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Editorial

March 2012 - MODERN MACHINE TOOLS 15

T

Importing Inspirations…Only

he growing dependence on imports, especially in the metal working value chain, is a cause of worry from an overall economic health point of view. The acknowledgement, acceptance and the uneasiness felt by Indian players over this import dependence, on the other hand, indicates that we are at least cognisant of this reality. The overall economic damage apart, the fact that while we are shipping in more than shipping out, we are in fact damaging and minimising the prospects of indigenous

products and services by opting to shop for the same in the global marketplace.

This trend on import dependence and trait is not without reasons though. With India’s domestic market flourishing, the demand for machine tools is multiplying and the local machine tools companies are finding themselves underequipped to deal with the surging industry demand. This means that 70 per cent of the demand is met by imports from countries such as Germany & China and the industry acknowledges that, unless swift measures are taken, this trend could further strengthen.

Substantiating this fact, the 2012 World Machine-Tool Output & Consumption Survey by Gardner Publication, our partners, has rated India as the fourth highest importer in the world, while the country trails down to the bottom of the list at the 27th spot to become one of the lowest exporters. When we asked experts about this disparity in EXIM, they were of the opinion that the imports are in terms of high-end, high-accuracy and high-performance reliable machines. The local manufacturers are, however, producing high-volume low-cost machines. This is the reason why the Indian contribution to machine tools manufacturing is just 23 per cent, while 77 per cent is imported. The volume of imported machines is low, but the cost of high-end & high-accuracy machines is very high.

There are three important things, which need to be changed. We primarily have to increase the technology and reliability of the machines so that we can make them fit for exporting. Secondly, the sub suppliers of critical parts, like ball screws, etc., are not available in India and we instead import the technology or the machine or import the components at high cost, which subsequently increases the cost of the final product. Thirdly, innovation is key. We cannot simply duplicate imported products. We instead have to come up with innovatively designed products, which are low cost and provide the same level of quality parameters.

Then again, as per the same survey, India stands as the 7th largest consumer of machine tools, but finds itself down the list at the 16th spot for its production capacity, thereby making the demand-supply gap apparent and indicating an urgent need to scale up domestic production.

If machine tools are the basic building blocks of manufacturing-based societies, then the rate at which a country installs new ones ought to say something about its pace of industrialisation. How the country controls its import dependence and lets the indigenous offerings rule the market will shape the future and fortunes. So, let’s import inspirations…only.

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]

April 2012 - MODERN MACHINE TOOLS 17

NEXT EDITION HIGHLIGHTSSpecial Focus: Metal Forming Insights & Outlook: Grinding & Finishing

Looking for a specifi c product?

We will fi nd the product for you. Just type MMT (space) Name of the

Product and send it to 51818 eg, MMT (space) Lathe and send

it to 51818.

Insights & Outlook Global Machine Tool Survey 2011 ....................................

One Q Many Views: Import Vs Export ............................

One Q Many Views: Production Vs Consumption ...........

Business Dynamics ............................................................

Advance Metrology Systems .............................................

Digital Optical Comparator ..............................................

Nanometrology ..................................................................

102

106

Contents

Special FocusDie & Mould India 2012 ...................................................

Reducing Import Dependence ...........................................

New Avenues .....................................................................

Seamless Integration ..........................................................

Technology Trends ............................................................

Micro Moulding .................................................................

Additive Manufacturing .....................................................

Tool Selection .....................................................................

50

52

In Conversation With

Volker Nesenhöner

CEO, OPEN MIND Technologies AG ... 42

Editorial ...................................................................... 15

News, Views & Analysis .............................................. 28

Technology & Innovation ............................................ 38

Event List .................................................................. 134

Products .................................................................... 138

List of Products ........................................................ 163

List of Advertisers .....................................................167

Regular Sections

64

101

Cover illustration: Sanjay Dalvi

49

74

76

Facility VisitPrecihole Machine Tools Pvt Ltd ..................................... 94

Automation Trends - Die & Mould ManufacturingEngineering Optimal Design Simulations ......................... 128

Strategy - Strengthening Business How a Global Builder Handles Changes Around the World? ........................................................................... 130

Tips & Tricks - Metrology OperationsOptimising CMM Usage & Maintenance .......................... 132

Event Report - Aurangabad Creating Yet Another Success Story .................................... 136

Special Focus Die & Mould

Insights & Outlook Global Machine Tool Survey

2011 & Metrology Equipment

62

78

90

108

114

116

118

126

Colophone


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MODERN MACHINE TOOLS - April 201228

News, Views & Analysis

� Members of Indian Foundry Association meet exhibitors to

discuss the prospects that the industry offers.

Bengaluru Hosts

IFEX-2012 After 33 Years

It took as long as 33 years for Bengaluru to bring

back India’s largest and only foundry exhibition

to the city. The 8th International Exhibition on

Foundry Technology, Equipment and Supplies was

organised concurrently with the 60th Indian Foundry

Congress and was jointly organised by The Institute

of Indian Foundrymen and Koelnmesse YA,

Tradefair Pvt Ltd. The three-day exhibition hosted

over 200 exhibitors from all corners of India and over

15 countries including China, Japan, Germany and

Italy. The exhibition widened the scope to promote

the foundry industry in Karnataka.

In an effort to promote the foundry industry in Karnataka, the State

Government has decided to set up a ‘Foundry Cluster’ at Dobbspet,

50 kilometres from Bengaluru, over the next six months. The state

has one of the largest deposits of iron ore in the country.

Revealing the State Government’s plan, Murugesh Nirani, Minister

for Industries, Government of Karnataka, said, “Earlier, we had

proposed a Foundry Cluster near Dobbspet, but it did not pick up due

to issues raised by the Karnataka State Pollution Control Board. We

will address all those problems to revive the project at Dobbspet at the

earliest by taking into consideration the growth prospects of the foundry

industry.”

The foundry cluster is one of the 14 such industry-specific clusters

being developed in Karnataka. “We are in the process of acquiring land

for these clusters. We will ensure that the Foundry Cluster becomes a

reality in the next six months,” the minister added. Nirani also expressed

the government’s commitment towards the growth of Micro, Small and

Medium Enterprises (MSME) and to resolve the various problems that

this industry faces.

At the proposed Foundry Cluster, the IIF plans to set up a Centre

for Innovation, including R&D facilities, with training and technology

demonstrations for foundries. The government has agreed to allot 2 acre

of land to IIF under a special plan. This will be the second industrial

estate for foundries in Karnataka, apart from Belgaum.

According to Sundara Murthy, President, IIF, the foundry industry in

the country is growing at the rate of 22 per cent. Automobiles, aerospace

and public infrastructure demand serve as strong growth indicators for

the foundry industry. “India’s share in the global market is approximately

10 per cent of 91.67 million metric tonne. India is the second largest

producer of foundry-based castings, while China is the market leader

with 43 per cent of the total output,” Murthy added.

Karnataka Foundry Cluster Project To Be Revived

DISA, India and Wheelabrator - the

world’s leader in surface preparation

technology and manufacturing - recently

launched two high-tech indigenous machines,

the DISA MATCH 20/24 horizontal flask-less

moulding machine and the MB 500 metal belt

tumb blast machine.

DISA India Ltd Launches

Two New Technologies

Danfoss-IIT Madras Collaboration To Enhance New Technologies in Climate & Energy

Danfoss has signed a Memorandum of Understanding (MoU)

with IIT Madras, India, an education institute with research

expertise in power electronics and power quality solutions. The

collaboration will enhance new technologies in climate & energy.

The research collaboration with IIT Madras will provide

several unique long-term benefits for Danfoss, such as focussed

problem-solving consulting for product improvement, patents enhancing

Danfoss’ intellectual capital, quick and cost-effective access to advances

in technology relevant to the power electronics business and exploring

the possibility of Danfoss engineers joining Masters and PhD programs,

etc. Jørgen M Clausen, Chairman, Danfoss A/S, who signed the MoU

with IIT Madras, said, “A key enabler to realising our vision is building

and leveraging external research collaborations with universities, like IIT

Madras, who are experts in the field.”



Date Topic Venue

10-11 April 2012 Workshop on Form & Positional Errors and their MeasurementSKF College Campus, SKF India Ltd.,

Chinchwad, Pune

10-11 April 2012Training Programme on Geometric Dimensioning and Tolerancing (GD & T) in Design

through ManufacturingChennai

11-12 April 2012Workshop on Workholding and Fixturing Techniques for Productivity Improvement on

CNC MachinesTechnology Centre, BIEC, Bangalore

12 April 2012 Seminar on Design and Processing of Injection Moulded Components Gurgaon

12 April 2012 Seminar on Value Engineering and Value Analysis Technology Centre, BIEC, Bangalore

13-14 April 2012Training Programme on Reducing Cycle Time & Machining Cost on CNC Machining

CentresGurgaon

17-18 April 2012 Training Programme on New Product Development on CNC Machining CentresSKF College Campus, SKF India Ltd.,

Chinchwad, Pune

18 April 2012 Workshop on Acceptance and Testing of CNC Machines Gurgaon

20 April 2012 Seminar on Lasers in metal workingSKF College Campus, SKF India Ltd.,

Chinchwad, Pune

20-21 April 2012 Workshop on Failure Mode & Effects Analysis (FMEA) Technology Centre, BIEC, Bangalore

24 April 2012 Seminar on Hydroforming and its applicationsSKF College Campus, SKF India Ltd.,

Chinchwad, Pune

25 April 2012 Workshop on Calibration of CNC Machine Tools Technology Centre, BIEC, Bangalore

26 - 27 April 2012 Seminar on Die & Mould Manufacturing Hotel CAG Pride, Coimbatore

27-28 April 2012 Workshop on Measurement Systems Analysis Gurgaon

IMTMA Training and Workshop Calendar for April 2012

Training Program On

CNC operation for SMEs

To improve the knowledge and

understating of CNC machines,

IMTMA organised a five-day

workshop in Bengaluru to give hands on

training to operate these high-end machines.

The workshop was an added benefit

for participants from small and

mid-sized companies who aim to upgrade their

shop floors.

“Every shop floor today is slowly graduating

from conventional methods to CNC machines.

We had participants who have never worked

on a CNC machines and also those who

wanted to know the ways to optimally use

the machines,” said M Krishnamoorthy,

Director - Training, IMTMA.

Shared his experience, Nagendra Rao, a

workshop participant and proprietor of New

Cast Die Casting Ltd, said, “I took part in the

workshop to understand the functionalities

of CNC machines. I want to set up CNC

machines in my shop floor and this program

would help me choose the right machines to

suit my manufacturing operations.”

Aiming to improve injection mould design practices and standards,

IMTMA organised a ‘Seminar on Design & Processing of Injection

Moulded Components’ in Pune. The seminar focussed on the

technical details and basics of mould design providing case studies to discuss

specific aspects of mould processing, finishing and production. The nature of

the seminar was geared more to benefit aspiring mould design engineers and

managers looking to be guided through mould manufacturing fundamentals

in industrial component production. This seminar emphasised designing

injection moulds for any product, correctly and reliably the first time, thus

avoiding any redesign or concept changes. The key speakers at the seminar

included N V Samant, Smart Consultants; S Raghavan, EUV Tech and

R Kallorath, Digimold.

Seminar To Improve Injection Mould Design Practices Organised

The continuous demand for efficient manufacturing has made it necessary for

high-quality and reliable control systems to be a part of the manufacturing

process. Programmable Logic Controller (PLC), also called ‘The

Work Horse’, is a key driver in automation, production and process planning

in the manufacturing industry. A day-long event hosted by IMTMA Bengaluru

discussed the various facets of Industrial Automation. The seminar was

conducted by Anil Purohit, Director, Leonardo Automation (India) Pvt Ltd,

who discussed the various facets of PLC right from the basic concepts to PLC

and Human Machine Interface (HMI) and evaluation of PLC power and

optimum selection.

Empowering Industrial Automation Through PLC Technology



Attempting to get closer to

customers, Carl Zeiss opened

its third Tech Centre in

Chennai. This is a technology and

expertise-driven centre catering to

the measurement needs of Indian

industries. The application specialists

in the centre would guide customers

on specific solutions for improving

part and component quality.

The centre offers solutions for

dimensional, form, surface finish

and contour measurements, reverse

engineering, measurement against

CAD data, off-line programming,

designing and building of fixtures,

probes & accessories.

The centre will also offer

scheduled seminars on metrology,

form and position, GD&Ts,

surface roughness and measuring

uncertainty.

Carl Zeiss Sets Up New Tech Centre

The company recently

inaugurated the Indian

headquarters for its

factory automation division.

After more than two decades

of direct engagement with the

Indian market, the company

has come a long way in being

part and parcel of imbibing the

psyche and trends in automation

for the manufacturing

environment in India.

In his inaugral address,

Dr Guenther Kegel, Managing

Director and CEO, said that the

new FA headquarters is a state-

of-the-art facility with a well laid out office, combining testing, conferencing, integrated

ERP and meeting facilities. This would help P+F bring higher quantity and quality

support to the market, leveraging its staff to deliver the best to its customers. He said

he believes that a country the size of India, with its legacy, has its own dynamics and

the decade of engagement with India has been a good learning experience.

Pepperl+Fuchs Opens Factory Automation HQ At Gurgaon

� Dr Guenther Kegel, Managing Director and CEO,

Pepperl+Fuchs Group of Companies inaugurated the new

facility

The Canada-based company has completed a decade

in the field of 3D portable optical measurement

technologies and 3D engineering services. As a

way ahead, Creaform’s quinquennial strategic plan is to

increase its growth rate and strengthen its position as a

major player in the industry of metrology. The company’s

R&D program aims to lead the development and launch

of several new technologies creating innovative, accurate,

reliable and easy to use devices.

Creaform CompletesPratt & Whitney To Enter MRO Segment In India

Gauging the opportunities in

the Maintenance, Repair

And Overhaul (MRO)

segment that India offers, leading

aerospace engine supplier, Pratt &

Whitney, plans to invest over $ 150

million in the next three years to set

up an MRO and an aircraft engine

components facility along with

training centres.

For the proposed MRO unit,

which alone would require an

investment close to $ 100 million,

the company is considering places

like Bengaluru and Hyderabad.

The company is already holding

talks with various Indian firms to set

up a joint venture. Apart from India,

the company is also considering a

few other Southeast Asian countries

for setting up the projects.

The presentation of the next edition of the Biennial Spanish Machine Tool Fair

recently took place in Pune. The fair will be held in Bilbao from May 28 to

June 2, 2012. Around 18 Spanish manufacturers of machine tools, accessories,

component parts and tools will take part in the Basque Prime Minister Patxi Lopez’s

trade mission to India.

As part of this mission, the Spanish Association of Manufacturers of Machine

Tools, Accessories, Component Parts and Tools, AFM and Advanced Manufacturing

Technologies visited India between March 19 and 23, 2012, with a delegation of 18

companies. The main objective of the association in this trip was to promote the sector

and the BIEMH, the Biennial Machine Tool fair. Over 1,000 firms from 25 countries

have confirmed their attendance.

BIEMH Attracts Buyers In India



Fluke Corporation, the global leader in portable electronic test and

measurement technology, has acquired TTL Technologies Pvt

Ltd, for an undisclosed amount. TTL has represented Fluke in

India since 2001 as a master distributor. The new business combines

TTL’s many years of experience in the Indian test and measurement

market, its national distribution network, its renowned customer care,

and accredited calibration labs with Fluke technological innovation,

manufacturing excellence and world-class business processes.

“We are excited to welcome TTL to the Fluke family,” said Peter

Van Den Broek, President – Emerging Markets, Fluke Corporation.

“TTL has been a great partner and now, together we will substantially

increase our overall customer offering. This agreement reinforces our

commitment to our customers in India and positions us for rapid growth

in an important market.” TTL businesses and employees will be integrated

into the Fluke organisation. There are no plans for changes in staffing or

facility locations. “Our top priority is our customers and meeting their

needs,” added Van Den Broek. “Our goal is for the transition to be as

seamless as possible.” “TTL’s acquisition by Fluke is a huge step forward.

We will utilise this new strength to widen and deepen our reach to

customers across India, creating tremendous excitement and growth,”

said Joey Joseph, CEO & Managing Director, TTL Technologies.

Fluke Corporation Acquires TTL Technologies Pvt Ltd

Vikram Solar Ltd Commissions 2 New PV Power Plants In India

A Kolkata-based Indian multinational

and leading solar module manufacturer,

announced the commissioning of two

new power plants – one each in Gujarat and

Rourkela, Orissa. The Gujarat power plant

is a 5-MW facility and the second plant in

Orissa is capable of producing 1 MW power.

The project in Gujarat is sponsored by

Konark Gujarat Pvt Ltd and the plant is

located at Bachchau in Gujarat. The second

power plant in Orissa is sponsored by Molisati

Vinimay Pvt Ltd and located at Ranja village,

Deogargh district. Speaking on the occasion

Gyanesh Chaudhury, Managing Director,

Vikram Solar Ltd, said, “We are pleased to

promote new, clean, cost-effective in-state

electricity generation with the establishment

of two new power plants. We are committed

to protecting and encouraging better use

of natural resources in our country by

implementing better technologies.”

The 15th Seoul International

M a n u f a c t u r i n g

Technology Show 2012

to be hosted at KINTEX, Korea

will raise the curtain from one of

the world’s biggest manufacturing

show. Organised by Korea

Machine Tool Manufacturers’

Association (KOMMA) between

April 17 and 22, 2012, the event

promises to be the best place to

get updated with the industry’s

latest technologies.

To tap the overall

manufacturing industry,

KOMMA this year has upgraded

the event from being just a

‘Machine Tool Show’ and instead becoming a ‘Manufacturing

Technology Show’. With this, the event will spread out to

be twice its original size and will expand its product exhibits

to new categories such as welding machines, CAD/CAM

equipments and machine tools as well. This year’s edition will

provide a new paradigm to the convergence of next generation

intelligent manufacturing

technology and existing main

industries under the catch

phrase, ‘United SIMTOS

Manufacturing, United

Manufacturing Technology

with Machine Tools’

Amid numerous countries

participating in SIMTOS

2012, this year, India will rise

as one of the main countries

in the event and will have a

huge participation from the

Indian machine tools industry

both in terms of exhibitors

and buyers.

Engineering Export

Promotion Council (EEPC) India will organise an Indian

pavilion at SIMTOS 2012 to mark its unprecedented presence

amid its Asian competitors. Along with this, KOMMA has also

invited the Indian Machine Tool Manufacturers’ Association

(IMTMA) to the event showing the growing importance of

the country.

SIMTOS 2012 To Stage Global Manufacturing Technology

� A survey conducted during SIMTOS 2010, showed that over

63.2 per cent of participants believed that the next edition would be double

the size. SIMTOS- 2012 has met that target



Industry, Academia Partner To Raise The Next Generation Of Indian Engineers

In an effort to bolster the opportunities available to aspiring engineering

students, Vishwakarma Institute of Technology, Pune, collaborated with

the State University of New York at Binghamton (Binghamton University)

and Anveshak Technology and Knowledge Solutions, and recently hosted the

1st International Conference on ‘Research Trends in Design, Analysis and

Manufacturing of Mechanical Systems’ at VIT, Pune.

The conference provided a platform for the industry and academia to collaborate

on an international level, to discuss research trends & the needs and challenges in the

manufacturing sector. The panel of speakers, comprising of Dr Bala Bharadvaj (MD,

Boeing Research & Technology, India), Prof K Srihari (Distinguished Professor and

Dean, Watson School of Engineering and Applied Science at SUNY Binghamton),

Devdutta Chandavarkar (Director at Mercedes-Benz India), Sanjay Sharma (CEO

of MESTECH Services) and Prof Nitin Afzulpurkar (Dean, Engineering and

Technology, Asia Institute of Technology), discussed the ‘Needs and Challenges for

Industry-Academia Collaboration in India’.

The development of skilled engineers sorely requires such efforts, which have

previously been difficult due to Intellectual Property issues, process hurdles and

industry perception of academia as slow and cumbersome. VIT, however, plans to

provide 3-6 month internships, in conjunction with the industry, for students in India

and abroad during their tenure of 4 years at the institute. Students from mechanical,

industrial and production engineering backgrounds were given an excellent overview

of state-of-the-art applied manufacturing and had the chance to network with

industry professionals.

Speaking about the partnership with VIT, Prof Bahgat Sammakia, VP,

Research at Binghamton University, said, “It has become increasingly important for

students to be equipped with diverse skill sets in order to serve the global economy.

Hence, we are pleased to partner with Vishwakarma Institute of Technology in

their endeavour to provide the students with enhanced academic experience and

an opportunity to work on cutting-edge projects made available by our industry

partners in US and Europe”

In brief...� AMT (The Association For Manufacturing

Technology) and AMTDA (The American

Machine Tool Distributors’ Association)

have announced a merger that will integrate

their products and services to serve the

members of both associations better.

� Rockwell Automation has purchased the

assets of SoftSwitching Technologies, a

leading provider of industrial power quality

detection and protection systems, located in

Middleton, Wis.

� Honda Motorcycle and Scooter India

(HMSI) will set up a fourth plant in

Narasapur, Bengaluru. The company will

invest ` 800 crore in this unit to raise their

total capacity to nearly 6 million units.

� The Institute of Indian Foundrymen (IIF),

is keen on setting up a one-of-a-kind

foundry innovation centre in Bengaluru.

The centre will be equipped with an R&D

lab, a small foundry to test inputs and raw

material, and a training centre.

� Chennai hosted Automotive Testing Expo

India 2012. The three day long expo had

over 150 exhibitors from across the globe,

including ABS Instruments Pvt Ltd,

ANSYS Software Pvt Ltd, Bruel + Kjaer

– Josts, National Instruments and MOOG

among others. The event exhibited wide

range of technology like test simulation,

NVH analysis, engine / emissions testing,

vehicle dynamics testing etc.

� Honeywell Technology Solutions, the

R&D arm of global technology major,

is setting up a new centre in Bengaluru.

The company has received approval from

the Karnataka government for setting up

the facility which entails an investment of

` 402 crore

� China’s FAW Foundry aims to enter the

automotive casting business in India. “We

want to know the nature of automotive

casting sector in India and want to partner

with a local company in the country,”

said Sun Feng, President, FAW Foundry

Company

China and India together, account for approximately 50 per cent of foundry

castings made globally and they plan to maintain this position over their

competitors through rapid expansion and enhanced production over the

next three years. Their combined production of castings is expected to reach 65

million metric tonne by 2015. At the second Asian Foundry Forum (AFF), hosted

during the 60th Indian Foundry Congress (IFC), the representatives of the foundry

industries from China, India, Japan, Taiwan and Mongolia, deliberated extensively

on enhancing production of castings through sustainable technology.

“China intends to increase production of castings to 50 million metric tonne by

2015 from the existing 35 million metric tonne. Similarly, India plans to enhance

production of castings from 9 million metric tonne to 15 million metric tonne

by 2015. Asia will continue to dominate the world foundry industry,” said B N

Krishna Samaraj, Chairman, Organising Committee, and 2nd AFF.

The key objectives of the AFF are to consolidate Asian foundries by improving

competitiveness and promoting sustainable development through cooperation along

with platforms for idea exchange.

China-India Plan To Maintain Dominance Over Global Foundry Castings


TECHNOLOGY & INNOVATIONTool and Mould Making

Extensive analyses of

production routines form the

basis for discovering potential

enhancements and laying the

basis for creating further

production and machine designs. The

method applied is broken down into :

� Analyzing the process chain

in order to indentify all of the

interrelationships and dependencies

� Derivation of potential for

o p t i m i z a t i o n i n c l u d i n g

documentation of effects

� Coming up with new ideas for

mechanical production including

upstream and downstream steps in

the process

� Rough and detailed planning of

technological processes and

� Dimensioning processing machines

Optimisation of Machining TimeIt is not only necessary to apply the

effects of state if the art technology

and the potential of cutting materials

to downsize production times in metal

cutting production. It is also necessary

to analyse and enhance the current

production process. We can discover

time reverses by enhancing technology,

engineering and organization.

The points of concentration in

relation to the analyses are:

� Analyzing the technological routines

in mechanical production

� Evaluating and enhancing specific

stages of production in terms of

the options of reduced main and

secondary processing times and

� Reduction in machine loading times

Machine Analysis There is a heated debate going on

these days on the potential for boosting

productivity and accuracy in tool and

mould making. The entire manufacturing

process is dominated by the cost and time

needed for mechanical machining due to

the major proportion for free forming

geometries and predominant small scale

and job lot production. Beyond this, the

accuracy of production defines the effort

required for working.

Furthermore, finishing is extremely

important both because of the great

amount of time it requires and as a

basis for subsequent breaking in and

Tool and mould making emerge at the crossroads of burgeoning product diversity and simultaneously plummeting product cycle times. Reducing throughput times is highest on the order of priorities while simultaneously driving down manufacturing expenditures is only possible by redesigning the entire process chain.

Creating Cost-Effective andTime-Saving Environment


adjustment work. Since the machining

velocities to be achieved with the

performance of the cutting material

used are limited, the greatest potential

is to be found in enhancing the

dynamic properties of the processing

machines. And indeed, aligning CAM

tolerances, NC control tolerances and

dynamic NC control settings can

save as much as 20 per cent in time

without even changing the machining

strategy. Of course, this requires a

holistic analysis of machining process

and adapting the parameters in the

process to the machining job.

That means we can make

statements on the working precisions

of tool machines under various process

and environmental conditions based

upon a comprehensive analysis of the

impact of faults along the mechanical

machining process chain. They offer

users and tool machine manufacturers

the point of departures for improvements

in producing tools or designing machine

elements.

5- Axis Machining The amount of machining effort and time

required for manufacturing free form

surfaces in tool manufacture is very high

so that it is necessary to find alternatives

to conventional 3 axis milling machining

for fast and economical tool production.

