomes a value proposition. Any discounting
on these is a very short-term strategy, and it is not HAAS’
philosophy. We are instead trying to focus on providing value
for money. We have been very successful with this in the
past. In future also, our focus will be on adding value to the
product and satisfaction of our customers.
Q
Q
Q
MM
T Ju
ly-2
012
Ad
Nam
e:G
anes
h Pg
No.
45
MM
T July-2012 Ad N
ame: Tungaloy Pg N
o.46
MM
T Ju
ly-2
012
A
d N
ame:
Tun
galo
y P
g N
o. 4
7
MM
T July-2012 Ad N
ame:Erm
aksan Pg No. 48
50 Industry Snapshot Lubricating Industry Potential
52 MWF Projection Demand Drenched: 2.5 Million Tonne Annual Global Consumption 2015
54 Advances in MWFs Innovation & Efficiency, in Every Drop
56 Occupational Hazards Making Fluids Health-Friendly
64 Mist Control Techniques for Healthy Manufacturing
66 6C—Metalworking Fluid Management Spraying Edge to Manufacturing
68 Cutting Fluid Costs The Changing Costs of Coolants
70 One Q Many Views Is Cryogenic Cooling an Emerging Alternative to MWFs?
76 Biodegradable Fluids Vegetable Oils Turn MWFs Green
78 Maintenance & Filtration The Faultless Fluids
82 MWF Additives The Key to Cost Effectiveness
86 Tips & Tricks The Right MWF
METALWORKING FLUIDS
SPECIALFOCUS
July 2012 - MODERN MACHINE TOOLS 49
SPECIAL FOCUSIndustry Snapshot
MODERN MACHINE TOOLS - July 201250
Global Industry Analysts (GIA), in a recent report, forecasts that the global market for functional fluids will reach $19.7 billion by the year 2017. With such a growth in demand, the opportunities in the market will be driven by innovations that meet the changing regulatory requirements and standards. Over the last year, the lubricating industry has seen burgeoning growth and expansion and promises greater potential for the future. Debarati Basu brings to the fore some of the latest happenings in this industry.
Lubricating Industry potential
Wrapping UpWith the increase in the
machining complexities,
the role of MWFs will
become more important
to ensure flawless
machining processes.
However, with the ever-
increasing competition in
this field, new products
need to stand out in
terms of technology and
performance. According to
a GIA report, biofluids are
expected to be seen as a
key area of expansion and
demand. Innovation in
lubricants and greases are
Fuchs opens a lubricant laboratory and technical centre in AustraliaUsing Australia’s position as a leading
lubricant industry development hub, Fuchs
Lubricants opened a world-class Regional
Lubricant Laboratory and Technical
Center. The new laboratory will be part
of the global research and development
as well as develop new products for the
market. It will also be responsible for
providing technical support to the region.
This is a step towards more research
and development and to set national
standards for lubricant product
development in Australia.
Greenbriar Equity Group acquire PetroChoiceGreenbriar Equity Group LLC—a
US-based company—acquired PetroChoice,
a leading, value-added distributor of
petroleum lubricant solutions. Greenbriar
acquired the company from KRG Capital
Partners. Headquartered in Riddlesburg,
Pennsylvania, PetroChoice is the largest
distributor of consumable commercial,
industrial, and passenger vehicle lubricants
in the Mid-Atlantic and Upper Midwest
regions of the US, providing its customers
with total fluid management for their
lubricant needs.
Hyundai Oilbank, Shell in a joint venture ( JV)Hyundai Oilbank, a South Korean
company, entered into the lubricant
base oil business by establishing a JV
with Shell Petroleum Co. With plans
to start production in the latter half
of 2014, the JV, named Hyundai and
Shell Base Oil Co, will break ground
in October this year for this new
venture.
Apache Oil with Houghton to distribute eco-friendly metalworking fluids (MWFs)Apache Oil, a Minneapolis-based
company, has partnered with Houghton
International—a world leader in high-
tech, metalworking, hydraulic fluids
and fluid management services—to
distribute Houghton’s premier line of
environment-friendly MWFs to the
customers.
Blaser Swisslube’s MWFs make titanium machining easyBlaser Swisslube’s expertise in
creating vegetable oil-based
MWFs led to a breakthrough
in the machining of titanium,
particularly in aerospace
applications, where stable and
safe working environments
are of paramount
importance.
Quaker becomes leading die casting lubricant provider in the USWith the acquisition of GW Smith & Sons, Inc—a leading manufacturer and
supplier of die cast lubricants—Quaker Chemical Corporation became the leading
die casting lubricant provider in the US. The acquired business has net sales
of approximately $14 million. GW Smith’s proprietary formulations of die cast
lubricants, metalworking lubricants and machining fluids are sold through direct
sales, distributors and agents in the US and international markets. GW
Smith now operates as a standalone subsidiary of Quaker.
required to match developments
in the equipment and machinery
industry. In future, while the
developing markets will drive
the lubricanting industry, the
industry will itself be volatile
to the demand trends of the
machining industry.
SPECIAL FOCUSMWF Projection
MODERN MACHINE TOOLS - July 201252
The impact of the recent
global economic recession
reverberated in markets
across the world, in
industries linked, directly
or indirectly, to the epicentre of
the collapse. The MWFs industry,
an integral part of manufacturing,
inevitably shuddered from these
reverberations, particularly in North
American and European markets. Yet,
the drop in demand was momentary,
although growth in Europe reduced to
1.8% CAGR post 2007, since major
regional markets, like in Asia, picked
up through the recession, growing at
3.3% CAGR.
Demand Driver: Asia & the Machine Tool SectorAsia, especially China, has by far the
biggest and fastest growing machine
tool industry globally. In the near future,
India is moving towards becoming one of
the top five consumers of machine tools.
As a direct result, MWFs are expected to
witness a surge in demand in the Asian
markets. With huge manufacturing hubs
established in Asia, the demand for
machine tools is bound to rise, resulting
in a surge in MWF consumption.
Supplementing this, modern machines
and processing equipment function
at higher speeds and temperatures,
demanding better performance, safety
and easy disposal for MWFs, all at lower
costs and volumes.
The largest markets that drove this
growth were Japan, India, China and
Korea, which undoubtedly indicates
that the future of the MWF industry
has shifted to Asia. But as economies
rebounded, major manufacturing
economies in Europe and North America
began recovering, buoyed by growth in the
transportation equipment and automotive
Little over a decade into the 21st century and consumption in the global Metalworking Fluids (MWFs) industry already finds itself driven by burgeoning automotive and transportation sectors. Moreover, the meteoric rise of Asian manufacturing and intraregional trade forecast a bustling 5% CAGR for the continent in MWF consumption leading up to 2015. By then, with over $6,500 million in value, the global MWF industry will see over 2.5 million tonne of lubricants flood the market. Tarun Tampi & Nishant Kashyap track the numbers, drop by drop…
Number Crunching
� Global CAGR through 2015: 3%
� Global expected consumption by 2015: 2.5 million metric tonne
� Removal fluids constitute 50% of total MWFs in use. Forming fluids, protecting fluids and treating fluids make up the rest in that order
� Two-third of total supply comes from 25 major suppliers
Asia-Pacific Region
� Growth rate (through 2010-2015): 5% (China fastest)
� Expected consumption in Asia by 2015: over one million metric tonne
� Largest clients/market sector: Transportation, followed by machinery
� Current total consumption: 891,330 tonne
� Current value: $3,160 million
MWF Projection
July 2012 - MODERN MACHINE TOOLS 53
sectors. As of today, the global functional
fluids market is set to reach $18 billion,
with 2.5 million metric tonne of MWFs
to be consumed annually by 2015.
IndiaIf we consider India alone, the country
has several greenfield steel projects
underway, aggressive automobile and
aerospace sectors are expanding rapidly,
numerous global companies are entering
its markets, and capacity expansion
projects alongside heavy infrastructure
development are underway. As a side-
effect of this progress, the consumption
and application of MWFs and associated
technologies has been rising. Dr AK
Singh, Scientist Emeritus, Specialty
Product, IIP Dehradun, estimates,
“In India, consumption amounted to
nearly 115,830 metric tonne in 2010.
Of this, straight oil and soluble oils are
the major types of MWFs used.” This
growth is in spite of rising crude oil
prices, heavy import dependencies and
the emerging shift from petroleum-
based lubricants to biodegradable
vegetable oil-based lubricants. As the
manufacturing industry leans towards
the adoption of ‘green’ solutions on
their shop floors, the global demand
for ‘green’ fluids is expected to grow by
more than 30%, along with substantial
growth in the overall MWF demand.
M Krishna, MD, Master Fluid
Solutions (India) Pvt Ltd draws a line
through current consumption and the
demand projection, “300,000 drums
is a rough estimate of annual usage of
MWFs in India. Overall, consumption
is dominated by water-miscible MWFs,
amounting to about 70%, while neat
oil contributed about 30%. Within
water-miscible MWFs, soluble oils
and emulsion-based oils account for
about 70% of it, with the balance taken
up by the rising use of synthetic and
semi-synthetic MWFs. In the next five
years, consumption volume could grow
at a CAGR of 15%. With growing
demand and rapid changes in machine
tool requirements, there will be a shift
in the percentage of MWF usage,
especially for water-miscible MWFs.
Additionally, the semi-synthetic and
synthetic-based MWFs will increase
to at least 50% of the total volume of
water-miscible MWF.” All these factors
will provide great opportunities for
MWF manufacturers and distributors
in India, to double their sales and step-
up production.
Highlights from the Kline Report on MWFs Global Series 2010
Market Analysis and OpportunitiesThe MWF market in North America, Asia and Europe is projected to grow at about 3% per year, from 2.1 million metric tonne in 2010, to nearly 2.5 million tonne in 2015.
Asia is the fastest growing market with 5% annual growth from 2010 to 2015. Over these five years, the projection says that the North American MWF market will grow at 2% and that of Europe’s by 1%, annually.
The report focussed on North America (United States, Canada and Mexico), Asia and Europe, whose estimated MWF consumption totalled 2.1 million tonne, valued at $6.9 billion, in 2010.
Since 2007, Asia’s MWF demand, annually, grew 3.3%, while Europe’s slipped 1.8% and North Americas fell 7.8% per year.
North AmericaNorth America’s MWF market amounted to 613,000 tonne in 2010. The United States accounted for 83% of total consumption, Canada for 11% and Mexico 6%.
The North American MWF market had the top 10 suppliers accounting for just 55% of the market. Those were Houghton (12%); Quaker Chemical (10%); Henkel (7%); Fuchs (6%); BP Castrol Industrial (5%); ExxonMobil, Milacron and Metalworking Lubricants (each at 4%); Chemtool (2%); and Master Chem (1%).
AsiaAsia’s MWF market amounted to 891,000 tonne in 2010. In 2010, China accounted for 43% of MWF consumption in Asia, Japan, 24 %, India, 13% and Korea, 10%. Other important Asian markets include Thailand, Vietnam and Indonesia.
EuropeMWF consumption in Europe – including Western, Central and Eastern Europe and Russia – totalled 601,000 tonne in 2010, falling around 1.8% per year from 2007 to 2010.
The European MWF market weathered the storm largely because of Germany (21% of the region’s consumption in 2010) and Russia (23%).
Automotive ManufacturingGlobal automobile production increased from 71.7 million in 2007 to 75.2 million in 2010.
Consumption ASIA EUROPE (including Russia)
NORTH AMERICA
Volume (tonne)
Current (2010): Projection (2015)
891,330 over 1 million
601,100640,110
612,900680,500
Approx Market Value
(Million USD)
Current (2010): Projection (2015)
3,160 over ~3,900
1,550 1,650
1,850 2,043
SPECIAL FOCUSAdvances in MWFs
MODERN MACHINE TOOLS - July 201254
New Test Method to Detect Microbes in MWFsBacteria, fungi and other
microbial contaminants are
a perpetual problem as far as
implementing MWFs is concerned.
Apart from health risks to those working
with such fluids, microbes degrade the
quality of the fluid, reduce its components
in its composition, increase tool wear as
well as corrosion, and can lead to the
formation of biofilms, thus plugging
filters. Conventional dipslide tests to
detect microbial contamination take too
long and can, at best, detect only 0.01–1%
of microbes in the MWF. They are also
limited to samples tested in laboratories,
which may not provide the most
accurate measurement. Hence, a new
method that tests MWFs for microbial
contamination has been developed.
This method can be conducted within
minutes, accurately and on-site. The test
works by measuring the concentration
of Adenosine Triphosphate (ATP), the
main energy-carrying molecule in all
living things. However, before the ATP
is extracted and measured, the MWF
sample is filtered through a 10-micron
filter to isolate bacteria from fungi, and
then through a 0.7-micron filter to isolate
the ATP from the organic chemicals
that may be dissolved in the sample. The
concentration of ATP directly relates to
the level of microbial contamination
in soluble oils and synthetic & semi-
synthetic fluids.
Boron Nanotechnology-based Lubricant AdditiveConventional solid lubricants
are being revisited as the
proliferation of nanotechnology
has led to research looking to use
nano-sized particles as lubricant
additives. One such material is boric
acid whose particles, sized between 50
& 100 nanometers, have been found
to reduce the coefficient of friction to
between 0.02 & 0.1, nearly two-thirds,
for lubricants used on ceramic or
metallic surfaces. They are also easier
to disperse in mineral oil-based stocks
than larger micron-sized particles and
are compatible with most additives
used in making lubricants. Nano
boric acid, however, is susceptible
to agglomeration when exposed to
water, although the technology is
being improved to remedy this as
well. Potassium borate nanoparticles
used in an ester matrix as an additive
result in better lubrication, anti-wear
and extreme pressure performance.
The dispersion of potassium borate
nanoparticles in the ester does not
agglomerate in the presence of water
and is not adversely affected by other
contaminants. It remains stable for
The global decline in fluid sales in the past few years and the ever-widening web of environmental and safety regulations have led the industry to rethink the manufacturing and applicability of Metalworking Fluids (MWFs). Further, the costs of MWFs have increased to constitute almost 17% of a manufacturer’s overall costs, leading to an increase in the number of out-of-the-box innovations and specialised lubrication techniques. Tarun Tampi reports on the various emerging solutions in the MWF industry to improve tool life, reduce wear & costs, and minimise shopfloor and environmental mishaps.
Advances in MWFs
July 2012 - MODERN MACHINE TOOLS 55
three to four years and results in a
coefficient of friction as low as 0.037.
Not only is the boron nanoparticle
containing lubricant additive better
in terms of replacing anti-wear and
extreme pressure additive packages, it
also exhibits some corrosion resistance,
thus allowing the concentration of
corrosion inhibitors to be reduced in the
lubricant mixture. The colour, viscosity
and tolerance to water are better and no
unpleasant odours are detected. Seen as
a replacement for chlorinated paraffin
additives, it can be used at one-third
the treat rate. A key application for
this nanoparticle containing boron
additive is in lithium greases, where it
has brought significant improvements
in the treat rate.
To Get More from Less…Over the last 20 years, the
disadvantages of metal-cutting
fluids and machining lubricants
have begun to weigh heavily against
the advantages. Reduced friction, wear
and corrosion were convincing positives
until MWFs were shown to pose serious
risks to health and environment. With
permissible exposure limits increasing
in their severity, along with the ever-
widening web of regulations, standards
and management practices, MWFs are
beginning to lose their lustre. At the
same time, in order to stay competitive,
manufacturers are looking to reduce
costs, of which MWFs form a growing
chunk, while simultaneously improving
productivity.
“From the machining perspective,
the MWF sector is at a nascent stage,
but growing at a rapid pace, moving
priorities from the ‘Need for Cost’ state
to ‘Need for Performance’ state. The
Indian industries growing globally,
feel the need for better productivity,
better process control beyond
machine parameters, better machine
maintenance and more advanced
machine tools. All these broaden the
spotlight on innovating and extract
better performance from MWFs,”
says M Krishna, MD, Master Fluid
Solutions (India) Pvt Ltd.
…by Dry Machining This has led to the increasing
prevalence of various machining
processes that are run ‘dry’,
without using MWFs. Although
the heat generated and questionable
surface finish were concerns in dry
machining, improved tool coatings
with impressive thermal properties, like
TiAlN, are making dry machining more
feasible. Milling and boring processes are
inherently more suited to dry machining,
whereas drilling, tapping and other
closed-face operations are still difficult to
perform dry due to chip removal issues.
Material has also been an issue for this
technique since several high-end alloys
and materials, like titanium, could only
be machined in the presence of cutting
fluids due to the quantity and temperature
of the heat generated. However, materials
that react with water, like magnesium,
can only be machined dry. Considering
all this, the use of dry machining is
becoming increasingly suitable if carefully
customised to the machining process, the
workpiece material and the tool.
…or Minimum Quantity Lubrication (MQL)Given that dry machining still
has some notable limitations,
near-dry machining or micro-
lubrication is a far more attractive
solution. If minimal quantities of oil-
based or vegetable oil-based coolant are
used, at flow rates around 50–500 ml/h,
and applied directly at specific points
between the tool and workpiece, then
huge savings in fluid, machining time
and costs can be made. Also known as
MQL, the aim is to maintain a thin
film of oil that will lubricate the cutting
surface, sometimes one drop at a time,
applied externally or through the spindle
and holes in the tool. For high-speed
carbide tools, MQL has been found to be
the most efficient method for lubrication
in terms of wear, tool life and accuracy.
The costs related to cutting fluids are
frequently higher than those related
to cutting tools. One study found that
Ford had reduced its costs by 13% when
MQL was implemented. The cutting
performance using MQL is far better
than when conventional flood-cutting
fluid supply is used since it reduces
the cutting temperature, improves
chip–tool interaction, reduces wear
and damage to the tool, and improves
dimensional accuracy in machining.
Moreover, most MQL lubricants
are biodegradable, thereby making
the technique environment friendly.
Globally, several companies, particularly
in Europe, retrofit MQL systems to
existing machining centres. HAAS
Automation also offers a Minimum Oil
Machining (MOM) as an option for its
machining centres.
Neat Oils, Emulsions & the EnvironmentMilky fluids are a factory
feature of the past. Synthetic
esters have long replaced mineral
oils and consequently increased sump
life. The same fluid can now be used for
over three years while extending tool life
and reducing corrosion. Tramp oil issues
have been largely dealt with as modern
day emulsions do not pick up tramp
oil, while still maintaining performance
and reliability. Further, environment
and regulatory measures have led to the
development of advanced emulsions, far
less prone to mist formation. Neat oils
are still most suitable for a variety of
low-speed applications, having become
lighter in colour, less prone to smoke,
odour and mist, and are inherently much
easier to recycle.
“Keeping environmental concerns,
improved performance, consistent
structure and characteristics in view,
there is a need to develop alternative
lubricants and emulsifier components
for soluble oils, which are biodegradable
and less toxic. Particularly those
developed from renewable sources,
like vegetable oil, show equivalent
performance properties to mineral
oil-based or synthetic lubricant-based
soluble oils. Biodegradable MWFs will
solve the disposal problem as well,”
says Dr AK Singh, Scientist Emeritus,
Specialty Product, IIP Dehradun.
SPECIAL FOCUSOccupational Hazards
MODERN MACHINE TOOLS - July 201256
Reduction of heat, friction
and removal of metal
pieces during machining
operations are the key
roles of Metalworking
Fluids (MWFs). They can be complex
mixtures of oils, emulsifiers, anti-weld
agents, and other additives. However,
the fluid gets compounded with the
contamination of substances from the
manufacturing process, such as tramp
oils and hydraulic fluids.
Water-based MWFs support
microbial growth, which introduces
biological contaminants and their
related biological byproducts, such as
endotoxins, in the fluids. A worker
is constantly exposed to the fluids by
breathing aerosols generated during
the machining process, or through skin
contact with them while handling the
tools and equipment.
Health Ailments Exposure to MWFs causes a range of
ailments, some of which are as follows:
Respiratory disorders: Hypersensitivity
pneumonitis, chronic bronchitis and
impaired lung function are some major
respiratory ailments caused by MWFs.
Work-related asthma is another most
prevalent occupational disorder. Water-
based MWFs are excellent sources
of bacteria and fungi, which cause
respiratory problems in the exposed
workers. A proper MWF system
management programme needs to be
maintained on shop floors which should
include fluid monitoring, record keeping
and maintenance, proper mist control
including close-capture ventilation,
machine enclosures and training
employees on the hazards and proper
use of MWFs.
Dermatological disorder: A direct skin
contact with MWFs causes allergic and
irritant dermatitis. Folliculitis, oil acne,
keratoses and other allergic reactions are
some other dermatological disorders.
Most shop floors need to incorporate the
following preventive measures:
� Use of safe, less irritating and non-
allergenic additives or MWF
� Process modification and isolation
to limit the dispersal of MWFs
� Work practice and administrative
controls to assure the proper MWF
Cancer: Studies show that some MWFs
increase the risk of larynx, rectum,
pancreatic, skin, scrotum and bladder
cancers.
Measures to be Taken According to the National Institute
for Occupational Safety and Health,
exposures to MWF aerosols should be
limited to 0.4 milligram per cubic metre
of air (thoracic particulate mass) or 0.5
milligram per cubic metre of air (total
particulate mass), as a time-weighted
average concentration up to 10 hours
per day during a 40-hour workweek.
Some important measures that need
to be taken are as follows:
Fluid selection: The MWFs selected
should be non-irritating and non-
sensitising. Petroleum-containing
MWFs should be evaluated for potential
carcinogenicity. Water-miscible
MWFs should be checked for safe-use
guidelines. To minimise nitrosamine
formation, nitrate-containing materials
should not be added to MWFs
containing ethanolamines.
Fluid use and application: Mist
generation should be minimised. Most
machines today are incorporated with the
necessary mist controllers to minimise
mist dispension during the process.
Fluid maintenance: An MWF
management plan that includes
maintenance of the fluid chemistry,
fluid filtration and delivery systems
should be developed. MWFs should be
maintained at low temperatures to slow
down the growth of microorganisms,
reduces water loss and change in
viscosity, and reduce fire-hazard risks in
the case of straight oils.
Alternative FluidsGiven the various issues related to the
use of MWFs, most manufacturers
are accepting Minimum Quantity
Lubrication (MQL) as an option. MQL
is an environmentally viable technology
that helps in reducing manufacturing
costs. It is the process of applying a small
amount of a quality lubricant directly
into the cutting tool workpiece interface
and is effective in a wide variety of metal
cutting processes, including sawing,
turning, milling, drilling and tapping.
According to one study, the use of MQL
led to a 13% decrease in overall costs.
It also led to better cutting tool life,
a significant fluid reduction, reduced
costs of coolant handling, decreased
maintenance and an increase in machine
uptime. Most Indian manufacturers too
are focussing on the benefits of MQL in
manufacturing technology.
Making FluidsHealth-
FriendlyWhile metalworking fluids are one of the significant ingredients of smooth machining, they are also a source of various health ailments on the shop floor. Debarati Basu brings out the measures to curb health hazards…
Mod
ern
Mac
hine
Too
ls (J
uly-
2012
) - F
ront
-Pg
57
Modern M
achine Tools (July-2012) -Pg58
Mod
ern
Mac
hine
Too
ls (J
uly-
2012
) Ins
ert 1
0 - F
ront
-Pg
59
Modern M
achine Tools (July-2012) Insert 10-Pg60
Mod
ern
Mac
hine
Too
ls (J
uly-
2012
) - F
ront
-Pg
61
Modern M
achine Tools (July-2012) -Pg62
SPECIAL FOCUSMist Control
MODERN MACHINE TOOLS - July 201264
Metalworking fluids are
used to cool, lubricate
and remove metal chips
from tools & metal
parts during grinding,
cutting and boring operations. Straight
oils, water-based oils, synthetic and
semi-synthetic fluids are the most
commonly used MWFs. Except for the
straight oils, all other MWFs are mixed
with water before use. However, using
MWFs in the technological process of
metalworking often generates aerosols
by atomisation, and this mist stream
represents a significant hazard to the
workers and the environment.
MWFs are complex mixtures and
some of their ingredients can be toxic.
Without adequate precaution, bacteria
and fungi can start growing in these
mixtures, especially if the fluid has been
used for a long time. Heavy metals
can also build up and become highly
concentrated over time.
Health Risks and Preventive Techniques MWFs can cause adverse health effects
through skin contact with contaminated
materials, spray or mist and through
inhaling MWF mist or aerosol. The
severity of health problems caused by
MWFs depends on a variety of factors
such as the type of fluid, the degree and
type of contamination, and the level and
duration of the exposure.
Failure to control MWFs has long
been associated with work-related
health problems, such as work-related
asthma, bronchitis, irritation of the
respiratory tract and other breathing
difficulties. It can also cause extrinsic
allergic alveolitis following repeated
exposure, which can result in severe
breathing difficulties in recurrent
episodes. Exposure may also cause
irritation to the eyes, nose and throat.
Many companies are making
Metalworking Fluids (MWFs) can cause adverse health effects through skin contact with contaminated materials, spray or mist and through inhaling MWF mist or aerosol. Workers engaged in the manufacture of automobiles, farm equipment, aircraft, heavy machinery and other hardware are exposed to the harmful effects of machining fluids. This has forced companies to adopt various mist-control programmes at their shop floors. Here, Nishant Kashyap discusses the different methods that are used to control and prevent the formation of mist.
HEALTHY MANUFACTURING Techniques for
Mist Control
July 2012 - MODERN MACHINE TOOLS 65
efforts to create greater awareness
about the problems as part of their
employee-safety programmes and are
actively targeting respiratory diseases
caused by inhaling MWF mists,
including bronchitis and asthma. To
achieve this end, many techniques
have been successfully implemented in
the industry. Some of the preventive
techniques are as follows:
� Use splash guards, where provided,
to control splashing and misting
� Minimise the production of mist and
vapours by controlling the volume
and rate of delivery of the fluid to
the cutting edge of the tool
� Use enclosures or ventilation to
remove or control any mist or vapour
produced
� Allow a time delay before opening
the doors of machine enclosures to
ensure that all mist and vapours have
been removed by ventilation
� Do not use compressed air to remove
excess MWFs from the machined
parts, plant or equipment.
However, mist- and vapour-control
programmes have not been properly
implemented in the small job shops;
they still lag far behind in applying the
required safety norms.
Mist-control ProgrammeVarious factors are responsible for
the formation of MWF mist in the
atmosphere of different manufacturing
industries. Some such factors are
high-speed dynamic forces involved
in machining operations, the chemical
composition of fresh fluids and
contaminants that enter fluids from
extrinsic machinery sources. The latter
considerations are important in the
design of devices for efficient removal
of mist from the workplace. M Krishna,
MD, Master Fluid Solutions (India) Pvt
Ltd, says, “In water-miscible cutting
fluids, the root cause of smoke and mist
on the shop floors is the high tramp
oil content in the coolant. Companies
need to ensure that the tramp oil level
in the coolant is maintained properly.
This can be done by reducing the tramp
oil contamination as much as possible in
the lubrication system leakages. Regular
cleaning of the MWF is also a good
measure to ensure that the coolant is
always cleaned. Our coolant recycling
equipment can help ensure that the
coolants in the machines are always as
good as new coolants.”
The role of tramp oil in the
formation of MWF mists in the
atmosphere of machining operations
is significant for all types of fluids.
Therefore, an effective mist-control
programme should include maintenance
measures to reduce the amount of fluid
leakage from machinery. Also, prudent
housekeeping, adequate ventilation and
mist enclosures can work together to
provide a comprehensive system of mist-
reduction practices. Proper utilisation of
chemicals and creating awareness among
the workers are some other mist-control
programmes.
Current TrendsWith greater emphasis on the reduction of
carbon footprints, several manufacturers
are experimenting with vegetable oil-
based coolants in their day-to-day
activities, as mineral oil and synthetic
alkanes are not appropriate to be used
as the base oil for environment-friendly
cutting fluid. This is because they have
poor biodegradability, and as a result,
they remain in the environment for a
long time causing pollution. Vegetable
oils and synthetic esters, on the other
hand, possess good biodegradability
and are thus safe. Pratap Marathe,
MD, Pratap Tex-Chem Pvt Ltd, says,
“Selection of base oils and additives to
ensure environmental aspects is a very
important factor, since it has become
absolutely necessary to take care of our
nature and deteriorating environment.
Therefore, we have to be constantly in
touch with the developments happening
in this field. For instance, the industry
is gradually implementing the usage of
esters and naphthenic base oils instead
of gum rosin and conventional base
oils, respectively, as they are easily
disposable and less harmful. The latest
advancement is the usage of synthetic
esters instead of mineral base oils
to save the reducing crude oil stocks.
Thus, we can divert these stocks towards
making fuel for vehicles, planes, etc.,
and buy time till we find an alternate
solution. Moreover, synthetic esters
have a single boiling point unlike
mineral oils that have variable boiling
points, and therefore, while machining
at elevated temperatures, they yield
excellent lubricity with less coolant
evaporation.”
Looking AheadIt is in the interest of industries to
provide a healthy environment to their
workers. In this regard, numerous
improvements have been made in
MWF products, engineering controls,
anti-misting technologies and industrial
hygiene procedures to reduce workplace
mists. It is noteworthy that many of
these advancements have been achieved
as a result of cooperative efforts between
MWF manufacturers and the end users.
As the science of MWF mist generation
is better understood, the industry can
expect more improvements in mist-
reduction technologies. At the same
time, we cannot employ similar methods
to control MWF mists and mineral oils,
as they are clearly different materials
and any considerations to pose limits
on them in a similar manner is neither
scientifically sound nor in the interest of
workers’ health.
How to Prevent Mist Generation
� Minimise the fluid delivery
pressure
� Match the fluid to the
application
� Use MWF formulations with
low-oil concentrations
� Avoid contamination with tramp
oils
� Minimise the fluid flow rate
� Cover the fluid reservoirs and
return systems wherever possible
� Maintain control of the fluid
chemistry.
SPECIAL FOCUS6C—Metalworking Fluid Management
MODERN MACHINE TOOLS - July 201266
If we perform a root cause
analysis for bad odour, skin
irritation, tool life, corrosion,
residue, paint peeling off, foam,
etc., from amongst the most
probable causes, such as concentration,
pH, water quality, tramp oil, filtration,
etc., we will find that there is a high
interaction among these variables. This
makes it difficult to pinpoint the root
cause. Hence, many times, a solution
to a specific problem in one company
may not yield the same result in another
company. In such scenarios, one of the
best proven and the most economic
methodologies in problem solving is to
have good preventive measures through
systematic approach to ‘Periodic Fluid
Management’ that will address all
the probable root causes within its
operational limits.
6C ConceptThe coolant management concept,
described here as ‘6C’, is a fundamental
and systematically choreographed
process for effectively managing
Metalworking Fluids (MWFs) and
holding the variables within
their operational limits, so that
productivity and performance
could be increased in all forms of
metalworking applications.
We start with the assumption
that the right coolant has been
selected for the application.
This is because the
coolant selection
p roce s s i s
‘ a p p l i c a t i o n –
m a n u f a c t u r e r ’
dependent. As the
process variables
are relatively
l a r g e a n d
highly interactive,
the same coolant may
not be necessarily suitable for
the same application across
different industry segments, or
sometimes, even within the same
industry at different locations.
Hence, coolant selection must
be done in conjunction with the
manufacturer. However, the 6C-MWF
management concept presented here is
generic and application–manufacturer
independent.
With these facts, let us now move to
individual ‘Cs’.
1C
Circulation
The method of mixing for circulation
forms an important process in the
coolant management cycle. ‘Premixed
coolant’ addition is generally the best
way to add new coolant in the machine.
This ensures homogeneity in the fluid.
Premix is done either through automatic
mixers or is mixed manually. While
handling emulsion products by hand,
one must ensure to add coolant OIL
(Oil In Last) in the agitated water to set
the fluid emulsion. This fluid emulsion
has small oil droplets suspended in
water phase that penetrate the point
of cut better and reduce carry off of
the fluid system. (Adding water to the
coolant oil will form reverse emulsion or
thick emulsion and is not what we want
to achieve!)
Thus, the 1st C of the
‘6C’ concept emphasises
the importance of having
good mixing and circulation
process, which form the
basis for realising effective
coolant value. It is generally
recommended to use an
automated mixer,
which could
be a low-end
venturi type
or high-end
proportional
pump, for
good mixing
and circulation.
2C
Controls
This ‘C’ is also the dashboard
of the Coolant Management
System (CMS). Therefore, most
of the coolant manufacturers or
service providers claiming to
provide coolant management
service focus only on this segment
The significance of Metalworking Fluids (MWF) is widely recognised, but very often treated only as a support function that is necessary, but not important. The average MWF cost in any industry lies approximately between 10% and 20% of the total production cost. Any lapse in fluid management, starting from the selection of right fluid, will result in failure in terms of quality issues and will also deteriorate the machine tool. To manage this important contributor, the industry must possess a robust management system.
Spraying Edge to Manufacturin
g 6C
CIRCULATION
CONTROLS
CONTAMINANTCLEANLINESS(SUMP)
CLEANING SCHEDULE
RECYCLING
6C—Metalworking Fluid Management
July 2012 - MODERN MACHINE TOOLS 67
of the 6C concept. The ‘Control’ section
is critical to ensure that the machine
tool sump is monitored for coolant level,
coolant concentration and coolant pH.
As water constitutes anywhere between
85% to 95% of the end coolant, the
water quality parameters need to be
monitored at least weekly or with an
increased frequency, depending on the
water source being used.
This ‘C’ is only the beginning of
CMS, but, for many, it is also the end
of CMS. It is up to the end user or the
customer to impress with their CMS
providers to look and move beyond this
‘Control C’ to complete the coolant
management cycle.
3C
Contaminant
The most common reason for many
MWF failures is contamination, or
rather the ‘unattended contamination’.
The two major contaminants are tramp
oil and metal chips & fine particles. In
a machine tool, it is rather economical
to have some system to remove or
reduce contaminants than preventing
the contamination itself. The coolant
dynamics in the machine should
first be properly understood before
selecting appropriate automatic tramp
oil removal and metal chips removal
systems. It is suggested that the end
user, in conjunction with the coolant
manufacturer, should decide the most
suitable methodology for automatic
contaminant control and have the
system installed.
4C
Cleanliness (Sump)
The cleanliness requirement of the
sump is the most important factor but
is the least attended to, as the machine
will have to be taken down for a
considerable time for cleaning the sump.
Moreover, designers of machine tools
often overlook the necessity for a good
accessible sump design for cleaning.
In many cases, the sump is a ‘design
filler’ and takes all sorts of geometry
that cannot be accessed by humans.
Moreover, cleaning is undertaken only
when the machine is down, thereby
not giving enough time for justifiable
cleaning action.
For effective cleaning within
the available cleaning time, it is
recommended to use such sump cleaners
that could completely empty the sump,
clean particulate matter to, say, 50
micron (commonly used filter size), and
charge back again into the tank either
manually or automatically. In this way,
the automation system will be much
more effective and the complete cycle
for a 1,000-litre sump cleaning will be
anywhere between 20 and 30 minutes.
On the other hand, the manual method
would normally need more than 4–5
hours. In this way, cleanliness could
well be achieved with good returns on
investment.
5C
Cleaning Schedule
Along with good cleaning, a sustained
cleaning schedule that ensures cleanliness
of the sump on a continual basis is
also essential. This scheduling could
be a part of Preventive Maintenance
(PM) or Conditional Monitoring
(CM) schedules. The adherence to the
schedule should be driven from top-
down, otherwise this will become just
a cleaning activity. Thus, ‘cleanliness’
is an activity and ‘cleaning schedule’
is a commitment. This could be
implemented through TPM.
6C
Recycling
Recycling is a well-planned and
executed activity on a continual basis for
enhancing the performance of a coolant
by increasing its useful life, which, in
turn, enhances the machine-cutting
performance, finally contributing to
greener initiatives by reducing the
disposal of coolants. All these, of course,
give better returns to shareholders.
We need to understand that
recycling does not transform old
coolant into a new one; it merely
reconditions the used coolant by
removing solid particles, contaminants
and tramp oil through recycling and
adding the necessary additives to
control the microbes. Thus, we need
to understand that the coolant that has
lost its efficacy cannot be brought back
to life through recycling. Another myth
about recycling is that the coolant’s
life becomes infinite by continuous
recycling. This is not the case; a coolant
has a designed life expectancy and it has
to be disposed of at the end of its life.
The recycling will only ensure that we
get the designed life expectancy of the
coolant. ‘Recycling’ is not ‘reclaiming’
of coolants. Therefore, a well-planned
and scheduled management programme
is necessary for recycling.
Wrapping UpMost of the organisations execute
2nd C—‘Controls’, wherein a chart is
displayed by the service provider in terms
of three or four controllable factors and
updated daily. This is done religiously
and rigorously without failure, as any
slippage on this ‘C’ will directly affect
the production. The other Cs do not
directly affect the production, but do
affect productivity and performance,
and as a result, the profit. Hence, a true
CMS must focus on all the 6Cs.
It is necessary that any (new)
business concept or philosophy should
be a set of simple principles/activities
put together in a choreographed
sequence of processes to address the
3Ps of business—business productivity,
business performance and business
profitability. The ‘6C’ MWF
management addresses all the 3Ps of
business, both directly and indirectly.
In terms of production, availability,
performance and quality are considerably
improved, thereby improving overall
equipment effectiveness. In other
words, 6C is an important component
of TPM activity, contributing to
increased business sustenance.
M Krishna, MD, Master Fluid Solutions (India) Pvt Ltd. He has over 27 years of progressive business experience. He is also a ‘Six Sigma’ and ‘Lean’ exponent with over 12 years of hands on implementation and training expertise.
SPECIAL FOCUSCutting Fluid Costs
MODERN MACHINE TOOLS - July 201268
The costs of Metalworking
Fluids (MWFs) have risen
over the last few decades, and
today, account for 10–18%
of the total production costs.
This has become increasingly significant
given that fluid sales declined in 2009,
the variety of fluids available in the
market has decreased, and costs
of raw materials have increased
along with purchasing costs
for MWFs. Moreover, stricter
environment and health
regulations have also placed
a huge burden on MWF
manufacturers and users.
Worldwide, over 2 billion
litre of MWFs are being
used annually, and this is
after taking into account
only the concentrate
volumes (excluding
the volumes used after
dilution that could be 10
times more).
Understanding the CostsThe costs involved
in MWFs go far beyond
just the purchasing costs.
Purchasing costs vary depending on the
price and supply of base oil, additives
and emulsions, and these costs have
been rising due to continuous increase
in the cost of crude oil and fluctuations
in the global economy. Yet for end
users, MWFs have a far bigger financial
effect, apart from the cost
of purchasing, in
their Total Cost of
Ownership (TCO). This TCO involves
hidden costs and performance leverage.
The hidden costs can be attributed to
fluid management (from procurement
to implementation), shop floor
maintenance, performance monitoring,
waste treatment and disposal.
Performance leverage costs arise from
the efforts used to ensure optimal
functionality from MWFs, process
quality, tool life, scrapping, reworking
and rejecting parts. Syed Md Samim,
Marketing Manager, Quaker Chemical
India Ltd, explains, “There are many
components in considering overall fluid
usage costs. As MWF demands change
and costs increase, it is imperative for
plants to implement a fluid
management programme.
In today’s competitive
markets , cus tomers
must continuously seek
improvement in their processes
to raise productivity, lower
costs, maximise efficiency
and generate more income.
You want partners to help
deliver all of these”. “We
have repeatedly demonstrated the
fulfilment of these objectives. Day in
and day out, everywhere in the world,
Leonardo da Vinci was the first to use lubricants and lay down the importance of tribiology. Its importance has grown steadily over the centuries. With over 2 billion litre of lubricants being used worldwide annually, the need and consumption of metalworking fluids (MWFs) have been firmly established. However, the downside is that the costs of lubricants have risen exponentially. Tarun Tampi and Nishant Kashyap look at how effective fluid management, customer collaboration and innovations in MWF technology can help in halting the rise in cost.
Cutting Fluid Costs
July 2012 - MODERN MACHINE TOOLS 69
we provide high-quality products, which
we incorporate into a unique offer of
teamwork, service, application know-
how and ongoing support. The result is
superior value for the customer, expressed
in lowered total cost, a combination
of chemical products, services and
technical expertise that help establish
sustainability, improve performance
& achieve a safe work environment,”
Samim adds.
Coolant Cost Vs Total Cost Per ComponentIn the recent years, there has been a
paradigm shift from coolant cost to total
cost per component and productivity
with MWFs, which is
significantly high and
more relevant in today’s
competitive market.
Manufacturers value and
acknowledge high-cutting
performance as the most
essential aspect of a
coolant. The industry is
focussing increasingly on
being more efficient in
every way. The cleaner
an MWF delivered to
the cutting zone is, the
greater the machining
performance and the
lower the cost per part
will be.
The main focus area for industry
has been to work on high cutting
performance with the help of better
lubricity in coolants and cutting oils.
It has been noticed that cutting-tool
cost is high as compared to the coolant
cost on all CNC machines, and hence,
focus on maximising tool performances
has increased. The net saving effect
can be higher as compared only to
the oil cost. Therefore, the focus for
continuous development in the coolant
industry will remain performance.
According to M Krishna, MD, Master
Fluid Solutions (India) Pvt Ltd,
“There are direct and indirect costs
involved in using MWFs. The direct
costs include coolant cost, tool cost
and rejection cost; while the indirect
costs include waste treatment, machine
downtime, maintenance cost, labour
cost and investment cost. Premium
quality coolants and proper coolant
management practices mean that the
coolant will perform better, will be
cleaner and its useful life will be longer.
A cleaner coolant will directly benefit
as it will have better lubricity, lesser
carry-off, better corrosion protection
and better dimensional accuracy &
repeatability. Other benefits that
contribute to increased profitability
arise from lesser consumption, lesser
disposal costs and improved machine
performance. Availability, performance
and quality will improve to get the user
a better overall equipment effectiveness
(OEE), and thus better capital and
capacity utilisation.”
Enhancing PerformanceA company needs to have an efficient
lubrication programme in place to
get maximum productivity from its
machines. A well-lubricated machine
constitutes an integral part of such a
programme. Without administering the
proper amount of lubricant at correct
intervals, a machine can experience
serious performance failures, resulting
in costly remedies. A centralised
lubrication system is a common tool
used in the industry to distribute a
precise amount of lubricant to specific
locations at a particular time by using
programmable timers, lubricant
pumps and lubricant injectors. Samim
highlights the need to have in-house
expertise for the customisation of MWFs
to suit a company’s requirements. “The
metalworking fluid specialist should
have the knowledge to grasp the unique
metalworking issues first, and then
identify areas where a change in fluid
could reduce the overall costs. MWF
manufacturer can then custom-engineer
fluids that enable the process to deliver
improved efficiencies with reduction in
total cost per unit, scrap/waste, operation
downtime and increment in productivity
and tool life,” Samim explains.
A company may use the best cutters
and the best coolant medium available,
but if the flood coolant is not
aimed precisely at the cutting
edge of each tool, it results
in the wastage of time and
money. “Metalworking fluid
manufacturers need to focus
on offering innovative products
that are cost effective and satisfy
customers’ changing needs. A
collaborative approach with
customers with increased focus
on research and development
and enhancing services would
go a long way to give a boost to
this market,” avers Samim.
Wrapping UpA host of eco-friendly solutions and
productivity-driven innovations have led
to the use of newer types of fluids, such
as macro-emulsions, semi-synthetics,
synthetics, biodegradable oils, etc., in
the the manufacturing sector. With
the growth of automotive, aerospace
and construction sectors in developing
countries, the demand for MWFs is
on the rise. Thus, it becomes all the
more important that end users reassess
their approach towards MWF usage,
i.e., they should be open to use semi-
synthetics, synthetics, etc., instead of
MWFs and work towards extracting
more with less while employing better
reuse and recycling methods to optimise
the material and investment.
Cutting Tools 4%
Coolant 8-16%
14% Coolant
EnergyPersonnel
Equipment
Disposal
Other
7%
7%
10%
40%
22%
Other Cost
� A break-up and distribution of coolant costs in manufacturing.
SPECIAL FOCUSOne Q Many Views
MODERN MACHINE TOOLS - July 201270
Cryogenic cooling, the latest in coolant technology, delivers liquid nitrogen through cutting inserts at -3210 F with a flow rate of 0.1 L/min per cutting edge. It dissipates heat like never before, extends tool life and increases material-removal rates. It provides a fresh, ‘cool’, approach to machining without liquid coolants, although like any other technology, it comes with a mixed bag of benefits and drawbacks. Tarun Tampi speaks to industry experts...
Cryogenic machining tests have achieved a 60% increase in speed
while milling Compacted Graphite Iron (CGI) with carbide,
and up to four times using Poly-Crystalline Diamond (PCD)
tooling. Additionally, with Minimum Quantity Lubrication
(MQL), we tripled speeds with carbide. We have focussed on
higher material removal rates, while keeping tool life equal to
what would be achieved with conventional wet coolants. This
technology dramatically improves the lifecycle cost for cutting
difficult-to-machine materials by reducing the required number
of machines and associated plant infrastructure, or possibly
increasing tool life beyond anything thought possible today.
It becomes even more competitive when you consider that it
is a ‘green’ technology. There is no coolant mist collection,
filtration, wet chips, contaminated workpieces or disposal cost,
and certainly less energy consumption without all the pumps,
fans and drives that go into handling coolant.
The limitations outweigh the benefits. First of all, obtaining
liquid nitrogen is a costly affair. Then, cryogenic cooling will end
up managing heat at the tool itself, instead of at the workpiece.
Hence, it results in comparatively high temperatures at the
surface of metal workpieces, thereby causing work hardening.
Further, the problem of corrosion on new metal surfaces will
not be resolved. Additionally, the issues of lubricity and chip
removal will also remain unresolved.
Eswari Prasad, President, MAG India
Dr AK Singh, Scientist Emeritus, Speciality Product, IIP Dehradun
an EMERGING ALTERNATIVE to MWFs?
It is an interesting concept,
but like other alternative
technologies (refrigeration
without using a compressor), it
needs to be proven, practically,
apart from the cost factor. The
question is if it can replace
not just cutting (lubricity and
cooling), but also non-cutting
functions of conventional
metalworking fluids (MFWs),
such as corrosion protection,
viscosity, oxidative and
hydrolytic stablising, etc.,
which go a long way in adding
to the quality of a machined
part. However, like any other
industry, MWFs will also
come out with options to
handle these innovations.
M Krishna, MD, Master Fluid Solutions Pvt Ltd, India
Verdict
Although cryogenic machining is not being seen
as a direct substitute for liquid MWFs, it could
still replace conventional coolants and lubricants
as a standard in several applications. With easy
retrofitting of existing machines becoming
possible, the benefits of cryogenic cooling (if
used along with MQL) like lower overall costs,
longer tool life, fewer health & environmental
risks, lower maintenance, etc., can be availed of
by any manufacturer.
MM
T Ju
ly-2
012
A
d N
ame:
Bla
ser
Pg N
o. 7
1
MM
T July-2012 Ad N
ame: O
bject Pg No. 72
MM
T Ju
lye-
2012
A
d N
ame:
Jyot
i Pg
No.
73
MM
T July-2012 Ad N
ame:N
eway Pg N
o. 74
SPECIAL FOCUSBiodegradable Fluids
MODERN MACHINE TOOLS - July 201276
The industry has long
been using mineral- and
petroleum-based oils as
the standard. However,
petroleum-based soluble oils
suffer from inherent limitations, such
as high toxicity to the environment,
poor biodegradability and inconsistent
characteristics with change in crude
oil composition. The disposal process
for such oils also adds an extra
financial burden to the users in the
manufacturing industry. As a result,
synthetic lubricants are increasingly
being used as an alternative to the
mineral- and petroleum-based oils.
Synthetic lubricants are especially
useful for use in extreme conditions of
temperature, pressure and radiation.
Some commonly used synthetic
lubricants are polyglycols, phosphate
esters, silicones, polyalpha olefins,
etc. However, synthetic lubricants can
also be toxic to the environment and
are not readily biodegradable, with
similar disadvantages to those found
in petroleum sulfonates and other
petroleum-based emulsifiers.
“In formulating eco-friendly
MWFs, the selection of the right
additives and components in the proper
ratio is a unique factor. Apart from
the vegetable oil base, emulsifiers and
additives should also be eco-friendly and
low cost. To strike a balance between
eco-friendliness, performance, cost,
availability in concentrated form, ease
of disposal and health issues, is not
easy task. This biodegradable MWF
is free from phosphorous, chlorine
and sulphur, with neem oil acting as
a natural fungicide. Emulsifiers are
obtained from natural products such as
oleates, sugar esters and rosin. Other
biodegradable MWFs are generally
based on synthetic esters, although this
increases the cost of MWFs,” says Dr
AK Singh, Scientist Emeritus, Specialty
Product, IIP Dehradun.
Biodegradability in MWFsThe biodegradability is primarily
determined by measuring the loss of
extractable hydrocarbon or complete
breakdown into CO2, H
2O, inorganic
salts and/or microbial biomass.
Vegetable oils are more prone to
microbial deterioration. This can be a
benefit when disposing of operationally
exhausted fluids, which can be
biocatalytically broken down by micro-
organisms using bioreactors.
Lubricating fluids usually have the
following composition:
� A base oil
� Emulsifier (if miscible)
� Extreme pressure (phosphorous and
sulphur compounds)
� Anti-wear and other additives,
which include corrosion inhibitors,
oil fog reducing additives, oxidation
inhibitors, etc.
For vegetable oil-based fluids, the
base oils often used are canola, rapeseed,
soybean and sunflower. They are used
in, more or less, the same application
areas as the conventional MWFs. They
are used as metal-removal fluids, metal-
protecting fluids and in conventional
hydraulic oils, gear oils, way oils, spindle
oils, and so on.