Using efficient 5-axis chip removal

technologies enables us to substantially

scale back machining time. For example,

we can measurably reduce the aspect

ratio of tools when machining cavities

and similar topological shaping, thus

guaranteeing reliable process production

conditions. On the other hand using 5

axis machining strategies for planning

and pre finishing machining makes it

possible to substitute ball headed milling

tools with more efficient torus milling

tools.

The major characteristic of surfaces

made by 5 axis machining is slight

values for scallop-height and roughness

because the machining tool is excellently

aligned to the work piece surface. This is

the reason why reworking effort can be

reduced to the minimum while boosting

the tool’s contact width and substantially

driving down the machine time.

There are major demands made of the

machine equipment used especially with

5 axis machining of tool components

made of cast iron and steel materials.

And the oscillating axes of machining

centres need a very high level of retention

moments in position regulated operation

especially with roughing down and

pre-finishing operations. Adapting the

machining strategies, to the machine’s

specific characteristics enables us to

achieve major benefits.

Milling Thermally Sprayed Hard MetalUsing hard metal in tool and mould

making frequently appears to be

uneconomical due to the high level of

material and machining cost. Previous

options have not offered any form

of efficient or economic hard metal

machining with complex contour

geometries.

State of the art production techniques

such as high velocity oxy fuel (HVOF)

enable us to apply the hard metal

material onto highly stressed tool zones

which makes it possible to measurably

improve protection against wear and

tear. These layers have hardnesses

in excess of 1,000 HV, giving them

approximately the same properties as

sintered hard metals, although they

require a final finishing in spite of a

high level of dimensional accuracy.

A new and even highly

economical machining option is

milling thermally sprayed hard

metals where setting up the process

and selecting tools in alignment

with the technique make it possible

to measurably boost economy

and flexibility. We were able to

document a 60 per cent reduction in

cost for hard metal machining with

geometrically intricate contours

in comparison to conventional

techniques (such as contour

grinding or electrical discharge

machining (EDM). Finally, milling

of hard metal with super hard

cutting materials not only generates

a virtually damage free edge zone, but

also excellent surface qualities.

Rough DrillingThe production of deep cavities in

mould making involves a very high level

of machining and expenditure in terms

of time. In order to cope with the need

for rapid tool production, alternatives

to conventional milling need to be

considered here too.

Making use of rough drilling

means that the rough machining can

be optimised to a considerable extent.

The process is based on machining

operations acting exclusively in the

direction of the axis of the spindle, the

use of optimised tool as well as a high

level of productivity due to an extended

radial machining distance.

The advantages of machining

strategy are:

� Reduction of machining time by

up to 30 per cent by comparison to

conventional processes.

� Boosting the rate of metal removal.

� Reducing the radial machining

forces.

� Reduction in the rise of component

temperature as a result of targeted

chip discharge.

� Increase in process reliability.

Courtesy: Fraunhofer Institute for Machine Tools and

Forming Technology IWU

Time reserves based on the use of modern tools

100

80

60

40

20

%

36,05%

41,28%

5,67% 5,67%9,45%

7,56%

36,05%

30,52%

9,45%

7,56%Process time - current Process time - optimised

Time saved by using high-performancetools: approx. 10%

Milling

Drilling

Organisation

Set-up

Tool Changing

Tool and Mould Making


IN CONVERSATION WITHVolker Nesenhöner

Q Industry TransitionsOver the last decade, the machine

tools industry has grown tremendously.

The CAD/CAM industry, especially,

has shifted gears to make simulating

software, which can now produce parts in

a more productive and competitive way.

The industry too, has diversified into

various segments like aerospace, moulds

and dies, automotive machinery, etc. The

improvements have also aided in reducing

time cycles. With technology, we can

now produce parts which were considered

impossible to produce 15 years ago.

Indigenous Market OverviewThe Indian market is not very

different from the global market.

Indigenous companies today are not

just producing for the Indian industry,

but also for the global market. With

this growth, the Indian market needs

to provide solutions—high in quality,

at competitive prices and with on-

time delivery. While the markets

in Europe, the US and Japan are

slightly saturated, the Indian market

is booming.

A decade ago, the situation of

the Indian industry was different.

The industry has achieved this level

because of its adaptability to the global

markets and standards. There are some

Q

… is what Volker Nesenhöner, CEO, OPEN MIND Technologies AG, feels as technology advancements have made the world a global network. Talking to Debarati Basu, he delved on the changing dynamics of the European markets and the transition of simulation technology over the years.

High technology, visionary strategies & motivated personnel—ingredients for sure success…

Volker Nesenhöner


discrepancies, but this segment will

certainly grow to a level where it will

be at par with global standards.

India has a few advantages over

other markets. Unlike the Japanese

or Chinese markets, it is easy to

communicate with the Indian industry.

However, there are a couple of things

that need to be improved. Precious time

is lost in commutation owing to poor

infrastructure. However, despite the

odds faced, I am impressed to see the

way some companies function. This is

just the tip of the iceberg; India is on

the right path to become a great player.

India’s StrengthsIndia, China and Russia are the booming

markets and each market is different from

the other. However, India has already

entered a niche sector—the aerospace

segment. The aerospace market today

is booming and the commercial air-

travel sector has witnessed huge growth.

Every major aviation giant has forayed

into the Indian market. History is proof

that it takes time to establish a successful

industry segment in any nation. India

is a huge country and growth in this

segment might take a decade or two, but

all it needs is highly motivated skilled

personnel, a stabilised economy and the

right political environment. We believe

in the strength of the Indian market

and that is the precise reason why we

decided to enter this industry.

Euro Crisis There is a wrong notion about European

businesses. Everyone is talking about

Greece and Portugal. However, compared

to the big businesses in Europe, this is

quite insignificant. Greece is a very tiny

part of the entire European business.

The European market is slightly

unstable due to high labour costs and

saturated markets. On the other hand,

India and China have established a huge

consumer market and this is the reason

why many European companies are

moving to Asian countries. The focus is

not to simply get parts assembled, but to

customise technology to suit the needs

of the market.

Q

Q

UP CLOSE & PERSONAL

What defines the growth of a company? High technology, with a good strategy and vision coupled with a motivated group

of personnel, are the ingredients for sure success. It is very important to have a

clear vision and know the direction. As a CEO, I need to look after my employees

and provide them with an environment that keeps them motivated, well trained

and interested in the work they do, so that they can make value additions.

Employees define 50 per cent of the company’s success.

Also, it is important to be focussed and clear about what you want to achieve.

Since the beginning, we have only focussed on milling processes. We have many

competitors who are into several things at the same time. But we prefer to

concentrate on one area, explore its dimensions and excel in it.

What it takes to get the right employee on board? I look for the right behaviour and attitude in my employees. We are an international

company and so, we have to think globally. It is very important that the character

fits in our culture. Skills and experience obviously follow suit. But more than that,

it is important that my employee knows the market. Selling a product is just one

part of the job. They should also understand the process and speak the language

of the customer.

What does it take to know the market?I travel to various places to understand the market culture and the work. Feeling

the pulse of the shop floor and understanding the problems first hand are highly

beneficial. Everything cannot be positive and we would want to see both the

aspects of the function to understand the things which would make the process

better.

Message for budding entrepreneurs Entrepreneurs today, need to understand the market, its customers and the

different cultures, because several companies which are providing solutions only

to the local markets today might become global players tomorrow. A lot of

companies have failed because they could not understand the culture and its

different mentalities. You have to provide solutions for a small world and if you

want to be successful, you always have to be a step ahead of others.

Forecast for CAD/CAM We foresee a consolidation in the CAM

industry. Today, there are around 40-50

companies producing CAM solutions

worldwide. However, I believe that in

the next five years, there will be less

than 10 global players. Most companies

will either merge or disappear. The

same trend was followed by the CAD

industry two decades back, and the

same is predicted for the CAM industry

as well. To survive in this race, there

needs to be a unique strategy. Our plan

in the next five years is to double our

revenue and market share. In terms

of the world ranking of all CAM

companies, we currently stand seventh;

while among independent companies,

we rank fourth—we will try to bag the

second slot in the next five years. We

have updated our technology to suit

modern needs. We have always been a

trend-setter in introducing technology;

and the market looks up to us as a

company which is at least five years

ahead of its time. This is our advantage.

We try to understand the industry

needs, demands and changes that it

will undergo over the next two years.

The market today demands complete

solutions having a consolidated CAM

environment with better functionality

and easy user interface.

[email protected]

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50 Die & Mould India 2012 Moulding Exuberant Opportunities

52 Reducing Import Dependence Enhancing Made In India Prowess

62 New Avenues Finding Opportunities Beyond The Conventional

64 Seamless Integration Transitioning Mould To Perfection

74 Technology Trends Die & Mould Technology: Innovations For Expansion

76 Micro Moulding Moulding Miniatures

78 Additive Manufacturing Additions In Manufacturing

90 Tool Selection Tooling Solutions For Machining Optimisation

DIE & MOULD

SPECIAL FOCUS

SPECIAL FOCUSDie & Mould India 2012


The booming Indian

economy has resulted in

large amount of investments

to provide for the ever-

increas ing consumer

demand and the required infrastructure.

In particular, the automotive industry

and its suppliers, construction,

home electronics and white goods

industries as well as the steel production

industry have benefitted from this

positive trend.

Riding on the back of this strong

momentum, the country’s die mould

industry is gearing up to meet the rising

demand. In recent years the industry

has found many new customers such as

plastic products, energy, medical, auto

ancillary, consumer durables, etc.

The 8th Biennial - Die & Mould

India International Exhibition is

scheduled at Bombay Exhibition

Centre, Goregaon Mumbai from April

19-22, 2012. The exhibition provides

an ideal opportunity for the dies and

moulds industry to upgrade its know

how and keep pace with the latest

developments in this segment. It also

provides unique opportunity for the

dies and moulds & the entire tooling

related industry to witness the latest

technologies in this niche sector.

Hallmark of SuccessOrganised by Tool & Gauge

Manufacturers Association of India

(TAGMA), the 1st edition of the

exhibition was held in Mumbai in the

year 1998. Since then the event has today

steadily grown to become the largest

‘Die Mould Exhibition’ spread over an

area of 20,000 sq mts with international

participation from over 25 countries.

The 2010 edition of Die & Mould India

witnessed a total of 25,400 visitors and the

categories of interest were 34 per cent, 35

per cent and 20 per cent for the machine

tools, dies & moulds and total tooling

industries, respectively. The event has

become the one stop platform for die &

mould manufacturers. It has become the

place to meet prospective customer and

showcase the latest technology. Being

the biggest die mould focused event, the

With fast-paced changes taking place in the manufacturing sector, the need for die mould cannot be undermined. As India is catching up on the adoption of the latest technology solutions, manufacturing will soon witness a dramatic change in the way it is being operated currently. Aimed at offering a platform to meet perspective buyers and increase the know-how within the industry, Die & Mould India 2012 is all set to provide a fertile ground for GenX manufacturing. Nishant Kashyap reports...

MOULDing Exuberant Opportunities

Exhibitors Profile

� Dies & moulds manufacturers, press tools

� Mould base & standard parts

� Hot runner system

� Tool Steel

� CAD/CAM system related to Dies & Moulds

� Die spotting

� Rapid prototyping & modeling

� Moulding machine/ die casting machine

� Accessories for machine tools

P N Surendranath, Executive Director, TAGMA

This edition of die & mould India will expose Indian tool rooms and solutions providers to the latest innovations and trends, which will help manufacturers keep pace with higher growth rates in the manufacturing sector. Tool rooms today, are under tremendous pressure from shrinking budgets and production cycle times. The solution lies in concerted team effort of software technologists, tool-cutting engineers and machinery manufacturers.

Visitors Profile

� Machine tools

� Dies & moulds

� Total tooling

� Measuring instruments & gauges

� Mechanical engineering

� Sheetmetal products

� Auto ancillary

� Automation provide

� Plastics

Die & Mould India 2012


[email protected]

What Exhibitors Say…

Vinod M Sutariya, Head-Marketing, Indo-German Tool Room – Ahmedabad

This edition of die & mould India will expose Indian tool rooms and solutions providers to the latest innovations and trends, which will help manufacturers keep pace with higher growth rates in the manufacturing sector. Tool rooms today, are under tremendous pressure from shrinking budgets and production cycle times. The solution lies in concerted team effort of software technologists, tool-cutting engineers and machinery manufacturers.

Joseph Killukan, Managing Director, Jergens India Pvt Ltd

We are participating in die & mould India as it will offer us the opportunity to connect with machine-tool manufacturers and metal and plastics tooling manufacturers on a single platform. At the exhibition, we will be showcasing our die-mould clamps, workholding products, specialty fasteners, swivel hoist rings to prospective customers and users.

Sambit Pradhan, Manager - Business Developement-Asia Pacific, Geometric Ltd

Die Mould India 2012 plays a vital role in drawing

attention of global investors towards Indian die

and mould industry. It helps us reach prospective

customers and showcase our capablities. This year

we will be showcasing design and manufacturing

automation technologies for the die and mould

industry as well as technologies like VoluMill

for high speed roughing and ElectrodeWorks for

electrode extraction that will help us focus on the

potential audience. During the event, we have

planned for series of CAMWorks and DFMPro

product demonstrations to suit the target buyers

requirements. Initial communication for this has

been sent via mailers to the prospective buyers.

exhibition leaves no stone unturned in

consistently meeting the expectations

of both exhibitors and visitors alike.

The event enables manufacturers and

traders from India and other countries

to showcase their products and services,

thereby gaining brand recognition

& additional customers. Also, many

visitors to these exhibitions, have gained

appropriate knowledge and solutions to

meet their specific requirements.

Concurrent EventThe event has always been a highly

focused B2B event and this year will

be no exception in offering a complete

range of die mould related technologies

such as die/mould polishing machines,

injection moulding, hot runner system,

press tool and latest automation

and measuring technologies. Many

international and national exhibitors

will present modern technology

and solutions, helping industry

professionals connect, network, update

their knowledge and explore business

prospects with the market leaders. As

demonstrated during the last seven

editions, Die & Mould India 2012

has all the prerequisites – participants

and visitors who mean business,

excellent infrastructure, organiser with

a repute etc – to make it a thumping

success even this year.

SPECIAL FOCUSReducing Import Dependence


The die casting and moulding

industry invariably forms the

mother of all manufacturing

processes. A firm foundation

in place is what ensures the

automatic progression of the industry

towards quality and reliability. However,

the Indian industry is largely dependent

on neighbouring nations for imports

related to this segment.

Judging by the statistics, the Indian

industry projects a high growth rate

in manufacturing segments; this will

automatically create immense growth

requirements in the die and mould

sector. “The Automotive Component

Manufacturers Association of India

(ACMA) has alone projected a growth

of 40 per cent year on year and the

main constraint for them is the supply

for castings from India. We have the

capability and the technology, but we

do not have the required infrastructure,”

said Dr Sundara Murthy, President –

Institute of Indian Foundrymen (IIF).

India today, is the second largest

in casting production around the globe

with 9.05 million tonnes of casting

produced annually. The country comes

second only to China which has over

40 million tonnes of casting annually.

Keeping pace with the production, IIF

projects a growth of 15 million tonnes by

2015 and 24 million tonnes by 2020.

“Export of foundry machinery to

India in 2011 was worth € 85 million

from Germany, China, Italy, Korea

and Japan. The steel melting unit has

a total export to India worth € 300

million. The dependence has not just

been on China and Taiwan, but also

on European countries,” reveals Rajesh

Nath, Managing Director – German

Engineering Federation (VDMA).

There are several reasons for the

strong dependence on imports in

this segment; however, the changing

requirements leading to growth of

this industry clearly indicate that the

Indian mould makers need to strengthen

their prowess.

The progression in the industry dynamics and technological upgradation has hiked the graph of quality parameters. However, when it comes to the core of all manufacturing procedures, the mould and dies industry in India is still crushed under the dependence of imports. Is it just the cost factor which the industry is trying to evade or has this dependence moulded the entire attitude of industrial growth? Debarati Basu talks to industry experts to find out ways in which the country can become self dependent.

EnhancingProwessMADE IN

Reducing Import Dependence


[email protected]

Cost EfficienciesReducing costs is the major prerogative

of every manufacturer today. However,

bringing down the cost has its own

repercussions, especially on maintaining

the same level of quality. Importing has

instead become the most viable option

for manufacturers to maintain quality

with lower investment.

“Better quality moulds require

investment to obtain right expertise and

personnel, right from designing to the

mould assembly. As an alternative, the

industry finds it easier to import the

mould which will evade the investment

on upgrading the infrastructure. The

perception however is now changing

because the production volume for

internal consumption is increasing,”

explains Kaushik Bhattacharjee, Country

General Manager – AgieCharmilles

(South East Asia)

Techno Tussles This segment of the industry has always

been dominated by manual operations.

According to Viraj Naidu, Managing

Director – DISA India, out of the 5,000

foundries in India, only 100 use high end

automated solutions. “Around 4,000

foundries depend on manual operations

with very low productivity and of the

1,000 which are considering automation;

only about 100 are using high end

technologies. Even with this disparity,

India ranks second largest globally. This

highlights the tremendous opportunities

of growth in the industry. Imports only

add to the cost. The general expectation

is that, India in the next five years will

see similar type of growth that China

has experienced over the last ten years.

This cannot be achieved manually. We

have to upgrade ourselves to automated

systems and the casting industry requires

a lot of assistance,” reflects Naidu.

With the growing competition, the

industry now needs to make a quantum

shift to automate its operations and

increase production. “We are still 1/5th

of China in terms of casting production;

and India today has to double its

capacity to meet the demand, but at the

same time we have to be cost effective.

The domestic technologies available

today are all out date and if we continue

buying casts and machines from Europe,

it would only add to the manufacturing

costs,” points out Manish Kothari,

Managing Director – Rhino Machines.

Manning Skill Set Acquiring high-end machines is not the

solution to the issue. Strengthening the

production base has to be complimented

with acquiring the skill set and adequate

know-how of the technology along with

the high-precision machines.

This segment of the industry is

dominated by the small and mid-sized

industries, which makes it labour centric.

As the industry pitches to step up to the

podium of technological advancements

to be at par with the international

demand, the know-how of the industry

also need to be in sync. The industry

needs to evolve from its conventional

methods and adapt to the new mould

making and casting technologies which

is ruling the industry.

Supporting the SMEs Being dominated by the small and the

medium scale companies, the entire

equation rolls back to the cost factor.

Heavy investments do not come to

the smaller companies by choice,

but more as an obligation. To boost

the overall production capacity

of the country and compete with

the global production, the weaker

links of the industry need to

be strengthened. These can

be strengthened not just by

adequate government aid, but also

with the assistance from the industry

itself. “The institute is coming up

with several courses ranging from ITI

module to a degree course. We are

developing clusters all across the country

to impart skill sets. The industry today

needs to innovate and grow,” explains

Dr Murthy.

A collective and focussed effort

needs to be applied to empower the

mould makers and the industry as a

whole to reduce the dependence on

imports. This can be made possible only

if this segment is given central position

around which the foundation of the

entire industry growth is entrusted on.

Strengthening this foundation will only

ensure a strong presence of all the other

industries in the global arena.

Dr Sundara Murthy, President – Institute of Indian Foundrymen (IIF)

Why should we import when we have the capability and the technology? All we need is proper infrastructure. Innovation is the only way for any quantum development.

Viraj Naidu, Managing Director – DISA India

The Chinese and Indian way of working is different. China invests in capacity first and then the business follows. This is more adventurous, but is possible because of low currency cost. Indian industry follows an incremental or gradual growth approach and expands as business flows in. This industry needs a quantum jump.

Kaushik Bhattacharjee, Country General Manager – AgieCharmilles (South East Asia)

Quality is not to be compromised for cost. Cost competitiveness should come from efficient management of manufacturing process and right management of resources. Industry can grow only when generating the right quality becomes a norm. This should be backed by the right resources & right ROI.

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SPECIAL FOCUSNew Avenues


Die and mould is

ubiquitously found in every

segment. How well these

segments are explored

is what defines growth

prospects. Even as the Indian industry

has comfortably proved its mettle in

the automotive industry, it is time that

the industry climbs the ladder to find

of new terrains where die and mould

industry can grow.

“Out of the 90 million tonnes casting

produced worldwide, about 1/3rd of it

goes into the automotive industry. In

India it is slightly higher as the growth

that this industry has encountered

over the recent years has been huge.

However, keeping pace with the growth

of the automotive industry is something

which the Indian foundry industry has

not been able to do primarily because

of slower rate of mechanisation trends.

This brings in immense opportunity

of growth for this segment alone,” said

Viraj Naidu, Managing Director, DISA

India Limited.

However, here are to list some of the

new avenues where the Indian die and

mould industry can expect to find growth

opportunities over the next decade.

Railways While 45 per cent of the casting

production is consumed by the

automotive industry, railway would

form the second largest segment. The

ever expanding railway network in India

offers a cauldron of growth opportunity

for the industry. While manufacturing

of railway tracks and coaches which will

rise tremendously, the railways division

is working towards lowering the weight

of the coaches. “Railways have been

the lifeline of the country and with

the increase in the passengers, there

is also a lot of emphasis on the cargo

transportation. There is a vigorous

attempt to make the railway coaches

lighter in weight so that it can carry

heavier load maintaining the balance at

the same time,” said S K Sharma, Addl

Member Mechanical (PU), Railway

Board, Ministry of Railways. This

had led to experimentation with new

low weight –high strength materials

and die and mould makers of railway

coaches has to meet up with new set of

challenges in moulding such materials.

From malleable iron to cast iron to the

use of ductile iron, the variety in the

new types of material is ever changing.

Along with this the rail flaw

detection instrumentation and probing

devices would also emerge as an

important segment to curtail the

derailment possibilities, ensuring the

balance between low coach weight and

high load carrying possibility.

Infrastructure and Construction EquipmentUrbanisation has brought in a high rate

of development in infrastructure and

construction segment. The government

of India plans to incorporate additional

investments over the next few years

in upgrading and modernising the

country’s infrastructure. For the die and

mould industry, equipments required

for road constructions and other

heavy engineering machineries will be

of prime importance. Requirements

for machineries with new designs,

multipurpose utility with high strength

will be the need of the hour. As more

number of Indian players are slowly

entering this segment, castings for the

engines of the construction equipments

will be more crucial both in terms of

quantity and heavy duty reliability.

Currently, the Indian companies face

abundant competition from global

players and the Indian companies

are working towards bringing out

construction equipments with new

features like Dozer Shovels, Dumpers,

loaders, compactors etc.

Progression is the key to growth. The automotive industry, for decades has governed the growth graph of the Indian manufacturing industry. But it is time now that the industry spreads its wings and tests new terrains. For the die and mould industry, the growth of new segments in the industry has come up with altogether a different set of challenges which this industry needs to conquer. Debarati Basu explores the ebbs of opportunity that awaits this industry segment.

BEYOND THE CONVENTIONALFINDING OPPORTUNITIES

New Avenues


Municipal CastingWhile the industry eyes at the bigger

chucks of development and investment,

smaller and unconventional segments

of the industry also lays out a lot of

scope for growth. Odd enough, but

the developments in the municipal

constructions has always been ignored.

“A manhole cover is a huge industry in

itself but has always gone unnoticed.

In a city’s drainage system, every half

a kilometer needs an access. Multiply

that with the length and width of the

country and it would show how huge this

industry is. It is technically a very simple

casting. These covers are made manually

and also do not need high end finishing

accuracy. In India many casting suppliers

are exporting these manhole castings.

Since it is so simple a work, the mature

markets do not want to take it up and the

production instead comes to the emerging

markets like India and China. With the

urbanisation, the volumes have grown

and it is no longer feasible to depend

on manual operations. The Howrah

belt of West Bengal specialises in this

casting with around 500 foundries is this

particular business,” explains Naidu.

This segment calls for an organised

set up and high level of automation for

more business to flow in.

FMCG and Electronics Industry This is by far the fastest growing segment

in the world today. With a rampant growth

in the utility of electronic gadgets like

mobile phone, laptops and innumerable

new designs in the consumer durable

products like television, refrigerator,

washing machines etc, the scope of

growth for the mould and dies industry

is immense. However, experts in the

industry feel that India is too late to enter

the race. With the fast paced change that

the FMCG and electronic device industry

is caught up with, the Indian industry is

far from making a mark of its own in

this industry. But, that is no reason why

the industry should stop their attempt to

enter this market in a big way. Assessing

the market potential, the die and mould

industry can bank on the opportunity

especially in the small mould parts. This

is a segment which is still in its infancy in

this segment and plastic moulded parts for

electronic gadgets, is an area which can be

explored and excelled in by the industry.

Aerospace and Medical Equipment The aviation sector has brought India to

the center stage of global market. While

the country has entered this industry at

the right time displaying the right attitude

needed to be a potential player in this

segment, this is the time when the ancillary

industry segments can grab the opportunity

and grow in their respective fields. Die

and mould being one among them. With

every major global OEM entering the

Indian market with joint ventures, this

is the time of knowledge sharing. The

need for high precision and accuracy in

moulds and die casting will change the

dynamics of the industry. Adopting new

technology in the process will only add

on to the value that this industry offers to

the globe. This segment will demand for

aero parts and components which are both

large and small and requires high accuracy.

Moulding new materials in itself will bring

in challenges and providing high finishing

accuracies and intricacies will be what the

mould makers needs to excel in.

The field of medical equipment

manufacturing is yet another field

which has yet not progressed much

in the Indian domain yet it offers an

important role for the Mould and dies

industry. With a handful of Indian

companies now entering this industry,

this would open up new domains for the

mould and die industry in the making of

surgical machines and equipments and

transplant parts.

Textile and Agriculture Machinery These are two industries which has for

long gone unnoticed of automation.

The agriculture centric country and the

textile pockets still traditionally in a large

way prefer to have manual operations.

However, the trend is now changing and

with the growing demand for volume

most farmers and textile merchants

are making way for the automated

operations. “The rate of mechanisation

in these fields is very low in India.

But with the importance given to the

agriculture industry, the mechanisation

is increasing and this will give a boost

to the industry,” said Rajesh Nath,

Managing Director, VDMA, German

Engineering Federation.

Pumps /Valves and House Construction Equipment A huge amount of casting is required in

this particular segment right from taps

and the water piping in a building to

pumps and valves required in various

sector segments. This industry too needs

to emerge from the manual mode of

operation to automation.

Apart from these, the rise in the

demand for earth moving equipments,

trucks and tractors also have opened up

potential avenues for the growth for this

industry. Now, it only depends on the

how much the Indian die and mould

industry can bank on.

Rajesh Nath, Managing Director, VDMA, German Engineering Federation.

Manual operations have its limitation. The level of automation in India is low but there will be a strong boost in future as automation application is spread across industrial areas. Better quality equipment is cost effective when we look at its value.

[email protected]

Kaushik Bhattacharjee, Country General Manager, AgieCharmilles (South East Asia) Pte Ltd.

India has not looked into FMCG and consumer durable industry seriously and now it is an oversaturated industry and we cannot do much in terms of great innovation in this segment now to become the world leader. The industry moved to China because they are now the experts in terms of volume and mass production. Our infrastructure never encouraged such mass production.

SPECIAL FOCUSSeamless Integration


The level of competition both

at the domestic and the

international market has

reached a threshold which

involves an entirely different

set of challenges. In such a situation, is

it enough to take a risk and plug into

untested terrains? Should the industry

instead be conscious in its investment

activities and take measured steps

ahead? What are the things which need

to be upgraded in developing India so as

to integrate it into the global industrial

evolution? These are some of the

questions which the industry ponders

upon today, as it finds itself caught in

the midst of age-old methods followed

traditionally and the sudden surge

in technological advancements being

incorporated universally.

Discussed below is a list of the do’s

and don’ts for the Indian industry as it

transitions to the next level:

Change in AttitudeThis is probably the first step in the

entire process of progression. The

industry needs to change its basic attitude

towards change itself. The industry

needs to assess itself in a new light in

comparison to the changes which are

happening worldwide. With the rate at

which the global industry is progressing

in terms of technology, investment and

industrial know-how, it is too late for

the Indian industry to continue with the

‘chalta hai’ (it’s okay) attitude. The global

market only wants perfection with not a

micron out of place. Hence, the country

needs to strive to enter that league of

manufacturing capability.

“New technology is the need. We

can no longer do it the conventional

way, and more Indian companies are

inculcating this trend fast. This has

resulted in an increase in the skill and

knowledge in the industry to operate

these machines,” explains Viraj Naidu,

Managing Director – DISA India

Create a NicheIn an age of tough competition, the

Indian industry needs to define its

own identity and carve its own niche.

If Europe today stands for precision,

Japan for innovation and China for

its mass production, where should

India create its domain? We can no

longer only be identified as low-cost

outsourcing destination for global

OEMs. Getting into a niche market

or domain probably may not be a

feasible option in terms of return on

investment. But the industry needs to

look beyond the horizon and calculate

the value in it, which would pay back

in the longer run.

“India is well advised to stay

on its path of domestic growth and

prosperity rather than try to excel

Simply identifying potential business is not where the challenges end; the industry needs to go through a quantum transition in order to seamlessly incorporate new manufacturing nuances. Debarati Basu tries to find out the missing links in the industry’s growth and ways in which these gaps can be plugged so that the conventional industry can easily evolve to the next level of manufacturing operations.

Seamless Integration


[email protected]

everywhere. Focus on your core areas,

make them strong and be independent

of fluctuations worldwide,” reflects

Christian Kleeberg, Managing Director

– MAGMA Engineering Asia Pacific

PTE Ltd.

Generate VolumeTo justify the investment, it is

invariably important to generate

the volumes. Most investment and

expansion plans fail because of the

lack of initial demand in the market.

However, by the time the volumes rise,

India will find itself lagging behind

the others in the race. The industry

needs to confront the reality and dare

to plug into new terrains and create

the need and expand the market.

Change in Buyer Attitude High-end manufacturing, investment

in latest technology, and precision in

production, all goes down the drains as

soon as the buyer demands reduction

in the cost of the final product.

The main prerogative of every buyer

today is to cut down on cost. Given

the competition, every business

house would bag the contract by

lowering the cost of the product but

this eventually trickles down to cost

cutting in the manufacturing process

compromising quality. This brings the

industry back to square one—that is

ensuring quality.

Change in Work Culture It is difficult to change habits. The

conventional work culture has seeped

in too deep and for too long for it

to change. But the world has moved

on. The global market, along with

quality demands on time delivery and

professionalism in approach. With

upgradation in technology, it is now

imperative to upgrade the working

environment that we provide. “Indian

foundries do not mind having 15 per

cent rejection but they avoid adopting

better technology which can drastically

bring down the rejection levels. They

are satisfied if one machine is able to

meet the current demand instead of

investing in a technology which can

double the production. The issue here

is also with the lack of human resource,

training the available resource and then

retaining them,” points out Kleeberg.

Do Your HomeworkWith so much variety in products in

offer and new demands being generated

by the market continuously, the avenues

for investment in the industry have also

opened up. It is now upto the industry to

assess the demand trends and emerging

opportunities in the market. The onus

lies on the intensity of homework done,

along with assessing the return on the

investments. Avenues are many, but

selection of the right path and excelling

in it makes all the difference.

Research Initiatives The area where the Indian industry lacks

is its inclination towards research. With

some of the premier technical institutes

generating waves in the global circuit,

the domestic market fails to benefit out

of it. There is a dire need to encourage

research initiatives in the industry

and excel in generating innovative

designs and technologies instead of

manufacturing prototypes.

Grow and Let Grow The Indian industry is a blend of

larger OEMs and small and mid-sized

companies. Each category has its own

forte of expertise. But today, each

segment of the industry has its own path

of functioning. What the market instead

needs is amalgamation of strengths and

expertise from every sector and grow as

one industry.

Sense of Competition In an age of cut throat global

competition, every country, no matter

how big or small, has an outward

outlook. Every country has grown big

by creating a global image for itself. The

Indian industry too should strive to put

the ‘Made in India’ brand on the global

map. It is not just the Tata’s or the

Mahindra’s, but the ‘Brand India’ which

the global industry should acknowledge

and accept with reverence.

This is just the beginning.

With time, the Indian industry

would itself grow out of its groove

to amalgamate into the global way of

operation and functioning. The only

prerogative is that the time taken should

not be a bit too long.

S Subbarayan, Deputy General Manager (Die Mould), Makino India.

Market is the driving force. You can get technology when you have volumes to justify it and you have volumes when you have the capability. It is a vicious circle.

Dr Sundara Murthy, President, Institute of Indian Foundrymen (IIF).

The industry has not yet considered investment in the niche market. Magnesium, aluminum and lithium alloys have tremendous opportunity which we have not yet explored. We have to enter these niche areas, explore and innovate.

Christian Kleeberg, Managing Director – MAGMA Engineering Asia Pacific.

You have everything in this country for it to grow. But despite very strong receptiveness of the Indian industry, the willing to adapt the best technology is very low here. People talk about improvement but they do not improve. Cost is not the factor hindering technological advancements, and whoever says so has not done a professional ROI or cost-benefit calculation.

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SPECIAL FOCUSTechnology Trends


The manufacturing

industry in India is

primed to grow by

more than 15 per

cent in 2012. For the

die and mould sector, an industry

fundamental to manufacturing,

this growth comes at a crucial

time. Approximately 70 per

cent of demand is met through

imports in a rapidly slowing global

economy, despite the Indian

manufacturing sector rising when it

was expected to slide. Government

policies are attempting to bolster

manufacturing to 25 per cent of

GDP by 2025 through initiatives

such as technology funds, training

centers, subsidies and policies

regarding joint ventures with

foreign manufacturers. Such

collaborations are being encouraged

to bridge the gap in technology

and manufacturing practices, all at

a time when indigenous demand

is expected to climb by 40 per

cent. There is a relative shortage

of capacity, innovation, in-house

development and technical talent

in Indian manufacturing companies

who are increasingly dependent on

foreign machining centres and rely

heavily on high-tech component

imports. Domestic manufacturing

has a market share of just 33 per

cent at present. In this regard, die

and molud manufacturers need to

invest in equipment and technical

know-how to exploit the high-

tech product market since that is

where the scope and scale of future

manufacturing exists.

The following technological

trends serve to guide the Indian

mold manufacturer through

prominent developments and

recent innovations in the industry.

Overall, the trends point towards

faster production cycles, shorter

lead times, more precise tolerances

and higher quality surface finishes

while molds increase in size and

complexity. These lead to machines

with increasing capabilities like

higher spindle rpm’s, higher multi-

axis velocity and acceleration,

control systems for greater positional

accuracy and micro-tolerances.

Advances in hard-milling and

multi-functional molds as well are

empowering mold manufacturers to

diversify and maximise the quality

of their products.

Rapid ToolingRapid tooling advances are

currently responsible for reducing

cycle times by 40 per cent

as compared to conventional

machining. Conformal cooling,

bimetal layering and better mold

materials, like aluminium, allow

Rapid technological advancements in global die & mould manufacturing are rising in relevance, particularly in India, where unprecedented growth in demand raises challenges in production and capacity. Tarun Tampi looks into the Indian machine tools industry in the grip of these advances.

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DIE & MOULD TECHNOLOGY:INNOVATIONS FOR EXPANSION

Technology Trends


for quicker thermal conductivity in

molds and rapid processes allow for

production of inserts and mold tooling

in less than 48 hours. Mixed metal and

gradient tools are also produced using

Rapid Solidification Processes (RSP),

Direct Metal Laser Sintering (DMLS)

and Selective Laser Sintering (SLS).

Rapid processes are capable of easily

producing modifications in the tool,

like undercuts or side-action. They can

be used to make high-volume parts in

large sizes and even transparent parts in

most engineering grade materials. Rapid

technologies can output moulds in two-

three weeks and can even be used to

reverse engineer parts or repair and

rebuild molds. With the development

of vinyl tooling gel coats and zero-

shrinkage resins, it is possible to build

within a day, durable molds with high

surface finish. Further, rapid tooling,

since it is based off a CAD file, offers

the option of customised production,

flexible design and standardisation of

parts. This is increasingly relevant since

mold designers have to often modify

their molds because of part re-design.

Hot Runner TechnologyHot runners are vital in delivering the

melt material from the injection nozzle

into the cavity and their application

helps illustrate the effect of gate quality

on overall part quality. Developments

in hot-runner technology has seen vast

improvements in thermal uniformity,

melt homogeneity, wall thickness, output

capacity and automated electric valve

gating. Electronically controlled gating

systems using servo control are replacing

hydraulic and pneumatic actuation.

Electric systems are more precise,

cleaner in function and can optimise

every parameter in the functioning of

upto 64 valves, improving melt pressure

and flow at each gate. Better process

controls, like in thermocouple controlled

nozzles and improved hot-runner nozzles

allow for easier application and simple

maintenance of hot-runner systems.

These advances have a direct impact on

the part quality, cycle times and costs.

They reduce resin costs and introduce

direct gating where cold-runners were

used, allowing for more cavities in a

single mold.

Aluminium MouldsIt has long been understood and proven

that aluminium tooling is capable of

reliable high-volume production. The

effects of wear, hardening, machining,

finishing and cycle time are all better

for aluminium tooling as compared

to traditional steel tooling, although

aluminium moulds must be built to the

same standard and design expectation

of steel molds. Aluminium moulds

can be half to one-third the weight of

traditional steel molds, reducing wear

and tear and have far better thermal

conductivity. The cycle times are

reduced by 30 to 50 per cent allowing

for greater production volume, costs

savings on production tooling as well

as lead times reduced by 10 per cent.

There is also reduced distrotion, internal

stresses and shrinkage. Such molds,

although they require more care and

adaptive techniques to design since the

material is aluminium, are also better

suited thermally to hot runner systems.

Hence, in terms of quality, time and

cost, these advances reorient the view on

aluminium, particularly aircraft-grade

aluminium, as a high performance, large

volume production material for molds

and not just for soft tooling.

High-speed MachiningHigh-speed Machining (HSM) has

had a significant impact on the mould

manufacturing process. EDM has long

been the choice technology for cavity

cutting and hard steel machining,

however, HSM has improved over the

years to match EDM in surface finish

and accuracy. HSM has several inherent

advantages, like higher cutting speeds

and feed rates, better surface quality

and accuracy. This also leads to lesser

tool loads, lower mould temperatures,

better thermal conductivity and reduced

machining costs. HSM reduces the

workload and costs of producing high

precision surface finishes. Tool life is

extended although care must be taken

to carefully tailor and balance the tool

and HSM machine according to the

requirement since spindle rates are very

high. Sharp internal corners and 90

Degree cuts are still possible only with

EDM, but mold manufacturers could

also look into complementing EDM

with HSM as and when possible.

Mould development is rapidly

shifting towards large-scale production.

To meet these challenges, larger molds

with better material properties need to

be developed. Multi-axis cutting and

deep-hole cavities need to be improved

to efficiently machine more complex

parts. Compound processing, where

multiple machining processes can

be done on a single machine, is still

to be realised at a level where mould

processing, mechanical, electro-chemical

and ultrasonic processing can all be

carried out on the same machine.

There is a 30 per cent growth in

demand expected in the machine tool

industry this year, with present demand

standing at about ` 10,000 crore. Large-

scale expansion in the automotive,

defense and railway sectors are primarily

responsible for this surge in machine

tool demand. To match this, small and

large manufacturers need to increase

their production capacities, invest

more in R&D and take advantage of

joint venture opportunities. Coupled

with the adoption and optimisation

of the latest technologies, the industry

could easily meet and surpass IMTMA’s

projected market size of ` 23,000 crore

by 2020.

[email protected]

Die and molud manufacturers need to

invest in equipment and technical know-how to exploit the high-tech product market since

that is where the scope and scale of future

manufacturing exists

SPECIAL FOCUSMicro Moulding


Even as the manufacturing

industry itself has taken

a leap towards higher

level of precision, most

manufacturers are trying to

cut down on the machining costs. To top

it up, miniaturisation is a trend which

is catching up across all the industrial

verticles throughout the world. With the

rise in micro components, machining

parts at the sub micron level has always

posed to be a great challenge.

As an alternative, technological

advancement has brought in micro

moulding as a cost effective option

to micro machining which can deftly

produce miniature parts supplying

similar precision and reducing the overall

cost of production and manufacturing at

the same time.

However, given the adversities that

the Indian industry faces, will this

technology be able to seep in as a cost-

effective option for the manufacturers?

Micro-level MouldingAs the domain of manufacturing processes

has expanded over the years, the next

criterion of immense importance is on

bringing down the cost of manufacturing.

Micro machining has traditionally been

the benchmark of precision machining

especially in industries which demand

for high intricacies and complex

designing parameters. However, as the

soaring volumes for such components

are in demand, the industry has deftly

accommodated new technology justifying

mass production.

Micro moulding, today can offer

a range of cost-effective alternatives

for components that are miniature,

complex and require high-precision

tolerances. In precision micro moulding

of a component, manufacturers have to

consider the mould tool design, the micro

moulding equipment used and ensuring

the quality of the final product.

Any component which is smaller

than one micron and has high-precision

tolerances are components which can be

micro moulded effectively. Additionally,

this technology can play an important

role for components made of metal,

ceramic, glass or plastic with high degree

of design complexity.

However, the ability to produce

acceptable metering accuracy and

homogeneity of very small quantities of

plastic melt is in itself a key challenge in

the micro moulding process.

Why Micro Mould?Along with bringing down the

manufacturing costs; this process also

saves time in production processes as

compared to that spent on machining

the parts. This has been found highly

effective especially in the segments

which demands parts in high volumes.

The advancement in this technology

has also guaranteed precision of parts

which has automatically brought down

the need for surface finishing.

As the trend for smaller

components is rising, it might become

more difficult to machine complex

geometries. Hence, micro moulding

comes in as a viable option as

this technology gives more freedom

to designers to include intricate

features in the products thereby

enabling easy manufacturing of

complex designs easily.

Applying Micro MouldingThe rising complexities in the field of

medical equipments have generated

opportunities for micro moulding.

Here are some areas of medical

equipments manufacturing made of

plastics where micro moulding can

play a bigger role along with other

manufacturing segments where it has

already make a mark:

� Some of the medical devices require

The word ‘micro’ has seeped deep into the manufacturing industry and with the rising demand for small and sleek products, machining such intricacies

is an expensive challenge. Micro moulding, however, has rose as a cost-effective alternative for the industry. Debarati Basu finds out the nuances that this technology

offers to the industry.

OULDING

Micro Moulding


visibility under an X-ray and are

typically made of metal. The density

of the material provides the contrast

needed to accurately locate the

position of the device inside the body

during the procedure. Plastic resins

filled with radiopaque compounds

can be visible under x-ray imaging

and can be used to replace metal

components.

� Medical devices that carry current

need to be isolated from the main

body of the instrument. This

additional component increases the

diameter of the product. Switching

to a moulded plastic component can

remove the need to add isolation to

metal components thereby reducing

the size of the device.

� Plastic with metal or ceramic filler

can be a suitable replacement for

metal injection moulding (MIM) as

it eliminates the need for secondary

operations associated with MIM

technology.

� Micro moulding can be vertically

integrated into an entire

manufacturing assembly process

that may include stamping, insert

moulding, bonding or conventional.

With the rise in the use of complex

parts in the field of medical,

defence and automotive industry,

increasing number of components are

manufactured so as to integrate them

in the process of micro moulding.

Hence, in this process, mould tooling

is also an important aspect. Micro

moulding is an extremely complex

process compared to conventional

moulding. At micron level of

moulding, the need for the right tool

increases due to tighter tolerances

and higher intricacies. Since this

process needs to guarantee similar

level of precision, as offered by micro

machining, jeopardising the quality of

mould tool would ultimately lead to

low quality product and loss of time

in surface finishing the component to

the required specifications.

Also high grade quality inspection

equipment plays a very important role

in the entire process to assess the

quality parameters of the final product

which need to be measured for its

precision and perfection at the micron

level. Measuring a micro moulded part

which is as small as 0.01 mm is not a

simple task. Every aspect in the entire

process forms a critical ingredient to

manufacture a perfectly micro moulded

component.

Gearing Up M i c r o

moulding, if

performed to

achieve the

exact parameters

of accuracy

required in

highly critical

s e g m e n t s

like medical,

e l e c t r o n i c

devices and

defence, can

prove to be an

excellent lower

cost alternative

to mic ro

machining. The

criticality of

this process will

only increase

with time and

the need for

even smaller

and intricate

designs. India,

which is on

its way to

adopt this technology, will redefine

its manufacturing parameters with

this technology. The only roadblock

remains the fear of the unknown as

this technology is still in its infancy and

most manufacturers and buyers need to

understand the dynamics of this process.

It is now upon the manufacturers

not just to develop the skills of micro

moulding but also to generate the

demand in this sector as a high quality

low cost alternative.

Advantages of Micro Moulding

� Low cost solution

� Incorporates intricate and complex geometries

� Reduces particle contamination

� Gives better surface finish.

� Decreases cycle time

S SubbarayanDeputy General Manager (Die Mould), Makino India.

Micro moulding and micro machining,

both have their own relevance. One

cannot replace the other but in

industries demanding mass production;

micro moulding becomes a more

practical, cost effective option. After

micro, people have started talking at

the nano level today.

[email protected]

SPECIAL FOCUSAdditive Manufacturing


Additive Manufacturing (AM),

a technology that is a few

decades old, has long been

viewed by the industry with

scepticism. Just a few years

ago, less than 22 per cent of mould makers

had adopted rapid prototyping, let alone

rapid tooling or manufacturing. There is

a reluctance to embrace AM techniques

as the next step in manufacturing even

though these techniques have since

outgrown their infancy and are rapidly

amassing potential to revolutionise how

we manufacture. Doubts linger; ‘Is the

technology fundamentally disruptive?’,

‘Would it really eliminate the need for

moulds and tooling?’, ‘Can it match

conventional manufacturing in product

quality, cycle times, costs?’

The mould industry is fundamental

to manufacturing and having seen

tremendous growth recently, mould

makers are increasingly looking for ways

to diversify their markets, extend their

capacities and bolster the competitiveness

of their businesses.

Processes and Classification:AM can satisfy each of these needs

considering recent improvements, and

its progressing ability to work with

plastic, ceramic, metal and composite

materials. Its applications can be sifted

into three broad categories:

Rapid Prototyping (RP): produces

functional prototypes with properties

similar to the product. Fit and form

testing, assembly compatibility and

design iterations can all be performed,

thus allowing for huge savings of time

and cost within the design stage itself.

Further, the manufacturing process

cycle can be optimised, having studied

the prototype. Samples may be quickly

made for cosmetics, marketing, safety

standards and conceptualisation.

Rapid Tooling (RT): is used to

create patterns and mould tooling, either

directly or indirectly, for low-medium

volume production. Although it trails

conventional mould-making methods in

surface finish, durability and part size,

RT allows for complex geometries to

be made using multiple materials while

reducing lead times for tooling, reducing

initial costs and improving the versatility

of the design since the CAD file is all

that needs to be modified.

Rapid Manufacturing (RM): involves

medium-high volume production of end-

user parts. For high volume production,

savings on tooling and skilled labour

still do not sufficiently offset the short

production cycles, high accuracy and

tolerances of conventional methods.

For these applications, there are

a host of processes and technologies

unique to AM. Depending on the form

of the raw material used, there are:

� Liquid – Sterelithography (SLA),

Jetted Photopolymer, Inkjet

Printing

� Powder – Selective Laser Sintering

(SLS), Direct Metal Laser Sintering

(DMLS), 3-D Printing (3DP)

� Solid – Laminated Object

Manufacturing (LOM), Fused

Deposition Modelling (FDM)

All of these processes share a similar

process structure in that a CAD model

of the desired part is made and then

converted into an STL file. The STL file

is sliced into layers or voxels (volumetric

units) and the machine builds the part

according to the STL file, after which

any post processing is done if required.

Benefits of AMSince there is no inherent tooling

required or any setup time, lead times

ADDITIONS IN MANUFACTURINGThe late Steve Jobs observed that, “The overall point is that new technology will not necessarily replace old technology, but it will date it. By definition. Eventually, it will replace it. But it’s like people who had black and white TVs when colour became available, they eventually decided whether or not the new technology was worth the investment.” For the die and mould industry, Tarun Tampi takes a contemporary look at how additive manufacturing is worth the investment today.

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Additive Manufacturing


[email protected]

to manufacture a part or prototype are

greatly reduced. Parts of almost limitless

complexity can be made using materials of

any type, as long as they are available in

the required form, which can be combined

to provide the desired mechanical

properties. Further, since manufacture

is directly linked to the CAD file, mass

customisation at low-volume production

is highly cost effective and extremely

versatile, which is why the medical and

jewellery industry are already benefiting

from the use of AM technology. For

rapid tooling, like indirect silicon rubber

moulding or epoxy tooling, various

features, moulding parameters and tooling

changes can all be evaluated in a matter

of days. FDM and laser sintering could be

used for thermoformed tooling as these

processes yield parts with porosity that

can be used to draw a vacuum through

the tool. These technologies give the

mould maker the ability to design and

quickly build his own moulds, cavities,

inserts, die casting tooling etc, thus

reducing his dependence on expensive

imports. Rapid metal mould technology

is a priority for metal-casters and tool-

makers in this regard. In addition, jigs

and fixtures can be designed, customised

and produced in-house without the need

for any special tooling. Similarly, since

AM can add material where needed, it is

useful in the repair and modification of

existing parts as well.

A significant advantage AM brings is

conformal cooling technology for mould-

making. Previously, mould makers were

restricted in their ability to build cooling

channels into the mould due to the

limitations of tool and drill geometry.

But with AM, cooling channels can be

built in to conform to the shape of the

mould, allowing for a variety of mould

configurations, faster cooling, better

quality parts and reduced production

time. Conformal cooling also allows the

mould to last longer, thus extending its

production volume for parts.

Since it successively adds material in

small quantities to build the part, only

as much raw material is used as the part

requires, allowing for savings in material

requirement and consumption. This is

in contrast to conventional machining,

where large amounts of scrap are

generated after a part has been machined

out of stock. Hence, accounting for the

design, manufacturers using the additive

approach could reduce 50 – 80 per cent

of the raw material used to make a part,

which would mean extracting twenty-six

times less material from the earth.

Challenges: Only a Matter of TimeLimitations still remain as the technology

grows to fit the size of its potential. Part

size, surface finish, accuracy, mechanical

properties, and tolerance are all areas

where AM needs drastic improvement if

it is to match conventional machining.

“There are three main challenges;

firstly, the huge capital investment in

the machinery. Secondly, the expensive

consumable cost which, over the years,

could overtake the capital invested.

Thirdly, the lack of a good ecosystem

of service providers, well-informed users

and attractive government policies.” –

explains G K Rao, CEO, Imaginarium

(India) Pvt Ltd.

Further, in terms of production,

AM is still suitable only at low-medium

volume since it still does not match the

cycle times, part quality, tool life and

overall costs of conventional machining

at high volume. Today however, AM

techniques can effectively produce

volumes of 10,000 – 15,000 parts. As

the practical application of AM grows,

a number of these disadvantages will

be resolved to make AM practical and

cost-effective in the future.

Adding the Future The nature of additive processes is such

that it alters our fundamentals about

manufacturing in terms of design,

investment, supply chains and equipment.

Materials available today for AM

processes, such as powdered metal alloys,

polyamides, nano-resins etc are increasing

in variety and quality. The processes are

more robust and highly customisable with

new processes being developed as well.

Today improvements and innovations in

DMLS, Laminate tooling, Laser sintering

and Laser-cusing are expanding their

scope and application to produce end-

user parts throughout the industry, in

aerospace, automotive, medical, defence

and general engineering sectors.