Global warming, limited oil reserves, environmental & industrial safety regulations, changing priorities in corporate ethics and government policies are driving the trend towards renewable lubricant technology, biodegradable metalworking fluids (MWFs) and other biomaterials. With IIP Dehradun indigenously developing a patented vegetable oil-based fluid, Tarun Tampi takes a look at the state of biodegradable fluids and what it means for India.
Vegetable Oils Turn
Biodegradable Fluids
July 2012 - MODERN MACHINE TOOLS 77
Advantages and DisadvantagesBoth mineral oils and vegetable oils
have advantages as well as disadvantages.
They are:
� Lubricity
Mineral oils have poor lubricity
as compared to vegetable oils.
Moreover, they carry a slight polar
charge that draws the vegetable oil
molecule onto the metallic surface.
This bond is strong and protects
vegetable oils from being wiped off.
No such charge exists for mineral
oils, and therefore, they tend to
adhere less tightly to a metal surface.
� Flash point
The flash point for vegetable oils
is higher, which means that fluids
based on these oils are less prone to
smoke formation and have a lower
risk of fire.
� Oxidative stability
Mineral oils are far more stable
and less prone to oxidation than
vegetable oils. As a result, vegetable
oils tend to form sticky and thick
polymerised residues, and can be
hard to clean. Their viscosity and
lubricating ability can also change.
However, this disadvantage of
vegetable oils has been turned to
an advantage and has led to new
applications as grease for guideways,
trucks, machinery, and so on.
Under heat, both will oxidise, but
vegetable oils are more prone to
oxidation.
� Hydrolytic stability
Vegetable oils, which are composed
of triglycerides, tend to break into
fatty acids. These broken down
components act differently from
the original vegetable oil. However,
mineral oils are resistant to such
hydrolytic reactions. Nevertheless,
innovations in biotechnology have
led to the development of genetically
enhanced oilseeds that are naturally
stable and may eliminate such
problems. These stability problems
can also be overcome by using
additives, like antioxidants, or
by chemically modifying the
vegetable oils.
� Viscosity index (VI)
VI measures the viscosity of the
fluid. Mineral oils are fairly viscous.
Yet, vegetable oils have far better
viscosity, particularly at high
temperatures. For example, soybean
oil has VI of 223 as opposed to
90–100 for mineral oil.
As machining temperatures rise,
the viscosity of vegetable oils decreases
far slowly than that of mineral oils.
Similarly, as temperature falls, vegetable
oils remain more fluid than mineral
oils, resulting in quicker drainage
and removal of metal chips from the
workplace. The higher VI of vegetable
oils ensures that they will provide
more stable lubrication across a range
of operating temperatures. The high
viscosity also means that vegetable oils
can be used as lubricants for guideways
and gears in machine tools.
India and Biodegradable FluidsIn India, over 50,000 kilolitre of MWFs,
developed from mineral oil bases, are
consumed annually. The rising costs of
crude oil, costs of disposal, filtration,
recycling, etc., make the switch to
vegetable oil-based lubricants easier to
understand. However, vegetable oils
are costly, and until now, could not
penetrate the Indian market.
IIP Dehradun has developed a
non-edible vegetable oil-based fully
biodegradable MWF, under Indian
Patent No. IN244501, and transferred
the technology to Ecocare Bio Lube
India Pvt Ltd under product name
EBL-Cut 12. It has been developed
from rice bran oil to form a soluble oil
concentrate.
According to Dr Singh, “At
present, industries in the public sector
(railways, SAIL, BHEL, defence, etc.)
are importing biodegradable MWFs
at a very high cost from the Western
manufacturers, and the private sector
has no other choice, but to use low-cost
petroleum-based MWFs. Indigenous
manufacturing is limited to IOCL,
HP and Castrol, the main producers of
petroleum-based MWF. The remaining
MWFs, prevalent across industries,
are imported. The Government of
India is trying to replace and reduce
the use of mineral oils, and promote
the use of vegetable oils. Biodiesel
programmes have been launched.
Fundamentally, biodegradable MWFs
are being developed for the greater
goals of saving petroleum, reducing
energy consumption in metalworking
and saving the environment. Improved
R&D will lower the financial
burden and increase work quality in the
public sector, encouraging the private
sector to use this innovative and eco-
friendly product.”
Differences between Mineral Oil-based and Vegetable Oil-based Lubricants
Criteria Mineral Oil Based Vegetable Oil Based
Biodegradability Slow to degrade Quick to degrade
Renewability No Yes
Pour point -300 F 50 to 250 F
Misting Medium Low
Dermal sensitivity (depends on additives used)
Can be harmful; can cause dermatitis
Minimal dermal harm
Carcinogenic Yes; can be low if solvent refined or hydro treated
Naturally low
Cost Depleting resources and political instability leading to high prices; cost comparable today to vegetable oils
Used to be more expensive. But cultivation has increased; cost now comparable to mineral oils
SPECIAL FOCUSMaintenance & Filtration
MODERN MACHINE TOOLS - July 201278
Monitoring, maintenance
and optimisation of
MWFs are critical
aspects in the
implementation of
coolant systems in manufacturing.
The emphasis on reducing costs and
addressing environmental and health
concerns, while, at the same time,
maintaining or increasing productivity,
has increased over the last decade. Such
an emphasis arises from the obvious
benefits of maintaining and optimising
MWF usage. The service life of fluids
is extended, thereby saving on the
costs for purchase and disposal. Tool
life maximises and becomes consistent,
ensuring quality productivity. “MWF
manufacturers should use their industry
knowledge and process expertise to
understand specific issues related to
MWFs, solve particular problems, and
implement demonstrated solutions.
Trained on-site teams serve as your eyes
and ears, capturing data and analysing
results to provide detailed reports and
recommendations on how to reduce
costs and improve performance. As a
result, customers of machined parts
and other products experience vast
improvements in productivity, quality
and profitability, immediately as well as
in the future,” says Syed Md Samim,
Marketing Manager, Quaker Chemical
India Ltd.
Maintenance and monitoring
systems, along with strict shop floor
policies and procedures, improve
the health of machine operators and
reduce the impact of MWFs on the
environment. Moreover, it would also
protect companies from the risk of
prosecution whenever more stringent
health, safety and environment
regulations are enforced.
Maintenance MWFs are complicated mixtures
containing an array of additives in
various concentrations. There are four
basic MWFs used in the industry—
straight oils, soluble oils (emulsifiable),
synthetic oils and semi-synthetic oils.
Of these, straight and soluble oils have
been in usage for the longest time.
However, as non-mineral oil-based
fluids are being increasingly used,
synthetic oils (based on water) are also
being developed. Semi-synthetic oils use
both mineral oils and water. The most
THE FAULTLESS FLUIDSMaintenance and monitoring systems, along with strict shop floor policies and procedures, improve the health of machine operators and also reduce the impact of Metalworking Fluids (MWFs) on the environment. Moreover, it would protect companies from the risk of prosecution whenever more stringent health, safety and environment regulations are enforced. Tarun Tampi & Nishant Kashyap explain how, even in the world of MWFs, prevention is better than any cure.
Cou
rtes
y: V
alen
ite
MODERN MACHINE TOOLS - July 201280
Maintenance & Filtration
important criteria in evaluating any
of these fluids over their lifetime are
performance and environmental impact.
The performance, of course, depends on
the application, the machining process
(broaching, grinding, milling, etc.) and
the metal being machined.
One of the biggest problems
faced in terms of performance is fluid
contamination, particularly microbial
contamination. The deteriorated
biomass impedes fluid flow, clogs filters
and reduces the ability of the fluid to
dissipate heat. Further, the numerous
additives deteriorate at different rates,
and therefore deplete at different levels.
The three major causes of failure that
prevent optimal use of any MWF are
biodeterioration, water quality (deioniser
and reverse osmosis systems) and other
contamination (metal particles, tramp
oil, swarf, dirt, etc.). In order to tackle
these issues, a common sense approach
involves using the following three main
steps in maintaining the quality of
MWFs:
� Monitoring the condition of the MWFs, especially their concentration
� Minimising contaminants
� Maintaining consistently high water quality and using deionised water to lower the mineral content.
Select biocides may be used to
reduce microbial growth to eliminate
corrosion, odour, filter plugging and to
extend fluid life.
MonitoringThe most important test is to measure
the concentration levels of a fluid.
Although these tests need to be
improved in terms of accuracy, precision,
output time and reliability, there are
several other tests, which if employed,
provide a good enough understanding
of the state of an MWF. To measure
concentration, a refractometer, which
measures the refractive index of a fluid,
is used. Alkalinity titration measures the
alkalinity of the MWF. Cationic titration
measures the anionic emulsifiers. Acid
split and wet chemical tests measure the
oil content in a fluid by reacting it with
mineral acids. A pH meter test is the
basic test to check fluid maintenance
as it measures the fluid pH, which
should be around nine for most MWFs.
Any deviation from this indicates
contamination. Instrument tests like
infrared analysis, X-ray fluorescence and
elemental analysis provide more specific
measurements of components in the
fluid. Then, there are a host of tests that
measure population density of microbes
in a fluid.
Filtration Filtration consists of the separation of
two phases using a physical barrier.
In the case of MWFs, this usually
involves the separation of chips.
Large oil droplets can be removed by
filtration, and depending on the affinity
of oil for the filter media, smaller oil
droplets can also be removed. There
are two kinds of filtration methods
that are generally used—membrane
filtration, which is used for bacterial
separation; and traditional filters used
in MWF recycling operation. When
the MWF enters the filter in the same
direction as it exits, it is called ‘dead-
end filtration’. In contrast, membrane
filtration typically operates with the
MWF entrance direction perpendicular
to the direction of filtration. This is
called ‘cross-flow filtration’.
A new MWF filtration technology
can help in achieving extended tool
life, improved component quality and
reduced maintenance & spare parts’
costs. Fluid Maintenance Solutions
Ltd has developed such a technology.
In fact, it was recently chosen as the
sole UK agent for its IFDR range of
advanced MWF filtration solutions for
machine tools and grinding systems.
Dead-end FiltrationDead-end filters can be disposable or
permanent. From the standpoint of
the environment, permanent filters
are preferred because disposable filters
present the problem of solid waste.
However, to the extent that in-plant
hazards and extension of MWF
life can be achieved using filtration,
disposable filters can be warranted from
the environmental perspective where
permanent filters are ineffective or
uneconomical.
Dead-end filtration operations
utilise gravity, pressure or vacuum as the
driving force. As filters clog, the driving
force required to maintain a given
filtration rate increases, otherwise the
filtration rate will decrease for a constant
driving force. After some time, demands
on driving force or declining filtration
rates become unacceptable. Disposable
media must be changed and permanent
media be cleaned. Permanent media
can be cleaned with high-pressure air
or MWF.
Cross-flow Membrane FiltrationMembrane filtration utilises a semi-
permeable barrier or a membrane
capable of separating feed stream
constituents according to their particle
size relative to the pore sizes of the
membrane. Membranes can separate
MWF ingredients from bacteria, tramp
oils and chips.
Membrane filtration is surface
filtration similar to that described
for the permanent filters. However,
membrane filters do not depend on a
cake layer for fine separation. Instead, a
porous membrane support is lined with
a thin skin where surface filtration takes
place. Pore sizes that have been used in
MWF recycling range from 0.01 to 0.1
μm (ultrafiltration) and 0.1 to 1.5 μm
(microfiltration).
Looking AheadThe industry should develop
quantitative guidelines with the help of
institutions like technical laboratories to
determine the useful life of an MWF as
well as parameters for when it should
be removed, such as reduction in tool
life, loss of surface finish, reduced
concentration, increased contaminants,
etc. This will help suppliers, maintenance
workers and end users work together to
optimise the use of MWFs.
SPECIAL FOCUS
MODERN MACHINE TOOLS - July 201282
MWF Additives
Metalworking fluids
(MWFs) are used in a
wide range of activities,
from simple grinding
and metal removal to
honing and broaching. Additives are
used both in water-soluble fluids and
in water-free neat oil formulations.
Over the years, many highly successful
additives have been developed that offer
formulators almost everything they
require. Syed Md Samim, Marketing
Manager, Quaker Chemical India Ltd,
says, “MWF manufacturers need to focus
on offering innovative products that
are cost effective and satisfy customers’
changing needs. A collaborative approach
with customers with increased focus on
R&D and enhancing services would go a
long way in giving boost to this market.”
Additives in Minimising WasteWaste minimisation has become one
of the biggest cost-cutting strategies.
It is an issue that affects the choice
of MWF additives when used in the
metal stamping process. Additives that
are stable to bacterial degradation and
hard-water salts, for example, are more
difficult to treat, but, at the same time,
promote longer tank life of MWFs,
thereby requiring less frequent disposal.
Metalworking lubricants are important
to the metal stamping process for
cleaning, stability, lubrication and
rust protection. MWFs evaluation is
often assessed by the amount of waste
disposal. The less waste produced, the
lower the disposal costs will be for
metalworking companies.
The waste disposal of MWFs is
a major issue that the metalworking
industry is facing. It is important to
find additives that are easy to treat
by most systems. This is the most
important element in minimising wastes
from MWFs. There are a number of
lubricants, corrosion inhibitors and
emulsifiers that can be evaluated for
their potential waste treatability. It is
important to be careful while deciding
the appropriate chemicals to use when
combining additives. This requires
thorough research and analysis.
Going ‘Green’Coolants are being increasingly utilised
to contain the heat generated during
machining. About two-third of all
coolant applications involve mineral
oil-based products, the rest utilise
Metalworking Fluids (MWFs) are a key production aid in the manufacturing of any kind of metal parts. They have come a long way from being just a coolant to becoming an ingredient for cost effectiveness and productivity. Many new additives are also being developed, which help in cost reduction and are also environment friendly. Nishant Kashyap provides insights on new additives and how they affect the overall industry dynamics.
The Key to Cost Effectiveness
Pho
to b
y: P
rate
ek S
ur
SPECIAL FOCUSMWF Additives
MODERN MACHINE TOOLS - July 201284
synthetic products, while only a few
use vegetable oil-based coolants. As
the manufacturing sector is adopting
green norms, and as this trend will only
increase in future, MWF industry will
witness huge demand for vegetable oil-
based coolants. M Krishna, MD, Master
Fluid Solutions (India) Pvt Ltd, says,
“Unfortunately, in the MWF sector,
the need for conserving environment is
at the ‘womb’ stage. Even some larger
multinationals seems to disregard the
need for better effluent treatment.
When the industry across developed
countries are running towards better
and stringent control mechanism,
India is learning to walk in these areas.
However, with global players setting
foot in India, the learning will become
faster for the Indian players.”
Choosing the Right Additives Choosing the right MWF for operations
is a Herculean and time-consuming task.
In order to select additives for a particular
application, both the advantages and
disadvantages of MWF products should
be compared through reviewing product
literature, supplier information and
usage history. Product performance
information shared by other machine
shops is another means of narrowing
choices. Ultimately, the best indicator
of fluid performance is through the
actual use.
While choosing fluids, it is
imperative that one should get value
for money. During fluid selection,
the benefits of fluids and their
versatility should be weighed against
its performance in each metalworking
application. Because of significant
improvements in fluid formulations,
fluids available today are capable of
handling a wide variety of machining
applications.
Usually, semi-synthetic coolants or
MWFs with Extreme Pressure (EP)
additives are used while machining
hard components made of titanium
and soft components like aluminium.
These EP additives help in reducing
friction between the tool and titanium
components, and provide proper finish.
It also strengthens aluminium, which
is comparably soft and melts even at
low temperatures. These EP additives
increase the chip welding property of
the coolant, thereby giving good finish
and ensuring fast removal of chips
from the tool that eventually increases
tool life. Machine shops that earlier
required several types of fluids may
now find that just one or two fluid
types meet their needs. Consolidating
the number of fluids used on the shop
floor simplifies fluid management.
Going Forward With emphasis on the reduction of
carbon footprints and adoption of
green process, several manufacturers
are experimenting with vegetable oil-
based coolants in their day-to-day
activities, as mineral oil and synthetic
alkanes are not appropriate to be
used as the base oil for environment-
friendly cutting fluids. This is because
mineral oils and synthetic alkanes are
poor at biodegradability, and remain
in water & soil for a long time,
causing pollution, whereas vegetable
oils and synthetic esters possess good
biodegradability properties. Since
the metalworking industry demands
environment-friendly and cost-effective
solutions, coolant industry constantly
needs to improve its products with
such additives that will reduce heat
generation and biocides to control the
bacterial growth and wastage, as well as
increase the tool life.
The World of Additives
� Boundary lubricity additives:
These are used to improve the
lubricity of the fluid by getting
adsorbed on the surface of the
metal to form a film, thereby
reducing metal-to-metal contact.
These additives generally have a
polar group that interfaces with
metal and a tail that is compatible
with mineral oil or water.
� Extreme pressure additives:
These are a special type of
boundary lubricity additives
that actually react with the
metal surface, instead of getting
adsorbed on the surface, to form
a metal-salt layer or a physical
barrier between the tool and
the workpiece under severe
metalworking conditions. They
contain molecular compounds
that react with metal surfaces
under extreme friction conditions,
producing a protective film that
prevents welding and surface
damage.
� Reserve alkalinity additives:
These are used for maintaining
the fluid’s corrosion by
neutralising acidic contaminants
and maintaining the pH in
a suitable range. It can also
form emulsifiers with other
components to stabilise the fluid.
� Stabilising oil-soluble additives:
These additives work in water-
dilutable MWFs by reducing
the interfacial tension between
incompatible components
by forming micelles (a sub-
microscopic aggregation of
molecules, as a droplet in a
colloidal system). These droplets
can then remain suspended in the
fluid. This is what happens when
we wash our hands.
MWF Additives
Syed Md Samim, Marketing Manager, Quaker Chemical India Ltd
MWF manufacturers need to focus on offering innovative products that are cost effective and satisfy customers’ changing needs.
M Krishna, MD, Master Fluid Solutions (India) Pvt Ltd
Unfortunately, in the MWF sector, the need for conserving environment is at the ‘womb’ stage.
TIPS & TRICKSThe Right MWF
MODERN MACHINE TOOLS - July 201286
Metalworking Fluids (MWFs) are crucial in the manufacturing and machining of metal products, from coins and wires to complex aerospace and medical parts. Apart from being a vital aid in producing high-quality finish, reducing tool wear and optimising machine performance, MWFs maintain a constant temperature and lubricity between the work piece and the tool, while simultaneously carrying metal chips away from the cutting area. Tarun Tampi reports...
Selecting the ‘PERFECT’ Cutting Fluid
Selecting an MWF for a particular machining operation requires an understanding of the basic types of MWFs and the
various compositions (additives, emulsions, etc.) they are available in. Although research is underway, there is no single
MWF that can be effectively used in every manufacturing facility, in every machining process and under every condition.
Some MWFs have better corrosion control, while others may lubricate better. Hence, an understanding of the benefits
and applications of each type of MWF along with corresponding machining processes are provided below.
Machining Process Synthetic Oil Semi-synthetic Soluble
Severity: Light milling, grinding (surface, double disk, rotary)
Rust inhibitors & cleaning agents only, no lubricants
Low oil content (5-10%), rust inhibitors
Severity: Moderate turning, grinding (tool room, internal, center and centreless)
Some polymeric lubricants High oil content (20-30%) High oil, esters & fats
Severity: Heavy drilling, sawing, tapping, reaming, gear cutting grinding (creep feed, form, thread & flute)
High level of polymeric lubricants + phosphate esters
High oil + EP lubricants High oil + EP lubricants
Excellent lubricity, rust control, long sump life, easy to manage
Expensive fill-up, excess heat generated, fire hazard, slip hazard, high mist formation
STRAIGHT OILS
Excellent physical lubricity, less heat generated, easy to manage
Heavy oil residues, affected by hard water, haze, mist and smoke formation
SOLUBLE OILS
Good heat reduction, physical lubricity, clean,
good rust control
May foam, affected by hard water
SEMI-SYNTHETICS
Very clean, excellent heat reduction, unaffected by
hard water, low foam, transparent mix
Poor physical lubricity, no oily protective films
SYNTHETICS
MODERN MACHINE TOOLS - July 201288
FACILITY VISITHittco Tools Ltd
H ittco Tools Ltd—a
B e n g a l u r u - b a s e d
company—started its
operations way back in
1974 as a High Speed
Steel (HSS) drills manufacturer, and
over the next four decades, it expanded
its portfolio to products like HSS taps
for threading operations. In 2008,
the company entered an entirely new
domain of carbide tools manufacturing.
“We took the decision to start
the carbide tool factory when most
people were wrapping up their business
activities due to recession. We had a
different perspective. When the market
is in full swing, manufacturers are so
busy executing the orders that they
do not observe the market trends. We
entered this segment during the deepest
recession, but when the market came
back to normalcy and orders started
to flow, we were ready to handle it,”
explains Rajib Ghosh Roy, Director -
Operations, Hittco Tools Ltd.
This segment of Hittco’s business
has grown by 80%, while the overall
growth of the company between 2008
and 2012 has been over 100%.
Keeping pace with the market
trends, Hittco Tools has found its
way to some of the major Indian
manufacturers in the automotive,
aerospace, railways, shipping, and
medical industries, among others.
Hittco now has experience and
theoretical knowledge in fields such
as tool material, tool geometry,
production process and quality
control. The company now has a pan-
India presence and its shop floor is
equipped with latest SPIBOMAT,
NORMAC, HERTLINE, WALTER
& ROLLOMATIC machines.
Business ModuleApart from being one of the key
suppliers to Indian companies, Hittco,
over the years, has been supplying to
various countries like Singapore, South
Korea, Philippines, Taiwan, Thailand,
Vietnam, Spain, Czech Republic,
Netherlands, West Asia, Turkey, South
Africa and the US.
“We are now working towards
making our global presence stronger
and bigger. The economic conditions
are confusing. And while the global
economic situation is difficult to
comprehend, the manufacturing is
shifting to Asia,” says Roy.
Hence, the company focusses on
manufacturing products to meet the
global demands. Roy further explains,
“Through our experience in various
countries and by understanding
their needs and demands, we have
Creating OPPORTUNITIES in Difficult Times
Sometimes, it is not the big investments but smart decisions that lead to success. From the 2008 recession to the precarious economic situation of the present time, Hittco Tools Ltd has learnt from its own experiences to widen its reach when others are going back into their shells. Debarati Basu finds out how a mid-sized company made the right moves during difficult times to strike the perfect equation of growth.
FACILITY VISITHittco Tools Ltd
July 2012 - MODERN MACHINE TOOLS 89
Hittco Tools Ltd
continuously tried
to bring changes in our
products. The tool geometries
have to change
with the
c h a n g i n g
demands and we have been
introducing around five to six
new products every year in the
market.“
Given the vast
array of industries
that the company
caters to, the
tool dimensions
offered by it
range from
0.4 mm to 36 mm.
The company has also
caught the pulse of t h e
industry. Therefore,
despite being a mid-
sized organisation, it has
been successful in keeping the cost of its
products comparatively low.
“Today, the overall cost of
manufacturing has gone up right from
the cost of raw materials to the wages
of workers. Hence, every company
wants tools that can cut faster with
more precision and decrease the time of
manufacturing to increase productivity,”
says Roy.
To be in the competition with major
tool manufacturers, Hittco has been
consistently reducing the overhead costs
to bring down the cost of tools offered
to the market. “Bengaluru has some of
the major brands like Guhring, Seco,
Tagutec, Kennametal, etc., which means
that we have to provide tools that are at
par with international quality standards
to sustain ourselves in the market,”
says Roy.
The company, to bring down its
overhead cost, works on the ‘Just In
Time’ strategy, commonly called JIT.
Roy elaborates, “We never increase the
raw materials inventory level too high
and we have the kind of product mix
that sells off very quickly. This way, our
finished goods inventory is kept low,
which automatically keeps a check on
the bank interest from shooting too
high. Our raw material-buying pattern
also helps us to bring down the costs.
Reducing cost is a closed loop where
every entity of production has to be
taken care of.”
Quality Quotient Even though the cost of the tools offered
has to be kept low, in order to cater to
the global market, quality just cannot be
negotiated. Hittco has adopted a stringent
process of product inspection to reduce
the rate of rejection. “Apart from the
regular monitoring at every level, we have
inculcated a sense of ownership in every
operator where they check the products
themselves and implement immediate
steps of correction at the primary level
of manufacturing itself. Every employee
should have a sense of ownership and
take decisions in a way they would take
for their own company,” says Roy.
Challenges EncounteredSustaining in the market for a mid-
sized company has never been a
cakewalk. Also, the competition from
big manufacturers is just enormous.
Therefore, the challenges faced by
Hittco are huge.
“The main challenge that every SME
and MSME face today is that they do
not get the real price of the products
they sell. Many times, when the bigger
Indian players buy their supplies, the
optimum price is not given. The industry
needs to understand that the MSMEs
do not receive any government support
that they are entitled to and most of
them are neck deep in loans. On the
other hand, while the big companies
are growing by making huge profits,
the same profits are not shared with the
SMEs. If the country needs to grow, the
backbone of the country, comprising of
SMEs and MSMEs, needs to be taken
care of,” avers Roy.
Expansion PlansThe company already has over 150
employees at it two manufacturing units
designated for HSS and carbide tools. It
has had an annual turnover of `10 crore.