A growing offshoot of these

technologies is hybrid manufacturing, a

combination of additive and subtractive

(conventional) manufacturing processes.

Rao believes that “One cannot replace

traditional tools and dies as a route to

large volume manufacture. RP will more

than complement them acting as a de-

risking tool for design validation while

highlighting costly errors at fractional

cost, thereby averting costly rework and

loss of precious time.” Complex parts

may be built using additive technologies

and finished or post-processed

using conventional machining, thus

using the best process where needed.

This brings with it the benefits of

both manufacturing techniques and is

easier to assimilate into existing

business models.

With annual growth in the

AM’s twenty-three year history at

26.2 per cent and with 100 per cent

of all future development expected to

focus on manufacturing, the prospects

are limitless. The point is to see

where this technology can be applied

cost-effectively and creatively by the

manufacturing industry.

Applications of AM, in Descending Popularity

� Functional Models

� Direct Part Production

� Fit, Fixtures, Assembly

� Presentation & Visual Aids

� Patterns for Prototype tooling

� Patterns for metal casting

� Tooling components

“If you can think it, we can make it!Additive Manufacturing, the futureof the next Industrial revolution, hascome here to stay!” – G K Rao, CEO, Imaginarium (India) Pvt Ltd

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SPECIAL FOCUSTool Selection


One should understand the

need and importance of the

product before finalising

on the right cutting tools.

For instance, if you have

to make a mould for a circuit-breaker,

cutting tool selection becomes crucial

as the tolerances to be maintained will

be very tight. To produce more accurate

parts, one should select precisely ground

cutting tools, sophisticated machines and

appropriate CAD/ CAM systems. For

sheet metal dies, you need big diameter

tools like dia 80 bull nose or ball nose

and so on. A form tool needs to be

machined with high-speed machines

for smaller groove areas and requires

smaller tools (as small as 0.1mm). While

machining mould bases finishing and

accuracy are the top priorities.

Material Type – (soft steel, steel up

to 50 HRc, steel more than 50 HRc,

stainless steel, aluminium, etc)

Tool life plays a major role once

you have harder material more than

52 HRc and soft materials like

aluminium. The tools selected for

hardened steel will not perform

efficiently if used for softer materials.

Also, to machine electrodes in copper,

you need a sharper tool and a thin PVD

coating. In the case of graphite, you need

a sharper tool with diamond coating

that can withstand its abrasiveness;

otherwise, one will struggle to get the

net shape within optimised time.

Type of MachinesIt is also very important to understand

the type of machines. For example, if you

want to machine hardened steel, HSM

technology is required to cut the steel

more efficiently. However, most HSM

machines may not be able to deliver the

high torque required for high depth of

cut in case of bigger size tools

Hence, while using bigger diameters

on HSM machines, it is important to

consult your cutting tools suppliers or

machine tools suppliers to understand

the limitation. Similarly, if you want

to machine with higher depth of cut

with conventional feed and RPM,

you should have a robust machine

spindle which may not have a high

RPM. In such a scenario, you need to

synchronise your need and availability to

select the appropriate tools considering

the machine type as well as the resources

available.

StrategisingAfter deciding on the material and

machine, one needs to focus on selecting

an appropriate machining strategy.

There are several strategies which

can be used for efficient machining like,

HSM, High Feed Machining (HFM),

High Performance Machining (HPM),

There are different types of dies & moulds which require different approaches and strategies while selecting cutting tools. So, how does one choose the most appropriate cutting tools for machining moulds and dies? Some considerations that need to be take into account while selecting tools…

For Machining Optimisation

TOOLING SOLUTIONS

For Machining Optimisation

Tool Selection


micro machining and conventional

machining.

Tools selection example: Let us take an

example of one forging die having the

following dimensions-

Envelope size – 500x250x60

Minimum radii to be achieved – 3.0 mm

Maximum depth to be machined – 57 mm,

this requires a minimum of 60 – 65 mm

overhang

Hardness of material – 55 HRc

Pointers for ConsiderationWhile doing the roughing, the first

question is—which type of tools (eg ball

nose, bull type or sharp end-mills) will

be more efficient? The answer is—“It

depends upon the shape of the die

or mould,” says Sashi Menon, DGM

– Technical Support, Seco Tools India.

He adds, “In other words, if you have a

bigger shape to be cut like 500X200X100

with hardened steel of 55 HRc—go for

high feed tools as they are an economical

way of cutting the material faster.” If

you have normal P20 steel for a bottle

mould with a size of 100X100X50, go

for ball nose end mill directly and carry

out high speed machining roughing. To

rough out a forming die in aluminium,

you need sharper tools with two flutes

for easy removal of chips, for eg Seco

–Jabro 400 Series. By using this, you

can achieve even 0.5mm thickness of

wall with 30.0 mm height. If you do not

have the right tool in this case, you will

have to struggle to get the net shape and

surface finish required.

Tool Holding This is another important factor that

requires consideration since the adaptor

is the key link between the cutting edge

and the spindle nose. Using sub-standard

holding devices or a damaged pull stud

(retention knob) may result in damaged

machines or improper dimensions and

forms. Balanced adaptors and tools are

inevitable while machining using the

HSM strategy or when the RPM is higher

than 12,000. A well balanced adaptor

with minimum unbalance of 3g.mm/kg

is a highly recommended HSM.

L/D Ratio This is another major factor that has

to be considered. Tool life and cutting

parameters are greatly influenced by the

overhang factor. It is always advisable

to use the lowest overhang possible and

while machining longer depths, divide

the NC programme and use overhangs

which will enable you to use optimised

parameters. Anti-vibration adaptors

like Steadyline from Seco are highly

recommended while machining larger

depths, like mould bases, for instance.

Parameters for Finishing ap (depth of cut), ae (step over) depend

upon surface roughness requirements.

These may vary in case of precision

moulds to forging dies. So, using proper

ap and ae will reflect on the surface

finish, tool life and the cycle time.

ap and ae, which are lower than the

recommendations, may result in poor

surface finish and bad tool life since

every cutting tool also needs to have

sufficient material to cut.

Stock Material This plays a vital role while finishing.

Enough material has to be left for

finishing cut. Parts with very low stock

may result in rubbing the tool on part. At

the same time, excess material may result

in bending of the tool, which may spoil

the net shape and surface finish.

Types of Dies and Moulds

� Injection and compression moulding

� Die casting

� Forging

� Sheet metal forming and cutting

Vipin Rajput, Product Manager-Jabro Products, Seco tools India Pvt Ltd, Pune

Table 1: Traditional Tool Selections - Roughing /finishing

Operation Tool type (Seco) dia (mm)

Cutting speed

(M/Min)

Feed per tooth (mm)

RPM (per min)

Depth of cut (mm)

Step over (mm)

No of teeth (Zn)

Table feed (mm/min)

Roughing-1 Dia 25R2 high feed-2 25 200 0.7 2544 0.7 75% 3 5342

Roughing-2 Dia 16R2 High feed-2

16 200 0.7 3975 0.7 75% 2 5565

Rest Roughing

Ball end-mill dia 6R3 6 200 0.1 10600 4% 35% 2 2120

Finishing-1 Dia 12 ball -JH111 (standard length up to 45 mm)

12 220 0.15 5830 scallop=0.010 2 1749

Finishing-2 Dia 12 ball –JH-111 (From 45 mm to 57 mm)

12 200 0.12 5300 scallop=0.010 2 1272

Finishing-3(corner)

Ball end-mill 6R3-JH111 ball

6 200 0.07 10600 scallop=0.010 2 1484


FACILITY VISITPrecihole Machine Tools Pvt Ltd

Spearheading deep hole drilling technology, with customised machines as their forte, Prechihole Machine Tools Pvt Ltd is a groundbreaking establishment that is relentless in pursuing sustainable innovation, functionally and reliably. During a visit to the company’s facilities, Nishant Kashyap & Tarun Tampi, take a look at the latest manufacturing technologies.

After gaining extensive

experience and expertise

in Deep Hole Drilling

Machines (DHDMs)

from overseas, Precihole

is credited for bringing this highly

specialised, yet much-needed niche

technology to Indian job shops. Deep

hole drilling practically defines a

drilling operation at a depth which

is 10 times the diameter of the hole.

It is a technology that comes with its

own unique possibilities and challenges.

This Indian company has come a long way

from being an indigenous manufacturer

of gun-drilling machines to becoming

an exporter of quality DHDMs to

Austria, Canada, Brazil and the US, to

name a few.

Production Capability The company manufactures a vast range

of DHDMs. These machines are available

as per clients’ specific demand. And to

meet this demand, the facility never

sleeps. The company has two different

facilities in Thane that reliably run three

shifts, round the clock, throughout the

week, transporting at a high throughput

rate to its clients. Machines are widely

appreciated for their greater functionality

and reliability. The cycle time for the

production of a single standard machine is

approximately four months while for more

complex or Special Purpose Machines

(SPMs), it takes around six months. An

average of five machines is completed

each month and Precihole is on its way

to double its production capacity. For a

machine, depending on the specification

and design need of the customer, while

about 25 engineers and technicians

engage themselves in the manufacturing

and assembling process.

In terms of specifications, drilling

machines are built to handle components

of diameters ranging between 1.5-

250 mm typically. Machines can be

automated if required and customised to

the component or part it is needed for.

Training for machine operation is also

provided for and usually takes a few days.

International standards are maintained at

every step, right from shop floor practices

to component and end-product quality.

Further, every machine is an improvement

or innovation in one way or another.

Product Range The company houses India’s largest state

of the art deep hole drilling manufacturing

centre. It houses three distinct sections of

the business – conventional machining

tools, subcontract assembly areas and

Gun or BTA drilling stations - all

complementing each other. Engineering

challenges are plenty and varied in deep

hole drilling. The company manufactures

single axis gun drilling machines, 3-axis

gun drilling machines, BTA and STS

drilling machines, X-Y BTA deep hole

drilling machines, skiving and burnishing

FACILITY VISIT

CUSTOMISED DRILLING SOLUTIONSPIONEERING


Precihole Machine Tools Pvt Ltd

machines. Apart from this, the company

also manufactures SPM’s.

Precihole has several hundred

machines implemented successfully at

several large and medium sized businesses

around the world. With giants like Honda,

TATA, BOSCH, Escorts, Godrej, L&T,

Cummins, Premier Ltd and Mahindra

as its key customers, the company has

made its mark in offering state-of-the-

art technology at affordable costs. The

machines are well designed with the

customers’ need in mind. The machine

tool range offered by the company

covers most materials and hole diameters

applied in the industry. The company has

designed and manufactured all types of

machines for deep hole drilling equiment

available in the world.

Challenges Encountered Precihole was considered more of a local

player during its initial days of operation,

but it implemented the necessary technology

and applications to go beyond the standard

product offering. When the market was

growing, the company’s think tanks were

under the pressure to make the most of

this promising environment. Gradually,

the company matured in terms of trained

manpower and applied technology to meet

these requirements. A A Qazi, Director,

Precihole Machine Tools Pvt Ltd observes,

“The main challenge was to optimise the

process which we followed and expand

the training of our employees. We have

incorporated lean manufacturing in our

system, which is not only helping us reduce

and identify unnecessary waste processes,

but is helping us increase the volume of

products being manufactured at our plant

without any added cost or investment.”

As one of Precihole’s engineers

explained during the visit, there are

several challenges that arise when you

are pioneering customised machines in a

niche segment like DHDM. For example,

when guard plates were made for gun-

drilling and BTA-drilling machines, a

curved design was given to add a visual

uniqueness to the product. However, the

curved plates were difficult to manufacture

and hence, the design had to be changed

to reduce the curve only to the corners,

making the plates more rectangular or

linear and thus, easier to manufacture.

In essence, the Thane facility has a well

trained team, headed by experts with

over 20 years of experience in quality

systems and industry procedures. To

meet the complex specifications of the

petrochemical industry, the company’s

design team has successfully upgraded

their systems constantly working to

enhance product quality.

Future Outlook From ramping up their marketing to re-

energising their branding, extending into

larger facilities to applying the latest in

production strategy, Precihole is primed

to take-off in the global DMDH market.

The company’s new facility situated in

Kalyan, around 35 kms outside Mumbai,

is in its final stage of completion.

Regarding the expansion plan, Qazi

explains, “The new facility, spread over

more than one lakh sq ft, will help us

double our capacity. We are planning

to manufacture around 10 machines

per month at our new facility. Apart

from this, we are aggressively looking at

overseas markets as well. There are some

customers in the European market who

are happy with our products and services

and this has prompted us to focus on

this market.” He further adds, “During

the recession, many companies in the

international market prioritised cost

effective products, which was a very tough

task in developed markets. That situation

became an opportunity for us; we provided

them with the same quality product at

lower cost. Now they are placing repeat

orders. We have skilled manpower who

can deliver the same quality product at

parity with global standards. Also, when

we deliver the product to customers, we

send our applications engineers to their

plant ensuring proper installation.”

Carving its future course,

Precihole has already charted out its

growth strategies and is now stepping

ahead into an era promising exponential

success. True to character, the company

persistently strives to hone its technology

through innovation and guarantees

its customers top quality bang for

their buck!

� Applying international standards in lubrication & machining techniques.

A A Qazi, Director Prechihole Machine Tools Pvt Ltd

We have incorporated lean manufacturing in our system, which is not only helping us reduce and identify unnecessary waste processes, but is helping us increase the volume of products being manufactured at our plant without any added cost or investment.

[email protected]@infomedia18.in

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102 Global Machine Tool Survey 2011 The World Survey at a Glance

106 One Q Many Views Import Vs Export: Can India Ever Bridge This Gap?

108 One Q Many Views Production Vs Consumption: Is India ready to be Among the Top Ten Global Machine Tool Producers?

114 Business Dynamics Gauging the Metrological Momentum

116 Advance Metrology Systems Aiding Accuracy... Adding ‘Measurable’ Advantage

118 Digital Optical Comparator Fully Automated Part-to-CAD Measurement Verification

126 Nanometrology Enabling Nanoscale Productivity

GLOBAL MACHINE TOOL SURVEY 2011 & METROLOGY EQUIPMENT

INSIGHTS &

OUTLOOK

INSIGHTS & OUTLOOKGlobal Machine Tool Survey 2011


Dollar-volume production

of machine tools around

the world during 2011

grew at 35 per cent.

Output by the 28 principal

producing countries was $ 92.7 billion.

That represents a gain from 2010’s $

68.8-billion, which in turn had been

an increase of one-quarter from 2009.

The hole caused by the deep worldwide

recession in 2009 was being filled.

Biggest percentage increases in

production came from Japan, Germany,

France, China, the US, South Korea,

and the UK, when measured in their own

THE WORLD AT A GLANCEcurrencies. Many showed even steeper

year-to-year percentage increases when

their output is converted to US dollars.

China’s 32 per cent boost in

shipments cements its place as number-

one producer. At $ 27.7 billion in

estimated output in 2011, China is more

than $ 9.3-billion ahead of second-place

Japan. Germany ranks third among

producing countries. Output from those

top three account for 64 per cent of

2011’s total world output measured in

this survey.

The US had a solid 25 per cent gain

in production, which increased to $ 4.1

billion in 2011. Consumption grew at

an even faster pace, up 53 per cent, as

imports also zoomed.

Largest consuming country in the

world continues to be China, which

installed an almost-unbelievable $ 38.4

billion worth of machine tools, one-third

of it in imports. Looking at consumption

on a per-capita basis China, with its huge

population, in the past had ranked low.

Now, with burgeoning local production

and a continued low export pace, its

expenditure per capita of $ 29/person/

year puts it in the middle of the pack,

with the likes of Canada and Belgium.

Rebound CompleteTaken as a whole, the global machine-

tool-producing industry finished making

its comeback from the precipitous decline

of 2009, in which some countries saw

production fall by half.

In 2011, total shipments by the

national industries that participate

in this World Machine Tool Output

& Consumption Survey amounted to

$ 92.7 billion, an increase of 35 per

centover the $ 68.8 billion for 2010

(table, left). Moreover, that 2010 figure

in turn represented a 26 per cent gain

over the dismal sum of $ 54.7 billion

for 2009. So, last year’s output just

surpassed the total for 2008 when the

downward slide started.

But what may be true for producers

at large does not necessarily apply evenly

across the board. Calamitous drops and

subsequent rebounds never treat all

participants equally.

Some weren’t hit by the recession as

hard as others. China is the classic case

in point: between 2008 and 2009, when

every other country in the survey saw

output decline, China’s increased 10 per

cent, and its market share thus climbed

(graph, below).

Production2011 (est.) 2010 (rev.) Change in

local currencyChange in

U.S. dollarsCountry $-Millions Cut-Form $-Millions1. China 27,680.0 69-31% 20,910.0 $ 32%2. Japan 18,353.1 89-11% 11,971.4 39% 53%3. Germany 13,494.7 74-26% 9,488.8 35% 42%4. Italy 6,232.6 49-51% 5,017.9 18% 24%5. Korea, Rep. of 5,641.0 69-31% 4,498.0 $ 25%

6. Taiwan 5,000.0 80-20% 3,877.0 29% 29%7. United States 4,161.1 73-27% 3,340.1 $ 25%8. Switzerland 3,462.7 84-16% 2,395.2 23% 45%9. Spain 1,053.3 64-36% 836.9 20% 26%10. Austria 1,001.8 54-46% 844.0 13% 19%

11. France 930.7 61-39% 662.2 34% 41%12. Brazil 873.4 81-19% 837.4 $ 4%13. Turkey 668.0 25-75% 555.0 20% 20%14. United Kingdom 658.0 72-28% 507.2 25% 30%15. Canada c639.3 60-40% c546.8 17% 17%

16. India 576.0 87-13% 512.0 13% 13%17. Czech Republic 446.0 80-20% 372.0 20% 20%18. Netherlands 400.7 20-80% 317.8 20% 26%19. Belgium 375.6 20-80% 298.0 20% 26%20. Russia 263.0 41-59% 219.0 20% 20%

21. Sweden 218.4 38-62% 207.9 0% 5% 22. Finland 166.9 20-80% 135.1 18% 24%23. Mexico c122.4 58-42% c165.5 $ -26%24. Australia 100.9 86-14% 113.6 $ -11%25. Denmark 76.5 40-60% 72.8 0% 5%

26. Portugal 73.7 21-79% 66.2 6% 11%27. Romania u42.5 71-29% 42.5 $ 0%28. Argentina 32.3 50-50% 29.0 $ 11%

Total $92,744.7 $68,839.3 35%

u = unrevised from previous year but converted at current ratesc = circa; rough estimate from fragmentary reports. $ = reported in U.S. dollars. % = ratio of cutting/forming in some cases estimated from previous reportsSource: Gardner Publications, Inc.

Global Machine Tool Survey 2011


Another aspect has been the rate

of recovery—call it the “bounce-back”

factor. In the 2008-to-2009 comparison,

six countries suffered production crashes

of 50 per centor more. Of those, Japan

and Taiwan subsequently have been able

to post substantial increases (see last

columns in Production table); France

and the Czech Republic have showed

only moderate resilience; and Finland

and Denmark continued to have slumps

and only in the past year have been able

to post increases.

United States production in that

’08-’09 crash dropped almost as

precipitously—down 44 per cent—but

it’s managed a 50 per cent comeback

in 2010 and another 25 per cent gain

last year.

Other countries in the Americas

have not been able to regain production

rates as quickly however.

One result of this uneven response to

global market turmoil is a geographical

shift in where most cutting and forming

machine tools are made. During the

recessionary 2009 and for several years

prior, Asian countries produced around

48 per centof total world output while

the 15 Western European countries

in the CECIMO consortium built

around 46 per cent. In 2010 those Asia/

Europe production

shares shifted to 61

per cent and 32 per

cent, respectively,

and in 2011 the same

percentages were seen

(bar chart, above).

The China FactorThe 13th-century

travelogue of Marco

Polo’s experiences in

China gained avid

attention in Europe.

But after the first transcription its

publisher quickly renamed it Il Milione

(“The Million”), in a nod to his audience.

European readers, it seems, couldn’t

grasp the size and scope of the culture

Polo described, so the title reflected the

notion it was full of a ‘million’ lies.

Westerners today sometimes

raise eyebrows at the pace of Chinese

machine-tool expansion. Statistics here

are reported in US dollars rather than

yuan renminbi by the national builders’

trade association, and they reflect a

continuing expansion of an industry

strained to meet voracious domestic

demand. China has been the world’s

biggest consumer of machine tools since

2002; back then imports satisfied much

of its requirements.

Inevitably Chinese production of

factory equipment grew as indigenous

entities like Shenyang and Dalian MT

Group integrated and expanded smaller

factories and as builders in Taiwan,

Japan and elsewhere opened Chinese

facilities.

For 2011, Chinese output of

machine tools is estimated at $ 27.7-

billion, or more than the combined

shipments of Italy, Korea, Taiwan, the

ExportsCountry 2011 (est.)

$-Millions2010 (rev.) $-Millions

Change in local

currency

Change in U.S. dol-

lars

Exports * as % of 2011

Pdtn1. Japan 11,380.6 7,517.2 37% 51% 62%2. Germany 9,460.2 6,721.0 34% 41% 70%3. Italy 4,451.9 3,260.5 30% 37% 71%4. Taiwan 4,000.0 2,960.0 35% 35% 80%5. Switzerland 2,955.1 2,058.7 22% 44% 85%

6. China, Peoples Rep. 2,380.0 1,850.0 $ 29% 9%7. Korea, Rep. of 2,301.0 1,678.0 $ 37% 41%8. United States 1,874.0 1,559.6 $ 20% 45%9. Spain 918.9 641.2 36% 43% 87%10. Belgium 870.9 642.3 29% 36% 232%

11. Austria 820.3 743.6 5% 10% 82%12. United Kingdom 818.5 629.7 25% 30% 124%13. France 747.1 513.8 38% 45% 80%14. Netherlands 484.1 401.3 15% 21% 121%15. Czech Republic 473.0 441.0 7% 7% 106%

16. Turkey 413.0 380.8 8% 8% 62%17. Canada c266.2 c264.6 $ 1% 42%18. Sweden 179.5 213.2 -20% -16% 82%19. Finland 139.1 112.6 18% 24% 83%20. Brazil 107.8 100.4 $ 7% 12%

21. Denmark 96.0 91.4 0% 5% 125%22. Romania u85.2 85.2 $ 0% 200%23. Australia 78.0 87.7 $ -11% 77%24. Russia 64.0 60.0 $ 7% 4%25. Portugal 50.1 43.7 9% 15% 68%

26. Mexico c30.6 c41.4 $ -26% 25%27. India 28.0 22.0 27% 27% 5%28. Argentina 10.4 11.0 $ -5% 32%

* = includes re-exported machinesu = unrevised from previous year but converted at current rates. c = circa; rough estimate from fragmentary reports. $ = reported in U.S. dollars.Source: Gardner Publications, Inc.



US, Switzerland, Spain, and Austria.

A different view of the global

machine-tool scene comes from looking

at consumption. For the purposes of

this survey, consumption is defined

as a country’s domestic production,

less its exports, and plus its imports.

It represents machines that have been

installed.

In 2011 the US showed the fastest

growth rate in equipment consumption

among all major indusrtrialised

countries, with a 53 per cent increase

in installations compared to 2010. It

remains a solid fourth in the world in

machine-tool consumption, after China,

Japan, and Germany.

It should be said, however, that

the growth rates, both in

production and in consumption,

may be starting to retreat from

their catch-up pace of the past

two years. Recent reports from

trade associations that measure

orders for new machines show

a slackening in the pace of

bookings, as pent-up demand is

starting to become satisfied.

Trade IncreasesWhether output will continue

at the current pace is unknown.

What the WMTO&C Survey

shows, however, is that imports

and export activities in the past year

have regained momentum.

Japan and

G e r m a n y

continue as the

leading exporters

of machine

tools, but their

p e r c e n t a g e

gains in 2011

exports were

matched by the

French, Koreans,

S p a n i a r d s ,

Taiwanese, and

several others.

American exports

grew 20 per cent.

The top five

countries on the

Exports table all

show a very high

ratio of exports to

production. That

metric, the last

column in the

table, can provide

an interesting

perspective on a nation’s reputation as

a major supplier to outside countries.

China, on the other hand, hardly exports

at all; despite placing at sixth position

with 2011 exports of nearly $ 2.4 billion,

its shipments outside China are less than

one-tenth of its production.

The ratios must be viewed with

caution, though. Some entrepôt nations

like Belgium, Denmark, and Holland

traditionally have exports that are far in

excess of their production as they ship

out machines that had been taken in for

re-export. Similarly, the last column in

the Imports table, which tracks imports

as a percent of local consumption, can in

some cases reflect port activity as much

as import penetration. Nevertheless,

survey figures provide insight to each

country’s proclivity toward offshore

sourcing.

The United States with its very open

market—showing an import penetration

of 65 per cent—ranks number two in

dollar-volume imports behind China.

American equipment consumption grew

53% last year, and its 71 per cent change

in imports suggests that much of that

demand was filled from overseas.

High import-penetration rates are

also evident in Mexico, Russia, France,

Turkey, and India during 2011.