The company also has been diversifying
its portfolio and has recently entered
into manufacturing tool holders.
Now with the target to increase its
production, the company is planning
open branch offices in the USA and
Singapore. “Initially, we thought of
opening manufacturing units in these
countries, but our idea was to make India
the global manufacturer. This would be
our first extension outside India and the
offices will become operational by the
end of this year,” informs Roy.
With this expansion, the company
expects a growth of around 30%. Roy
positively affirms, “There is nothing like
a recession. It is the fear psychosis that
is making the bigger companies hold
back on the investment. How would the
market grow if money does not flow in
the market?”
The company is not just expanding
its business, but is also creating a
strong team that can make the brand
international.
Rajib Ghosh Roy, Director - Operations, Hittco Tools Ltd
The big companies, as they make money, need to share their profits with the SMEs and MSMEs. If the country wants to grow, the backbone of the country, comprising of SMEs and MSMEs, needs to be taken care of.
What is JIT?JIT or ‘Just in Time’ is a management
philosophy, a production strategy that
strives to improve a business return
on investment by reducing in-process
inventory and associated carrying
costs. This method is also called
the ‘Toyota Production System’. It
originally referred to the production
of goods to meet customer demand
exactly, within time, without failing
in quality and quantity. [email protected]
MM
T Ju
ly-2
012
A
d N
ame:
L&
T P
g N
o. 9
1
MM
T July-2012 Ad N
ame: L&
T Pg No. 92
MM
T Ju
ly-2
012
A
d N
ame:
Rin
g
Pg N
o. 9
3
MM
T July-2012 Ad N
ame: B
irla Pg No. 94
96 Industry Snapshot Tracking the Growth
98 Construction Equipment Machining Creating an Era of Opportunity
100 Machining Solutions Offering Construction a Cutting Edge
104 Compact Rebar Shop Pumping Adrenaline into Process Efficiency
106 Manufacturing Modules Encountering Challenges in Construction
CONSTRUCTION EQUIPMENT
INSIGHTS & OUTLOOK
July 2012 - MODERN MACHINE TOOLS 95
MODERN MACHINE TOOLS - July 201296
INSIGHTS & OUTLOOKIndustry Snapshot
The global construction equipment industry is experiencing robust development. While 2007 saw the growth of this industry at its peak, year 2008—09 saw a cumulative fall of 35.4%. However, it subsequently picked up, with skyrocketing momentum, and in 2011, its growth rate was approximately 26%, with the market value of roughly $190 billion. As the global construction equipment industry grows, India, too, is entering the league in a big way. Debarati Basu draws out the latest happenings in the construction equipment market from across the globe.
Caterpillar India sets up new manufacturing facility Construction and mining equipment maker, Caterpillar India, launched the
company’s new backhoe loader manufacturing facility at Thiruvallur near Chennai.
The new facility will strengthen the company’s presence in India and would
augment the distribution channel for earth-moving machines by bringing in
enhanced local production capabilities. This is the fourth manufacturing operation
in India. Caterpillar manufactures construction and mining equipment, diesel and
natural gas engines, industrial gas turbines and diesel-electric locomotives.
Isgec, Hitachi in joint venture ( JV)Isgec Heavy Engineering and
Hitachi Zosen Corporation,
Japan, joined hands to form Isgec
Hitachi Zosen to make specialised
and critical process equipment
with an investment of `100
crore. Isgec Heavy Engineering
is a leading global supplier of
process equipment and Hitachi
Zosen Corporation is a Japanese
engineering giant. The JV will
use one of the manufacturing
facilities of Isgec located at Dahej
in Gujarat. Isgec will hold 51%
stake in the new venture.
Hyundai Construction Equipment expands in Tamil NaduHyundai Construction Equipment India Pvt Ltd (HCEIPL), a subsidiary of
Hyundai Heavy Industries, opened a 3S facility at Puddukottai in Tamil Nadu
to cater to the needs of the fast-growing market in the South Indian state. It is
the fifth such facility, and along with Shristi Construction Equipment—a dealer
for HCEIPL—it will cover areas like Puddukottai, Tanjore, Sivagangai and
Tiruvarur. The expansion will help develop and expand operations in the Indian
excavator and backhoe loader business. Excavators in this region are employed
mainly for blue metal quarry (black stone) and granite quarry applications.
Tracking the GROWTH
Industry Snapshot
July 2012 - MODERN MACHINE TOOLS 97
The Future TrendsLooking at the global business
environment in the construction
equipment market, we can say that the
Indian industry is well placed to enter
this market with with new developments
that meet the global requirements and
quality standards.
Ashok Leyland, John Deere enter into JVHinduja Group flagship Ashok Leyland
entered the construction equipment
business, along with American company
John Deere, with the launch of the 435
backhoe loader. Backhoe loader was
the first product to roll out the 50:50
JV. Around `200 crore was invested
in the first phase of the 435 backhoe
loader. The product will be sold under
the ‘Leyland Deere’ branding and
manufactured at a greenfield facility at
Gummidipoondi, near Chennai.
Volvo Rents acquires Action Equipment RentalVolvo Rents, a worldwide
provider of small to medium-sized
construction equipment, announces
the expansion of its operations in
New Mexico with the acquisition
of Action Equipment Rental,
a three-location construction
equipment rental company with
stores in Alamogordo, Las Cruces
and Silver City. With these
acquisitions, Volvo Rents now
has 120 outlets in North America,
including four in New Mexico.
Hitachi Construction expects record sales this yearHitachi Construction Machinery Co,
the world’s biggest maker of giant
excavators, expects its global sales of
mining equipment to reach a record
this year. The company won an order
from Vale SA (VALE5) to supply
excavators and dump trucks for an iron
ore project in Africa and has secured a
contract for gold mining equipment in
Turkey. Sales from mining companies
may surge by a third to ¥ 200 billion
($2.5 billion) in the year to March.
Volvo goes green with construction equipment To reduce greenhouse gas emissions, save resources, lower costs and help
protect the environment, Volvo Construction Equipment (Volvo CE) is offering
customers a range of revitalised components with its Volvo Reman programme.
In view of environmental care and cost effectiveness, more and more people are
willing to recycle, reuse and make the best use of limited resources. Volvo CE is
imbibing the same in the construction industry—evidenced by the Volvo Reman
programme, arguably one of the company’s most resource-friendly initiatives.
Chinese equipment maker acquires German concrete pump makerSANY, a fast-expanding Chinese construction equipment producer, in January
this year, acquired German concrete pump maker, Putzmeister Holding GmbH
for €525 million, making it one of the biggest purchases of a niche German
business by Chinese company. SANY intends to use its German acquisition to
reach new markets in the Western world, as well as to accelerate development of
its own technology and design.
SANY Heavy Industry starts crawler crane production in India SANY Heavy Industry India, subsidiary of one of China’s fastest-growing
manufacturing companies, SANY Group, started its first integrated crawler crane
production line at Chakan near Pune. The plant will substitute the import of
crawler cranes from China and cater to India’s growing needs. Earlier, the cranes
were imported from SANY China as per customer requirements. However, looking
at the constant growth of crane market and products receiving higher appreciation
by Indian customers, SANY has taken this step to start the production of cranes
at its manufacturing centre in India.
Hitachi unveils $15 million project in ZambiaTaking advantage of the Multi
-Facility Economic Zones of Zambian
economy, Hitachi Construction
Machinery Zambia Co Ltd recently
announced its re-manufacturing
factory project. The $15-million
project is the first-ever investment in
the Zambian manufacturing sector
by the Japanese company. Hitachi
is one of the largest manufacturers
of construction, mining and earth-
moving equipment in the world.
The plant will have value addition
activities through the provision and
repair of processing equipment.
MODERN MACHINE TOOLS - July 201298
INSIGHTS & OUTLOOKConstruction Equipment Machining
Infrastructure is an important
component for industrial and
overall economic development
of a nation. It is considered
as the yardstick to measure
the investment viability of a nation.
However, in India, there is a wide
gap between the potential demand for
infrastructure and its available supply.
To minimise this gap,
an investment
of around
$445 billion is required over the next
five years, which will directly affect the
overall business dynamics of construction
equipment manufacturers. The industry
will also have to grow at a Compounded
Annual Growth Rate (CAGR) of 15%
over the next five years to support the
growing requirements of every sector of
the economy.
Indian Construction Industry Considering the present industrial
growth, industries working for railways,
power sector, and construction
machinery, among others, are doing
extremely well. Companies like BHEL,
L&T–MHI and Siemens are finding
it difficult to cope with the orders
in hand. To cater to these demands,
they are investing in new technologies
to reduce the machining time of the
components, leading to an increase in
production.
According to market research firm
RNCOS, the Indian construction
equipment industry has been witnessing
a consistent double-digit growth over
the past few years. Though the economic
slowdown had a moderating effect on
the industry, it regained momentum
in 2010, showing a stupendous growth
that is expected to continue in the years
to come. The earth-moving segment, in
particular, has been driving the overall
construction equipment industry in
India, with strong demand emanating
from the government-backed
infrastructure projects. The
segment is poised
to register
a remarkable CAGR of around 21%
during 2011–2015, as per estimates.
According to Ramesh Chandak,
MD & CEO, KEC International Ltd,
“The Indian machine tool industry and
automation providers have an important
role to play in the infrastructure
sector. They can develop solutions to
achieve better quality with better safety
standards. Higher accuracy and better
interfaces, along with intelligence and
remote diagnostics that automation
processes offer today, are the trends
that can help India. This must not only
be restricted to large manufacturers,
but must be used by medium and small
units as well. Today, the availability
of skilled manpower is a constraint in
the construction segment and if better
technologies and automation requiring
lesser manpower can be developed, it
would be useful.”
In India, market penetration for
construction equipment used to be
very low. But growth in the Indian
construction industry has picked up
quite significantly over the past few
years. This industry is estimated to be
of around $12–14 billion by 2015. The
rapid pace of industrial development
in India is driving up demand for the
use of process automation to improve
manufacturing processes, especially for
high value-added applications. Indian
tooling firms have an important role to
play in helping manufacturers achieve
cost optimisation, enhanced productivity
and improved product quality by
introducing the latest automated
solutions in the market.
Creating an Era of Opportunity With the government projecting a whopping $1 trillion investment in the infrastructure sector during the 12th Plan Period (2012–17), several foreign firms are planning to enter the Indian market. This will certainly make the Indian machine tool builders more competitive and adopt international standards in their production process. Nishant Kashyap tracks the opportunities for machine tool builders in the construction equipment industry.
Construction Equipment Machining
July 2012 - MODERN MACHINE TOOLS 99
Technology Trends Globalisation has forced companies to
use modern manufacturing methods.
Technology has increasingly altered the
manufacturing process of construction
equipment. While equipments
are being produced at faster rates,
manufacturers must continue to
balance increased productivity and
efficiency with quality & innovation.
Some modern technologies that can
boost manufacturing in the automotive
industry are programmable machines
& tools, industrial robots, data
management, supercomputing, virtual
manufacturing & complex visualisation
and advanced forging techniques.
G Devraj, MD, IMT Exim
India (P) Ltd, says, “Some of the
technologies, such as milling machine,
moving column, 5-axis machine,
double column and VMCs, are
mostly used for construction
equipment manufacturing. The size
of the machines ranges from 5–10 m.
But I feel that Indian machine tools
companies still need to work on their
technology to cater to the construction
equipment industry.”
Machine tools builders are constantly
developing new tool geometries and
technologies. Various tool geometries
are available to address the varied nature
of composite materials.
Metalworking OpportunityThe increasing number of infrastructure
projects in the country has created huge
demands for machine tool builders.
The construction sector is growing by
leaps and bound and so is the demand
for automated machines by the Indian
companies. The requirement in this
segment—in terms of volume—is also
increasing. As far as the competition
from the other Asian countries are
concerned, industry experts believe that
Indian machine builders can compete
with them in terms of technology and
knowledge, easily manufacture cost-
effective products and also provide
good service. “Because of infrastructure
development, the demand is picking up
for the construction equipment, which
will also positively impact the machine
tool industry. As of now, Indian
companies are only able to fill 20–30%
of the total infrastructure requirement.
Machine tool builders have a huge
opportunity in construction equipment
industry,” feels Devraj.
The machine tools manufacturers
in India produce general purpose
machinery of international standards in
terms of quality, precision and reliability.
However, they lag behind in design and
engineering capability. As a result, they
are not able to manufacture very-high-
precision CNC machines.
Future TrendsAs of now, Indian machine tool sector is
not very demanding. However, growth
in construction equipment, including
small component manufacturers who
are sub-suppliers to major infrastructure
projects, will create huge demand for
machine tools. Moreover, India is
gradually becoming a manufacturing
hub for all the major industries
worldwide. This will also lead to an
increased demand creation in the Indian
machine tool sector in the near future.
As a result, it becomes important
that Indian manufacturers invest in
sophisticated and flexible multi-purpose
machines for better productivity and
quality in manufacturing in order to
meet stringent international standards.
The Indian machine tool industry is all
set to leverage this demand. Going by
the statistics and recent developments,
the construction equipment industry
seems to be the next big focus for Indian
machine tool industry.
Infrastructure: Deficit and Eleventh Plan Physical Targets
Sector Deficit Eleventh Plan Targets
Roads/Highways 65,590 km of NH comprise only 2% of the network; carry 40% of traffic; the 12% four-laned; 50% two-laned; and 38% single-laned
Six-lane 6,500 km in Golden Quadilateral; four-lane 6,736 km NS-EW; four-lane 20,000 km; two-lane 20,000 km; 1,000 km Expressway
Ports Inadequate berths and rail/road connectivity New capacity: 485 m MT in major ports; 345 m MT in minor ports
Airports Inadequate runways, aircraft-handling capacity, parking space and terminal buildings
Modernise four metro and 35 non-metro airports; three greenfield in NER; seven other greenfield airports
Railways Old technology; saturated routes; slow speed (freight: 22 kmph; passengers: 50 kmph); low payload to tare ratio (2.5)
8,132 km new rail; 7,148 km gauge conversion; modernise 22 stations; dedicated freight corridors
Power 13.8% peaking deficit; 9.6% energy shortage; 40% transmission and distribution losses; absence of competition
Add 78,577 MW; access to all rural households
Source: Eleventh Five Year Plan, Government of India
MODERN MACHINE TOOLS - July 2012100
INSIGHTS & OUTLOOKMachining Solutions
Welding Technology The Construction
equipment industry
is one of the biggest
customers of welding
equipments. Some of the
commonly used welding
processes are S h i e l d e d
Metal Arc Welding
(SMAW), Gas Metal
Arc Welding (GMAW),
Flux-Cored Arc Welding
(FCAW) and Gas
Tungsten Arc Welding
(GTAW). SMAW is the most common
type of welding. It is fairly inexpensive,
and can be used both on the shop floor
and out in the field. GMAW has a higher
welding speed than SMAW. FCAW
has an even higher welding speed, along
with better metal penetration. GTAW
is used when a weld is very important,
such as in aircraft applications. Some
other features of these welding processes
are discussed below:
� SMAW: It is defined as an arc
welding process in which metals
are coalesced with the help of heat
produced from an electric arc. This
arc is maintained between the tip
of a flux-covered electrode and the
surface of the base metal in the
joint being welded. This process
is commonly referred to as ‘stick
welding’. SMAW is one of the most
widely used welding processes in
the construction industry. The cost
is low and the equipment can be
portable. It can also be used in areas
of limited access in all positions, and
is a viable process for joining most
metals and alloys.
� GMAW: It is used to weld all
commercially important metals,
including steel, aluminium, copper
and stainless steel. It can be used
to weld metals in any position,
including flat, vertical, horizontal and
overhead. It is usually connected to
use direct current electrode positive
(DCEP). It is an arc welding process
that incorporates the automatic
feeding of a continuous, consumable
electrode that is shielded by an
externally supplied gas.
� FCAW: This welding process is
widely used on ferrous metals. The
consumable electrode can have an
interior flux or a mix of flux and
metal powder and has a tubular
form. The process can use DCEP
or DCEN (direct current electrode
negative) polarity, and is suitable for
all welding positions with the correct
filler metal selection, depending on
the flux composition.
� GTAW: It is versatile and can be
used both on ferrous and non-ferrous
metals and, depending on the base
metal, in all welding positions. The
process can be used to weld thin or
thick materials with or without a
filler metal.
Robotics Application Automated and semi-
automated means of
production have already
been introduced in the
construction industry,
and are being widely
used to manufacture
excavators, bulldozers,
draglines, etc. The automobile and
aerospace industries are widely using
Robotics systems. Robots used in the
manufacture of construction goods,
whether it is I-beams or insulation,
are becoming more advanced and are
gaining popularity. In the manufacturing
sector, robots are stationary while
product moves along the assembly
line. Therefore, automation is easier
to incorporate because each product is
identical with respective tasks done over
and over. However, construction robots
Employing new-generation cutting-edge technologies in the construction machinery manufacturing industry will greatly improve the state of our infrastructure, which, in turn, will stimulate revenue growth. It will also generate a huge demand for machine tools and better machining techniques. Nishant Kashyap discusses some new technologies that are being used in the machining field.
MODERN MACHINE TOOLS - July 2012102
Machining Solutions
face different demands than conventional
industrial robots. These robots are
mostly used for welding, cutting and
material handling operations. Therefore,
they have to be specialised for their
respective functions. Such specialised
robots have the potential to raise
productivity by doing repetitive tasks
efficiently. They also improve working
conditions by working in areas that are
hazardous for humans.
Metal-cutting MethodsDue to high cost, less
speed and adverse side
effects of traditional
metal-cutting methods,
technologies such as
chip-less machining
processes automation,
Numeric Control
(NC) technique, electro discharge,
waterjet, plasma cutting system and
laser machining techniques have been
developed. Many equipment in the
construction industry have complex
shapes, and therefore, techniques, such
as multi-axis machining, which can be
used for manufacturing complex shapes
that are required. The use of computers
has also increased the precision and
efficiency of metal- cutting tools.
Nowadays, NC controls have become
more sophisticated as the concern
for environment has increased in the
manufacturing sector. However, new
metal cutting advancements are gaining
acceptance and applicability in the
industry. These advances could again
bring significant changes in the methods
employed to cut metal.
Lathe Machines A metal lathe or
metalworking lathe is
a large class of lathes
designed for precisely
machining relatively hard
materials. These rigid
machine tools remove
material from a rotating
workpiece via the (typically linear)
movements of various cutting tools,
such as tool bits and drill bits. “Turning
machines can be classified into various
categories like CNC lathes, which are
now replacing the older lathes due to
their ease in setting and operation. These
are designed to utilise modern tooling
and fully used modern processes. These
processes have been widely accepted in
the construction equipment industry
for sheet metal cutting operation,” says
Tom Sangho Shin, GM – Overseas
Sales Team, Machine Tools & FA BG,
Doosan Infracore Co Ltd. The part may
be designed, the tool paths programmed,
and the resulting file is uploaded to the
machine. Once it is set, the machine
will continue to turn out parts under the
occasional supervision of an operator.
On the other hand, for work requiring
extreme accuracy, a Swiss-style lathe is
often used.
Shin elaborates, “The collet sits
behind the guide bushing, while the
tools sit in front of it, holding stationary
on the Z-axis. The rigidity of the tool
makes it ideal for slender workpieces. To
cut lengthwise along the part, the tools
will move in and the material itself will
move back and forth along the Z-axis.”
Waterjet TechnologyIn the current scenario, where saving
the planet has become the most popular
mantra, companies are
adopting technologies
that are more
environment friendly. As
one of the most valuable
and extensive green
manufacturing methods
of metal-cutting process,
waterjet technology is gradually gaining
acceptance in the construction equipment
manufacturing. This technology has
proven to be a highly effective method
for cutting any flat material, including
stainless steel and aluminium. Waterjet
tool has parameters to define minimum
and maximum cutting lengths, and the
simulation checks for errors such as jet
cutting through multiple sections of
the workpiece, cutting through fixtures
when it should not, and cutting either
too close or too far from the jet nozzle.
It can cut large pieces of reusable scrap
material and prevent unnecessary waste
that gets creative from using traditional
cutting methods. It uses no chemicals,
gases or harmful liquids. It is a very
clean process and does not produce
any by product and wastewater. Thus,
waterjet technology provides a much
safer working environment.
Plasma CuttingSpeed, accuracy and the range of
materials that plasma cutting system
can cut have made it a
useful technology for
automobile and steel
companies to utilise
on a large scale. At the
same time, the demand
for this technology
is also increasing in
the construction equipment industry.
Plasma arc cutting is faster and cheaper
than oxyfuels, especially for cutting steel
up to 2-inch thick.
It also provides greater speed than
laser cutting systems for thickness over
0.125 inch. The plasma cutter has many
advantages:
� It is equipped with the latest
techniques to cut metal.
� It prevents the warping and paint
damage that occur while cutting.
� It is faster and cost effective than
other equipment.
� It cuts the metal accurately.
These aspects make plasma cutting
one of the best options in the industry
for cutting metals.
Looking AheadAs our economy is growing, it will create
new challenges and opportunities for
construction equipment manufacturers.
Moreover, as the Indian companies are
now working in a highly competitive
global environment, it becomes all
the more important that they employ
cutting-edge technologies. Such
technologies will not only help them
become quality conscious and cost
effective, but will also improve India’s
infrastructure, thereby contributing to
India’s growth story.
MODERN MACHINE TOOLS - July 2012104
INSIGHTS & OUTLOOKCompact Rebar Shop
Economic pressures and the
huge opportunities lying
unclaimed in developing
markets have forced the
construction and associated
equipment industry to embrace advanced
technologies and concepts more readily.
Symptomatic of this shift is the gradual
rise in the implementation of automated
equipment for the processing and
handling of rebar. The Compact Rebar
Shop incorporates the latest equipment
for the cutting, bending and handling
of reinforcing bars, and all this, off-site.
Reassessing RebarThe common practice is to cut, bend
and process rebar on-site with the use
of large manpower. The process is
inefficient, expensive, time consuming
and results in unnecessary wastage of
steel, sometimes upto 5–7% of the total
volume. Improvements in productivity at
construction sites mean that one can build
a structure in 12 months as opposed to
two or three years, while simultaneously
supplying multiple projects from a rebar
shop. Aditya Mehta, Director, Jaypee
India Ltd, points out, “Site fabrication of
rebar, though effective in terms of instant
modifications or last-minute changes,
requires a detailed planning schedule
and highly skilled fabricators. In the
event of improper planning or unskilled
fabricators, it can result in an increase
in the wastage of steel by as much as
6%. Efficient off-site fabrication can
eliminate these costs.” One of the major
obstacles is the touch time involved
in the transportation and handling of
materials, using cranes, forklifts and
other lifting equipment involving manual
labour. Addressing the need to reduce
the touch time and minimise the use of
manual labour, Mehta explains, “With
rising costs of manpower and shortages
in the supply of skilled labour at job sites,
most construction companies find it
difficult to get enough skilled manpower
to execute large requirements in rebar
fabrication, thus, the need to have more
efficient equipment, which can fabricate
a higher tonnage of rebar, with the use
minimal manpower.”
Compact Rebar Shop: Who and How?The concept of the Compact Rebar Shop
was developed by KRB Machinery, US,
a company founded in 1986 that today
controls 70% of the market in the US and
is among the four largest manufacturers
of such equipment in the world. The
modular rebar shop concept is highly
specific to the optimal processing of
fabricated rebar with minimal touch
time. KRB tied up with the pioneers of
this technology in India, Jaypee India
Ltd, to commission two centralised
Pumping Adrenaline
In this era of rapid urbanisation, industrialisation and infrastructure development in the developing countries, the construction equipment industry is a rather volatile business, dependent on the fluctuations of unstable material costs and labour issues. Yet, the onus is on the industry to build faster and quicker, to squeeze phenomenal productivity from less and less. With technology, Tarun Tampi observes, this task is becoming increasingly possible. Nowhere is this more evident than in the Compact Rebar Shop, an innovative solution for rebar fabrication that pumps adrenaline into process efficiency.
into Process Efficiency
Cou
rtes
y: J
aype
e In
dia
Ltd
Compact Rebar Shop
July 2012 - MODERN MACHINE TOOLS 105
steel service centres in the country.
Established in 1982, the company
has led the industry in manufacturing
bar-bending and cutting equipment in
India. Jaymac, an iconic brand in rebar
processing equipment from Jaypee
India Ltd, is ubiquitous in the industry,
wherever rebar is processed. Therefore,
it was only natural that the two
companies would collaborate together
in introducing the technology in India,
thereby bringing the best and most
efficient international-standard
automatic equipment to the nation’s
construction industry. Reflecting
on the opportunities that this tie-
up provides to the Indian market,
Mehta observers, “The concept of
centralised rebar fabrication shops
is a budding concept across the
country, wherein many sectors of the
industry have found cost advantages
in the automatic method. The use
of highly efficient control systems,
in order to maintain the accuracy of
the final product, is very important
in these machines, and as a result,
had kept domestic manufacturers at
bay, considering the high costs of
developing the systems.” Therefore,
it was expensive and difficult to
develop such technology in a purely
indigenous fashion but that is where such
collaborations help. “Both international
collaborations and technology transfers
have a significant role in the growth of
the manufacturing sector in India. Such
collaborations give long-drawn technical
and commercial support to the home
industry. Also, such automated concepts
would not be practically feasible in India
since high-end electronics, drive systems
and requisite software are not currently
available here.”
Inside the ShopIt all begins when rebar arrives as raw
material at the facility. It needs to
be handled and transported from the
suppliers’ flatbed truck or railcar to a
storage or inventory space. Overhead
cranes then lift the rebar, as required,
onto processing machines. Till this
point, the efficiency cannot be improved
unless an excess of modern technology
devices and controls are used. One
of the first processing equipment
implemented in the compact rebar
shop is the AutoShakeout machine that
does the work equivalent to two men
in separating the required number of
bars for processing. The cutting system
is optimised to ensure a cutting strategy
that minimises scrap material, with
in-built controllers, logging scrap and
reducing inventory.
The bars are then fed, via walking
bins that index the bars, into automatic
double headed bending machines like the
MagnaBend (which can cut 25–40 tonne
of rebar in a single shift) or single headed
ones like the DuraBend. It is interesting
to note that so far, only one operator is
required to cut as much as 50 tonne of
rebar (depending on the size and shift)
with parametes fed in directly, say, by
scanning. Both the bending machines
required only one operator, aided by
user-friendly touch screen computer
controls that make the need for trial
and error bending redundant. The
ServoForm allows for the bending of any
other configurations that the other two
machines cannot handle, like stirrups and
ties. This again is completely automated,
with electromechanical servo motors and
pneumatic cylinders. Overall, the compact
rebar shop reduces the total manpower
required for the processing and handling
of rebar by 1/10th to 1/20th, resulting
in just three to four men operation—a
process whose output is virtually the
same as a full fledged factory. Illustrating
its benefits, Mehta says, “Being fully
automated with no dependence on
labour efficiency and productivity, even
our lowest capacity rebar processing
equipment outputs about 0.8 tonne per
hour of finished product, with variations
of approximately 0.1% from quoted
values, whereas in manually driven
processing, the variation could be as
high as 7–8% at minimum. Wastage
incurred in automated rebar shops
is approximately 2% at best, thus
the productivity increase would be
near about cent per cent. On site,
with manual operation, the wastage
could go as high as 7–8% of total
production.”
The Market OutsideImplementing the compact
rebar shop requires a thorough
understanding of how the system
works, what quantities and types of
rebar are required to be processed,
and what the total cost of ownership
involves. Jaypee experienced this first
hand while dealing with large and small
clients in India for the compact rebar
shop. Mehta charts the response from
the market, particularly in convincing
potential customers of the initial
investment, “The whole concept came in
India with much fanfare with many shops
being set up in a very short span of time.
No sooner did the companies realise that
the cost dynamics of this shop are much
more complicated than they assumed it
to be, which led to a slowdown in new
shops being set up. But the market has
matured since then, and the industry is
now looking at the process with a much
warmer perspective.”
As labour costs rise and automated
technology becomes cheaper and
easier to implement, the Compact
Rebar Shop is a natural solution to
increase productivity in a sustainable
and reliable manner.
� Aditya Mehta, Director, Jaypee India Ltd, next to the Multi-
Form 1016M that automates the bending and shearing of
deformed straight or coiled rebar.
Cou
rtes
y: J
aype
e In
dia
Ltd
MODERN MACHINE TOOLS - July 2012106
INSIGHTS & OUTLOOKManufacturing Modules
Since the process of selection
is closely associated with
the factors that influence
the quality of end products,
selection of methods, tools and
processes becomes extremely important
in manufacturing any product. Some
key factors that should be taken into
account before opting for a specific
selection process are the type and size
of equipment, efficiency, working
conditions, job type and operator’s
experience. Many new developments
have taken place in construction
equipment manufacturing, such as
using new materials & machines and
increasing use of automated systems
like robots and Product Lifecycle
Management (PLM) systems, among
others. Moreover, many new materials,
such as alloys, coatings, etc., are being
developed for use in construction
equipment manufacturing. These new
materials are not only corrosion free, but
are also very strong.
Significance of MetalsThere is no simple definition for ‘metal’;
any chemical element having ‘metallic
properties’ is classified as a ‘metal’. Some
of these metallic properties include
sheen or shiny metallic appearance, good
electrical & thermal conductivity, the
potential of being permanently deformed
or shaped at room temperature and
malleability & ductility. Metal is used as
a structural framework for large buildings
such as skyscrapers, or as an external
surface covering and in manufacturing
earth-moving equipment such as loaders,
cranes, etc. Metals are also used for
building construction equipment such as
titanium, chrome, gold or silver.
An example of alloy that finds
extensive use in construction equipment
manufacturing is steel. It is a metal
alloy whose major component is iron
and is the most common choice for
structural building materials because of
its strength, versatility, durability and
economic value. Among its most popular
uses today are standing seam metal roofs;
it is also 100% recyclable. Earlier, A7
grade steel was used in the construction
equipment industry. However, A7’s
successor—A36/A36M, the standard
specification for carbon structural
steel—is now widely used in riveted,
bolted or welded construction of bridges
& buildings and for general structural
purposes. As corrosion can harm steel
quality, ultimately contributing to
product failure, protection against rust
and corrosion is critical to the life-span
of steel and its continued use in various
applications and products. Therefore,
steel is protected by a number of
methods ranging from internal alloying
to metallic coatings.
Though these new materials and
alloys provide efficiency and durability
to the construction equipment industry,
they need special attention in machining.
Some of these materials with complex
geometries require multi-axis machining
and tools. They also need high-tech
welding systems.
Machining Technologies In the construction industry, the metals
used for manufacturing the parts change
as per the project and geography.
Often, to manufacture the same kind
of product, two different categories of
metals are required, which call for using
different machining techniques. For
instance, to cut a metal into 3-cm thin
strips, depending on the type of metal,
waterjet or laser cutting technique is
used.
New technologies are continuously
being developed in the construction
industry. They involve special tool
materials & tool geometries and specific
tool design, matching the uniqueness of
operations that are indispensible for the
Construction equipment as a segment faces some fundamental challenges in tool selection, use of materials, operation & maintenance and replacement of equipment components. Nishant Kashyap looks into some of the critical factors that affect the overall dynamics of construction equipment manufacturing.
Manufacturing Modules
July 2012 - MODERN MACHINE TOOLS 107
future growth of the tooling industry.
Methods like laser, plasma, Electrical
Discharge Machining (EDM), waterjet,
etc., are used as per the job specification
and requirements, resulting in better
productivity, speed and reduction in the
cost of machining.
The key to producing quality
work and making wise investment in
equipment is having information on the
type of cutting method that would be
most suitable for a particular application.
While waterjet cutting is perceived as
competing with laser, plasma and EDM,
many shops view these processes as
complementary to each other and use
more than one method.
Advantages of PLMPLM system helps manage product
data and integrate & automate business
processes. Thus, it helps in improving
efficiency, which consequently enables
companies to develop more new
products, shorten time to market, reduce
costs, increase productivity and improve
the quality of products & procedures.
As a result, all major construction
equipment manufacturers have adopted
the PLM solution.
Vivek Marwaha, Director –
Marketing, Siemens PLM Software,
explains, “Three application areas of
PLM have evolved—traditional design
mechanical automation (CAD/CAM/
CAE), digital life-cycle management
and digital manufacturing solution (this
is all about simulation and manipulating
processes, before putting the product
for the actual manufacturing). In an
ideal solution, with the use of digital
manufacturing, a company should
be able to simulate the entire plant/
factory they plan to set up and arrive
at the most optimum architecture for
their new plant/factory.” Huge demand
from the customers and the need to
deliver products in time have made
these companies realise the importance
of using the latest technology to grab
maximum market share. All these
factors have forced PLM solution
providers to offer affordable solutions to
these companies.
Future Trends The current trend in the construction
industry is to minimise the cycle time
& quality variance, and achieve these
objectives with optimum cost by keeping
the effective cost/component as low as
possible. This trend has posed challenges
to metalworking and allied industries
to provide better and cost-effective
solutions to the construction equipment
manufacturers. With the government
determined to increase the contribution
of the infrastructure sector to the national
GDP, the sector will provide immense
opportunities for the metalworking
industry, PLM solution suppliers and
automated (CAD/CAM) solution
providers & material vendors in the form
of simple trading and sourcing, setting up
partnerships, wholly-owned subsidiaries,
manufacturing units and in exploring
technology collaborations in India.
MODERN MACHINE TOOLS - July 2012108
INSIGHTS & OUTLOOKEnergy Magement
The increase in energy costs has made the efficient use of kilowatts more important than ever. European firms have long known this, as energy costs are much higher in Europe than in North America. Although some retrofitting of older equipment may be helpful, newer equipment is designed and built to use less energy than machines put in service only five years ago.
Motors, drives, controls
and machine design
improvements can save
operating cost, thereby
reducing overhead
costs. Some of these advancements are
reviewed below.
Electric Feedback in All Drives Power source regeneration uses the
concept that motors act as generators
whenever they decelerate, which is
about as often as they accelerate. Turret
indexing motors on Index and Traub
machines, for example, are also used
to drive rotating tools, and therefore,
decelerate frequently. With modern
machine tools, it is possible to recover
power from both the axis and spindle
motors.
Regenerative drives on advanced
machines convert the motion energy of
all braking operations on spindles and
axis drives directly into electrical energy
and feed it back to the supply network.
This reduces energy consumption on a
sustainable basis and reduces the heat
emission in the proximity of the machine.
Drives capable of power source
regeneration can redirect it and return it
to the power supply through intelligent
power modules. The result, it has
been estimated, is that power-source
regeneration can cut net energy use by
as much as 40%.
Power source regeneration yields
the best returns for applications with
high speeds and frequent changes in
acceleration. Multi-tasking machines
with multiple tool changes in a cycle
and only one second between cuts means
that the spindle motor has to decelerate
from 8,000 rpm to zero almost instantly.
As the motor decelerates or brakes, a lot
of energy is released. Capturing it and
returning it to the power supply is a
great example of efficiency.
Use of Synchronous Motors Properly sized motors and drives also
add savings. Alternating current (AC)
motors feature a rotor spinning with
coils passing magnets at the same rate
as the AC and resulting magnetic field
that drives it, avoiding energy-wasting
slip under most operating conditions.
They operate synchronously with line
frequency. An induction motor, on the
other hand, slips in order to produce
torque. Synchronous motors are a
highly efficient means of converting
AC energy to work. They are typically
used in positioning machine axes where
high precision and constant speed are
required. Most European builders are
prepared to provide power consumption
details because of the required energy
tags (CE) mandated in Europe.
Reduce Energy Also, there are clever mechanical
designs are also appearing, which reduce
the weight of the axis components in
the machine tool, thus requiring less
USING ENERGY EFFICIENTLYCan Boost Profi tability
ENERGY MANAGEMENTDrives & Motors
MODERN MACHINE TOOLS - July 2012110
Drives & Motors
energy to move them. The turret slides
of an Index automatic lathe move in the
‘X’ and ‘Z’ directions on a single slide,
plate-type slide system. This system,
unique to Index, permits rapids as much
as 60 m/min and accelerations as much
as 1 G while maintaining rigidity. Using
this plate-type guideway for the turret
slides also means that turrets glide
directly on the machine bed, resulting
in high stiffness and dampening, longer
tool life and better surface finish while
reducing energy consumption.
Saving through Shorter Cycle Times As machines use energy when they are
switched on and even more while they
are cutting, the two most cost-effective
options for reducing consumption
are to optimise machine usage and
minimise run time. An idle machine
can use several hundred watts simply at
rest. Properly sized motors and servos
relative to the mechanical weight and
structure of the machine can also save
energy, potentially reducing peak-
power requirements. Plus, they respond
quicker, and therefore, can help reduce
cycle times. Compared with a less well-
designed machine system, it has been
estimated that a machine designed
with this type of efficiency in mind can
save 1 to 2 kW an hour per machine,
per shift.
Reduced Consumption If a machine has some scheduled stops
during the shift or at the end of an
unmanned job, the controller should be
able to turn off affected parts of the
machine—as any PC does. Turning
off motors, such as those running fans,
pumps and chip conveyors, can save a
lot of energy, and while the spindle is
not turning, it may also be powered
down. Adjusting the cycle of the chip
conveyor can contribute to meaningful
energy savings, particularly when
combined with turning it off completely
at the end of production. The automatic
shutdown function of machines today
automatically shuts down all high energy
consuming units after a user-defined
time elapses following an unplanned
production interruption (standby mode).
Centrally Controlled Machine Cooling System Older Direct Current (DC) motors and
some large Variable Frequency Drives
(VFDs) include resistors on top of the
control cabinet to dissipate the heat
directly into the shop. Smaller VFDs,
however, include bleeder resistors inside
the drive housing, which means the heat
is retained inside the cabinet.
In these cases, a larger air conditioner
is installed on the cabinet to protect the
electronics inside. But this arrangement
results in an energy efficiency loss, plus
the electricity to cool the cabinet and/or
the shop costs money.
The cooling concept from Index Corp
cools the spindles, hydraulics and control
cabinet constantly and the captured heat
can be fed to another useful application
via a ‘water interface,’ for example, for
service water heating or as process heat
for other manufacturing steps.
The cold water interface provides
the ability to dissipate heat in a climate-
neutral manner if the machine waste
heat stored in the cooling medium
cannot otherwise be used. The cooling
unit can, with the aid of the water
interface, be used outside the shop as
well as centrally across several machines.
This offers considerable potential energy
savings for shop cooling/climate control,
and/or increased efficiency, as a result of
centralised heat disposal.
Targeted Heat Dissipation All high-loss heat sources of advanced
machines can be cooled directly with
different cooling media via multiple
fluid circuits. In addition to the cooling
circuits for the main spindle, counter
spindle and milling spindles, the
hydraulic system and control cabinet
also have a separate cooling circuit. The
lost heat energy is absorbed directly
in the fluid and conducted from the
machine to a central location.
Offline Simulation Techniques Programme simulation offers a
major opportunity to optimise a
machine’s operation, and therefore,
reduce wasteful, energy-using motion
even before the machine’s power
switch is turned on. Machining
programmes can be created, checked
and optimised on a PC before they
are loaded into the control with 3D
simulation. Optimised cycles permit
field-oriented applications, tested and
reliable operation, maximum flexibility,
shortest possible machining times and
optimum machine usage.
As machines become more
complicated, simulation becomes more
helpful in saving setup time—potentially
50% to 75%—because users do not have
to tool and run the machine to complete a
setup. Machine time is very expensive and
if users can save 50% on setup time, they
can get that much more production out
of a 24-hour day, avoiding machine idle
time and maximising productive time.
Wrapping UpCost savings are where you find them,
and these are only some of the ways
that machine builders are responding to
the demand for more energy-efficient
machine tools. The quest is on, and it’s
delivering tangible results.
� In addition to more energy-eff icient electronics,
such as axis drive and spindle motors,
mechanical designs using less mass are being
incorporated to reduce energy requirements for
motion without sacrif icing rigidity. Courtesy: MMS Magazine
MM
T Ju
ly-2
012
A
d N
ame:
Sam
kris
h P
g N
o. 1
11
MM
T July-2012 Ad N
ame: Shutter Pg N
o. 112
MM
T Ju
ly-2
012
Ad
Nam
e:K
orea
Pg
No.
113
MM
T July-2012 Ad N
ame: G
udel Pg No.114
MODERN MACHINE TOOLS - July 2012116
REPORTACMEE-2012
The year 2012 has been an
excellent one for Tamil
Nadu in striking the best
investment deals. Yet the
amount of investment
trickling in is just the beginning of what
the state has to offer. The 10th edition of
the biennial international machine tools
exhibition, ACMEE-2012, is being
held at just the right time.
Organised by Ambattur Industrial
Estate Manufacturers Association
(AIEMA), the event is the ideal tool for
Chennai to advertise its potential to the
world. ACMEE-2012, was inaugurated
on June 14, 2012, at Chennai Trade
Centre amidst the august presence of
Thiru MC Sampath, Hon’ble Minister
of Rural Industries and Nutritious Noon
Meal. Dr Niranjan Mardi, Principal
Secretary, MSME Department, presided
over the event. Other luminaries who
graced the inauguration ceremony
included Thiru Hans Raj Varma, CMD,
TANSIDCO; P Sriram, Chairman,
CIT; Satish Sadasivan, MD, Schunk
India; John Donlon, Executive VP,
HURCO; Brijesh Agarwal, COO,
Indiamart.com; P Ramdas, MD, ACE;
RSS Satish Babu, Chairman ATC; and
K Ayyappan, President, AIEMA, among
others.
Commenting on the importance of
ACMEE at the inaugural ceremony,
MV Robert, Chairman, ACMEE,
said, “The Government of Tamil
Nadu recently announced its Vision
2023, which focusses on two main
strategic initiatives for upgradation of
manufacturing technology and MSME
development. ACMEE is working
towards this.”
Talking about the extensive growth
in the Ambattur Industrial Estate,
Sampath elaborated that Ambattur,
being one of the oldest industrial
estates in the small and medium sectors,
offers direct and indirect employment
to nearly 2,80,000 people. It has a
turnover of nearly `8,000 crore. He
added, “AIEMA has been established
to champion the cause of the small and
medium sectors, to help voice their
grievances and other difficulties in their
business operations to the government,
and collaborate with the state & central
government agencies to provide suitable
solutions.” ACMEE-2012 saw heavy
participation from overseas delegates,
as well as from companies from all
over India.
Visitors to ACMEE-2012 witnessed
a variety of technologies including
abrasives, automotive component parts
& supplies, bearings, CAD/CAM
solutions, power tools, and low-cost
automation solutions, among others.
Expanding Global ReachThe exhibition has grown exponentially
through each of its 10 editions so far.
This edition had over 430 exhibitors
(both national and international) who
participated in the exhibition. A host of
Tamil Nadu, over the years, has developed the perfect ecology for manufacturing, metalworking and automotive industries. But is that enough? With the exponential growth of the global industry, coupled with rising demands and challenges, the state has to go beyond the conventional to prove itself as an enviable investment destination. Promising to be a platform to upgrade, build technology awareness and foster business prospects, ACMEE-2012 opened its doors for investment to pour in. MMT reports…
Thiru MC Sampath, Minister of Rural Industries and Nutritious Noon Meal
Exhibitions like ACMEE will strengthen the rapid progress and industrialisation in the state and help usher in economic development, not only for the people of Tamil Nadu, but the whole country as well. Trade shows like these also help in extending the benefits of the local industry to various overseas participants.
Broadening the Scope of Opportunities
ACMEE-2012
July 2012 - MODERN MACHINE TOOLS 117
Photos by Prateek Sur
countries participated in the exhibition,
with special pavilions for companies
from Taiwan and South Korea. In-Ho
Shin, President, Korea Machine Tool
Manufacturers’ Association (KOMMA),
expressed, “We had earlier taken part in
the expo held in Bengaluru and realised
that Chennai too is a potential market.
This is the first time we are here with
seven Korean companies.”
He added, “India is the 7th largest
consumer in the world and is one of the
fastest growing industry. Being a major
automotive hub of the country, Chennai
has a huge potential for machine tool
builders. All these make it important
for Korean companies to showcase their
expertise in India.”
Thiru Hans Raj Varma, CMD, Tamilnadu Small Industries Development Corporation Ltd (TANSIDCO)
Dr Niranjan Mardi, Principal Secretary, MSME Department
I congratulate ACMEE-2012 for the overwhelming response that it has received. As a part of the recently released Vision 2023 document for Tamil Nadu, the initiatives taken by government include the allotment of `50 crore for the development of district industrial centres in 32 districts, implementation of common facilitation centres for 20 industrial clusters and programme to encourage first-generation entrepreneurs. The Department acts as a catalyst for the development of the medium-scale industries.
We have been working towards the promotion and development of the MSME industry in Tamil Nadu. We have taken up skill-development initiatives, best technology and management practices for which we are seeking proactive partnership from the industries. We will be further working towards making the MSME industry proactive. Further to this, I complement ACMEE for taking up this initiative of encouraging business in the state.
� Thiru MC Sampath, Hon’ble Minister of
Rural Industries and Nutritious Noon Meal,
Government of Tamil Nadu, inaugurates
ACMEE-2012 by lighting the traditional
lamp in the presence of eminent dignitaries.
� Thiru MC Sampath, Hon’ble Minister of
Rural Industries and Nutritious Noon Meal,
Government of Tamil Nadu, witnesses a live
demonstration at the FANUC stall after the
inauguration.
This was the first time that we exhibited in ACMEE. This exhibition is a way for us to increase our exposure and reach in Chennai. We are the only company exhibiting fully-automated products. Since we displayed our machines and demonstrated the process, the visitors could touch, feel and know the machines better.
The quality of the exhibition has significantly gone up both in the number of participants and the quality of exhibits. My main purpose is to understand the new trends in the market & promote parts & components of my company to the exhibitors here.
The range of exhibits this year is wonderful and I could meet many companies of my interest. I am into valves manufacturing and this exhibition has broadened my knowledge in this segment. The wide range of companies also gives opportunities to strike good deals.
AV Srinivasan, CEO, Meiban Engineering Technologies Pvt Ltd
KS Srinivasan, GM - Marketing, Star Circlips & Engineering Ltd
S Raghuram, Director - Operations, Oliver Valves India Pvt Ltd
We have been regularly participating in ACMEE and have been in association with this show since its 2005 edition. ACMEE is more of a platform to propagate our brand and create awareness about our products among the visitors. We have had a good response and many of the visitors have also shown serious business interest in our products.
Satyanarayanan A, GM - Regional Sales, UCAM Pvt Ltd
Exhibitors’ Views
Visitors’ Views
Taiwan participated with more
than 13 machine and tool companies
in the exhibition. Henry Chen, Chief
Executive, Evergreat Yota Machine Co
Ltd, who participated in this event for
the first time, said, “I was mainly looking
for dealers in India and have already met
some potential clients. Next time, we
would come with bigger stalls and more
machinery to display at the event.”
Other countries present at the
expo included Austria, Australia,
Brazil, China, France, Germany, Italy,
Malaysia, Norway, Russia, Singapore,
Spain, Switzerland, Thailand, Turkey,
the UAE, the USA and the UK.
MODERN MACHINE TOOLS - July 2012118
EVENT PREVIEWAMTEX 2012
The Asian Machine Tools
Exhibition (AMTEX)
has grown by 300% since
its inception 12 years
ago, and has now become
one of the largest shows of machine
tools, machineries and manufacturing
technologies in Asia. It is working
towards creating a platform where
all relevant sectors and technologies
could interact. It offers the exhibitors
an opportunity to present brand new
approaches to enhance productivity by
optimising the production process. Here,
the key industrial sectors can display
their individual strengths, and, at the
same time, engage in interdisciplinary
knowledge transfer.
An International EventThe 8th Indiamart AMTEX 2012, as
in the past editions, will provide its
visitors with technological solutions
to enhance their competitiveness. A
large proportion of visitors from the
metalworking, automobile, aerospace,
industrial automation and general
engineering industries are expected
to visit the exhibition in search of
innovative solutions. It will present the
visitors a unique cross section of key
metalworking technologies.
The grand event would witness
representation from 16 countries
including Germany, Italy, Switzerland,
Czechoslovakia, the US, Sweden,
Belgium, Spain, Israel, Turkey, Japan,
China, Korea, Malaysia, Sri Lanka
and Singapore. Exclusive Chinese,
Taiwanese and Korean pavilions will be
the principal attraction.
Opportunities GaloreAMTEX 2012 will be a splendid
spectacle of the latest advances in
machine tools and manufacturing
solutions. More than 1,600 exhibitors,
sprawled in Hall Nos. 2A, 8, 10, 11,
12 and 15, will be participating in the
event and will put their efficiency and
innovative power to test before eager
national and international visitors.
Terrence Miranda, MD, HAAS
India Pvt Ltd, says, “AMTEX promises
to be a key exhibition for us this year,
which is why we opted to be one of
its sponsors. The events in Europe,
currency fluctuations and global
economic uncertainty are all combining
to create tough trading conditions,
especially for importers like HAAS.
However, irrespective of where a small-
to mid-sized machine shop is based,
they all share the need for reliable,
high-productivity, well-supported and
affordable machine tools.”
Triune Exhibitors Pvt Ltd, India’s leading organiser of industrial exhibitions, is all set to host the 8th
Indiamart AMTEX 2012 at Pragati Maidan, New Delhi, India, from July 27–30, 2012. The exhibition will offer a superlative stage for showcasing the latest in machine tools, be it product service or new-age applications. It facilitates interaction between manufacturers, suppliers and users of the growing Indian market on one platform. Nishant Kashyap reports…
A Gateway to Exciting Opportunities
Exhibitors’ Profile
� Lathes & CNCs
� Machining centres
� Electric Discharge Machines
� Hydraulic, mechanical &
pneumatic presses
� Shearing and bending machines
� Metal-forming machine tools
� Drilling and boring machines
� Milling and grinding machines
� Gear-cutting and finishing
machines
� Assembling systems & industrial
robots
� Sawing and cutting machines
� Measuring and testing
instruments
(This list is only illustrative and features only a
limited number of profiles.)