American dependence on foreign

suppliers for its factory-equipment

demand is also seen in its balance

ConsumptionCountry 2011 (est.) 2010 (rev.) Change

in local currency

Change in U.S.

dollars

1. China 38,370.0 28,480.0 $ 35%2. Japan 7,620.5 4,889.8 41% 56%3. Germany 6,956.0 4,677.5 42% 49%4. United States 6,611.9 4,313.4 $ 53%5. Korea, Rep. of 5,131.0 4,264.0 $ 20%

6. Italy 2,963.3 2,672.5 6% 11%7. India 2,352.0 1,775.0 $ 33%8. Brazil 1,990.0 1,861.3 $ 7%9. Taiwan 1,800.0 1,623.0 11% 11%10. Mexico c1,360.9 c1,060.4 $ 28%

11. Russia 1,317.0 1,165.0 13% 13%12. Turkey 1,285.0 864.9 $ 49%13. Switzerland 1,240.7 850.5 24% 46%14. France 1,182.5 850.2 32% 39%15. Canada c1,143.6 c848.8 $ 35%

16. Austria 632.2 446.3 35% 42%17. United Kingdom 561.7 422.1 28% 33%18. Spain 451.5 473.4 -9% -5%19. Sweden 372.8 259.6 37% 44%20. Netherlands 328.3 256.9 22% 28%

21. Belgium 301.9 252.9 14% 19%22. Czech Republic 291.0 130.0 $ 124%23. Romania u243.0 243.0 0% 0%24. Argentina 211.5 146.3 $ 45%25. Australia 167.0 220.9 $ -24%

26. Finland 128.0 108.6 12% 18%

27. Portugal 104.3 115.2 -14% -9%

28. Denmark 43.1 41.1 0% 5%

Apparent Consumption = local Production, less Exports, plus Importsu = unrevised from previous year but converted at current rates. c = circa; rough estimate from fragmentary reports. $ = reported in U.S. dollars.Source: Gardner Publications, Inc.

$20-B

$40-B

$60-B

$80-B

$100-B

2009 2010 2011

Total World Production

World Output by Region

Asia’s Share Grows

Asia excl Austr; W. Europe = CECIMOSource: WMTO&CS; Gardner Publications, Inc.

Asia W. Europe Americas



Per-Capita ConsumptionCountry 2011

Consumption $-Millions

Population 000s

Spend $/capita

1. Switzerland 1,240.7 7,604 $163.162. Korea, Rep. of 5,131.0 48,508 $105.783. Germany 6,956.0 82,329 $84.494. Taiwan 1,800.0 22,974 $78.355. Austria 632.2 8,215 $76.95

6. Japan 7,620.5 127,078 $59.977. Italy 2,963.3 58,126 $50.988. Sweden 372.8 9,059 $41.169. Canada 1,143.6 33,487 $34.1510. China 38,370.0 1,323,591 $28.99

11. Belgium 301.9 10,414 $28.9912. Czech Republic 291.0 10,211 $28.5013. Finland 128.0 5,250 $24.3814. United States 6,611.9 307,212 $21.5215. Netherlands 328.3 16,715 $19.64

16. France 1,182.5 64,420 $18.3617. Turkey 1,285.0 76,805 $16.7318. Mexico 1,360.9 111,211 $12.2419. Spain 451.5 40,525 $11.1420. Romania 243.0 22,215 $10.94

21. Brazil 1,990.0 198,739 $10.0122. Portugal 104.3 10,707 $9.7523. Russia 1,317.0 140,041 $9.4024. United Kingdom 561.7 61,113 $9.1925. Australia 167.0 21,262 $7.85

26. Denmark 43.1 5,500 $7.8427. Argentina 211.5 40,913 $5.1728. India 2,352.0 1,156,897 $2.03

Source: Gardner Publications, Inc.

of trade in machine tools. The largest exporters

typically top the trade-balance rankings, and the

largest importers are at the bottom. At a minus-$ 2.5

billion for 2011, American trade balance worsened

dramatically from a negative-$ 975 million in 2010.

The US has the second-poorest balance after China

among countries that have domestic machine-tool-

producing industries.

Dollar-volume balance in machine-tool trade

for 2011 is seen in the table below. Compared to

2010, the largest increases in positive trade balance

were made by usual-leader Japan and by Germany,

Switzerland, and Taiwan.

Patterns of ConsumptionIf machine tools are the

basic building blocks of

m a n u f a c t u r i n g - b a s e d

societies, then the rate at

which a country installs

new ones ought to say

something about its pace

of industrialization. For the

past decade China has led

the world in acquisition. For

2011 the pattern continues,

and as the pie chart above

shows, more than two-fifths

of the output by value of

the world’s machine-tool

producers has been put

in place on Chinese

factory floors.

Imports Country 2011 (est.)

$-Millions2010 (rev.)$-Millions

Changein local

currency

Changein U.S.dollars

Imports*as % of ‘11cnsmptn

1. China, Peoples Rep. 13,070.0 9,420.0 $ 39% 34%2. United States 4,324.8 2,532.9 $ 71% 65%3. Germany 2,921.5 1,909.7 46% 53% 42%4. India 1,804.0 1,285.0 40% 40% 77%5. Korea, Rep. of 1,791.0 1,444.0 $ 24% 35%

6. Mexico c1,269.1 c936.3 $ 36% 93%7. Brazil 1,224.4 1,124.3 $ 9% 62%8. Italy 1,182.5 915.1 23% 29% 40%9. Russia 1,118.0 1,006.0 11% 11% 85%10. Turkey 1,030.0 690.7 49% 49% 80%

11. France 998.9 701.9 35% 42% 84%12. Taiwan 800.0 706.0 13% 13% 44%13. Belgium 797.2 597.3 27% 33% 264%14. Canada c770.5 c566.5 $ 36% 67%15. Switzerland 733.1 514.0 21% 43% 59%

16. United Kingdom 722.2 544.6 28% 33% 129%17. Japan 648.0 435.6 35% 49% 9%18. Austria 450.6 345.9 24% 30% 71%19. Netherlands 411.8 340.4 15% 21% 125%20. Sweden 333.9 264.9 20% 26% 90%

21. Czech Republic 318.0 199.0 60% 60% 109%22. Spain 317.2 277.7 9% 14% 70%23. Romania u285.7 285.7 $ 0% 118%24. Argentina 189.6 128.3 $ 48% 90%25. Australia 144.0 195.1 $ -26% 86%

26. Finland 100.2 86.1 11% 16% 78%27. Portugal 80.7 92.7 -17% -13% 77%28. Denmark 62.6 59.6 0% 5% 145%

* = includes machines imported for re-exportu = unrevised from previous year but converted at current rates. c = circa; rough estimate from fragmentary reports. $ = reported in U.S. dollars.Source: Gardner Publications, Inc.

Another, perhaps more subtle,

pattern emerges: one of consolidation.

In 2011 the top five consumer countries

accounted for installing 70 per cent of

surveyed world output. By contrast,

in 1995 the top five—namely the US,

Germany, Japan, China, and Italy, in

that order—purchased only 55 per cent

of total surveyed output.

One more way of looking at

consumption is the amount each country

spends compared to its population

(right). Switzerland, at $163/Swiss, tops

the list and has led for decades. China,

with 1.3-billion people, not long ago

had ranked with India at the bottom

and now is in the middle.

Source: Gardner Publications, Inc.

ONE Q MANY VIEWSImport Vs Export


With so big a nation, the Indian industry has forever been caught in the dilemma of ways to meet the domestic demand. Failing to meet the requirement, the country’s dependence on imports has consistently gone up. The 2012 World Machine Tool Output & Consumption Survey by Gardner Publication has rated India as the fourth highest importer in the world while the country trails down at the bottom of the list at the 27th spot to become one of the lowest exporters. Debarati Basu asks the industry leaders to point out the measures which need to be taken to bridge this gap and indulge in exports. Here is what they said…

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Verdict

Vikram Sirur, President, Indian Machine Tool Maufacturers’ Association

The main reason is the technological gap because of which we still have to depend on import and this is the reason why our machines are not fit for export as it does not match the quality parameters set according to the global standards. We also need to work closely with the government so that certain things can be put in place and we too will be able to garner the quality and quantity required for reducing the dependence on imports. The industry is working in this direction so that in the next 15 years we can match the level of quality required by the global market.

Tosher Hormusjee, Director, G W Precision Tools India Ltd.

Indian machine tool as a capital sector is bound to be higher in import than in export level. If you want to make world class products you would require world class machine tools as well. There is not a single machine manufacturer in the country who can provide the standard that is required. Also, the metrology equipments which is required to ensure quality is not there. The quality required is not available in the country and therefore there is no choice but to import this. Against this, the local demand is so huge that all that is manufactured is consumed internally and the local requirement is not necessarily of export quality. For high production and high efficiency, we require machine tools specific to the requirement. Whereas, India mostly has generic tools. One measure which needs to be taken is to strengthen the small scale industries. We can have many Bosch, Mahindras and Tatas, but ultimately it is the SMEs who support them. We have to create an atmosphere and a situation in which SMEs’ growth is treated as paramount and proper infrastructure should be provided to them.

Sreekanteswar S, President- India Sales and Operations, Korber Schleifring GmbH

The imports happening are in terms of high end, high accuracy high performance reliable machines. The local manufacturers are however producing high volume low cost machines. This is the reason why the Indian contribution to the machine tool manufacturing is just 23 percent and 77 percent is imported. The volume of imported machine is low but the cost of high end machines, high accuracy machines are very high. There are three important things which need to be changed. We primarily have to increase the technology and reliability of the machines so that we can make it fit for exporting them in a big way. Secondly, the sub suppliers of critical parts like ball screws etc is not available in India and we instead import the technology or the machine or import the components at high cost which subsequently increases the cost of the final product. Third, innovation is the key. We cannot simply duplicate imported products. We instead have to come up with innovatively designed products which are low in cost and provide the same level of quality parameters.

The industry certainly needs to

indulge in more research activities

to create new technology and

increase the quality products which

are fit for exports. And all of this

will only be possible when the

small scale industries see a balanced

growth and support to double its

contribution in adding numbers to

domestic manufacturing.

THIS GAP?CAN INDIA EVER

Production Vs Consumption


ONE Q MANY VIEWS

According to the latest global machine tools industry survey, India stands as the 7th largest consumer of machine tools but finds itself down the list at the 16th spot for its production capacity. This clearly quantifies the huge demand-supply gap and the urgent need to scale up domestic production. Nishant Kashyap talks to leaders in the Indian machine tools industry to find out ways in which India can balance this demand-supply gap.

The manufacturing sector in India was largely unaffected by the global economic recession as demand and orders in domestic as well as international markets grew steadily. Domestic manufacturers are aiming to achieve 50 per cent market share by 2017, despite fierce global competition, and in order to do that, several initiatives need to be taken in tandem, by the government and native manufacturing companies.

IS INDIA READY TO BE AMONG THE TOP TEN GLOBAL MACHINE TOOL PRODUCERS?

[email protected]

Verdict

Nikhil Nayak, Managing Director, NN Combined Engineering Agencies Pvt Ltd

It is a fact that the consumption

of imports is fast increasing in the

industry and this is a reflection on

the growing maturity of the industry.

As the industry matures, the need

for quality and reliability becomes

more important. Indian industries

today are increasingly linked to

higher quality standards either as

a result of international companies

participating in the India growth

story or as they seek to participate

in the global supply chain. In order

to meet the growing demands of the

industry, Indian manufacturing has

to efficiently “scale” up production

and quality. Government policy

is a very important factor and the

National Manufacturing Policy is a

very big step in that direction. The

programs detailed in the policy have

to be implemented efficiently to help

us move forward in this area. Quite

simply, if manufacturing growth is

a priority then all that industry and

government have to do is identify the

factors impending growth and find

ways to alleviate the problems. A lot

can be learned from the gains made

by the IT industry in this area.

Ramesan Kallorath, Managing Partner, Digi Mold, India

To bridge the widening chasm

between surging demand and

indigenous production, there are

several areas where solutions need

to be implemented. Government

support in terms of policies,

subsidies, technology transfers and

facilities is poor in India. Further,

customers in India lack the technical

know-how in design and production

to understand what is possible for

mould manufacturers, leading to

constant re-design of the component,

hindering the need for shorter runs

and turn-around times. There is also

a fundamental shortage of capacity

which until satisfied, results in orders

being turned down. Resolving these

hurdles would leave nothing in the

way of Indian manufacturers realising

their global potential.

Anil Kumar, Vice President - Marketing & Technology Services, CERATIZIT India Pvt Ltd

Demand is very high for machine tools

in India and that is the reason we are

in the top ten rankings. Demand for

the machines mainly depends on the

fact that consumers want high quality

machines at low cost. When it comes

to low cost machines, we are lagging

behind China, Korea and Taiwan

and when it comes to high quality

machines within India, there are not

many options besides German and

Japanese technology.

Indian companies need to

invest much more in research and

development. They should intensify

focus on design activities. Skilled

manpower is also one of the biggest

concerns in India so they should

invest in training and development

activities as well.

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Business Dynamics

Upcoming sectors like

infrastructure, nuclear,

aerospace, defence equipment,

energy, medical and power

are fuelling the demand for

high precision metrology systems in the

country. Many metrology technologies

like CMM, portable CMMs, laser probe

technology are gaining acceptance and

applicability within the industry.

Demand Trend The biggest growth factor for CMMs

is India’s ‘Manufacturing Hub’ tag.

Ever since global companies have setup

their base in the country, the demand

for CMMs is on the rise. To make the

product at par with the global standards

every component and equipment

provider has to deliver the product with

high precision and after passing all

quality checkups.

Apart from the traditional

customers like automobile and heavy

engineering, other sectors like medical

equipment, energy, aerospace, electrical

& electronics, etc have entered into

India in a big way. All these industries

require very small components, which

needs to be manufactured using cutting

age technologies. As inspection and

measurement is one of the key processes

to ensure the product quality, CMMs

become the most essential apparatus

in any products manufacturing process.

On the demand trend, M Kumara Giri,

Regional Manager – FARO Business

Technologies India explains “Currently

the demand for laser technology

has increased. But 10 years back we

all used parts which were positions

oriented. Now most of the parts are

profile oriented and very critical. Die

and mould manufacturers prefer laser

technology. If you consider any big die

and mould manufacturer, once the part

is semi finished they validate the part

before final finish. It is not just in India,

worldwide the demand for the laser tech

is on the rise.”

Adoption of CMMsEarlier Indian companies were always

focussed on high volume manufacturing;

to achieve this, quality was not given

much attention. Indian companies were

not really concerned about investing on

quality control machines and techniques.

Lately all companies have realised that to

be competitive and to become a global

player they have to have a proper quality

control systems in place. To accomplish

The field of industrial metrology rel ies heavily on the Coordinate Measuring Machine (CMM) to verify the precision, reliability and accuracy of manufactured products. As Indian manufacturers focus on exports, the quality checkups at every stage become very important. Nishant Kashyap tracks the rise of home grown metrology companies and how it will change the overall dynamics of the quality in the Indian manufacturing

the quality

standard and

increase productivity

many Indian companies

including SMEs have

installed proper measuring

and inspection instrument into

their systems.

“Today, along with Tier I

companies, the Tier II and Tier

III customers are also gearing up to

adopt CMMs. Apart from this, there

are many global players coming into

market and they insist on quality, so we

follow and have to fulfil the customers

expectations.” avers Giri. Many Indian

manufacturing companies have started

exporting products worldwide, which is

one of the main reasons for adoption

of CMMs, as they have to match the

global standards. Apart from the global

companies; Indian customers have also

become more demanding and are forcing

companies to adopt CMMs and have

proper quality control procedure.

Adding Productivity Reduction of errors and increasing

repeatability has been the core focus

areas of metrology system manufacturers

for better customer satisfaction. These

features help them add quality and trust

factor in their products. Connecting

highly reliable measuring instruments to

machining lines has helped manufacturing

companies to address the challenge

of delivering high-quality products,

which are at par with global standards.

Commitment to quality is a continuous

process. New technology, equipment,

products and applications have led to a

continuous change in the manufacturing

line across machine tool industry.

As India strengthens its base as an

automotive hub, with concurrent steps

INSIGHTS & OUTLOOK

Business Dynamics


towards increasing volume of business

coming in from the aerospace and

medical industry, digital inspection

process significantly advances the

performance benchmarks of CMM

productivity. The manufacturers of

metrology products have joined hands

with the industry leaders and standard-

setting organisations to work out an open

metrology technology platform that allow

unhindered interoperability between

different makes & kinds of CMMs and

other inspection equipment to avoid

huge capital investments in replacing

obsolete metrology equipment.

Changing Dynamics Indian manufacturers were always

dependent on global OEMs for high

precision metrology devices. However,

today there are new domestic players

entering the market and gearing up to

be in sync with the global parameters of

accuracy and precision especially in cost

effectiveness. This has not only increased

the access of high precision metrology

system for SMEs, but is also helping them

in productivity enhancement. As yet,

many SMEs have not installed CMMs

on their shop floor, and using the manual

and conventional measuring methods.

Simply, the reason is high investment,

skill manpower and special maintenance.

Not having a proper measuring system

also affects the overall productivity.

Sensing the demand from the SMEs,

few Indian companies have started

manufacturing CMMs and providing other

cost effective metrology solutions. The

result of home grown metrology system can

directly be seen as growth and productivity

enhancement of Indian SMEs.

Future OutlookAs the manufacturing industry is

bullish on the future growth prospects,

the optimism also spills over to the

metrology industry. The key factor that

sets one company apart from the other

continues to be of quality and trust in

the brand & products that promise to

help companies reduce their time and

money spent on quality checks. Factors

like standardisation and globalisation

have increased the level of precision

needs in the country. India is gradually

establishing its image as one of the

biggest economies of the world, and

this has positively affected the sale

of CMMs. With new avenues like

aerospace and wind power giving the

metrology industry a shot in the arm,

the future looks positive for metrology

solution providers.

[email protected]

Reasons to Invest in CMM

� Tap global market requirements

with quality at par with global

standards

� Improve existing measurement

system’s efficiency to achieve the

highest possible accuracy

� Identify and rectify smallest

uncertainty in measurements

� Monitor the process with suitable

measurement systems


INSIGHTS & OUTLOOKAdvance Metrology Systems

Metrology is fundamentally

driven by the need for

information; the need to

know every measurable

aspect of a product for

certain and to make decisions based on

this certainty. The evolution of metrology

has come a long way since hands and

feet were units of measurement. Today

with nanometrology, we are beginning to

accurately measure what we can’t see, from

the atomic to the macroscopic.

Advances in metrology are primarily

driven by factors of speed, accuracy,

measurement size, environmental control

and lower costs. This article will talk

about the emerging technologies on the

very edge.

Metro-tomographyThis is an application of computer

tomography, where X-rays are used to scan

a rotating part to obtain an accurate 3-D

model. This 3-D model can be converted

into various formats, including CAD,

for part analysis. This non-destructive

measurement of a component allows,

in addition to traditional evaluation, for

material and assembly inspection as well

as porosity, damage and defect analysis.

Parts with interiors or very complex parts

can be measured completely, quickly and

easily. The process is highly automated

and requires minimal training. While

providing vast amounts of information in a

single scan it allows for reverse engineering

applications, geometry comparisons and

process optimisation.

Portable Coordinate Measuring Machine (PCMM) Unlike traditional stationary CMM’s,

portable CMM’s allow for versatile use of

a CMM anywhere on the shop floor or

industrial site, at any stage of production.

A touch probe is mounted on the end

of a highly articulated, lightweight arm.

It has six degrees of freedom and can be

used along with lasers or infrared light

to measure objects at distances of a few

hundred feet. No calibration or custom

fixtures are needed, unlike traditional

CMM’s. Rapid digital data collection is

possible using PCMM software and the

user can also compare dimensional data to

a CAD file directly. This does away with

the use of hand tools, gauges and single

dimension measurement devices. PCMM’s

are increasingly robust and only limited by

the reach of the articulated arm, although it

can be repositioned as required, such is its

flexibility. It can also be combined with laser

scanning to provide 3D measurements.

Multi-sensor MeasuringThese involve the use of more than one

sensor in one machine that is automated

and uses software to manage the sensors.

It can involve the use of chromatic point

sensors, confocal microscopes, white

light interferometers, film thickness

sensors and atomic force microscopes.

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Is the manufacturing process undergoing a transition? The demand for better metrology systems which can effectively provide multi axis measurements is rising. Tarun Tampi finds out how new metrology systems like 3D coordinate machines, laser tool probing and improved sensors are trying to make the measurement process extremely quick, increasing precision and accuracy in measurement.

Aiding Accuracy...Adding ‘Measurable’ Advantage

Advance Metrology Systems


There are vision sensors, touch-trigger

probes, analog scanners and laser sensors

which can all be used now on a common

platform using a single software package.

In some cases, over 20,000 data points

can be gathered per second. If there is a

conflict between sensors, for example, a

trade-off in accuracy and speed between

laser and analog scanning, multi-sensor

machines can be programmed to switch

automatically to optimise the measurement,

minimising cost per measurement. They

also save time by combining measurement

processes, like video metrology with a

touch probe, thus eliminating the need for

repeated calibration and reducing the need

for multiple measurement fixtures. With

improved integration of sensors, between

themselves and with CAD models, multi-

sensor measuring machines are the way of

the future, increasing choice and potential

in productivity and inspection quality.

Lasers TrackingThis technology has come a long way since

its inception. It involves the use of laser

beams to measure objects within the accuracy

of a few microns within a range of tens of

meters. The beam follows a retro-reflective

target, placed wherever a measurement is

needed on the part, and records distance,

azimuth and elevation which are converted

into cartesian coordinates. The tracker

is easy to use, can measure large parts,

requires only a single operator and can

quickly provide high value measurements.

Laser trackers can be integrated with

robotics or be made part of the assembly

line as a metrology tool.

Another great example is Equator, a

radical new gauging system developed

and patented by Renishaw. It combines

the flexibility and versatility of CMM’s

with the quick accuracy of hard gauges. A

production line part can be directly used as

a master part through the calibration file

from a CMM. It uses a parallel kinematic

structure which greatly reduces time spent

in setup and calibration while maintaining

stiffness for repeatability. Several parts,

from different machines, can be measured

in a matter of minutes with a comparison

accuracy of 0.002 mm. The stylus can

be quickly reconfigured in an integrated

stylus changing rack, allowing for high

speed comparative gauging of high volume

production parts. Since it can be calibrated

for thermal measurements as well, it can

be used directly on the shop floor with

customisable measuring software thus

reducing waiting time and gauge costs.

This technology was developed in

collaboration with and for use in automotive,

aerospace, medical and other component

manufacturing industries.

As non-contact sensors and vision

inspection systems develop further, software

is being improved to integrate several such

sensors and interface with the design to

compare geometries and ensure accuracy.

Reducing inspection time and costs at a

stage where parts are becoming smaller,

more complex and more precise, is becoming

easier as point-cloud software meets multi-

sensor technology, as retrofitted sensor

technology meets CMM’s and as particle-

microscopes meet nanometrology.

[email protected]


Digital Optical Comparator

Optical comparators,

or profile or contour

projectors, are often

used to verify that these

manufactured parts

are within tolerance. They provide

a comparison between a part and its

drawing to allow the operator to make

an overall pass/fail determination. These

instruments are easy to use and are well

suited for use on the shop floor as well

as in metrology and QC labs.

While these measuring tools are

generally considered to be versatile

and cost effective, their dependence on

an overlay (also called a template or

Mylar) can be viewed as a drawback.

Besides the added cost and time for

printing, calibration and setup, these

overlays can increase the likelihood of

operator error.

Going DigitalThe VisionGauge digital optical

comparator was designed to alleviate

possible concerns with traditional optical

comparators. Developed by VISIONx

and distributed in North America by

Methods Machine Tools Inc, the

instrument uses a high resolution digital

camera and a low-distortion telecentric

lens to capture a high resolution

image that exactly matches the part

geometrically. The instrument’s software

then projects the images, along with

the part’s CAD overlay, onto a quad

monitor display.

The software’s Auto-Align tool

automatically aligns the CAD data to

the part. The tool typically takes less

than two seconds to produce its result,

and its operation is very straightforward.

Auto-Align produce repeatable and

accurate results that are completely

operator-independent. It supports

both XY and XY-rotation alignment

of the CAD drawing to the part. The

automated functionality helps users

to reduce inspection times and obtain

increased accuracy, lining the CAD

drawing up with the part along one or

The complex geometries of parts that are produced in today’s shops are known to have tight tolerances that require highly detailed measurement for quality control. But to stay competitive, shops need to make sure these inspection operations do not add unnecessary time to the production process.

INSIGHTS & OUTLOOK

Fully AutomatedPART-TO-CAD MEASUREMENT VERIFICATION

� The VisionGauge digital optical comparator uses a high-

resolution digital camera and a low-distortion telecentric lens

to capture a high resolution image that exactly matches the part

geometrically


multiple data points or doing an overall

‘best fit’ alignment.

The auto pass/fail tool automatically

determines, accurately and in real-time,

if a part is within tolerance. It can be

point-based or can consider complete

geometric entities, and it can perform

both operations simultaneously on

the same part. In point-based mode,

the part’s deviation from nominal is

evaluated at precise user-specified cross-

sections to verify that the part is within

tolerance at all of these locations. The

geometry-based auto pass/fail tool

verifies that the part is within tolerance

over complete geometric entities. It

supports bi-directional tolerances

and imposes no restrictions on the

tolerance values. Therefore, tolerances

can be either the standard “plus/minus”

tolerances or “minus/minus” and “plus/

plus” tolerances.

“We are very excited about the

release of these new CAD Auto-Align

and Auto Pass-Fail tools to enable the

fully automated verification of a part

against its CAD data,” says Patrick

Beauchemin, VISIONx president.

“These innovative new tools have been

extensively validated at key customer

sites, and all of the early adopters are

delighted with the benefits that these

new tools provide.”

Saving TimeThe digital optical comparator can act

as a fully digital, drop-in replacement

for a traditional optical comparator.

It works directly with the part’s

CAD data and does not require any

overlays, Mylars or templates. The

comparators are available in industry

standard 5×, 10×, 20×, 50× and 100×

magnifications. Systems are Windows

based and deliver a network-ready

“rolling cart” configuration for ease

of use on the shop floor. Built for

speed and accuracy, the comparators

can be set up to automatically collect

complete electronic documentation

and device history.

Because the systems are software

driven, all operations can be automated.

As a result, it is possible to operate the

system using only a bar code reader

and a joystick, increasing productivity.

The digital optical comparator’s camera

produces a digital image that is sent

to the system’s on-board computer.

The software can then carry out

further corrections on the image to

eliminate the last minute geometric

distortions and inaccuracies. The

mathematical corrections to the image

make it virtually perfect.