Event List - National
MODERN MACHINE TOOLS - July 2012120
AMTEX 2012AMTEX (Asian Machine Tools Exhibition)
has constantly strengthened its position as
one of the largest shows of machine tools,
machineries and manufacturing technologies
in Asia. The event will showcase the latest
advances in machine tools and manufacturing
solutions; July 27-30, 2012; Pragati Maidan,
New Delhi.
For details, contact:
Triune Exhibitors Pvt Ltd
25, 3rd Floor, 8th Main Road
Vasanthnagar, Bangalore 560 052
Tel: +91 80 4330 7474
Fax: +91 80 2235 2772
Email: [email protected]
Web: www.triuneexhibitors.com
Automation 2012The event will showcase the power of
collaboration between solution providers,
ie, vendors, engineering companies
and actual users of the technology. The
conference held during the course of the
event also provides an excellent insight in
the latest practices; September 7–10, 2012,
Bombay Exhibition Centre, Mumbai
For details, contact:
IED Communications Ltd,
243, Shiv Shakti Industrial Estate,
Marol, Andheri Kurla Road,
Opp Mittal Estate, Andheri (E)
Mumbai 400059
Tel: 28505138/ 28514673
India Manufacturing Show 2012 The exhibition is an ideal platform of
all Indian and global manufacturing,
engineering and other ancillary industries
including Public Sector Undertakings
(PSUs), especially for the micro, small and
medium enterprises; September 27-30,
2012; Bangalore International Centre,
Bengaluru.
For details, contact:
IMS Foundation
#15/47, 47th A Cross, 8th Block, Jayanagar
Near Gelli Apartments, Bengaluru
Tel: 80 2665 1234/4171 6085
Email: [email protected]
Web: www.indiamanufacturingshow.com
CeMAT India 2012One-stop shop for the automotive and
transport, infrastructure, manufacturing,
pharmaceuticals, dry ports, steel and food
processing sectors; November 21-24, 2012;
India Expo Centre, Delhi.
For details, contact:
Hannover Milano Fairs India Pvt Ltd
No 13/16, Vatika Business Centre
Wing B, 7th Floor, Supreme Business
Park, Hiranandani Gardens,
Powai, Mumbai 400076
Tel: 91 22 40050681/82
Fax: 91 22 40050683
Email: [email protected]
Web: www.cemat-india.com
Industrial Automation India 2012International trade fair for process &
production, automation and industrial
building automation; November 21-24,
2012; India Expo Center, Delhi.
For details, contact:
Hannover Milano Fairs India Pvt Ltd
No 13/16, Vatika Business Centre
Wing B, 7th Floor, Supreme Business
Park, Hiranandani Gardens,
Powai, Mumbai 400076
Tel: 91 22 40050681/82
Fax: 91 22 40050683
Email: [email protected]
Web: www.ia-india.com
IMTEX 2013The 16th Indian Metal-cutting Machine Tool
Exhibition, with international participation,
will showcase the exhaustive range of
innovations and technological refinements
in the complete product segment of metal-
cutting machine tools and manufacturing
solutions.
The concurrent event—Tooltech 2011—
the international exhibition of cutting tools,
tooling systems, machine tool accessories,
metrology and CAD/CAM, will feature
the latest trends in cutting tools and tooling
systems from across the globe; January
24-30, 2013; at Bangalore International
Exhibition Centre (BIEC), Bengaluru.
For details, contact:
Indian Machine Tool Manufacturers’
Association
Bangalore International Exhibition
Centre, 10th Mile, Tumkur Road
Madavara Post, Bengaluru
Tel: 080 6624 6600
Fax: 080 6624 6661
Email: [email protected]
Web: 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
Infomedia18 Ltd, Ruby House, 1st Floor, JK Sawant Marg, Dadar (W), Mumbai 400 028.
Mob: 09819552270 • Fax: 022 3003 4499 • Email: [email protected]
• Web: www.engg-expo.com
LUDHIANAPunjab
Dec 21-24, 2012
AHMEDABADGujarat
Oct 5-8, 2012
CHENNAITamil Nadu
Nov 22-25, 2012
PUNEMaharastra
Nov 2-5, 2012
INDOREMadhya Pradesh
Jan 11-14, 2013
AURANGABADMaharastra
Feb 1-4, 2013
RUDRAPURUttarakhand
Feb 23-26, 2013
Event List - International
July 2012 - MODERN MACHINE TOOLS 121
MTA VIETNAM 2012 The 10th exhibition will serve as a platform to
network with pioneers from machine tools,
precision engineering and metalworking
technology sector; July 3–6, 2012; Saigon
Exhibition & Convention Centre, Ho Chi
Minh City, Vietnam.
For details, contact:
Singapore Exhibition Services Pte Ltd
1 Jalan Kilang Timor
09-02 Pacific Tech Centre
Singapore 159303
Tel: +65 6233 6638, Fax: +65 6233 6633
Email: [email protected]
Web: www.mtavietnam.com
IMTS 2012 America’s largest manufacturing
show—the International Manufacturing
Technology Show (IMTS) 2012—is
one of the largest global industrial trade
shows, with over 1,100 exhibitors &
82,000 visitors; September 10–15, 2012,
McCormick Place, Chicago, USA.
For details, contact:
The Association for Manufacturing
Technology
John Krisko, AMT Director –
Exhibitions
7901 Westpark Drive, McLean,
VA 22102-4206, USA
Tel: 703-827-5252
Fax: 703-827-5250
Email: [email protected]
Web: www.imts.com
AsiaMold 2012Innovative technologies, informative
events and increasing business
opportunities make the exhibition the
most distinguished mould-making and
tooling design exhibition; September
19-21, 2012; Guangzhou Poly World
Trade Center, China.
For details, contact:
DEMAT GmbH
Carl-von-Noorden-Platz 5
60596 Frankfurt/Main
Tel: +49/69/27 40 03-0
Email: [email protected]
Web: www.asiamold.de
BI-MUThe 28th international event will
showcase latest in metal-forming
& metal-cutting machines, robots,
automation and auxiliary technologies;
October 2-6, 2012; Fiera Milano, Italy.
For details, contact:
BI-MU c/o
CEU-CENTRO ESPOSIZIONI
UCIMU SPA
viale Fulvio Testi 128
20092 Cinisello Balsamo MI, Italy
Tel: +39 0226 255 234/860
Fax: +39 0226 255 897
Email: [email protected]
Web: www.bimu-sfortec.com
METALEX Vietnam 2012 The international exhibition will be
the all-under-one-roof meeting centre
for new machine tools, metalworking
technologies; October 4-6, 2012; Saigon
Exhibition & Convention Center
(SECC), Vietnam.
For details, contact:
32nd floor, Sathorn Nakorn Tower,
North Sathon Road, Silom, Bangrak
Bangkok, Thailand
Tel: +66 2686 7299, Fax: +66 2686 7288
Email: [email protected]
Web: www.reedtradex.com
EuroBLECH 2012The world’s largest International Sheet
Metal Working Technology Exhibition
will emphasise on energy-efficient
technology, environment-friendly
manufacturing processes and intelligent
use of material; October 23 -27, 2012;
Hanover, Germany.
For details, contact:
Mack Brooks Exhibitions
Romeland House, Romeland Hill
St Albans, Herts AL3 4ET, UK
Tel: +44 0 1727 814400
Fax: +44 0 1727 814401
Email: [email protected]
Web: www.euroblech.com
JIMTOFThe 26th Japan International Machine
Tool Fair will contribute to the
promotion of industry and trade through
increased international transactions and
technical exchanges of machine tools
and their related equipment; November
1-6, 2012; Tokyo Big Sight (Tokyo
International Exhibition Center), Japan.
For details, contact:
JIMTOF Fair Management
(Tokyo Big Sight Inc.)
3-11-1 Ariake Koto Tokyo,
JAPAN 135-0063
Tel: 03 5530 1333 (Direct dialing)
Fax: 03 5530 1222
Web: www.jimtof.org
EuroMold 2012International trade fair for Moldmaking
and Tooling, Design and Application
Development; November 27-30, 2012;
Frankfurt, Germany.
For details, contact:
DEMAT GmbH
Carl-von-Noorden-Platz 5
60596 Frankfurt am Main
Germany
Tel: +49 69 27 40 03 - 0
Fax: +49 69 27 40 03 - 40
Email: [email protected]
Web: www.euromold.com
Th e 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
Tenders
MODERN MACHINE TOOLS - July 2012122
Latest Popular Tenders brought to you by www.tendersinfo.com
Org: Organisation’s name, TRN: Tendersinfo Ref No, Desc: Description, DSLD: Doc Sale Last Date, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type.
INFORMATION COURTESY: TENDERSINFO.COM1, Arch Gold, Next to MTNL Exchange, Poisar, S.V. Road, Kandivali (W), Mumbai - 400067, Maharashtra, India
Tel: +91-22-28666134 • Fax: +91-22-28013817 • Email: [email protected]
CNC MACHINING CENTRE
Org : Ordnance Factory Board
TRN : 11519333
Desc : Tenders are invited for supply of CNC Machining Centre for 03 Nos.
BOD : July 17, 2012
LOC : India
BT : Tender
SB CNC TURNING CENTRE
Org : Ordnance Factory Katni
TRN : 11495402
Desc : Tenders are invited for supply of double-ended pedestel grinding machine.
BOD : July 18, 2012
LOC : India
BT : Tender
2000 MM LATHE MACHINE
Org : Ministry of Defence
TRN : 11481955
Desc : Tenders are invited for supply of 02 Nos of 2000 mm Lathe Machine
BOD : July 10, 2012
LOC : India
BT : Tender
TOOLED UP CNC CYLINDRICAL GRINDING MACHINE
Org : Rifle Factory
TRN : 11463998
Desc : Tenders are invited for supply of tooled up CNC Cylindrical Grinding Machine for grinding operation of barrel of 5.56 mm Insas Rifle, 0.315” Sporting Rifle & 30.06 Sporting Rifle
BOD : July 31, 2012
LOC : India
BT : Tender
CNC LASE CUTTING MACHINE BELLOWS
Org : Diesel Locomotive Works
TRN : 11419450
Desc : Tenders are invited for supply of spare parts for CNC laser cutting machine bellows with
installtion and commissioning
BOD : July 2, 2012
LOC : India
BT : Tender
UNIVERSAL AXLE JOURNAL TURNING & BUMISHING LATHE
Org : Central Organisation For Modernsation Of Works (Indian Railways)
TRN : 11434696
Desc : Tenders are invited for Universal Axle Journal Turning & Bumishing Lathe (BG).
BOD : July 26, 2012
LOC : India
BT : Tender
CNC POLISHING MACHINE
Org : Opto Electronics Factory
TRN : 11287027
Desc : Tenders are invited for supply, erection, commissioning & proving of CNC polishing machine.
BOD : July 2, 2012
LOC : India
BT : Tender
CNC BILLET CUTTING MACHINE
Org : Hindustan Aeronautics Limited
TRN : 11174699
Desc : Tenders are invited for CNC Billet Cutting Machine with accessories.
BOD : July 4, 2012
LOC : India
BT : Tender
DEVELOP A MANUFACTURING GROWTH CENTRE FOR INCLUDING A SWITCHGEAR UNIT AND ANOTHER TO MAKE PRECISION TOOLS, DIES AND COMPONENTS FOR THE AVIATION INDUSTRY
Org : Larsen & Toubro Limited
LOC : India
Contact : Larsen & Toubro Limited, L&T House, Ballard Estate, Tel: 91 22 22685656 Fax: 91 22 22685858, Mumbai, Maharashtra 400001, India
Products - National
MODERN MACHINE TOOLS - July 2012124
This section gives information about the national and international products available in the market
Looking For A Specific Product?Searching and sourcing products were never so easy.
Just type MMT (space) Product Name
and send it to 51818eg. MMT EDM and send it to 51818
CNC swiss machineThis CNC lathe features heavily ribbed cast-iron construction to dampen cutting vibration for enhanced productivity, superior surface finish and improved tool life. A 10-HP Mitsubishi spindle motor drives the powerful 6,000-RPM spindle. Both the main and sub spindle use 32mm Traub A-32 collets for easy part transfer and complete “done-in-one” machining efficiency, including all radial, end-working, and Y-axis live tooling work on both the front and backside of the part. It weighs over 7800 pounds, making it the heaviest machine in its class.
Ganesh Machinery, Inc
New Delhi
Tel: 818-3499166
Mob: +91-9810133968
Email: [email protected]
Website: www.ganeshmachinery.com
Solid state relaysThese solid state relays features 5mm wide pluggable/PCB mountable single-in-line AC and DC output SSRs, single channel DRS series sockets for CN series SSRs, and DIN rail mounted CNseries SSR/socket assemblies. These relays meet industry standard pin out configurations for both solid state and electromechanical relays and are designed for plugging into Crydom DRSCN series sockets or soldering into printed circuit boards. The marker strips for the sockets are also offered to allow easy circuit function identification for each socket.
CST Sensors India Pvt Ltd
Bengaluru - Karnataka
Tel: +91-080-41132204
Email: [email protected]
Website: www.cstsensors.com
Flange facer The electro-mechanical flange facer is offered for ID clamping or OD clamps or face clamping, depending upon the job requirement. The flange facer consists of a rotary drive unit, horizontal arm, electrical control panel & operator’s console. Powered quill mechanism is optionally offered for depth of cut setting and for boring operations. The spindle (rotary drive shaft) is supported by a
pair of heavy duty taper roller bearings in the front and by a pair of ball bearings in the other end. Bearings are lubricated for life with molybdenum sulfide grease. The rotary movement ranges from 2 to 20 rpm in a step-less range through vector VFD. The spindle is made of EN-24, hardened and ground. The box type ram and the ram housing are made of high grade CI.
Shenoy Engineering Pvt Ltd
Bengaluru - Karnataka
Tel: +91-080-28361767
Email: [email protected]
Website: www.spm-india.com
Radial drilling machineThis machine is used for radial drilling. It has 16 steps of spindle speed & feed which brings about economic & high-efficiency cutting. All mechanical & electrical controls are centralized on headstock. Clamping for assemblies & speed change of spindles is done by hydraulic power. Maximum drilling diameter is 50 and range of spindle speeds lie between 25-2000 r/min.
Macht Exim LLP.
Ahmedabad - Gujarat
Tel: +91-79-40087600
Mob: 9925700006
Email: [email protected]
Website: www.machtexim.com
Peening machineThe machine consists of robustly built and sturdy blast cabinet having servo driven rotary turn table. A six-axis robot with controller unit with teach pendant is stationed inside the cabinet having arm provided with sand blasting hose pipe with boron carbide long nozzle for peening application. The media recovery system consists of vacuum recovery unit with double chamber pressure blaster for continuous shot peening operation. Online spiral separator is provided for removing broken shots, hollow shots & shot with sharp edge. The cartridge type dust collector is provided for ventilating blast cabinet. The movement of robotic arm is pre-
Products - National
July 2012 - MODERN MACHINE TOOLS 125
programmed as per job requirement for peening application. The quantity of shots to air ratio is precisely monitored by magna valve provided at the outlet of bottom chamber.
Surface Finishing Equipment Co
Jodhpur - Rajasthan
Tel: +91-0291-2740128,+91-291-5120021
Email: [email protected]
Website: www.sfecindia.net
Junction boxesThe output junction box has t r a n s m i s s i o n range up to 50 to 60 meters for indoor application and 1.2 km for outdoor application. Its working band of frequency is 2.4 GHz. It accepts 24 V DC as a supply voltage. It has a very wide application in the field of machine to machine communication. It accepts M12 socket connection of sensor / input.
Katlax Enterprises Pvt Ltd
Gandhinagar - Gujarat
Tel: +91-2764-286784
Mob: 09724506614
Email: [email protected]
Website: www.katlax.com
Products - National
MODERN MACHINE TOOLS - July 2012126
Digital readoutIt can be used to replace many models of competitive digital readout displays. It accepts 5v quadrature encoder feedback (TTL) and is compatible with many models of Acu-Rite, Anilam, Mitutoyo, Fagor linear encoders as well as several others. Adapter cables are available for many models. Topaz Digital is available in 2 and 3 axis variants and is also available for Mill and Lathe applications. They are available in two versions, SA100 and SA100-R, where SA100-R is the rotary version of the SA100.
CST Sensors India Pvt Ltd
Bengaluru - Karnataka
Tel: +91-080-41132204
Email: [email protected]
Website: www.cstsensors.com
CNC LatheThis twin spindle CNC lathe is equipped with 2 Strong headstock and spindles assembled with angular contact bearings for more powerful cutting. Spindle speed is 300-3000 RPM. Spindles can be either mounted with Colet system or pneumatic or hydraulic type. Two main motors provided for more speed range to complete various turning and machining, even powerful cross drilling or milling head can be provided for turn milling option. Machines can be provided with either single CNC system or Double CNC system. This machine will be very useful for manufacturing auto parts, textile parts and motor parts.
Arrow Machine Tools
Chennai - Tamil Nadu
Tel: 044-2658 2694,09840236534
Email: [email protected]
Website: www.arrowmachinetool.com`
Treated fresh air unitsThe DRI TFA is manufactured in accordance with the best technology in casing manufacturing. It offers all the prerequisites for creating a ventilation system with the lowest running costs possible to suit retail application with the added advantage of Energy Recovery which cuts down the aircon costs. The FlexAir Treated Fresh Air Units with Eco-Fresh Molecular Sieve Coated Heat Wheel inside provides a complete solution for IAQ and Energy Saving in a single unit, with the option to add modules for cooling, heating, humidification, high efficiency filtration, mixing, sound
Products - National
July 2012 - MODERN MACHINE TOOLS 129
attenuation, etc. The FlexAir Series TFA from DRI is designed in accordance with European Standard for leakage Class B. All functions like coils, heat exchangers etc. are optimized to give lowest possible pressure drop in proportion to highest possible efficiency resulting in very low LCC. Deep folded bag filters with big filter areas and good sealing. The good tightness ensures clean air supply to the room is of high quality.
Desiccant Rotors International Pvt Ltd
Gurgaon - Haryana
Tel: 91-0124-4188888
Email: [email protected]
Website: www.drirotors.com
Heavy- duty lathe machineThis extra h e a v y duty lathe m a c h i n e VEH is o f f e r e d
with height of centre up to 1066 mm, length of bed ranging up to 12000 mm, between centres up to 11000 mm, main spindle hollow ranging 150 mm and main spindle nose is A2-12 type. Dynamically balanced spindle enable the spindle run at vibration free motion. The spindle carries the 10 T job weight. The norton gear box is able to cut the any of metric, modules and pitch. The bed is made from graded cast iron. Also offered are face plate, carrier plate, steady rest, follow rest, motorised coolant pump with tank and fittings, rear tool post, quick change tool post. The machine is maintenance free and is easy to use.
Vinit Engineering Works
Rajkot - Gujarat
Tel: 0281-2311734 ,09879022052
Email: [email protected]
Website: www.balajilathe.com
affordable media blasting to clean, peen, deburr, or finish parts. The larger enclosure (50” x 39” x 43” tall) accepts powered turntables. The suction blast cabinet come with a unique pilot actuated air logic system to maximise airflow to the blast gun.
Prism Surface Coatings (P) Ltd
Bengaluru - Karnataka
Tel: +91-8110-417999,09844400285
Email: [email protected]
Website: www.prismsurface.com
Website: www.prismsurface.com
Abrasive blasting machinesThese air-powered blasting machines are used to clean, deburr, shot peen and to remove coatings. The 4,500 litre capacity unit supports four blasters and is widely used for long duration of blasting in
ship building industry and on site structures and large f abr i c a t ions . The BNP 220 pressure blast cabinets deliver e f f i c i e n t ,
Products - National
MODERN MACHINE TOOLS - July 2012130
HMC MachineHorizontal machine center machine H630B incorporates the optimum machine structure design and the latest technology with versatile features to suit different applications from heavy duty die mold application to feather weight aluminum auto component without bottleneck; H630B extended its strength for flexible manufacturing needs with programmed six pallets changer with the user friendly software that enhances scheduling efficiency, reduces non cutting time and boosting high productivity. The integrated built-in-high precision spindle is powered by 30 KW for zero vibration cutting, the entire axis are equipped with high performance digital servo to match the speed with very little power.
S&T Engineers Pvt Ltd
Coimbatore - Tamil Nadu
Tel: +91-0422-2590810, Mob: 9489079060
Email: [email protected]
Website: www.stengineers.com
SoftwareThis EPLAN software keeps users flexible in the process and the new update macros function makes sure that all data is updated to the most current state, either individually or automatically. Partial circuits can been inserted and can be updated effortlessly. Macro master data changes can easily be adopted into currently active specific projects. These high-quality templates gives consistent quality in the project and a standardised engineering process. The check run messages highlighted in message management can be synchronised with the opened navigators. The user can apply check routines specifically to newly entered corrections during a project edit.
Rittal India Pvt Ltd
Bengaluru - Karnataka
Tel: +91-080-41515497
Email: [email protected]
Website: www.eplan.in
Corrosion protectionThe ECP (Enhanced Corrosion Protection) has been established which can provide an improved rust resistance over 120 hours in salt spray atmosphere. It has a zinc coating with black passivation for valve component parts in steel and cast iron, black opaque anodizing for aluminium caps, electronic boxes and protection and natural gloss light grey anodizing for aluminium name plates. It also provides black plastic encapsulation (Rynite) for other coils and for coil’s nut rings
ATOS SPA
Bengaluru - Karnataka
Tel: +91-80-23613840
Email: [email protected], Website: www.atos.com
MM
T Ju
ly-2
012
A
d N
ame:
Sam
kris
h P
g N
o. 1
31
MM
T July-2012 Ad N
ame:C
otec Pg No. 132
MM
T Ju
ly-2
012
A
d N
ame:
Hyu
ndai
Pg
No.
133
MM
T July-2012 Ad N
ame: U
niversal Pg No. 134
Products - National
July 2012 - MODERN MACHINE TOOLS 137
Machine oilSpecialized “Electrical Discharge Machining” (EDM) Oil is highly refined mineral oil with low viscosity which is free from aromatics and unsaturated hydrocarbons especially applicable for “Spark Erosion Metal Working Operations”. It is colourless and odourless, making it operator-friendly. This oil, which is neutral and pure, can substantially reduce the chance of effects on skin of the operators. Its lower viscosity improves flushing and fast particle settling and both of these contribute to faster machining rates and fine surface finishes. Also low aromatic content eliminates smoking during machining and higher flash point ensures safety of the environment. It has exceptional long service life due to stability towards thermal oxidation. It is used in as Dielectric fluid in finish-cut electrical discharge (spark erosion) machining operations. It is also used in manufacture of electronics, extrusions, air-craft components, hardware, tools, fasteners, silver-ware, cutlery, valves and regulators etc.
Eastern Petroleum Pvt Ltd
Mumbai - Maharashtra
Tel: 022-2529 9990,09821531709
Email: off [email protected]
Website: www.easternpetroleum.in
Products - National
MODERN MACHINE TOOLS - July 2012138
Lathe chuckThe Rota-S plus lathe chuck has an optimized wedge bar drive system and an improved lubricant system ensure consistently high clamping forces from the new lathe chuck. Since higher speeds and cutting speeds are possible, users can apply more efficient cutting materials, which shorten the manufacturing time. An optimized drive allows fast, comfortable, and repeat accurate jaw changes. This lathe chuck is fully compatible, and already existing base jaws can be used in it. Its unique three-fold jaw safety device prevents operating errors. It has located an indicator pin at the chuck circumference, which displays the individual clamping status. Protection sleeve system and expansion arbor are categorized as additional equipments.
Schunk Intec India Pvt Ltd
Bengaluru - Karnataka
Tel: +91-080-40538999
Mob: 09741211766
Email: [email protected]
Website: www.in.schunk.com
Auto tool settersThese TM26 auto tool setters are direct acting type, specially designed for CNC machining centres with IP67 Protection. Basically it is used for length detection of tools such as drills,
BP Bharti,
Managing Director,
Rightvision (India) Private Limited
I am glad to share with the readers that advertisements in SEARCH
have fetched us a contract of €3 million from the Indian markets. I
really would like to thank them for the support and my best wishes
to them.
Products - National
MODERN MACHINE TOOLS - July 2012140
end mills, and cutters mounted on machining centres, drilling machines, milling machines, and boring machines. It can detect tool wear while accommodating the thermal expansion of the machine for the compensation. The operating speed is 100~200 mm/min, parallelism of contact is 0.01 / 12 mm, stroke is 5 mm & contact rating is DC24V 20mA(max).
Metrol Corporation India
Bengaluru - Karnataka
Tel: +91-080-42105031
Email: [email protected]
Website: http://www.metrol.co.jp/en/
lightweight Lathe chuckCompared with conventional power chucks, the weight of the ROTA NCL in steel version is reduced by 35%, in aluminum by 54%, and in carbon by 62%. Only the steel chuck is in series production. The patent pending double cylinder version of the base jaws ensures that the forces are optimally distributed on the chuck body. For fully maintaining clamping force, rigidity, and precision, every
Products - National
MODERN MACHINE TOOLS - July 2012142
component which is in the direct flux of force are made of extremely resistant hardened steel. The chuck bodies themselves are completely made of steel, aluminum or CFK.
Schunk Intec India Pvt Ltd
Bengaluru - Karnataka
Tel: +91-080-40538999
Mob: 09741211766
Email: [email protected]
Website: www.in.schunk.com
AC drivesThe Vacon 20 series incorporates a built-in programmable logic controller(PLC) functionality which conforms to the IEC61131-3 standard. In addition, the functionality can be extended via optional modules, including field bus cards and tools for easy parameter copying from one unit to another. Efficient volume manufacturing is possible as they are fast to install and easy to set up. Also, the products can be modified and tailored to the needs of the customer.
Vacon Drives & Controls Pvt Ltd
Chennai - Tamil Nadu
Tel: +91-044-24490024
Email: [email protected]
Website: www.vacon.com
Back artwork
Front artwork
Products - National
July 2012 - MODERN MACHINE TOOLS 145
Buffing & polishing machineThis machine is used for mirror finishing of stainless steel, aluminum pots & pans, pressure cookers, water filter, mixer jars & hollowware in general. The job to be polished is held by specially developed vacuum chucking system. The machine is operated pneumatically and controlled by relay logic (optional PLC). Automatic buff wear compensation ensures consistent finish and high productivity. The buffing can be done by unskilled operator.
Grind Master Machines Pvt Ltd
Aurangabad - Maharashtra
Tel: +91-240-2376262
Email: [email protected]
Website: www.grindmaster.co.in
Surface grinding machineThe surface grinding machine ranges are 150 x 450 to 1600 x 6000mm with various types of machines. The main spindle is cartridge type which ensures the spindle run out with in 2μ and completely sealed and lubricated for high durability and accuracy. The base is one piece design and having good rigidity, the movement and durable accuracy, the hydraulic pumps are vane pumps and having the high precision direction control valves
Products - National
MODERN MACHINE TOOLS - July 2012146
Hydrogen gas detection systemThis hydrogen gas detection system is used for detection of hydrogen gas. It uses a 3-status technology which displays in terms of low/medium/high concentration. It has selectable slide switch for audio & visual built-in solid state buzzer. The system has the facility to function five gas detectors with independent alarm latching facility, potential free N.O/N.C contact, and recorder output. The system is equipped with 4-wire technology and maturity timer.
Subtronics (India) Pvt Ltd
Mumbai - Maharashtra
Tel: 022-2422 4461
Email: [email protected]
Website: www.subtronicsindia.com
and cross feed driven by ball screw with higher cost can obtain a grinding effect of more smooth and high precision and maintain longer life.
S&T Engineers Pvt Ltd
Coimbatore - Tamil Nadu
Tel: +91-0422-2590810,+91-0422-2593487
Mob: 9489079060
Email: [email protected]
Website: www.stengineers.com
Ashok Kumar Gupta,
Chairman, Crane-Bel
Hydraulics
We are pleased to share with the readers that SEARCH has helped us to reach out to our customers with the new launch of the high performance product range of EATON VICKERS. We have been able to achieve it through advertisements and product profiles, which have been continuously published in this excellent magazine having a good reach in the industry, especially in the widely spread industrial areas such as Uttar Pradesh and Uttarakhand.
We have been able to promote the exclusive range of EATON VICKERS Hydraulic products in our target sectors of whole U P and Uttarakhand to our entire satisfaction and able to increase our turnover to a big extent.
Products - National
July 2012 - MODERN MACHINE TOOLS 149
Breath analyser with printerIt detects alcohol in the breath and gives an audio-visual indication. It has 3-status technology which includes bright graphic display, easy & quick testing, reading latching, non-volatile memory, password protected critical menu settings, subject sample blow indicator, print readings with data & time, user selectable multiple number of prints for evidential record documentation etc. The instrument is housed in a robust plastic enclosure.
Subtronics (India) Pvt Ltd
Mumbai - Maharashtra
Tel: 022-2422 4461
Email: [email protected]
Website: www.subtronicsindia.com
Honing machineThis ML-2000 power stroked honing machine has twice the power and more speed than older style honing machines. It has fast & easy setup. Complete setup is handled from the front of the machine without raising a cover. It has unique roll-out coolant cart for easy maintenance and coolant changeover. It can be used with sunnen’s turbo hone multi-stone mandrels for fast stock removal. It is built to be durable with a rigid machine base constructed of reinforced structural steel and cast iron. It offers lifetime application service with every machine purchase. The diameter range depends on manual stroking, power stroking & automatic sizing. It has a stroke length of 6 to 170 mm.
Omira Marketing Pvt. Ltd.
Mumbai - Maharashtra
Tel: +91-22-26400791, 91-22-26165032
Email: [email protected]
Website: www.omira.co.in
Grinding / Polishing MachinesThese Direct Drive Tool Post Grinding / Polishing Machines are specially designed for use on lathes, shapers, and planer machine etc. for operations like cylindrical external grinding, face / radius / surface grinding. It has a heavy duty direct drive head complete with motor, bearing loaded spindle, sturdy guard & mounting plate. Direct Drive Grinders
are available in 1 HP & 2 HP, 2800 RPM,200 diam. & 25 mm width whereas Direct Drive Polishers are available in 2 HP & 3 HP, 2800 RPM, 300 diam. & 50mm.
Prem Brothers
New Delhi
Tel: 011 28117456, 28117464, 45595068
Email: [email protected], Website: www.powermaster-india.com
Products - National
MODERN MACHINE TOOLS - July 2012150
Conical nozzle torchThese conical nozzle torches of duramax are available for five more plasma cutting systems: Powermax600, Powermax800, Powermax900, MAX42, and MAX43. Duramax series of torches, provide more reliable arc starting. They also enable consumables to last up to six times longer.
Hypertherm (India) Thermal Cutting Pvt Ltd
Chennai - Tamil Nadu
Tel: +91-044-28345361
Email: [email protected], Website: www.hypertherm.com
Bandsaw machinesThe bandsaw machines use linear motion (LM) guides and bearings instead of conventional hard chrome plated columns and bushes for sliding of cutting arm. With the use of LM guides the up-down movements of cutting arm is very smooth leading to productivity. The steel enclosure is provided to prevent coolant from splashing and spillage.
ITL Industries Ltd
Indore - Madhya Pradesh
Tel: +91-0731-3044400
Email: [email protected], Website: www.itl.co.in
Pankaj Dhingra,
Properiter
Prem Brothers
Advertisement of our products in Modern Machine Tools (MMT) has increased our exposure to prospective customers, helping us enhance our reach to clients all over India.
The quality and presentation of the magazine is appealing at the first look, inducing readers and subscribers to go through its informative articles and product advertisements.
A truly modern magazine having useful articles on the latest innovations and technologies.
Products - National
MODERN MACHINE TOOLS - July 2012152
Panel Air ConditionerPanel Air Conditioners are used to dissipate heat generated by AC/DC drives, Electrical/Electronic components inside a control panel. In industries environment is hot and to avoid entry of dust, dirt and moisture inside the panel use of ambient air is refrained and a closed loop air conditioner is used to maintain desired temperature.
Reliance Engineering Company
Coimbatore - Tamil Nadu
Tel: 91-0422-6538340, Mob: 09244420143
Email: [email protected]
Website: www.relianceengineeringcompany.com
Variable speed polishing machinesThese machines are specially designed for flexible operation of polishing by varying R.P.M on the same machine. Different finish can be obtained using the same buff at different R.P.M. It is a robust design double ended machine 7.5 KW of 10 HP, has a variable RPM stepless of 500-3500 max. It has dust covers with dust collector electro-magnetic brake for instant stopping.
Prem Brothers
New Delhi – 110 064
Tel : 011 28117456, 28117464, 45595068
Email: [email protected], Website: www.powermaster-india.com
MM
T Ju
ly-2
012
A
d N
ame:
Cer
tazi
t P
g N
o. 1
53
MM
T July-2012 Ad N
ame: M
acpower Pg N
o. 154
MM
T Ju
ly-2
012
A
d N
ame:
Aus
tin P
g N
o. 1
55
MM
T July-2012 Ad N
ame: EngExpo Pg N
o. 156
Products - National
July 2012 - MODERN MACHINE TOOLS 157
Energy recovery ventilatorThey are capable of recovering upto 80% of sensible and latent energy from the stale exhaust air and transferring it to the fresh outside air. The heart of the ERV is the Eco-Fresh desiccant coated energy recovery wheel, which slowly rotates between its two sections. The stale air is passed through the wheel, and exhausted to the atmosphere. The wheel absorbs sensible and latent energy from the conditioned air, which is used to pre-condition the incoming fresh air in the other section, during the second half of its rotation cycle. The rotating wheel transfers the sensible and latent energy between the counter flowing exhaust and supply air and in the process preconditions (cool/ heat/ dehumidify/ humidify) the fresh air.
Desiccant Rotors International Pvt Ltd
Gurgaon - Haryana
Tel: 91-0124-4188888
Email: [email protected]
Website: www.drirotors.com
Power cuttersThe Nile pneumatic Nipper can cut metallic wires, aluminium cables, piano wires, gold, steel wires up to diam. 6 mm, Copper up to diam. 7 mm, Soft plastic up to diam. 13 mm, and hard plastics up to diam. 4.5 mm. Just by changing the blades, several
Products - National
MODERN MACHINE TOOLS - July 2012158
manufacturing applications are possible with same types of tools. They are of light weight & have long life.
Arhan Technologies Pvt Ltd
Pune - Maharashtra
Tel: +91-20-65603200
Email: [email protected]
Website: www.arhan.co.in
CirclipsThe circlips are used for restraining axial movement of components of shafts and where there are space restrictions. They are also applicable in small mechanism. They are manufactured from suitable high carbon steel, such as C80 of IS: 1570-19621 or EN42J. They are hardened and tempered. They are also available in SS-304 materials of construction.
R K Engineering Company
Mumbai - Maharashtra
Tel: +91-022-22671141
Email: [email protected]
Website: www.rkengineeringco.com
Products - National
July 2012 - MODERN MACHINE TOOLS 161
Mini Jewel Foot SwitchIt has a 3 Terminal Micro Switch, 1 Common Change Over to NO/NC & Foot Switch is Powder Coated in Black Structure Coating. These are available in current range of 10A/250VAC, 15A/250VAC & 10A/500VAC. Dimension is 95X70X25 & Weight is 300gms. Two core 2 meter wires provided with the Switch free.
Precision switchgear industries
Mumbai - Maharashtra
Tel.: 02522 – 645770, Mobile: 09225100895.
Email: [email protected], Website: www.footswitch.co.in
Induction cap sealerThe water cooled Fluxosealer AFX3000 is a heavy duty induction cap sealer for high speed sealing and special applications. Bottles with neck diameters ranging from 10mm to 150mm can be sealed with ease. Standard features include no foil detection system which consists of sensors to detect induction seal inside the cap, easy line relocation & plug & play system. Enclosure is of MS Powder coated/SS304.
Arshad Electronics Pvt Ltd
Mumbai - Maharashtra
Tel: +91-022-24451709
Email: [email protected], Website: www.arshadelectronics.in
Products - National
MODERN MACHINE TOOLS - July 2012162
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
VLT drivesThe D-Frame VLT® drives are among the smallest in its class and designed to support any automation application. Its back-channel cooling concept keeps electronics safely within optimal operation temperatures, the advantage being the system installation and operating costs are reduced dramatically. For robust protection, all drives come with coated printed circuit boards. Using a ducted back-channel, air is allowed to pass over the unit’s heat sink with minimal air passing through the electronics area.
Danfoss Industries Pvt Ltd
Chennai - Tamil Nadu
Tel.: 044-5550 1555
Fax: 044-5500 1444
Email: [email protected]
Website: www.danfoss.com
Products - International
MODERN MACHINE TOOLS - July 2012164
Cable and hose carrierIt was developed specifically for use in environments with heavy contamination from chips and dirt. The all-round closed structure effectively prevents the intrusion of foreign bodies into the cable space, and allows for reliable protection right up to the connection area. The covers can be opened and removed easily on the inside or outside to load the cable carriers. The interior can be modularly partitioned with various divider solutions for even cable distribution. The optimised geometry and a triple encapsulated stroke system allow it to span extensive unsupported sections. The integrated gliding surfaces make the cable carrier the ideal solution for long travel lengths. Integrated noise damping ensures that the cable carrier is running silently and with low vibration at all times.
Kabelschlepp India Pvt Ltd (Subsidary of Kabelschlepp GmbH)
Bengaluru - Karnataka
Tel: 080-4115 8997
Email: [email protected]
Website: www.kabelschlepp.com CNC graphite machining centerThis closed bridge type-high speed CNC Graphite Machining Center has patent design on its structure, as its super structural rigidity is combined with advanced technologies. It has a 30000 RPM high speed spindle, resulting in high quality graphite electrode performance. The Graphite Dust Suction & Filtration
implements high-speed, high-precision machining by reading 200 blocks in advance for acceleration/deceleration control. It has a synchronous built-in servo motor installed. The number of blocks to be read in advance can be increased, thereby enabling up to 1,000 blocks to be read in advance for acceleration/deceleration control. This enables high-speed, high precision machining without feedrate variations even for a program consisting of super-minute line segments. Additional 1-axis control can be added to enable simultaneous contour control of up to 4 axes. Spindle is directly coupled with its motor. Least maintenance due to grease sealed bearings. The high speed and high precision ball bearing is used for the high-speed spindle.
GE Fanuc Automation Europe SA
Germany
Tel: +49-352-7279 79213
Email: [email protected]
Website: www.fanucrobotics.com
RobodrillIt is a small machining center with spindle taper size No. 30 for milling, boring, drilling and tapping. This machine is characterized by Nano CNC system, HRV control, AI contour control which
Products - International
July 2012 - MODERN MACHINE TOOLS 165
Steel barsThese bars are processed with center-less grinding & hard chrome plating after cold drawn. The bar is abrasion-proof & corrosion-proof. These are hard chrome coated where thickness is minimum 20 microns. Standard length of mass product is 3000 mm-6000 mm.
Fu-Long Metal Industrial Co., Ltd.
Taoyuan Hsien - Taiwan
Telephone: 886-3-4852858; Fax: 886-3-4787597
Website: www.flweb.com.tw
System (GDSFS) results up to 99% dust disposal efficiency. The Dry Type GDSFS is implied here. It has high efficiency dust-collecting equipment & incorporates zero wear-out draught fan function.
Hsiu Fong Machinery Co Ltd
Taichung City - Taiwan
Tel: 886-4-22792121
Email: [email protected]
Website: www.surefirst.com
Vertical machining centreThe model VM-2 vertical machining centre is designed for mould industries. It is a high-performance machine with a 30” x 20” x 20” work cube, 36” x 18” table, 12000 rpm inline direct-drive spindle and high-speed control with full look-ahead. High-precision linear guides on all axes further increase
Laser cutting systemThe Sirius automation-ready flying optics laser cutting system is used for fast, efficient sheet metal processing. This system is designed to provide efficient processing of parts at optimal speeds and accelerations to suit the part geometry, offering reliable cutting performance at an affordable price-performance ratio. It is optimised with additional features and automation capabilities and provides quick and precise positioning and consistently accurate laser processing. The combination of a dynamic machine with an excellent laser beam quality allows high-speed laser cutting.
LVD Company NV
Gullegem - Belgium
Tel: +32-56-430511
Email: [email protected]
Website: www.lvdgroup.com
Products - International
MODERN MACHINE TOOLS - July 2012166
rigidity and stiffness, while providing a low coefficient of friction and long-term reliability. High-speed brushless servos, combined with fine-pitch ball screws and high-resolution digital encoders, ensure ultra-precise positioning and extreme repeatability.
Haas Automation, Inc
California - USA
Tel: +1-805-2781800
Email: [email protected]
Website: www.haascnc.com
Boring headsA wide range of rough and finish boring heads producing diameters from 8 mm up to 500 mm plus all different couplings and accessories are offered. There are 3 basic boring heads, viz, micro boring heads fitting indexable boring bars with carbide insert pockets; finish boring heads; and rough boring heads with a synchronised adjustment. All the boring heads are radially adjustable for boring different diameters. The first two models feature a micrometer adjustment with 0.002 mm increments.
Pinzbohr Boring System
Barcelona - Spain
Tel: +34-93-5720873
Email: [email protected]
Website: www.pinzbohr.com
Products - International
MODERN MACHINE TOOLS - July 2012168
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
RobocutThis machine has high-performance CNC coupled with digital servo technology. It has a high-rigidity casting and a thermal insulation structure. It is incorporated with Twin-servo wire tension control, advanced AWF2 enabling safe unmanned operation, customised Fanuc PC FAPT Cut programming software & Servo water level control for stable cutting. It comes with a 15-inch LCD touch panel & an USB I/O. For high precision, it has an upgraded AI pulse controls 2 & finish cutting generator.
GE Fanuc Automation Europe SA
Germany
Tel: +49-352-7279 79213
Email: [email protected]
NC servo slideThe major material used here is FC30 casting, which is for long life usage. Position accuracy could achievable in ?m grade. It is controlled by C5 ball screw and it could have less friction but raise efficiency to keep in stable precision with fully support. RH series is u Specifications are: Width: 200,250,300mm; length: 400,640,520,760,1000mm.
Hann Kuen Machinery & Hardware Co Ltd
Taiwan
Tel: +886-4-2486 0602
Email: [email protected]
Milling heads unitsThe gears and axis are all made from SCM415, and have heat-treatment and precise girded to JIS 1 level. Most of components are lubricated by auto-pump and auto-injection. High Precision, low noise and vibration free, each model has different speed for machining and some models also could be used for drilling. These milling heads most equipped on Plano milling machine for vertical and horizontal milling or the retrofit work shop.
Para Mill Precision Machinery Co Ltd
Taichung City - Taiwan
Tel: 886-4-26800678
Email: [email protected]
Website: www.paramill.com
List of Products
MODERN MACHINE TOOLS - July 2012170
Product Pg No Product Pg No Product Pg No
Abrasive belt grinder .................................. 166
Abrasive blast cleaning ....................................152
AC gear motor ..................................................22
AC servo motor ................................................22
Acoustic rooms ................................................152
Adaptor ...........................................................130
Advance cutting materials .................................25
Aerosol multispray ............................................63
Air gun ............................................................134
Air pollution control .......................................152
Airline fluid .......................................................63
Aluminum extrusion .......................................142
AMTEX 2012 ................................................148
Angle encoders ...............................................BIC
Assembly & high temperature grease ...............63
Automation .........................................37, 51, 132
Automation products ......................................123
Bags bailing press ...................................... 151
Ball bearing ...............................................81, 155
Bar feeder ..........................................................33
Bars .................................................................145
Bearing ......................................................12, 155
Belt grinder .....................................................163
Bench grinder cum polisher ............................166
Bench grinding machine .................................163
Boring ................................................................60
Boring and milling machines ............................74
Boring bars ........................................................35
Boring mill ......................................................142
Buffing powder .................................................35
Building automation .......................................132
Cabinet ..................................................... 112
Cable carrier ......................................................12
Cable conduits ...................................................29
Cable connector ................................................12
CAD/CAM software ........................................16
CAM followers ...............................................158
Carbide ............................................................130
Carbide endmill tool ............................... 137, BC
Carbide rods ....................................................153
Carbide tools .....................................91, 130, 159
Centre drill ......................................................130
Centreless grinding machine ............125, 179,138
Ceramic ...........................................................181
Cermets ...........................................................181
Chain .................................................................12
Chain oil ...........................................................63
Chillers ............................................................168
Chrome bars/ shafts ........................................145
Chuck ..............................................................130
Clamping tool ......................................... 137, BC
Cleaners ...........................................................143
Close frame hydraulic press ............................151
CMM ..............................................................177
CNC......................................................5, 73, 154
CNC controller .................................................37
CNC cutting machines ...................................132
CNC cylindrical external grinding machine ...179
CNC double column machining centre ............10
CNC engraving machines ...............................145
CNC equipment ...............................................31
CNC external grinding machine ....................179
CNC horizontal borer .......................................83
CNC horizontal boring & milling machine .....10
CNC horizontal machining centre ...................10
CNC horizontal turning centre ........................10
CNC internal grinding machine .....................179
CNC laser cutting machine ............................132
CNC lathe ................................ 11, 45, 58, 74, 83
CNC machine tool .........................................133
CNC machines ..............................6, 73, 111,154
CNC machining center ...............................14, 73
CNC milling machine ......................................45
CNC multi-tasking centre ................................10
CNC oxy fuel cutting machine .......................132
CNC plasma cutting machines .......................132
CNC precision lathe .........................................36
CNC small machining center ...........................14
CNC tool holders ...........................................171
CNC tools ..................................................51,130
CNC turning center ............................11, 73, 154
CNC turn-mill centre .......................................10
CNC vertical machining center ...........10,73, 154
CNC vertical turning lathe ...............................10
CO2 laser marker series ..................................157
Coating machines ............................................132
Coating plants .................................................132
Coating systems ..............................................132
Collets ........................................................94,130
Collets chuck .....................................36, 130, 171
Column hydraulic press ..................................151
Compressor oil ..................................................63
Connector ....................................................12, 41
Control cabinet .................................................41
Control panel ....................................................41
Control system ..................................................41
Controlling machine tool ...............................BIC
Conventional precision lathe .............................58
Conveyor lubricators ........................................87
Coolant ..............................................................71
Coolant pump .................................................166
Coro mill .......................................................FGF
Coro thread ...................................................FGF
Corrosion preventive .......................................143
Countersink ................................................FIC, 8
Looking For A Specific Product?Searching and sourcing products were never so easy.