Like traditional optical comparators,

the VisionGauge uses collimated back

illumination to produce clear and crisp

images with sharp edge profiles. But

instead of halogen bulbs, this system

uses longer lasting LED technology

that can provide stable illumination for

as much as 10 years. As with traditional

optical comparators, front illumination

is also available for operations such as

surface inspection.

Since its introduction in September

2009, this innovative digital optical

comparator has found its way into a

range of industries, including medical

device and orthopedic manufacturing,

aerospace, cutting tool manufacturing,

automotive and general machining.

It is also appropriate for higher

magnification and very high accuracy

applications such as Micro Electro-

Mechanical Systems (MEMS) device

manufacturing, electronics and

semiconductor.

Courtesy: MMS Magazine

� The Auto-Align tool allows users to reduce inspection times and obtain increased accuracy by lining up the

CAD drawing with the part along one or multiple data points

� The digital optical comparator is designed for precision part verif ication in a range of industries including

orthopedics, medical device manufacturing, automotive, aerospace and energy

Digital Optical Comparator

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INSIGHTS & OUTLOOKNanometrology

Nanometrology essentially

refers to the science of

measurement at a nanoscale

level. Nanometrology has a

vital role in manufacturing

technology—producing nanomaterials

and devices where the requirements

are highly demanding and challenging.

Moving from manufacturing,

nanometrology now encompasses

measurement of species or events on a

nano-scale also.

After the end of the 20th century,

the development in the metrology

field has reached nanometrology and

will further proceed to picometrology.

The past 40 years have noted the

increasing importance of computer-

aided production metrology as a means

to control industrial manufacturing,

to test technical products with high

accuracy on the basis of geometrical

product specifications and verification,

and to improve the quality of all kinds

of products and processes. Therefore a

sophisticated measurement technique

must be considered as a very crucial

requirement for the production of

industrial goods of controlled and

optimised quality.

Why Nanometrology?The problems of the work piece accuracy

in modern industrial production

technique gained increased importance

in the last few years through constantly

increasing demands on the quality of

the parts produced. As the tolerances of

workpieces and their features decrease

the interaction and correlation between

the dimensional tolerances and surface

finish becomes more important, which

demand for nanometrology.

Consumer products like pocket

cellular telephones, air bags, fax

machines, video game players

require length measurements many

times finer than human eyes can

observe, all these products required

precision measurements of length

voltage, frequency, velocity, pressure,

radiation and temperature. Apart

from this, medical equipment device

and semiconductor industry and chip

manufacturers have also created huge

demand for nanometrology.

Mechanical NanometrologyThis is a key technology required

to support the important industrial

sector of thin films and coatings in

industrial applications. It is also

important for the development of

micro and nanotechnology devices

and components. Nano-indentation,

or nanoscale instrumented indentation

testing is one of the very few techniques

that can measure both the elastic

and plastic properties of very small

volumes of materials and so, this is

one of the most useful test methods for

determining the mechanical properties

of nanosized elements of materials or

coatings. Nano-indentation allows for

the measurement of other properties

such as modulus, creep and visco-

elasticity as well as hardness. Besides,

applications in material research, nano-

indentation is now widely used for

quality assurance in industry, mainly

in the microelectronics industry and

microsystems technology.

Electrical NanometrologyThis technique became increasingly

important during the last two decades.

This is mostly due to the semiconductor

industry where failure analysis and

optimisation of nanoelectronic

devices demand knowledge of their

electrical properties.

This is the era of microtechnology to nanotechnology, which require special metrologies and production methods for the realisation of manufacturing accuracies in the nanometric range. Nishant Kashyap takes a look at some of the application areas and importance of nanometrology.

Courtesy: Renishaw Plc.

Enabling NANOSCALE Productivity

Nanometrology


Electrical industry has become

one of the biggest customers of

nanometrology in recent years, as

the demand from consumer’s for

devices such as mobile, television,

camera, computers, etc have increased

substantially. All these electronic

devices have several nano components,

which demand nanometrology and

micromachining systems. Laser probing

systems and portable CMMs have

been well accepted by this industry

for measuring small components like

chip, semiconductors, power supply

unit, processor, motherboard, memory

card, video card, etc that needs special

attention while producing.

Nanometrology of Structured MaterialsNanostructured materials have internal

or surface structure at the nanoscale.

Whilst these types of material have

been produced for many years, recent

advances in manufacturing now mean

that nanostructured materials with

new properties are being produced.

It is important to fully characterise

these materials on the nanoscale and

build a relationship between this and

the macroscale.

The manufacturing route for the

nanoscale component is, to be produced

separately from the final material as

nano-objects and then incorporated

into the final structure. Measurement

of nano-objects such as nanoparticles,

nanotubes, nanowires, etc has drastically

increased the demands for the

nanometrology. The characterisation of

materials is an important part in these

objects development process and it

serves two broad purposes. Firstly, as

part of the R&D into new processes,

materials and products, and secondly as

quality control and assurance during the

pilot plant and manufacturing stages.

There are numerous techniques

used to determine the dimensional

properties of nanoparticles. However,

the techniques can be broadly broken

down into three groups. The first

group is ensemble techniques where a

large number of particles are analysed

simultaneously, for example Dynamic

Light Scattering (DLS) and small angle

x-ray scattering. The second group

is imaging techniques that analyse

individual particles using high-powered

microscopic techniques (such as SPM

or electron microscopy), where a large

amount of information can be obtained

on small numbers of particles (typically

200–1000) out of a sample size of many

millions. The third group covers the

methods that perform a classification

of the nanoparticles in terms of their

(apparent) size. These techniques are

now well accepted in the development

of new materials.

Future Trends According to industry sources, the

global market for nanotechnology

is predicted to reach $ 1 trillion

by 2015. However, without the

ability to measure and characterise

molecules at the resolution of

a nanometre level, much of the

predicted potential of nanotechnology

will not be achievable.

The current global measurement

infrastructure is rapidly extending into

the nanoscale and beyond, to bring

nanotechnology based products or

manufacturing processes successfully

and safely into the marketplace. It must

provide the ability to measure in three

dimensions with atomic resolution over

large areas. For industrial application

this must be achieved at a suitable

speed/throughput. In the future, this

industry is likely to see rise in demand

for nanometrology.

In coming years the science

and innovation programme in

nanometrology will find new directions

to help shape the future areas of

importance in nanomedicine and the

design of new structural materials, while

facilitating knowledge transfer into the

healthcare, chemical, semiconductor and

instrumentation industries.

To meet the needs of this emerging

manufacturing community it is

important to boost and scale-up the

research of nanotechnology for high

rate production, reliability, robustness,

yield, efficiency and cost issues for

manufacturing products and services.

To achieve this, new research directions

must include a systems approach that

encompasses nanoscale materials and

structures, fabrication and integration

processes, production equipment and

characterisation of instrumentation and

control tools, biomimetic design and

integration of multi-scale functional

systems, three dimensional nanoscale

metrology, production-hardened

metrology, and other areas driven by

industrial applications. The impact is

expected in energy systems, electronics,

medical/health, transportation,

pharmaceutical, chemicals, defense and

aerospace sectors.

[email protected]

ACHIEVABLE ACCURACY

Measuring instruments

Vernier Calipers

Mechanical Comparators

OpticalComparators

ElectronicComparators

(Non-contact)Laser

Measuring Instruments

High Precision Laser Measuring

instrumentsSEM STM AFM

0.3nm

0.00lμm (1nm)

0.0lμm

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lμm

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0.1mm

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lμm

0.1μm 0.1μm00.05μm

0.01μm0.005μm

0.001μm

1μm

Norm

al Machining

Precision Machining

Ultraprecision Machining

� Achievable manufacturing accuracy and dimensional metrology and measuring instruments respectively


AUTOMATION TRENDSDie & Mould Manufacturing

The automation industry

has witnessed a surge

in the recent past, with

the increased importance

in design, especially in

the manufacturing and Architecture,

Engineering & Construction (AEC)

verticals. Any company—large or

small—looking to stay ahead in a highly

dynamic and competitive ecosystem

needs to deploy the latest CAD/CAM

and simulation solutions in their

systems. Also, such solutions provide a

competitive edge for companies to out-

innovate their competitors and deliver

products faster, command marketshare

and maximise a product’s potential.

As dies and moulds are the back

bone of many industries, there have been

many automated technologies developed

which are helping manufacturers to

produce the product in high speed with

better productivity. In today’s fast paced

world, the automation systems have

become an essential element in die mould

manufacturing companies. Mould makers

faces many challenges in the competitive

business environment and it’s very crucial

for them to upgrade technologically to

survive global competition, which has

resulted in the development of many die

& mould related software’s and adoption

of these solutions by the die & mould

manufacturers.

The Evolution Machining complicate shapes with

high accuracy was the most challenging

task in the early years for the dies &

moulds industry. It is now moving

towards automation to achieve high

end machining. The implementation

of automation in the dies and moulds

industry is driven by many factors,

including shortage of skilled labour and

high labour cost. There is a need to

reduce lead time, and achieve higher level

of accuracy & repeatability. Automating

the recent developments in automation

provide significant benefits for High-

Performance Machining (HPM) of

electrodes and steel mould components.

In earlier days die & mould were

manufactured using traditional methods

and conventional machines which

required highly skilled manpower

and domain experts. This leads to

inconsistency in productivity & quality

as skilled manpower & domain experts

were not readily available.

“Currently Automation has helped

in getting rid of the earlier issues and

helps in automating the complete

process of die & mould manufacturing

which includes mould CAD designing

& CAM process without any manual

intervention. Now things are changing

because of latest technologies and

development in hi tech machineries

and CAD/CAM tools. It helps in

automating the manufacturing process ,

reducing time to market, and consistency

in quality”, says, Sambit Pradhan,

Manager - Business Developement

(Asia Pacific), Geometric Ltd. The use

of highly accurate palletising for work

pieces and electrodes on HPM and

EDM machines is widely credited with

reducing the set-up times on machines

Registering a phenomenal growth, the die & mould sector is garnering user attention with its latest technological advancements, especially engineering simulation and design optimisation. Nishant Kashyap traces latest software developments in sheet metal and mould making process and how it has changed the way dies and moulds are manufactured.

Engineering

ptimalDesign Simulations

Sambit Pradhan, Manager - Business Developement (Asia Pacific), Geometric Ltd

Complete process of die & mould from design to manufacturing can be automated, tools can be developed to map the organisation standards practices of design and manufacturing processes and take help of the latest technologies to automate it

Die & Mould Manufacturing


[email protected]

and improving the overall tolerance levels. The use of these

systems enables high levels of throughput and significant

improvements in accuracy & repeatability across components.

The standardisation of these palletising units also allows jobs

to be targeted for a range of different machines within the

shop. This flexibility can significantly increase throughput while

reducing the scheduling complexity.

Benefits of Automation Today, mould manufacturers need to develop mould designs

that are more accurate, save time, and improve profitability.

With newly developed software solutions, not only does one

have the ability to define mould geometry, but one can also

have access to a wide range of automated mould design tools.

As a result, it is possible to validate critical aspects of mould

designs before releasing them for production. Further, one can

automatically identify undercuts, complete side cores, verify draft

angles, define parting lines, create parting surfaces, assess proper

fill characteristics, and ensure mould durability.

The role of software today, goes hand in hand with the

manufacturing industry. 3D simulation not only eliminates

errors, but also gives the manufacturer an opportunity to visualise

the path and act according to fastest machining. Pradhan says,

“Complete process of die & mould from design to manufacturing

can be automated, tools can be developed to map the organisation

standards practices of design and manufacturing processes and

take help of the latest technologies to automate it. For example -

Once the CAD design is ready automation can help in getting the

die design done automatically and then move into manufacturing

where the CAM process is automated using the best practices of the

organisation. Other intermediate process also can be mapped and

linked to the automation tool so that the complete process operates

seamlessly.” The output of dies is tremendously complemented as

it reduces the trial and error method and advances the scope of

manufacturing and time taken for the output of a die or mould.

Tool & die makers are hard-pressed to cut down on lead times

and optimise the material/tool costs to compete in this demanding

market. This has led to increased use of software solutions to

simulate the outcome of the processes, long before the dies are

built or even designed.

ForecastIn the era of delivering quality in products, there is no limit

in the speed of machining and production. The definition of

high speed machining has changed. With the right automation

solution companies can achieve every parameter to be perfect

solution provider.

The die & mould industry will continue to

demand more advanced softwares that cost less than

the existing ones. Industry will need more efforts to

develop better quality mould parts economically and

locally. In future higher productivity and efficiency

will depend on the collaboration of both the industries.


STRATEGYStrengthening Business

The US unit of Mazak had

raised prices in June 2011,

following a similar move by

competitor Okuma America.

Then came the plan to have

Mazak Corp (Florence, Ky) export a

total of 15-20 units per month of more

low-end compact, and medium-size

lathe models in October. According

to the Mazak Group, the reverse

imports, as the Japanese call such an

arrangement, were in the past intended

to help meet temporary excessive demand

from Japanese users. In addition, the

US subsidiary will soon, for the first

time, export to South America and

Asia outside of Japan, starting at about

ten units per month of two compact

lathe models.

Meanwhile, for the first time since

it began production in 2000, Yamazaki’s

Little Giant Machine Tool Corp Ltd

(Yinchuan, Ningxia Hui Autonomous

Region, China) raised by 5 per cent

its prices for Chinese users. That was

possible because of the strong demand

for all the plant’s machines, including

two horizontal-spindle machining

centers added in 2011, according to

President, Tomohisa Yamazaki at

the parent company. He also predicted

that the original Chinese unit’s capacity

would rise to 270 units per month,

up 70 per cent, alleviating the four-

to five-month wait that Chinese users

typically encounter.

Yamazaki Mazak also has started

construction of its newest plant,

choosing Dalian in China’s Liaoning

Province, the city that already houses

Dalian Machine Tool Group, the

country’s largest builder. Some 200

joined in the Oct. 19 groundbreaking;

the Mazak facility will be run by a new

unit-Yamazaki Mazak Machine Tool

(Liaoning) Co. Ltd. Completion is

slated for the end of 2012. A year later

it is expected to assemble 100 units per

month of small lathes and machining

centers. Mazak invested $ 65-million

including land, plant and equipment

as well as parts facilities. The Dalian

project includes parts and components

to be used by Mazak plants worldwide.

(The company nine factory complexes

around the world include five in Japan.)

For Chinese customers, it will offer

In a bid to counter the yen’s strength versus the US dollar, Yamazaki Mazak Corp (Oguchi, Aichi, Japan) has chosen two means: imports from America and price hikes (widely seen as taboo in China’s emerging market).

How a Global Builder Handles CHANGES AROUND THE WORLD?

Strengthening Business


post-sales services including

repair of main spindles, which

to date have had to be done in

Japan, incurring shipping costs

and added time.

Mazak expects the Dalian

factory will slash parts production

costs and counter the yen’s quick

rise versus currencies in the US

and other countries. According

to Motohiko Yokoyama, JTEKT

Corp, Chairman and current

chairman of the Japan Machine

Tool Builders’ Association,

currency problems are faced

not only by Yamazaki Mazak

but other Japanese builders. He

adds that some of his group’s

members also faced continuing

power shortages from the

earthquake/tsunami earlier in

the year.

The builder also plans

expansion at its Yamazaki

Mazak Singapore Pte Ltd.

location founded in 1988 in that

state’s Jurong Industrial District,

with the construction of a new

factory building adjacent to

its existing one. The original,

200,000 sq.ft. plant produces

70 compact lathes per month;

the new one will assemble 50

machining centers per month.

The Singapore enterprise is seen

internally as an entrée to markets

in India and throughout the ten-

nation ASEAN (Association

of Southeast Asian Nations)

bloc. That strategy originally

had been forged back in 2008,

President Tomohisa Yamazaki

allowed, adding that year’s global

financial crisis (the Lehman

Brothers Shock, as the Japanese

call it) forced Mazak to put it

aside. But in 2010 Singapore

and India signed a tariff-

reducing free-trade agreement

at the same time demand from

the automotive sector recovered,

yielding for Japanese producers

a kind of ‘divine wind’.

Courtesy: Gardner Publication Inc

Principles of Management at Yamazaki, by YamazakiSeveral reporters in the room at the 1974 northern-Kentucky press conference announcing the

launch of a Yamazaki factory in the US recognised that the man taking questions was not your

run-of-the-mill corporate type. Given that the plant was being located practically across the Ohio

River from the world seat of power in machine tools, some of those present probably thought this

competitor to be an upstart, even cheeky. ‘Visionary’ would have been a far better depiction.

A couple of years before he died in September at age 82, Teruyuki Yamazaki published a

book commemorating his company’s 88th anniversary, Mazak’s Management Principles. In it, he

outlined some 75 guiding beliefs he said helped him manage the family-held company he chaired

for decades into becoming the largest machine-tool builder in the world. Here are some:

If we manufacture machines based on sales forecasts, only 30 per cent would meet customers’ specifications.

We should develop our own unique products and use those new advanced machines for our production.

A Kimono (formal dress) must be accompanied with the Haori (mid-length coat), Obi (belt), Zori (sandals), and all other required accessories. We gain customer trust by being a total systems developer.

Our challenge is to focus on increasing market share more so than the sales volume.

Machine-tool manufacturers enjoy a high ratio of profit to net sales, but they suffer from an extremely low ratio of profit when compared to total assets.

We do not seek to be listed on the stock exchange because no considerable benefit is realised, and we want to maintain autonomy.

We have been derided as being a party-loving company. However, we consider such activity to be a necessary investment to promote better communication.

We act as a doctor in the factory-automation industry. A good doctor always carries a stethoscope.

A machine-tool manufacturer must continue to exist so that it can be responsible for its own machines.

The best way to pick mushrooms is to patiently keep looking in the same area. (After learning of the exporting strictures that would be caused by the 1980s Voluntary Restraint Agreements between the U.S. and Japan.)

I am saddened that many top manufacturers in Western countries have disappeared one-by-one. I remind myself of their mistakes from time to time.


TIPS & TRICKSMetrology Operations

Optimising CMM Usage & Maintenance

[email protected]

10

Axes motor magnets should be periodically checked and cleaned for carbon deposits. Also it should be ensured that magnets are placed back in the same orientation.

9

It is necessary to dry-run the new or unproven programs and not place any components/parts/ fixtures on CMM table during dry-run. Also, if you are using simulation software it is advisable to check before dry-run.

8

Extra caution needs to be taken while programming with special probes or star probes. Length/diameter ratio of probes should be taken extreme care of as advised by OEM.

7

CMM should be placed in a dust free, temperature controlled (about 20 – 21 Degrees symbol Celsius) environment.

6

Generally CMM is placed near shop floors. It should be ensured that the layout where CMM is placed is isolated from vibrations.

5Pneumatic air pressure as advised by OEM must be maintained and accordingly apneumatic compressor with higher rating & tank size should be used, else compressorwill run continuously and get heated quickly. Additional filters should be used to filter off oil and moisture from atmosphere/air. Also regular checks should be carried out todrain off the oil/water from filters.

4

CMM should be cleaned daily to make it dust free; especially the path, through which air-bearings travel. It should be ensured that this passage is free from scratches, dust, scrap, oil, moisture, etc.

3

Always buy pneumatic compressor and air-dryer from reputed brand. Place pneumatic compressor/air-dryer outside CMM room to reduce noise levels/temperature rise.

2CMMs should be ideally run in all axes at least five times daily. CMM probe shouldbe calibrated at least once daily before starting to avoid any possible flaw during the operation due to any prior miss handling of the system.

1

It is advisable to carry out the annual calibration of CMM by OEM/service engineersduring night time as temperature variation is lower.

In any manufacturing system, quality control is one of the most critical aspects in ensuring that the finished product conforms to the specifications or demands of the customers. Thus, optimum use of metrology equipment becomes the need of the hour to ensure the quality parameters. Nishant Kashyap provides pointers for optimum utilisation of Coordinate Measuring Machine (CMM).

Event List - National


Modern Machine ShopThe event offers an ultimate platform

to demonstrate potential and futuristic

technologies in the product segment to a

large cross-section of business visitors,

from the entire engineering industry;

April 5-8, 2012; India Expo Mart,

Greater Noida

For details contact:

Indian Machine Tool Manufacturers’

Association

Bangalore International Exhibition Centre,

10th Mile, Tumkur Road, Madavara Post,

Bengaluru

Tel: +91 80 6624 6600

Fax: +91 80 6624 6661


Web: www.imtma.in

DIEMOULD India 2012 The 8th edition of this international

exhibition will provide an ideal opportunity

for the die & mould industry to upgrade

its know how and keep pace with the latest

developments in this segment; April 19 –

22, 2012; Bombay Exhibition Centre, NSE

Complex, Goregaon, Mumbai.


Tool & Gauge Manufacturers Association

of India (TAGMA)

A-33, NandJyot Industrial Estate,

Safed Pool, A K Road

Mumbai - 400 072

Tel: +91 22 28526876 / 28508976

Fax: +91 22 28503273


Website: http://www.tagmaindia.org

Automotive Engineering Show 2012The premier event on automotive

components will demonstrate the latest

technology in the automotives segment;

April 26-28, 2012; Auto Cluster Exhibition

Centre, Chinchwad, Pune.


Focussed Event Management Pvt Ltd,

Head Office : Plot No. F/11 & F/12, Camlin

Fine,WICEL Compound,

Opp. SEEPZ Main Gate, Andheri (East),

Mumbai – 400 093

Tel: 91-22-3201 9137

Fax: 91-22-2832 4404


ACMEE 2012The event will showcase various innovations

made in automobile and engineering

industries over the past few years and

act as a forum for exchanging diverse

product information, technical details and

development of new business contacts;

June 14 -18, 2012; Chennai Trade Centre,

Chennai

For details contact

ACMEE 2012- AIEMA Technology Centre,

1st Cross Road, Ambattur Industrial Estate, Chennai 600 058 Tel: +91 44 2625 8619 Fax: +91 44 2652 0814 Email: [email protected]: www.acmee.in

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 the Asian region. 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


Web: www.triuneexhibitors.com

Automation 2012The seventh international automation

exhibition and conference will be held at

the Bombay Exhibition Centre, Mumbai;

between September 7 – 10, 2012.

Automation Exhibition will showcase the

power of collaboration between solution

providers i.e. 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.

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

Electronics, Material Handling and Safety Equipment.

For details

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

Mob: 09819552270 Fax: 022 3003 4499 • Email: [email protected]

• Web: www.engg-expo.com

PUNEMaharastra

Nov 2-5, 2012

RUDRAPURUttarakhand

Feb 23-26, 2013

LUDHIANAPunjab

Dec 21-24, 2012

CHENNAITamil Nadu

Nov 22-25, 2012

AHMEDABADGujarat

Oct 5-8, 2012

INDOREMadhya Pradesh

Jan 11-14, 2013

AURANGABADMaharastra

Feb 1-4, 2013

Event List - International


MACH 2012MACH organised by the Manufacturing

Technologies Association (MTA), attracts

almost 450 exhibitors and over 20,000

visitors who will showcase some of the best

innovations and latest developments from

the manufacturing technologies sector; April

11 – 16, 2012; NEC Birmingham, UK

For details contact

The Manufacturing Technologies

Association

62 Bayswater Road,

London, W2 3PS, United Kingdom

Tel: +44 (0) 20 7298 6400

Fax: +44 (0) 20 7298 6430


Web: www.mta.org.uk

China CNC Machine Tool FairChina CNC Machine Tool Fair (CCMT) has

been successfully held since 2000 in Shanghai

every year. It has developed into one of China’s

biggest machine tool and metal-working

exhibitions; April 16 -20, 2012; Nanjing

International Expo Center, China.


IMAG - Internationaler Messe - und

Ausstellungsdienst GmbH

Am Messesee 2, 81829, München

Germany

Tel: +49-89 9492 2113

Fax: + +49-89 9492 2114


Web: www.imag-db.de

SIMTOS 2012SIMTOS 2012 will be divided into six

brand pavilions by exhibit product ie metal

cutting and die & mould working, press

& metal forming, cutting-off & welding

tools & related equipment, CAD/CAM,

measuring system & robotics and motion

controls; April 17 – 22, 2012; Korea

International Exhibition Center (KINTEX),

Seoul Korea.


4th Fl Tower Crystal Building,

1008-1 Daechi-dong, Kangnam-gu,

Seoul, 135-280, South Korea

Tel: +82-2-3453-2721

Fax: +82-2-6280-2721


Web: www.simtos.org

AUSTECH 2012The show exhibits with new manufacturing

technologies and techniques to cut costs.

More than 10,000 decision-makers

regularly attend Austech and National

Manufacturing Week to get ideas, find

innovative ways of making things and solve

manufacturing problems; May 8 - 11 2012,

Sydney Showground Sydney Olympic Park,

Australia.For details contact

AMTIL

Suite 1, 673 Boronia Road

Wantirna, 3152, Victoria, Australia

Tel: +61 3 9800 3666

Fax: +61 3 9800 3436


Web: www.amtil.com.au

INTERMACH 2012The show focuses exclusively on industrial

machinery and aims at introducing the

latest high-tech machinery and cutting edge

technology from around the world; May 17-

20, 2012; at Bangkok International Trade

& Exhibition Centre (BITEC), Thailand.


UBM Asia (Thailand) Co Ltd

503/23 K S L Tower

14th Floor Sri Ayuthaya Road,

Kwaeng Thanon Phayathai,

Khet Rajathewee, Bangkok 10400 Thailand

Tel: +66 0 2642 6911

Fax: +66 0 2642 6919

E-mail: [email protected]

Web: www.ubmthailand.com

BIEMHThe 27th edition of the event will showcase

latest developments and technologies from

leading companies in their specialty; may 28

– June 2, 2012; Bilbao Exhibition Centre,

Bilbao, Spain.


Bilbao Exhibition Centre

Ronda de Azkue 1, 48902 Ansio-

Barakaldo

Tel: 34 94 40 40 000

Fax: 34 94 40 40 001


Web: www.biemh.com

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; at Saigon

exhibition & Convention Centre, Ho Chi

Minh City, Vietnam


Singapore Exhibition Services Pte Ltd

1 Jalan Kilang Timor

09-02 Pacific Tech Centre

Singapore 159303

Tel: +65 6233 6638, Fax: +65 6233 6633


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, at McCormick Place, Chicago,

USA.


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


Web: www.imts.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

Event Report


In this era of ‘glocalisation’ where

every leading company is trying to

establish its footprint in regional

markets and create a stronghold,

sensing the pulse of customers is

one of the old and most powerful adages.

In order to explore the tremendous

opportunities to get established in regional

markets, trade shows play a very critical

role. Holding the fort in organising multi-

location trade shows, Engineering Expo

is a brand to reckon with. Keeping up

with its rich tradition and a fresh vigour

& enthusiasm, the maiden edition of

Engineering Expo Aurangabad portrayed

the poised locational advantages to the

manufacturing community. The latest

edition of Engineering Expo, an established

trade show from the stable of Network18,

with support from Aurangabad Industrial

Suppliers Association (AISA), held from

February 17-20, 2012, turned out to be a

huge success in terms of its quest towards

bringing out the message to the entire Indian

manufacturing fraternity of an emerging

manufacturing hub – Aurangabad.

Expo takes off on a high noteDignitaries including Mukund Kulkarni,

President, CMIA and MD, Expert

Group Solutions; Millind Kelkar, Owner,

Grind Master; Jayant Soni, President,

AISA; Ravindra Naidu, Joint President,

Birla Precision Technologies and Sunil

Daga, Sr VP – Business Banking, Kotak

Mahindra Bank along with Sudhanva

Jategaonkar, Associate Vice President,

Infomedia 18, were present at the Expo’s

inauguration function.

Elaborating on how Engineering Expo

is all set to offer a fillip to the trade prospects

of Aurangabad, Naidu said, “This is one of

the largest SME gathering in Aurangabad.

As we all know the potential this place has,

this Expo comes across as a catalyst that

will further boost its growth. It is a matter

of pride for Aurangabad. Earlier, it was

only known as a historic city; but now, it is

also known as an automobile hub.”

Complementing Naidu’s views, co-

organiser, Soni added, “We were looking

for a platform in Aurangabad and now,

with Engineering Expo, we found the

best and one of the most preferred

platforms. We can say that with this

maiden edition, Engineering Expo

has brought an international standard

show to the doorstep of users. The

small and medium business units will

reap a lot of benefits from the Expo.”

Offering a financial perspective, Virat

Diwanji, Executive Vice President

& Head – Branch Banking, Kotak

Mahindra Bank said, “We are delighted

to be associated with Engineering Expo.

SMEs are the backbone of India’s

economy. The sector has played a critical

role in achieving wide measures of

industrial growth, and is instrumental in

generating large-scale employment across

the country. We, at Kotak Mahindra

Bank, believe that with the right mix of

capital, technology and innovative ideas,

SMEs have the potential to push India’s

growth to the next level. Our customised

business solutions, backed with customer

friendly service, are designed to meet the

challenges and growing requirements of

this sector.”

The maiden edition of Engineering Expo held at Aurangabad was a runaway hit among the growing manufacturing and general engineering sector, as well as SMEs based in and around the historical city. The Expo had a positive impact on the developing manufacturing industry in Aurangabad and is poised to come back with more offerings and opportunities for exhibitors and visitors in the next edition. Nishi Rath reports... � Dignitaries unveiling the exhibitors’ directory during the inaugural ceremony

Creating yet another SUCCESS STORY

Aurangabad17-20 February, 2012

Ayodhya Nagari

No of exhibitors 250+Business visitors 18,013+

Exhibiton area 1,00,000 sq ftBusiness transacted ` 70 crore

Business leads generated 17,000+ Products displayed 6,250+

More than 1,10,000 kg machinery moved in for display

Event Report


Engineering Expo opens account at AurangabadThe latest edition of Engineering Expo

highlighted the potential that a new and

developing place like Aurangabad has to

offer. The fast-paced industrial growth

in Aurangabad will not only improve the

employment avenues, but will also raise

the standard of living in this city, opined

Kulkarni. He added, “An Engineering Expo,

like this, is vital for the competitiveness of

industry, especially for SMEs.”

Offering an organiser’s perspective on

the choice of a new location for organising

Engineering Expo, Jategaonkar said,

“Engineering Expo has come a long way

by becoming one of India’s largest multi-

location trade shows (other places include

Ahmedabad, Chennai, Indore, Pune,

Rudrapur and now, Aurangabad). Over

the years, it has successfully delivered its

goal of becoming a preferred destination

for SMEs, manufacturing and engineering

companies to connect, transact & leverage

ideas to foster the growth of organisations

as well as that of the industry at large.”

Exhibitors attract audience Engineering Expo Aurangabad, held

during February 17-20, 2012, boasted of

huge industry participation from various

manufacturing areas, including machine

tools & accessories, material handling

equipment, hydraulics and pneumatics,

automation & instrumentation, light and

medium engineering, safety & security and

packaging machinery, among others.

Elaborating on the excellent response

generated at Engineering Expo Aurangabad, SJ

Gijare, GM – Equipment Division, CTR

Mfg India, articulated, “Engineering Expo

is definitely not below expectation. It has

helped the SME sector, which is fast growing

in Aurangabad, find potential customers.

We showcased some of our best products

here and even received very good response.

CTR already has a strong presence in the

segment and by participating in this Expo,

we want to retain that position in the years

to come.”

Discussing the scope Aurangabad

has to offer, Aniket Nanajkar, Profit

Centre Manager – Mechanical Division,

Phoenix Mecano, explained, “Engineering

Expo has provided us a good platform to

understand the market demands here. We

were delighted to find potential customers

visiting our stall at the Expo.”

Visitors in AWEThe responses from visitors were encouraging

as well. Most visitors emphasised that more

such events should be organised in future.

“Engineering Expo provides companies an

excellent platform to know more about new

technologies. It helps local manufacturers

meet global standards. The Expo has been

organised very well and is a huge success

among visitors. Trade shows of this stature

will help this growing manufacturing hub,”

said Satish Adsul, AGM – Corporate

Purchase, Endurance Technologies

(Casting Division).

Rajesh Baheti, DGM – Corp Materials

& VEPL – Head, Varroc Engineering, who

was also present at the Expo, visited stalls

and interacted with various exhibitors. “In

its first edition itself, the Expo has become

a huge success. We saw various companies

showcasing their best products and

solutions here. This will definitely help the

SMEs located in and around Aurangabad.

Considering the fact that Aurangabad is

developing, organising such events will

definitely offer a boost to the growth

prospects of this region,” Baheti added.

Engineering Expo Aurangabad

also attracted overseas visitors. Russell

Small, Sales Manager, Asia Pacific,

Precision Polymer Engineering,

England, was in Aurangabad mainly

to attend the Expo. “I saw some

of the best automation products displayed

here by quality exhibitors. Such trade shows

can be very helpful for a developing place

like Aurangabad,” he exclaimed.

Promising times aheadWith various other companies looking

forward to investing in Aurangabad, the

region is set to witness further growth over

the coming years. The huge turnout at the

Expo is proof enough of the increasing

awareness among local businessmen about

new technologies and their value-added

benefits. With an optimistic outlook,

Jategaonkar informed, “As we look forward

to making further value additions for

an even better experience and reach to

the target audience, we welcome large,

medium and small industries in

the manufacturing and servicing sectors

to be a part of the Expo in its

exciting journey.” With this huge success,

Engineering Expo is slated to make it

even bigger in the next edition with more

promising opportunities to be tapped and

more areas to be covered.

[email protected]

Panel discussion on ‘Shifting Status From Why Aurangabad To Why Not Aurangabad?’The panel discussion was jointly organised by Infomedia 18 and in association with Aurangabad Industrial Suppliers Association (AISA) recently. The endeavour was a part of its value additions intended to bring the manufacturing and dealers community of Aurangabad to talk about the critical issues related to the growth of the region with an aim and intent to position Aurangabad and in and around areas a most sought after manufacturing hub.

SME Meet: An informal discussion on the pain and gain areas of SMEs: A large gathering of SMEs shared their pain & gain areas of working in & around Aurangabad. Some of the major issues discussed during the meet were banking & government policies, availability & procurement of land, which deters expansion, and most importantly, the shortage of skilled labour in & around the region. The major solutions that were arrived at include amendments in regulatory laws and a clear exit policy to change the product line.

INITIATIVES AROUND ENGINEERING EXPO AURANGABAD

Delegations who visited the Expo…

� Varroc Engineering

� Forbes & Company

� Larsen & Toubro

� NRB Bearings

� Videocon

� Wipro

� Crompton Greaves

� Bajaj Auto

Products - National


This section gives information about the national and international products

available in the market

Die and mould machineThe Sirius-Ul+ is a high-speed die and mould machine with a rapid speed of 40 m/min in all axis and spindle speed of 20,000 rpm. This machine has built-in spindle motor of capacity 22/18.5 kW. It has bridge-type column structure having Z-axis with 6-LM blocks on two guideways. The spindle is designed with oil jet lubrication system to minimise its thermal deformation. The machine has a 30-station ATC, which is servo driven and comes with arm-type of changer. Hwacheon made Optima cutting feed optimisation system is provided for unbeatable reliability. Also included is 3D simulated and FEM analysed frame design.

Stitch Overseas Pvt Ltd

Gurgaon - Haryana

Tel: 0124-4755400, Mob: 09313361202


Website: www.stitchtools.com

Products - National


Vertical honing machineThe hydraulic auto stroking vertical honing machine improves bore geometry of medium and heavy jobs. The spindle rotation and reciprocation is mechanical. Honing mandrels are linked with spindles by universal joints. The stroke length is adjustable depending upon the length of the jobs. This honing machine has very compact design with all the features of auto-stroking machine having high productivity. The machine is very useful for honing large varieties of components, like cylinder liners, hydraulic valves, pneumatic valves, brake cylinders, rocker arms and con rods, etc.

Khushbu Engineers

Kolhapur - Maharashtra

Tel: 0230-2468859, Mob: 09371658016


Website: www.khushbuindia.com

Angle grindersThe models BG7 and BG9 high-speed angle grinders are available in 180 mm and 230 mm with 2200 W motors. These angle grinders maintain their rated output even under the most

Products - National


exacting heavy-duty conditions. Both the grinders find applications in all heavy weld dressing work, foundry grinding and in cutting off risers and runners. The angle grinders are especially useful where fast cutting is required and are capable of handling continuous production grinding and cutting work. Both the machines are 100 per cent indigenous so that all parts are locally available.

Nippon Electrical Industries

Ahmedabad - Gujarat

Tel: 079-22822750, Mob: 09376710401


Website: www.nipponpowertools.com

CNC latheThis CNC lathe is suitable for machining small-sized parts. It has a compact foot print, cartridge spindle with maximum speed up to 6,000 rpm, rapid rates of 20 m/min on both axes, and a rigid bed. This machine lends itself well for cell manufacturing. Other features include saddle (Z) with V and flat guide ways, cross slide (X) with dovetail guide ways, special execution with load/unload system, etc. Maximum turning

MM

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Products - National


diameter is 140 mm, maximum turning length is 200 mm, chuck size 135 mm, and spindle power is 5.5 kW.

Ace Designers Ltd

Bengaluru - Karnataka

Tel: 080-22186700


Website: www.acemicromatic.com

Drilling-cum-milling machineThe model SI-6DMU geared pillar-type drilling-cum-milling machine is used for drilling, milling, tapping, lapping and counter boring. Drilling capacity of the machines is 40 mm, with face mill capacity of 25 mm, tapping capacity of 22 mm in cast iron, and drilling capacity of 35 mm in mild steel. Quill spacers are made of steel while the main spindles are made of EN steel with six slots. With a spindle speed of eight gears, the product is made from the best quality material and is helical teethed for smooth and noiseless running.

Siddhapura Industries

Bhavnagar - Gujarat

Tel: 0278-2445048, Mob: 09924241999


Website: www.siddhapuradrills.com

Products - National


Tilting rotary tableThe model DDT-125 NC tilting rotary table comes with twin-shaft connect and direct drive motor. This rotary table is available to match European controllers, such as Heindenhain, Siemens, Fagor, etc. It is suitable for engraving machines, modular manufacture, optical manufacture, etc. The tilting rotary table features high-speed and no backlash.Spintop Machinery Co, Ltd

Taiwan - China

Tel: +884-4-25682975


Website: www.spintop.com

Micro grain carbidesThe micro grain carbides are used for aluminum alloy processing end mills. These are suitable for copper, aluminum, aluminum alloy, copper alloy, nickel alloy, titanium alloy and plastic processing. The micro grain carbides are high-performance tools with 5-axis CNC grinding machines.

Zen Wu Zheng Sun Tool Co Ltd

Kaoshiung City - Taiwan

Tel: +886-7-3525743

Email: f [email protected]

Website: www.jsk-tools.com.tw

Products - National


Surface grinding machinesThe Sumo series surface grinding machines are available in various models, such as GSH-8, GSH-50, GSH-75, GSH-100 and in NC/CNC versions. These machines have robust base structure and have internationally accepted fixed column design. The heavy box type column casting with honey-combed ribbing is rigidly clamped to heavy base casting. The spindle housing supports cartridge-type spindle unit and is assembled with super precision bearings grease packed with imported grease to have long trouble-free service. The table drive is hydraulic with soft reversal device.

Pinnacle Engineering Enterprise

Surendranagar - Gujarat

Tel: 02752-230552, Mob: 09879190585


Website: www.pinnaclegrinder.com

Tool trolleysA wide range of tool trolleys for various types of application such as machining centres, CNC machines, automobile workshop,

Products - National


wiring, etc, is available. Also offered are customised systems for specific requirements and specified tools cabinet to serve as cassette type tool cabinets for safely storing of press brake tools. Salient features include spacious storage facility with ease in mobility, innovative designs that fits customers every single need, easy access for machine solutions, adjustable drawer as per customer need, superior quality at less price and state-of-the-art & user-friendly, etc.

Basic Engineers

Ahmedabad - Gujarat

Tel: 079-25831575, Mob: 09825344527


Website: www.basiengineers.com

Radial drilling machineThe all-geared auto-feed radial drilling machine (40 mm capacity) has gearbox of 9-speed with all 9-gears of EN9 steel and hardened up to 50 HRC. Oil bath gearbox and hardened gear gives very long life to the drilling machines. Auto-feed gears are also hardened. All the gears in the machine are supported through good quality bearings and not the bushes. The machine is supplied with complete electrical panel board with five push-button switches and one limit switch and two ISI electrical motors. Rotation and easy sliding of gears in bearings give very high reliability.

Prakash Engineers

Bhavnagar - Gujarat

Tel: 0278-2438241, Mob: 09852356226


Website: www.prakashmachines.co.in

Super-abrasive diamond and CBN grinding wheels The super-abrasive diamond and CBN grinding wheels and tools are high-power equipments that enable easy, efficient and economical redressing of worn-out buttons on tungsten carbide button drill bits at drilling site. The effectiveness of the equipment results in minimising the regrinding time of worn-out button bits. These equipments redress the tungsten carbide buttons and grind the steel portion of

Boring tool system The large diameter boring tool system combines various technical feature like super light execution, which ensures minor stress for operators and presetter spindles. With full HSC capability, it renders highest precision and performance. The system is based on aluminium extension slides of different lengths, which supports variety of aluminium and steel components for roughing and finishing tool assemblies. The mounting component is pinned to fit specific locations on the slides and is secured with steel bolts. The precise location of the components on the slide along with incremental adjustment scales for insert holders permit diameter and lengths setting without a tool presetter.

Quattro Engineering India Ltd

Coimbatore, Tamil Nadu

Tel: 0422-257 1606,098947 88663


Website: www.microtoolings.com

the body of button bits for the relief. The pneumatically operated equipments are very compact in operation and usage.

Wendt India Ltd

Hosur, Tamil Nadu

Tel: +91-4334-276851


Website: www.wendtgroup.com

Products - National


Tensioner nuts & bolts The tensioner nuts and bolts are multi hex-head clamping screws, a direct replacement of hex nut. These can be threaded directly on to an existing bolt/s t u d / t h r e a d e d rod or shaft. The washer rests on load bearing surface of parts which needs to be clamped and is protected. Tightening force (torque) is also distributed due to multi-clamping screws. The tensioner nuts and bolts allow usage even in the restricted and constrained space.

NMTG Mechtrans Techniques Pvt Ltd

Ahmedabad - Gujarat

Tel: 079-22821527, Mob: 09328271660


Website: www.nmtgindia.com

Reversible tapping attachmentsThese are low-weight, high-speed reversible tapping attachments that are suitable for use with standard HSS taps on any drilling machine vertically or horizontally, for right or left hand tapping

Products - National


Radial drilling machineThe model SMT 40/1000 DC double-column radial drilling machine is used for drilling, tapping, lapping, screwing and counter boring operation. This radial drilling machine is also used for screwing in cast iron, steel, plastics and other materials. Drilling capacity is about 40 mm and spindle nosed is of MT-4. The double-column is ground by German-make cylindrical grinder.

of blind or t h r o u g h holes. Made of alloy steels with all moving parts h a r d e n e d and ground to precision. The tapping attachments are available in capacities ranging from 2-3 mm. An ultra-sensitive and smooth operating ball-clutch protects the tap against breakage when, tap is bottomed in a blind hole or core hole is shallow or tap is dull.

Tools & Appliances Corporation

Ahmedabad - Gujarat

Tel: 079-22740375, Mob: 09825126659


Website: www.imitoolsindia.com

Products - National


Headstock is bored on imported boring machine (TOSS). Accuracy conforms to IS-2425 standards. The radial drilling machine is useful for every toolroom and maintenance purpose.

Syndicate Industrial Corporation

Bhavnagar - Gujarat

Tel: 0278-2445148, Mob: 09426207129


Tapping chuckThe QCSL non-reversible tapping chuck is specially developed for builders of heavy machinery, turbines, motors, nuclear reactors and other such types of heavy equipment. Capacity of the tapping chuck ranges from M30 to M200. It is available in Morse Taper, ISO taper or in special shanks. The chuck is suitable for heavy jobs and are suitable for tapping on higher diameter. This chuck is provided with length compensation features that allow the tap to act as its own lead screw.

IMI Machine Tools Pvt Ltd

Ahmedabad - Gujarat

Tel: 02764-233983, Mob: 09825146659


Website: www.imitoolsindia.com

Universal drilling systemRigid construction of the innovative tool makes maximum feed rates for lengths up to 5 x D possible. It notably increases productivity while maintaining process security through the optimally designed chip pockets and controlled drill deviation thanks to the special insert position. In combination with the recently developed universal grade CTPP430, the new drilling system MaxiDrill 900 is an unbeatable new product which finds optimum application in all fields of mechanical engineering.

Ceratizit India Pvt Ltd

Kolkata - West Bengal

Tel: 033-24940581


Website: www.ceratizit.com

High-speed spindle unitThe BEX-15 high-speed spindle unit is designed for spindle speeds up to 20000 rpm.Standard spindle and tool holder options are ER 25, ISO 30, HSK, ABS and Weldon. All spindle options are available with coolant through the spindle applications.

Products - National


Radial drilling machineThe model 38-PRD universal radial drilling machine is available in 38 mm capacity with fine-feed or auto-feed arrangements. This drilling machine comprises of latest technology and well-designed parts made up of special materials. The spindles and rams are made up of material EN-8 and also hardened to increase the hardness. All gears are made of EN-8 and cut helically to achieve perfect transmission ratio. Safety clutch is provided for autofeed mechanism. Its

With five different tool holder options, many drilling and milling applications are possible. Advantages are make real use of carbide tools, less vibrations and high precision, long life time in view of sturdy design and reinforced bearing option, deep hole drilling operations, etc.

Suhner India Pvt Ltd

Bengaluru - Karnataka

Tel: 080-27831108

Email: blroff [email protected]

Website: www.suhner.com

Products - National


Shot blasting machineThis mega shot blasting machine has 16-wheel station and is used for heavy fabricated structures in the automobile industry. The job is loaded on load bar of automatic trolleys having auto hoisting arrangement. Two trolleys are coupled through load bar for loading of heavy structures. These loaded trolleys carry the job into blast chamber where the 16-wheel stations are located strategically at descaling angle. The job pass through the high velocity stream of abrasive thrown by blast wheel stations resulting into thorough single-pass cleaning of job. The cleaned job comes out from the outlet vestibule of blast cabinet.

Surface Finishing Equipment Company

Jodhpur - Rajasthan

Tel: 0291-2740128, Mob: 09829022624


Website: www.surfacefinishing.org

design prevents the damage of gears in case of wrong operating condition.

Powermatic Engineers

Ahmedabad - Gujarat

Tel: 079-25620703, Mob: 09727100033


Website: www.drillmachineindia.com

Pillar drilling machine The model AP-40 all-geared pillar drilling machine has spindle gearbox with 8 mechanical speeds, which ranges from 90 to 885 rpm. The gear is made from steel. Totally enclosed 2 HP motor is directly coupled with gearbox. The levers for changing the speed are avoided by means of providing special gear system. Change in speed is possible while the operation is still on. Feed gearbox has two feeds 0.05 and 0.1, for the vertical movement of the ram. The drill spindle is made from the best quality steel.

Poly Kraft Machines

Ahmedabad - Gujarat

Tel: 079-22743639

Mob: 09898003625

Products - National


CNC milling machineThe model OM-1 CNC milling machine is an ultra-compact milling machine designed for office environment. This machine brings high-performance and reliability to industries that are unable to fit a normal CNC machines into their facility. Designed for high-production or rapid prototyping of small, precision 2D or 3D parts, the milling machine fits through a standard 36” door and into most freight elevators. Features include full enclosure, 50,000 RPM electric spindle, high-speed machining software, coolant system, 4th axis drive, 25 mm precision ball screws, ¼” collet maximum capacity, 757 IPM rapids, and quick disconnect cord.

Haas Automation, Inc

California - USA

Tel: +1-805-2781800


Website: www.haascnc.com


Website: www.polykraftmachines.com

Products - International


Vertical machining centreThe model VMC-850 CNC vertical machining centre is installed with high accuracy C3 level ball screws with special structure pre-pulled, rapid and accurate. Salient features include: main structure with high-level casting, stable & high quality, box guideway design provides high rigidity & stable structure, Y-axis supported by 4 rails provides the best carrying capacity of workpiece, dual speed gearbox provides ability of heavy cutting, spindle head with boon-structure provides stable support for the spindle, umbrella type ATC system, full enclosed guard cover keeps safe & clear working surrounding for operator, auto-lube system provides lubrication of railways and the ball screws, oil skimmer device keeps using time of coolant, etc.

You Ji Machine Industrial Company Ltd

Kaohsiung Hsien - Taiwan

Tel: +886-7-6983068


Website: www.youji.com

Vertical machining centreThe model WV108A vertical machining centre is structurally designed for heavy and rough machining requirements with ultra wide machine base and column. The ultra wide machine base structure provides most stable construction rigidity which assures the overall machine performance and accuracy. Modular headstock design offers both IDD spindle design ideal for high-speed machining and 2-speed gear head for heavy machining requirements. The unique IDD spindle design offers low spindle vibration and optimal heat isolation that results in excellent surface finish while maximising both spindle and tool life under hard milling conditions.

Yeong Chin Machinery Industries Co, Ltd

Taichung - Taiwan

Tel: +886-4-2562 3211


Website: www.supermax.com.tw

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. Rough boring heads do feature



simultaneous adjustment of the slide blocks. Couplings are available in several executions to suit the most popular machine spindles.

Pinzbohr Boring System

Barcelona - Spain

Tel: +34-93-5720873


Website: www.pinzbohr.com

Hydraulic cylindrical grinder The model PUI-450 hydraulic cylindrical grinder is a light heavy-duty machine meant for high-precision grinding of gauges, dies and punches for toolroom applications, with an accuracy on dia 0.002 micron. The one-piece machine body is made from close grain casting with maximum grinding length of 450 mm, and center height at 125 mm. Table is flat on one side and V-grooved on other side, with Turcite-B linear material coating and precision hand-scraped to match corresponding surface of the guideways.

Pitroda Utility Industries

Wadhwan - Gujarat

Tel: 02752-243795, Mob: 09825416108


Website: www.pitrodautilityindia.com



CNC vertical grinderPalmary CNC vertical internal, end face and external composite grinder offers more choice when need to grind internal, end face and external diameter at one time setting. Honeycomb type Meehanite cast iron machine bed structure is used to assure the best possible rigidity and stability with high quality. The 2nd axis angle auto off-centering function is used to grind the sleeve type or gear type internal taper hole. For the controller Mitsubishi M70, it is developed together with the supplier with the user-friendly control panel frame system in order to reduce the input mistake.

Palmary Machinery Co Ltd

Taichung County - Taiwan

Tel: +886-4-24929799


Website: www.palmary.com.tw

Copper alloy wires and rodsThese copper alloy wires include commercial bronze wire, low-silicon wire, and high-silicon wire. The commercial bronze wires are used industries such as architectural (etching bronze grill work, screen cloth, weather stripping), hardware (escutcheons, kick plates, line clamps, marine hardware, rivets, screws, screw shells, munitions: (primer caps, rotating bands), miscellaneous: compacts, lipstick cases, costume jewellery, ornamental trim, screen wire, base for vitreous enamel wave guides, etc. Low-silicon and high-silicon wires are used in aircrafts, hardware, industrial applications, marine industry, etc. Yuang Hsian Metal Industrial Corp

Changhua City - Taiwan

Tel: +886-4-7612689


Inverter chillerThe high-precision inverter chiller is used in CNC vertical and horizontal machine centre, CNC wire cutting machine, CNC high-precision grinding machine, CNC machining centre (5 surface), optoelectronics, semi-conductor and solar energy industries. This high-precision inverter chiller is individually designed for LCD control panel and temperature precision could maintain ±0.1°C. Using inverter compressor keeps electric current smoothly and saves energy 33 per cent. The energy saving and high precision are from the operation of low load. It reduces the temperature rise and



maintains the precision during process. Filling the high-efficiency environmental refrigerant is without pollution.