Just type MMT (space) Product Name
and send it to 51818eg. MMT EDM and send it to 51818
Sl. No Product Pg No Sl. No Product Pg No Sl. No Product Pg No
List of Products
July 2012 - MODERN MACHINE TOOLS 171
Coupling regulator ..........................................134
Crush blade .................................................46, 47
Customised tooling solution .............................94
Cutting fluids ..................................................143
Cutting machines ............................................132
Cutting oil ...................................................35, 71
Cutting tool ........................39, 46, 47,91,113,153
Cutting tools carbide metal working tool .......181
Cylindrical grinding machine .....................30,125
Dampers ......................................................93
Desktop printer .................................................72
Diamond cutting & processing systems .........139
Diamond tool .............................................8, FIC
Didactic equipment for training .......................41
Die coater ....................................................46, 47
Diode end pumped laser marker .....................157
Diode side pumped laser marker ....................157
Disc couplings ...................................................93
Drawing & forming compound ......................143
Drill chuck arbor .............................................130
Drill mill .........................................................130
Drilling machine .............................................103
Drilling tool .............. FIC,8, 39, 91,113, 137,BC
Drive technology ............................................BIC
Dust collectors .................................................163
EDM sinker machines ............................... 145
Element shrink disc ........................................158
End mills .........................................................130
Exhaust brake system parts ...............................94
Exhibition- AMTEX 2013 .............................128
Exhibition-Engineering Expo .........................156
Exhibitions ......................................................101
Expandable mono block-reamers ......................59
Exposed linear encoders .................................BIC
Factory automation .................................... 132
Ferrous casting ................................................142
Fiber laser marker ...........................................157
Flexible shaft grinder ......................................166
Floor automation .............................................114
Forged components .........................................142
Form measurement ...........................................23
Freewheel-one-way-clutches ...........................158
Fuel injection system .......................................94
Fuel injection system parts ................................94
Gantry automation..................................... 114
Gantry machining center ................................142
Gap frame press ..............................................152
Gauges .............................................................147
Gear box ............................................................90
Gear milling solution .......................................79
Gold purity (xrf) systems ................................139
Sl. No Product Pg No Sl. No Product Pg No Sl. No Product Pg No
List of Products
MODERN MACHINE TOOLS - July 2012172
Gomet bearings .................................................81
Grease ................................................................63
Grinding machine ..............30, 115, 125, 179,163
Grinding tool for hard material ......................115
Grinding wheels ................................................35
Grooving & parting tools ...............................153
Guide rods .......................................................145
Gun drill.................................................... FIC, 8
Handling system module ..............................41
Handy probe ...................................................159
Handy scan ......................................................159
Hard chrome plating bars ...............................145
Heat exchanger machines ...............................103
Heavy duty cycling duical bearing ....................81
Heavy duty lathe machine ................................30
Helical gear box ................................................90
High performance spindles ..............................61
High power ups system ...................................167
High precision machining services ...................94
High precision tool holders ..............................21
High precision wire cut EDM machine .........145
High speed drill tap centres ..............................83
High speed machining center ...........................73
HMC ..............................................................103
Hold back ........................................................158
Holders ..............................................................35
Hole making .....................................................25
Hole making tools .......................................46, 47
Horizontal CNC machines .............................154
Horizontal hydraulic press ..............................151
Horizontal machining center ...........5,73, 83, 154
Horizontal spindle rotary table surface grinder 179
Hose ................................................................134
Hydraulic & gear oil .........................................63
Hydraulic accessories .......................................134
Hydraulic centerless grinding ..........................125
Hydraulic chucks ...............................................94
Hydraulic cylinder ...........................................162
Hydraulic cylindrical grinding machine ..125, 179
Hydraulic machine ............................................33
Hydraulic press ........................................151, 152
Hydraulic shearing machine............................152
Hydraulic valve housing ....................................94
Hypercad ...........................................................16
Imaging & vision systems .......................... 132
IMTMA - AMTTF .......................................160
IMTMA - Finishing School Summit ............136
Indexable cutting tools ......................................35
Inductive proximity switches .............................29
Industrial robots ..............................................169
Integrated shot blasting rooms .......................152
Internal grinding machine...............................125
Iron & steel parts ........................................46, 47
Jewellery polisher ....................................... 166
Keyless transmission element ..................... 158
Lamp pumped laser marker ........................ 157
Large part drilling machines ...........................103
Laser cutting machine .....................................157
Laser cutting system........................................139
Laser engraving machine ................................157
Laser exhibition ...............................................101
Laser marking - engraving system ..................139
Laser marking machine ...................................157
Laser medical ..................................................139
Laser micro machining ...................................139
Laser robotic welding ......................................139
Laser shaping ..................................................115
Laser welding system ............................... 139,157
Lathe ...................................................................5
Lathe machine...................................................30
LED ..................................................................29
Length gauges ................................................BIC
Lens mould .................................................46, 47
Light duty lathe machine ..................................30
Linear rods ......................................................145
Lm shafts ........................................................145
Load break switches ..........................................29
Locking elements ..............................................93
Lubes .................................................................71
Machine & tools lubricators .........................87
Machine measurement ...................................BIC
Machine taps .....................................................35
Machine tools ....................................................51
Machined castings .............................................94
Machined components ....................................142
Machining & grinding fluid ...........................143
Machining centre ..............................................83
Magnescale technology ...................................131
Magnetic modular encoders ...........................BIC
Material handling ............................................127
Material testing .................................................23
Measured value acquisition and display .........BIC
Measurement equipment...................................23
Medium duty lathe machine .............................30
Metal bellow couplings .....................................93
Metal cutting tool .............................................57
Metal scrape baling press ................................151
Metal spray booths ..........................................152
Metrascan ........................................................159
Metrology equipment ........................................23
Metrology instrument & solutions .................177
Micron drills................................................46, 47
Milling ....................................... 25, 39, 113, BIC
Milling centres ....................................................5
Milling cutter .....................................FIC, 8, 153
Milling grade .................................................FGF
Milling machine ........................................45, 103
Milling tool ............................. 46,47,91, 137, BC
Mobile cylinder hydraulic press ......................151
Modular tooling system .............................FIC, 8
Mold components .......................................46, 47
Sl. No Product Pg No Sl. No Product Pg No Sl. No Product Pg No
List of Products
July 2012 - MODERN MACHINE TOOLS 175
Motor ................................................................90
Motor protection circuit breaker .......................29
Multi function turret .........................................33
Multi functional tools .....................................153
Needle roller bearings ..................................81
Oil coolers ................................................. 168
Optical measurement ........................................23
Paint booths .............................................. 152
Panel coolers ...................................................168
PCB drills....................................................46, 47
PCD & carbide reamers ...................................59
PCD & CBN tool ..........................................181
Pedestal grinder ...............................................166
Pedistar buffer .................................................166
Peening ............................................................152
Photonic exhibition .........................................101
Pillar type hydraulic press ...............................151
Pilot lights .........................................................29
Piston bars .......................................................145
Planning machine ............................................138
Plano-millers ...................................................138
Plant lubrication systems ...................................87
PLC operated hydraulic press .........................151
Plugs and sockets ..............................................29
Pneumatic accessories......................................134
Pneumatic tools ...............................................134
Polishing machines .........................................163
Post processor ....................................................16
Power press .....................................................152
Power sources ..................................................109
Precision measuring instruments ....................147
Precision steel ..................................................115
Precision switches single & multiple ................29
Precision universal cylindrical machine ...........125
Press brake machine ........................................152
Pressure sensor for wet packaging application ..135
Printing system .................................................72
Process automation and control equipment ......41
Product assemblies ..........................................142
Programmable logic controllers.......................123
Pull stud ..........................................................130
Push buttons .....................................................29
PVC flexible braided hose ..............................134
Rack .......................................................... 112
Reamer ...............................................FIC, 8, 130
Rear cylinder hydraulic press brake ................152
Robotic automation .........................................114
Roller bearing ..................................................155
Rolling oils ......................................................143
Rotary ..................................................................5
Rotary encoders ..............................................BIC
Rotary switches .................................................29
Rust preventing ...............................................143
Safety protection devices ..............................29
Screw machine ..................................................45
Sealed linear encoders ....................................BIC
Servo-drives .....................................................123
Servo-insert couplings .......................................93
Shafts ...............................................................145
Shearing machine ............................................152
Sheet metal working machinery ........................48
Shrink fit adaptors ............................................94
Shrink fit technology ........................................35
Side lock adaptor .............................................130
Single limit switches .........................................29
Sinking EDM .................................................181
Slant / flat bed ..................................................83
Sleeve bearings ..................................................81
Small size ball bearings .....................................81
Solar cell scribing system ................................139
Solid carbide drill ........................................57, 59
Solid carbide drill with ic ..................................57
Solid carbide mill ..............................................57
Solid carbide reamer..........................................57
Solid carbide reamer with ic .............................57
Solid carbide special drill ..................................57
Solid carbide special mill ..................................57
Solid carbide special reamer ..............................57
Solid mono block reamers .................................59
Solid rotating tools ............................................35
Solid state laser cutter .....................................157
Special boring bars ............................................59
Special fine boring tools ....................................59
Special induction hardening machine .............109
Special line boring tools ....................................59
Special reamer ...................................................59
Special tools.....................................................130
Speciality oils .....................................................35
Spindle nose tooling ........................................153
Standard fine boring tools.................................59
Standard induction hardening machine ..........109
Straightening machines ...................................138
Super precision bearings ...................................81
Surface grinding machine ...........................30, 83
Surface preparation solutions ..........................152
Tapping systems ........................................ 171
Taps .......................................................8,FIC, 34
Tensioner nut ..................................................158
Thread mill .......................................................79
Thread mill cutters ............................................35
Thread milling cutters & taps holders ..............34
Threading tool ................................... 59, 137,BC
Thrush ball bearings .........................................81
Tool holders ......................................................94
Tool holding systems ........................................35
Tooling system ..................................25, 137, BC
Tools ...............................................................130
Touch probes .................................................BIC
Track rollers ....................................................158
Trade show ......................................................101
Transparent gel .................................................63
List of Products
MODERN MACHINE TOOLS - July 2012176
Product Pg No Product Pg No Product Pg No
COC - Cover on Cover FGF - Front Gate Fold FIC - Front Inside Cover BIC - Back
Inside Cover BGF - Back Gate Fold BC - Back Cover
Travelling column milling machines .................60
Tubing accessory ...............................................41
Turbo charger parts ...........................................94
Turned components ........................................142
Turning ..................................... 25, 39, 113, BIC
Turning holders ..............................................153
Turning tool ................................46, 47, 137, BC
Twist drills ......................................................130
Ultra high pressure apparatus ................. 46, 47
Vacuum /pneumatic recovery and
conveying system ....................................... 152
Vacuum chuck ...................................................33
Valve ..........................................................41, 134
Valve terminal ...................................................41
Vehicle lubricators .............................................87
Ventilation .......................................................152
Vertical and horizontal machining centres .......74
Vertical machining center ...................................5
Vertical machining centres-single /
double column ...................................................83
Vertical turning lathe ......................................142
Vertical turret lathe ...........................................24
Wear parts ................................................. 153
Wear resistant tools ....................................46, 47
Wire cut EDM ...............................................181
INTERNATIONAL
Associations .................................................18
Brass wire .................................................. 161
Carbide ball end mills ..................................62
Carbide drills .....................................................62
Carbide end mills ..............................................62
Carbide reamers ................................................62
Carbide spotting drills.......................................62
Cast iron cutting .............................................119
Centerless ..........................................................44
Centerless grinding machines ...........................27
Centralized lubrication systems.......................126
Chuck ..............................................................166
Circular cold saw .............................................162
CNC angular cylindrical grinding machines ....27
CNC cylindrical roll grinder ...........................150
CNC lathes .....................................................141
CNC plunge/angular cylindrical grinder ........150
CNC rotary tables ...........................................146
Coordinate measuring machine ......................129
Copper anode ..................................................161
Cutting tools ...................................................165
Cylindrical .........................................................44
Diamond grinding wheels for LCD glasses . 157
Diamond scribers for sapphires.......................157
Diamond tools for semiconductors .................157
Diamond tools for silica tile industry .............157
EDM wire ................................................. 161
Electro magnetic chuck ...................................166
End mills .........................................................165
EUROBLECH 2012 ........................................85
Fine-pole permanent magnetic chuck ......... 166
For precision grinding wheels .........................157
Free cutting brass rod & wire .........................161
Fully automatic circular sawing machine ........162
Fully automatic tungsten carbide
sawing machine ...............................................162
Grinding machine ........................................44
High-speed centerless grinding machines .....27
Horizontal band ..............................................140
Horizontal machinery center ..........................107
Hydraulic angle lock vise ................................137
Hydraulic automatic type aluminum copper ...162
Hydraulic automatic type metal sawing machine ..162
Hydraulic machinery .......................................158
Hydraulic press ................................................158
Hydraulic press brakes ....................................158
Hydraulic punch presses .................................158
Internal grinding machines .................... 27, 44
Lathes-automatic ....................................... 141
Magnetic block unit ................................... 166
Manufacturing equipment ...............................158
Measurement systems .....................................129
Measuring gauge .............................................129
Measuring machine .........................................129
Measuring tools ...............................................129
Metal circular pipe / bar stock end chamfering
machine ...........................................................162
Metal forming .................................................158
Mold changing systems ...................................149
Natural/polycrystalline/single crystal
diamond dies ............................................. 157
NC cylindrical grinder ....................................150
Nickel silver wire .............................................161
Permanent magnetic chuck ........................ 166
Phosphor bronze wire .....................................161
Precision cutting wheels ..................................157
Press brake ......................................................158
Quick die change system ............................ 149
Quick mold change system .............................149
Rolling machine ........................................ 140
Rotary permanent magnetic chuck .................166
Sawing machines........................................ 140
Saws .................................................................140
Shafts ...............................................................140
Shear series ......................................................158
Shearing machines ..........................................158
Sheet metal working technology exhibition ......85
Silicon bronze wire ..........................................161
Special form cutting tools .................................62
Spindles ...........................................................125
Standard (powerful) magnetic base .................166
Standard (powerful) permanent magnetic chuck .. 166
Thread ...................................................... 140
Traditional cylindrical grinder ........................150
Twin-spindle compound grinding machines ....27
Universal .....................................................44
Universal cylindrical grinder ...........................150
Universal cylindrical grinding machines ...........27
Vertical machinery center ........................... 107
Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No
List of Advertisers
MODERN MACHINE TOOLS - July 2012178
Accut Machinery Co. Ltd. 142
T: +86-411-84804589
W: www.accutmachinetools.com
ACE Micromatic Group 11
T: +91-80-22186700
W: www.acedesigners.co.in
Atul Machine Tools 30
T: +91-281-2360227
W: www.atulmachine.com
Austin Engineering Company Ltd 155
W: www.aec-bearings.com
Autotech Machine Tools Sales & Services 6
T: +91-20-25690044
W: www.autotechcnc.com
Baker Gauges India Ltd 147
T: +91-20-66093800
W: www.bakergauges.com
Big Daishowa Seiki Co. Ltd 21
T: +81-729-828277
W: www.big-daishowa.com
Birla Precision Technologies Ltd 94
T: +91-22-67933000
W: www.indiantool.com
Blaser Swisslube India Pvt. Ltd. 71
T: +91-124-4994000
W: www.blaser.com
Cenlub Industries Ltd 87
T: +91-129-4113701
W: www.cenlub.in
Ceratizit India Pvt Ltd 153
T: +91-33-24947146
W: www.ceratizit.com
Champkraft Machine Tools 179
T: +91-2752-241881
W: www.solcogrinder.com
Changhua Chen Ying Oil Machine Co., Ltd. 126
T: +886-4-2639-3751
W: www.chenying.com.tw
Coatec India 132
T: +91-172-5063436
W: www.coatecindia.com
Creaform India 159T: +91-11-65022218E: [email protected]: www.creaform3d.com
Dees Hydraulic Industrial Co. Ltd. 158T: +886-2-2601-8661E: [email protected]: www.spc.com.tw
Doosan Infracore India Pvt Ltd 10T: +91-80-42660122E: [email protected]: www.doosaninfracore.com
Dowel Machinery Pvt Ltd 151T: +91-281-2362465E: [email protected]: www.thedowel.com
Durga Bearing Pvt Ltd 81T: +91-22-6876073E: [email protected]: www.durgabearings.com
EFD Induction Limited 109T: +91-80-7820404E: [email protected]. W: www.efd-induction.com
Electromech Material Handling Sys P 127T: +91-20-66542222E: [email protected]: www.emech.in
Emuge India Pvt Ltd 34T: +91-20-39310000E: [email protected]: www.emugeindia.com
Engineering Expo 156T: +91-9819552270E: [email protected]: www.engg-expo.com
Ermaksan Sheet Metal Working Machinery 48T: +90-224-2947500E: [email protected]: www.ermaksan.com.tr
ESA Eppinger Gmbh 161T: +91-9900588559E: [email protected]: www.eppinger.de
Essor International Inc 164W: www.essor.com.tw
Euroblech 2012 85W: www.euroblech.com
Everising Machine Co. 140T: +886-4-2359-3178E: [email protected] W: www.everising.com
Festo Controls Ltd 41T: +91-80-22894100E: [email protected]: www.festo.com
Finechrome Shafts Pvt Ltd 145T: +91-22-29204209E: [email protected]
Fong Ho Machinery Industry Co., Ltd. 162
T: +886-4-2406-6769
W: www.fongho.com.tw
Forwell Precision Machinery Co., Ltd. 149
T: +886-4-8345-1960
W: www.forwell.com
Freeze Tech Equipments Pvt Ltd 168
T: +91-44-42152387
W: www.freezetechequip.com
Fullton Machinery Co Ltd 24
T: +86-411-82767678
W: www.fulltontech.com
G W Precision Tools India Pvt Ltd 57
T: +91-80-40431252
W: www.gwindia.in
Ganesh Techmachinery Pvt Ltd 45
T: +91-11-41612203
W: www.ganeshmachinery.com
Ganro Industrial Corp. 146
T: +886-4-2537-6266
W: www.ganro.com.tw
Greenleaf Corp 119
W: http://www.wexper.com
GSK Cnc Equipment Co. Ltd 31
T: +91-9886835186
W: www.gsk.com.cn
Guang Dar Mangnet Industrial Ltd. 166
T: +886-4-2436-0757
W: www.guangdar.com
Gudel India Pvt Ltd 114
T: +91-20-25459531
W: www.gudel.com
Guhring India Private Limited FIC
T: +91-80-40322500
W: www.guhring.in
Haas Automation India Pvt Ltd 5
T: +91-22-61392800
W: www.haascnc.com
Heattrans Equipments Pvt. Ltd. 142
T: +91-79-25840105
W: www.heattrans.com
Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No
List of Advertisers
MODERN MACHINE TOOLS - July 2012180
Heidenhain Optics & Electronics (I) BIC
T: +91-44-30234000
W: www.heidenhain.in
HG Technology Co., Ltd. 165
T: +886-4-7362-725
W: www.hgt.com.tw
Hyundai Wia India Pvt. Ltd 133
T: +91-9940653703
W: www.hyundai-wia.com
IFM Electronics India Pvt Ltd 135
T: +91-2312672770
W: www.ifm-electronic.in
Igus India Pvt Ltd 12
T: +91-80-39127800
W: www.igus.in
Indian Machine Tool Mfgr’S Association 128
T: +91-80-66246600
W: www.imtex.in
Indian Machine Tool Mfgr’s Association 160
T: +91-80-22731625
W: www.amttf.in
Indian Machine Tool Mfgr’s Association 136
T: +91-80-66246600
W: www.imtma.in
Isgec Heavy Engineering Ltd 83
T: +91-120-3301001
W: www.isgec.com
Jainnher Machine Co.,Ltd. 150
T: +886-4-2358-5299
W: www.jainnher.com.tw
Jin Year Precision Co., Ltd. 137
T: +886-4-2523-2817
W: www.jinyear.com.tw
Jyoti Cnc Automation Pvt. Ltd. 73
T: +91-2827-287081
W: www.jyoti.co.in
Kabel Schlepp India Pvt. Ltd., 137
T: +91-80-27839111
W: www.taegutec-india.com
Kao Fong Machinery Co. Ltd. 107
T: +886-4-2566-2116
W: www.kafo.com.tw
Kim Union Industrial Co., Ltd. 140
T: +886-4-2533-1131
W: www.threadrolling.com.tw
Komet Precision Tool India Pvt Ltd 59
T: +91-80-280780000
Korloy India Tooling Pvt. Ltd. 113
T: +91-124-4930080
W: www.korloy.com
Larsen & Toubro Limited 91
T: +91-22-67051093
W: www.larsentoubro.com
Larsen & Toubro Ltd 123
T: +1800-2335858
W: www.larsentoubro.com
Lexis Tooling Systems 171
T: +91-422-3052110
W: www.lexisindia.com
Lico Machinery Co., Ltd. 141
T: +886-4-2563-0950
W: www.licomachinery.com
Macpower Cnc Machines Pvt Ltd 154
T: +91-2827-287930
W: www.macpowercnc.com
Mehta Cad Cam Systems Pvt Ltd 157
T: +91-79-26840551
W: www.mehtaindia.com
Metrol Corporation India Branch Off 14
T: +91-80-42105031
W: www.toolsensor.com
Mitutoyo South Asia Pvt Ltd 23
T: +91-11-26372090
W: www.mitutoyoindia.com
MMI India Pvt Ltd 101
T: +91-9811090046
W: www.photonicsindia.net
Montfort Shanghai Co Ltd 75
T: +86(0)21/52136600
Neway Cnc Equipment (Suzhou)Co., Ltd 74T: +(281)276-7100E: [email protected]: http://www.newaycnc.com
Nicolas Correa S.A. 60T: +91-20-25654891E: [email protected]: www.correanayak.es
Nikon India Pvt Ltd 177T: +91-124-4688 500 E: [email protected]: www.nikon-instruments.jp/eng/
Nmtg Mechtrans Techniques Pvt Ltd. 158T: +91-79-22821527E: [email protected]: www.nmtgindia.com
Objet Ap Ltd 72T: +852-2174-0111 E: [email protected]: www.objet.com
Openmind Cadcam Technologies (I) Pvt Ltd 16T: +91-80-30504647E: [email protected]: www.openmind-tech.com
Optical Gaging (S) Pte Ltd. 129T: +65-6741-8880E: [email protected]: www.smartscope.com.sg
P R Sales Corporation Pvt Ltd 33T: +91-20-25437591E: [email protected]: www.prsales.in
Palmary Machinery Co., Ltd. 44T: +886-4-2492-9799E: [email protected]: www.grinding.com.tw
Paragon Machinery Co., Ltd. 27T: +886-4-2539-5678E: [email protected]: www.paragoncnc.com
Pitroda Utility Industries 125T: +91-2752-243795E: [email protected]: www.pitrodautilityindia.com
Pramet Tools India Pvt Ltd 39T: +91-124-4703825E: [email protected]: www.pramet.com
Precihole Machine Tools Pvt Ltd 22T: +886-3-329-9968E: [email protected]: www.peei.com.tw
Precimac Solutions 61T: +91-20-32538701E: [email protected]: www.precimac.com
Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No
List of Advertisers
MODERN MACHINE TOOLS - July 2012182
Ou
r co
nsi
sten
t ad
vert
iser
s
FGF - Front Gate Fold FIC - Front Inside Cover BIC - Back Inside Cover BGF - Back Gate Fold BC - Back Cover
Prem Brothers 163T: +91-11-28117456E: [email protected]: www.powermaster-india.com
Quaker Chemical India Ltd 143T: +91-33-22822181E: [email protected]: www.quakerchem.com
Quattro Engineering India Limited 51T: +91-80-25585439E: [email protected]: www.quattroengg.com
Quickmill Inc. 103T: +705-745-2961E: [email protected]: www.quickmill.com
R S Electro Alloys Pvt Ltd 145T: +91-11-25280488E: [email protected]: www.rselectro.com
Raj Petro Specialities Private Limited 63T: +91-44-42288900E: [email protected]: www.rajgrp.com
Riat Brothers (India) 138T: +91-161-2530805E: [email protected]: www.riatbrothers.com
Ringfeder Power Transmission India Pvt. Ltd 93T: +91-44-26791411E: [email protected]: www.ringfeder.com
Robin Precision Products Pvt Ltd. 130T: +91-2827-287631E: [email protected]: www.bloodtools.com
Rotomotive Powerdrives India Ltd. 90T: +91-2692-230430E: [email protected]: www.rotomotive.com
Royal Precision Tools Corporation 125T: +886-4-2338-2068E: [email protected]: www.royal-spindles.com.tw
Sahajanand Laser Technology Ltd 139T: +91-79-23287461E: [email protected]: www.sahajanandlaser.com
Samkrish 131T: +91-44-23612310E: [email protected]: www.samkrish.com
Samkrish Machine Tools 111T: +91-44-23612310E: [email protected]: www.samkrishmachinetools.com
Sandvik Coromant India FGFT: +91-20-27104800E: [email protected]: www.sandvik.coromant.com/in
Seco Tools India Pvt Ltd 25T: +91-2137- 667300E: [email protected]: www.secotools.com/in
Shailesh Sales Corporation 152T: +91-281-2461102E: [email protected]: www.shaileshmachines.com
Shuter Enterprises India Pvt. Ltd. 112T: +91-44-32407116E: [email protected]: www.shuter.in
Siemens Ltd 37E: [email protected]: www.siemens.com/industry
Synco Industries Ltd 152
T: +91-9214407024E: [email protected]: www.synco.co.in
Taegutec India Ltd BCT: +91-80-27839111E: [email protected]: www.taegutec-india.com
Taiwan Diamond Industrial Co., Ltd. 157
T: +886-3-363-6971E: [email protected]: www.taiwandiamond.com
Taiwan Machine Tool & Accessory Builders’
Association 18
T: +886-4-2350-7586E: [email protected]: www.tmba.org.tw
Takamatsu Machinery Co Ltd 36T: +81-76-2741403E: [email protected]: www.takamaz.co.jp
Teknic 29T: +91-22-26592392E: [email protected]: www.tecknic.co.in
Trident Products Pvt Ltd 162
T: +91-124-4300626E: [email protected]
Trigon Tooling Solutions Pvt. Ltd. 35T: +91-124-2370250 E: [email protected]: www.trigontools.com
Triune Exhibitors Pvt Ltd. 148
T: ‘+91-80-43307474E: [email protected]: www.amtex2012.com
Tungaloy India Pvt Ltd 46, 47T: +91-22-61248888E: [email protected]: www.tungaloy.co.jp.in
Tussor Machine Tools Ind P Ltd 58T: +91-422-3200183E: [email protected]: www.pinachoindia.com
Tyrolit India Superabrasive Pvt. Ltd 115T: +91-80-40953259E: [email protected]: www.tylolit.com
Uniline Energy Systems Pvt Ltd 167T: +91-11-46661111E: [email protected]: www.unilineindia.com
Universal Corporation 134T: +91-22-23422238E: [email protected]: www.samson-grp.com
Vargus Limited 79T: +91-9730028248E: [email protected]: www.vargus.com
Vijay Machine Tools Pvt Ltd 166T: +91-22-24950886E: [email protected] W: www.elmacovijay.com
Wexper India Ltd 181T: +91-124-2210020E: [email protected]: www.wexper.com
Yaskawa Robotics India Ltd 169T: +91-124-4758534E: [email protected]: www.motoman.com
YG Cutting Tools Corporation Pvt Ltd. 8T: +91-80-43543636E: [email protected]: www.yg1.co.kr
Yuang Hsian Metal Industrial Corp. 161T: +886-4-761-3688E: [email protected]: www.yhm.com.tw
Zen Wu Zheng Sun Tool Co., Ltd. 62T: +886-7-352-5743E: [email protected]: www.jsk-tools.com.tw
Looking For A Specific Product?
Searching and sourcing
products were never so easy.
Just type MMT (space)
Product Name
and send it to 51818eg. MMT EDM and
send it to 51818
pe
MODERN MACHINE TOOLSJu
ly 2012
184
Reg No: MH / MR / WEST / 235 / 2012 – 2014 RNI No: MAHENG / 2008 / 24347 Licence to Post at Mumbai Patrika Channel Sorting Office, Mumbai GPO., Mumbai 400 001
Date Of Posting 5th & 6th Of Every Month / English & Monthly. Date Of Publication: 28th of Every Month