Wexten Precise Industries Co, Ltd

Taichung City - Taiwan

Tel: +886-4-24180799


Website: www.wexten.com.tw

Robotic assembly systemThe Syfast robotic assembly system is used for medium volume production. It is specially suited for medium volume production, complex products with four or more components or assembly process, large numbers of variants, quick changeover times, progressive investment in assembly equipment, etc. Features include: standard platform with movable guarding; mineral casting for the machine frame; industrial PC cell control; clean-room 10,000 compatible; scara robot; and basic software management package.

Mikron Tool SA Agno

Bioggio - Switzerland

Tel: +41-91-6106500


Website: www.mikron.com



Precision machine viceThe precision machine vice body is made of ductile iron FCD60. Down thrust with semi-sphere prevents workpiece lift. The vice has side-lock to work (perpendicular of side lock 90-degrees = 0.015/100 mm). Vice bed is hardened to HRC45-degrees and maintain accuracy for long. The vice slide-chunk can be taken out, as it is convenient to clean away chips inside of vice. Vice bed height-size and guide block side are all made with full control along with 2.3 or 4 vices to perform a job at a time is available.

Jin Year Precision Co, Ltd

Taichung City - Taiwan

Tel: +886-4-25232817


Website: www.jinyear.com.tw

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

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List of Products


To know more about the products featured in this magazine, fax us on 022-3003 4499 or tear and post to us the ‘Product Inquiry Card’ by following the 5 easy steps given there. Alternatively, you may also write to us at [email protected] or call us on 022-3003 4684, and we will send your inquiries to the advertisers/companies directly

to help you source better.

Sl. No Product Pg No Sl. No Product Pg No Sl. No Product Pg No

1 3-axes high-speed machining centre ............. 992 3D printing system ......................................................... 70

3 4-column hydraulic press .............................. 145

4 5-axes high speed machining centre ............. 995 5-axes machining centre .................................... 61, 143

6 5-face double column milling machine ............. COC

7 Abrasive belt grinder ..................................... 1578 Accessories ..............................................................Booklet

9 Adapter ..................................................................... 81, 138

10 All-geared planning machine ...................................148

11 Angle encoder .................................................................BIC

12 Angle grinders ................................................................139

13 Appliance switch ............................................................. 27

14 Application and precision component

machining ................................................................Booklet

15 Auto-feeder hydraulic press .....................................145

16 Automatic grinding machine ...................................155

17 Automation ....................................................60, 151, 153

18 Bags bailing press .......................................... 14519 Balancing machine .......................................................109

20 Balancing system .........................................................BGF

21 Baling press .....................................................................145

22 Ball bearing ....................................................................... 55

23 Bar feeder ........................................................................... 82

24 Bearing ..............................................................................142

25 Belt grinder ......................................................................124

26 Bench grinder .................................................................157

27 Bench grinder-cum-polisher .....................................157

28 Bench grinding machine ............................................124

29 Bench polisher ...............................................................157

30 Boring machine .............................................................148

31 Boring tool system .......................................................149

32 Broaching machine .................................................18, 20

33 BTA/ejector counter boring machine ..................... 24

34 BTA/ejector drilling machne ....................................... 24

35 Cabinet .............................................................. 7236 Cable and hose carrier ................................................129

37 Cable carrier ....................................................................142

38 Cable conduit ................................................................... 27

39 Cable connector ............................................................142

40 CAD/CAM software......................................................... 10

41 CAM follower ..................................................................146

42 Carbide end mill tool .....................................................BC

43 Carbide end mill .............................................................. 58

44 Carbide rod ........................................................................ 97

45 Carbide tool...........................................91, 138, 161-162

46 Carbide ..............................................................................138

47 Casting ................................................................................ 87

48 CBD .....................................................................................133

49 Centre drill .............................................................122, 138

50 Centreless grinding machine .........................149, 157

51 Ceramics ...........................................................................169

52 Cermets .............................................................................169

53 Chain ..................................................................................142

54 Chuck jaw ........................................................................... 60

55 Chuck ......................................................................... 82, 138

56 CI casting ..........................................................................148

57 Clamp.................................................................................139

58 Clamping tool ...................................................................BC

59 Close-frame hydraulic press......................................145

60 CMMs .................................................................................147

61 CNC double-column machining centre ................. 14

62 CNC equipment ............................................................... 29

63 CNC grinding machine ...............................................155

64 CNC horizontal borer ..................................................... 61

65 CNC horizontal boring and milling machine 14, 143

66 CNC horizontal machining centre ............................ 14

67 CNC horizontal turning centre................................... 14

68 CNC lathe .................................................39, 61, 100, 140

69 CNC machine tool .................................................booklet

70 CNC machine ....................... 8-9, 71, 99, 107, 141, 144

71 CNC machining centre ...........................................58, 99

72 CNC multi-tasking centre ............................................. 14

73 CNC precision lathe ........................................................ 41

74 CNC small machining centre ...................................... 58

75 CNC system ....................................................................... 89

76 CNC tooling .....................................................................138

77 CNC turning centre .............................................. 99, 107

78 CNC turning machine .................................................... 71

79 CNC turn-mill centre ...................................................... 14

80 CNC vertical machining centre ................. 14, 99, 107

81 CNC vertical turning lathe ........................................... 14

82 CNCs ............................................................... 7, 88, 99, 107

83 CNC-type 3D co-ordinate measuring

machine ................................................................151, 153

84 CNC-type video measuring machine ..........151, 153

85 Coin press ........................................................................145

86 Collet chuck ............................................................. 41, 138

87 Collets ................................................................................138

88 Connector .............................................67, 142, 151, 153

89 Control cabinet ................................................................ 67

90 Control panel accessories ............................................ 27

91 Control panel .................................................................... 67

92 Control system ................................................................. 67

93 Controlling machine tool ............................................BIC

94 Conventional precision lathe ...................................100

95 Coolant pump ................................................................157

96 Coolants .............................................................................. 69

97 Coro mill .......................................................................... FGF

98 Coro thread .................................................................... FGF

99 Corrosion preventives ................................................... 47

100 Counter sink ....................................................... FIC, 12-13

101 Crush blade ....................................................................... 45

102 Cutting oil .......................................................................... 69

103 Cutting tap ......................................................................112

104 Cutting tool ........................ 21, 31, 45, 58, 91, 97, 123,

................................................................... 161-162, Booklet

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

106 Cycle time reduction and programming software

for CNC for milling .......................................................... 57

107 Cycle time reduction and programming software

for CNC for turning ......................................................... 57

108 Cylindrical and internal grinding machine .........111

109 Cylindrical grinder machine .............................. 11, 149

110 Deep-drawing hydraulic press ...................... 145111 Deep-hole drilling machine ........................................ 24

112 Deep-hole drilling sub-contracts .............................. 24

113 Desktop printer ................................................................ 70

114 Diamond lapping and polishing systems ...........BGF

115 Diamond tool .................................................... FIC, 12-13

116 Didactic equipment for training ............................... 67

117 Die and mould machine .............................................138

118 Die coater ........................................................................... 45

119 Die/mould machine ................................................... COC

120 DNC system for networking CNC machine ........... 57

121 Drill chuck arbour .........................................................138

122 Drill mill .............................................................................138

123 Drill tool ..............................................................................BC

124 Drill ................................................................................58, 81

125 Drilling and milling machine ....................................125

126 Drilling machine ............................................................125

127 Drilling tool.............. FIC, 12-13, 31, 91, 123, 161-162

128 Drilling-cum-milling machine ..................................146

129 Drive technology ............................................................BIC

130 Dust collectors ...............................................................124

131 Electrical connectivity ............................151, 153132 Element shrink disc ......................................................146

133 End mill ...................................................................122, 138

134 Engineer’s files ...............................................................122

135 Exhibition - Acmee ......................................................... 56

136 Exhibition - Modern Machine Shop-2012 ............. 16

137 Expandable monoblock reamer ................................ 81

138 Exposed linear encoder ...............................................BIC

139 Extruding system ............................................................ 87

140 Filtration unit .................................................... 20141 Fix frame hydraulic press ...........................................145

142 Fixtures ..............................................................................139

143 Flexible shaft grinder ...................................................157

144 Floor plate ........................................................................148

145 Form measurement ........................................................ 25

146 Forming tap ....................................................................112

147 Freewheel-oneway-clutches .....................................146

148 Gantry and NC boring and milling machines 39149 Gear cutting machine................................................ COC

150 Gear hobbing machine ................................................. 79

151 Gear milling solution for CNC milling/turn-mill

machine .............................................................................. 93

152 Gomet bearing ................................................................. 55

153 Grinding machine ..............................46, 124, 149, 155

154 Grip plier ...........................................................................139

155 Grooving and parting tool .......................................... 97

156 Gun drill ............................................................... FIC, 12-13

157 Gun drilling and reaming machine .......................... 24

158 Handling system module................................. 67159 Handy probe ...................................................................133

160 Handy scan ......................................................................133

161 Hard cut end mill ............................................................ 58

162 Heat exchanger machine ...........................................125

163 Heavy-duty bearing ....................................................... 55

164 Heavy-duty CNC machine..........................................140

165 High-precision tool holder .......................................... 23

166 High-pressure hydraulic clamping system .........BGF

167 High-speed drill tap centre ......................................... 61

168 High-speed spindle unit .............................................152


List of Products


169 HMCs ..................................................................................125

170 Hold back .........................................................................146

171 Hole-making tool ............................................................ 45

172 Horizontal boring mill ............................................... COC

173 Horizontal CNC machine ............................................107

174 Horizontal handle clamp ............................................139

175 Horizontal hydraulic press .........................................145

176 Horizontal machining centre ................ 7, 61, 99, 107

177 Horizontal milling machine ..................................... COC

178 Hydraulic centerless grinding machine................149

179 Hydraulic cylinder ....................................................18, 20

180 Hydraulic cylindrical grinder .....................................155

181 Hydraulic cylindrical grinding machine ...............149

182 Hydraulic equipment ..................................................... 18

183 Hydraulic internal grinding machine ....................149

184 Hydraulic machine .......................................................... 82

185 Hydraulic power pack ............................................18, 20

186 Hydraulic press................................................ 18, 20, 145

187 Hydraulic surface grinding machine .....................155

188 HyperCAD .......................................................................... 10

189 IMTMA - AMTTF ................................................ 22190 IMTMA - Finishing School Summit ........................... 96

191 IMTMA - Productivity Summit .................................... 44

192 Incremental rolling dies ................................................ 73

193 Indexable tool .................................................................. 58

194 Induction seal/wad .............................................151, 153

195 Inductive proximity switch .......................................... 27

196 Industrial data logger and bespoke solution .....140

197 Industrial grinding and cutting machine .............. 87

198 Industrial packing machine .......................................151

199 INO and battenfeld hydraulic composite press 115

200 Integrated machine safety solution .......................113

201 Intelligent Ethernet system .......................................140

202 Interface electronics ......................................................BIC

203 Interference-free PC board ........................................140

204 Internal grinding machine .........................................149

205 Iron and steel parts ........................................................ 45

206 ISO and milling insert .................................................... 58

207 ISO turning insert ............................................................ 58

208 Jewellery polisher .......................................... 157209 Jigs ......................................................................................139

210 Keyless transmission element ....................... 146

211 Large part drilling and milling machine ...... 125212 Large size machining centre .................................. COC

213 Lathe chuck ....................................................................... 60

214 Lathe machine................................................................148

215 Lathe .......................................................................................7

216 LED ........................................................................................ 27

217 Length gauge ..................................................................BIC

218 Lens mould ........................................................................ 45

219 Linear drive laser cutting machine .......................... 48

220 Linear encoders and scale ...............................151, 153

221 Linear motor thread and gear grinder ................... 77

222 Load break switch ........................................................... 27

223 Lube ..................................................................................... 69

224 Lubricant ............................................................................ 47

225 Machine measurement ...................................BIC226 Machine tool protection system ............................BGF

227 Machine vice ..................................................................BGF

228 Machining centre ............................................................ 79

229 Magnescale technology .............................................121

230 Magnetic modular encoder .......................................BIC

231 Masonry drill ...................................................................122

232 Material testing machine ............................................. 25

233 Maxshot ............................................................................133

234 Measured value acquisition and display...............BIC

235 Measurement equipment ............................................ 25

236 Measuring instrument .................................................109

237 Metal cutting tool ........................................................... 59

238 Metal scrape baling press ..........................................145

239 Metal working fluid ........................................................ 47

240 Metrascan .........................................................................133

241 Metrology equipment ................................................... 25

242 Metrology instrument and solution ......................147

243 Micro grain carbides ....................................................147

244 Micron drill ........................................................................ 45

245 Milling centre .......................................................................7

246 Milling cutter ..............................................FIC, 12-13, 97

247 Milling grade .................................................................. FGF

248 Milling machine ...................................31, 123, 125, BIC

249 Milling tool .......................................45, 91, 161-162, BC

250 Mobile cylinder hydraulic press ..............................145

251 Modular tooling system ................................ FIC, 12-13

252 Mould component .......................................................... 45

253 Monitoring of grinding systems.............................BGF

254 Motor protection circuit breaker .............................. 27

255 Motors and control..................................................18, 20

256 Moulding machine ......................................................... 87

257 Multi-functional tool ...................................................... 97

258 Multi-functional turret................................................... 82

259 Multi-media software for learning CNC milling

and turning technology ............................................... 57

260 Needle roller bearing ....................................... 55

261 Optical measurement ...................................... 25262 Other automation accessories ................................... 89

263 Packaging solutions ...............................151, 153264 Packaging test equipment ..............................151, 153

265 Paint spray system ........................................................115

266 PCB drill ............................................................................... 45

267 PCD and carbide reamers ............................................ 81

268 PCD and CBN tool .........................................................169

269 Pedestal grinder ............................................................157

270 Pedistar buffer ................................................................157

271 Persico forming ..............................................................115

272 Pillar drilling machine .................................................154

273 Pillar-type hydraulic press .........................................145

274 Pilot light ............................................................................ 27

275 Planning machine ..................................... 140, 148, 157

276 Plano-miller ...........................................................148, 157

277 Plano-milling machines ..............................................140

278 PLC-operated hydraulic press ..................................145

279 Plug and socket ............................................................... 27

280 Pneumatic .......................................................................... 82

281 Polishing machine ........................................................124

282 Position display unit .....................................................BIC

283 Post processor .................................................................. 10

284 Power source .................................................................... 65

285 Precision bearing ..........................................................163

286 Precision fabrication work .........................................139

287 Precision gear cutting tool ...................................... COC

288 Precision grinder ............................................................. 11

289 Precision switch ............................................................... 27

290 Precision universal cylindrical machine ...............149

291 Process automation and control equipment ....... 67

292 Productivity tracking system for CNC machine .. 57

293 Profile projector ...................................................151, 153

294 Pull stud ............................................................................138

295 Pull-action clamp ..........................................................139

296 Pump.............................................................................18, 20

297 Punching and laminating presses ..........................115

298 Push button....................................................................... 27

299 Rack rolling dies ............................................... 73300 Rack ...................................................................................... 72

301 Rack-type spline rolling machine ............................. 73

302 Radial drilling machine ..................148, 149, 151, 153

303 Real-time Ethernet system for Ethercat

and Profinet ....................................................................140

304 Real-time open source PAC system .......................140

305 Reamer ..............................................FIC, 12-13, 122, 138

306 Reversible tapping attachments .............................150

307 Robot .................................................................................115

308 Rotary encoder ................................................................BIC

309 Rotary indexing table .................................................BGF

310 Rotary machine ...................................................................7

311 Rotary switch .................................................................... 27

312 Rotating electrical connector .........................151, 153

313 Safety protection device ................................. 27314 Scanning white-light interferometry

microscope ............................................................151, 153

315 Schleicher automatic sandwich line ......................115

316 Schleicher robotic waterjet cutter ..........................115

317 Sealed linear encoder ...................................................BIC

318 Servo motor and drive .................................................. 89

319 Shaping machine ..........................................................148

320 Shot blasting machine ................................................154

321 Shrinking technology ..................................................109

322 Side lock adaptor ..........................................................138

323 Single and double column vertical

machining centre ............................................................ 61

324 Single and multiple precision switch ...................... 27

325 Single limit switches ...................................................... 27

326 Sinking EDM ....................................................................169

327 Slant/flat bed .................................................................... 61

328 Sleeve bearing .................................................................. 55

329 Small size ball bearings ................................................ 55

330 Solder paste ..........................................................151, 153

331 Solid carbide drill .....................................................59, 81

332 Solid carbide mill ............................................................ 59

333 Solid carbide reamer...................................................... 59

334 Solid carbide special drill and mill ........................... 59

335 Solid carbide special reamer ...................................... 59

336 Solid monoblock reamer .............................................. 81

337 Special boring bar........................................................... 81

338 Special fine boring tool ................................................ 81

339 Special hydraulic expansion technology ............... 60

340 Special induction hardening machine .................... 65

341 Special line boring tool................................................. 81

342 Special purpose machine................................... 79, 140

343 Special reaming tool ...................................................... 81

344 Special thread milling tool .......................................... 81

345 Special tool ......................................................................138

346 Spindle nose tooling...................................................... 97

347 Spline rolling machine .................................................. 73

348 SPMs ..................................................................................... 24

349 Standard and special PCD tools ................................ 81


List of Products


COC - Cover on Cover FGF - Front Gate Fold FIC - Front Inside Cover BIC - Back

Inside Cover BGF - Back Gate Fold BC - Back Cover

Looking for a specifi c product?We will fi nd the product for you. Just type MMT (space) Name of the Product and send it to 51818

eg, MMT (space) Lathe and send it to 51818.

350 Standard fine boring tools .......................................... 81

351 Standard induction hardening machine................ 65

352 Standard thread milling tool ...................................... 81

353 Stationary work holding ............................................... 60

354 Stepper motor and drive ............................................. 89

355 Straightening machine ...............................................157

356 Straight-line action clamp .........................................139

357 Submersible hydraulic press .....................................145

358 Super precision bearing ............................................... 55

359 Super-abrasive diamond and CBN grinding

wheels ...............................................................................149

360 Surface and profile grinding machine ..................111

361 Surface grinder....................................................... 61, 155

362 Surface grinding machine ...............................148, 155

363 Surface plate ...................................................................148

364 Tap ................................... FIC, 12-13, 81, 98, 122365 Tapping chuck ................................................................152

366 Tensioner nut .................................................................146

367 Tensioner nuts and bolts ...........................................150

368 Thread mill ......................................................................... 93

369 Thread rolling machine ................................................ 73

370 Thread whirling tool ................................................... FGF

371 Threading tool ...........................................................81, BC

372 Thrush ball bearing ........................................................ 55

373 Tilting rotary table ........................................................147

374 Toggle action clamp ....................................................139

375 Toggle press ....................................................................139

376 Tool bits ............................................................................122

377 Tool grinding machine ...............................................111

378 Tool holder ......................................................................109

379 Tool holding system ...................................................... 60

380 Tool logistics system ....................................................109

381 Tool monitoring system ............................................BGF

382 Tool path simulator for CNC milling and turning ..... 57

383 Tool trolleys .....................................................................148

384 Tool .....................................................................................138

385 Tooling system ..........................................................81, BC

386 Tool-maker microscope ....................................151, 153

387 Touch probe.....................................................................BIC

388 Track roller .......................................................................146

389 Tubing accessory............................................................. 67

390 Turn mill centre .............................................................143

391 Turning holder ................................................................. 97

392 Turning machine ...........................................31, 123, BIC

393 Turning tool ...............................................................45, BC

394 Turnkey solution.............................................................. 81

395 Twist drill ................................................................122, 138

396 Two-solvent spray line ................................................115

397 Ultra-high pressure apparatus ........................ 45398 Universal drilling system ............................................152

399 Vacuum chuck................................................... 82400 Validation of packs .............................................151, 153

401 Valve terminal .................................................................. 67

402 Valve ..................................................................................... 67

403 Vertical and horizontal machining centre ............. 39

404 Vertical boring machine .............................................148

405 Vertical handle clamp ..................................................139

406 Vertical honing machine ............................................139

407 Vertical lathe machine ................................................143

408 Vertical machining centre....................................... 7, 61

409 Vertical turn mill centre ................................................ 79

410 Vertical turning lathe ...................................................140

411 Vertical turning machine ................................... 79, 148

412 Vertical turret lathe ........................................................ 26

413 Wear parts ......................................................... 97414 Wear resistant tool ......................................................... 45

415 Wire cut EDM ..................................................................169

416 Work-holding solutions .............................................BGF

INTERNATIONAL PRODUCTS

417 Battery-type lifting magnetic chuck ............ 150

418 Bites ....................................................................................138

419 Boring heads ...................................................................156

420 CAM-type permanent lifting magnetic chuck .. 150

421 Centerless machine ......................................................159

422 Chuck controller ............................................................150

423 CIMES-2012........................................................................ 68

424 Circular cold saw ...........................................................148

425 CNC cylindrical roll grinder .......................................156

426 CNC machine .................................................................... 53

427 CNC milling machine .........................................155, 157

428 CNC plunge/angular cylindrical grinder ..............156

429 CNC rotary table ............................................................152

430 CNC vertical grinder .....................................................158

431 Copper alloy wires and rods .....................................158

432 Cutting machine ............................................................160

433 Cutting tool .....................................................................154

434 Cylindrical grinder ........................................................159

435 Deep-hole drilling machine ............................. 37

436 Demagnetiser .................................................................150

437 Diamond circular saw ..................................................138

438 Diamond core bit ..........................................................138

439 Diamond dresser ...........................................................138

440 Diamond grinding wheels for LCD glasses .........138

441 Diamond scribers for sapphires ..............................138

442 Diamond tools for semiconductors .......................138

443 Diamond tools for silica tile industry ....................138

444 Diamond/CBN electroplated tools .........................138

445 Electro magnetic chuck.................................. 150

446 End mill cutter ................................................................158

447 End mill .............................................................................154

448 Fine-pole permanent magnetic chuck ......... 150

449 For precision grinding wheel ...................................138

450 Forming milling cutter ................................................158

451 Fully-automatic circular sawing machine ............148

452 Fully-automatic tungsten carbide sawing machine.....148

453 Grinding machine ........................................... 159

454 Hard alloy turning cutter ............................... 158

455 Heat treatment steel cutting machine .................148

456 High-speed double column milling machining center...119

457 Horizontal band .............................................................163

458 Hydraulic angle lock vise ...........................................150

459 Hydraulic automatic-type aluminum copper .....148

460 Hydraulic automatic-type metal sawing machine ... 148

461 Hydraulic machinery ....................................................146

462 Hydraulic press brake ..................................................146

463 Hydraulic press...............................................................146

464 Hydraulic punch presses ............................................146

465 IMTS-2012 - International Manufacturing

Technology Show ........................................... 117

466 Industrial cleaning automation ...............................160

467 Internal grinding machine .........................................159

468 Inverter chiller ................................................................158

469 Iron fillings separator...................................................150

470 Knocking cylinder........................................... 160

471 Machine tools ................................................. 160

472 Magnetic block unit .....................................................150

473 Magnetic induction block ..........................................150

474 Magnetic roller ...............................................................150

475 Magnetic separator ......................................................150

476 Magnetic steel sheet separator ...............................150

477 Manufacturing equipment ........................................146

478 Metal circular pipe/bar stock end

chamfering machine ....................................................148

479 Metal forming machine ..............................................146

480 Milling cutter ..................................................................158

481 Mororised rotary magnetic chuck ..........................150

482 Natural/polycrystalline/single crystal diamond dies ... 138

483 NC cylindrical grinder ..................................................156

484 On/off permanent lifting magnetic chuck ... 150

485 PCD multi-edged blades for PCB industry ... 138

486 Permanent magnetic chuck ......................................150

487 Precision cutting wheels ............................................138

488 Precision machine vice ...............................................160

489 Press brake.......................................................................146

490 Professional high-speed machine ..........................119

491 Robotic assembly system .............................. 159

492 Rolling machine .............................................................159

493 Rotary permanent magnetic chuck .......................150

494 Saw blade sharpener ..................................... 148

495 Saw .....................................................................................163

496 Sawing machine ............................................................163

497 Shaft ...................................................................................159

498 Shear ..................................................................................146

499 Shearing machines .......................................................146

500 Spindle ..............................................................................139

501 Standard (powerful) magnetic base ......................150

502 Standard (powerful) permanent magnetic chuck .... 150

503 Thread ............................................................. 159

504 Traditional cylindrical grinder ..................................156

505 Tunnel-type magnetizer .............................................150

506 Universal cylindrical grinder .....................................156

507 Universal machine ........................................................159

508 Vacuum system ..............................................................150

509 Various types of wear-resistant parts ....................138

510 Vertical machining centre................................119, 156

511 Waterjet machine ..........................................................160

Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No

List of Advertisers


Aiema Technology Centre 56

T: +91-44-26258731

E: [email protected]

W: www.acmee.in

Asso For Manufacturing Technology 117

T: +703-827-5270

W: www.imts.com

Autotech Machine Tools Sales & Services 8-9

T: +91-20-25690044


W: www.autotechcnc.com

Bei Jyu Precision Machine Co Ltd 160

T: +886-4-2350-1280


W: www.beijyu.com.tw

Big Daishowa Seiki Co. Ltd 23

T: +81-729-828277

W: www.big-daishowa.com

Blaser Swisslube India Pvt Ltd 69

T: +91-124-4994000


W: www.blaser.com

CADEM Technologies Pvt Ltd 57

T: +91-80-26634767


W: www.cadem.com

Castrol 47

T: +91-44-42198885


W: www.castrol.com/industrial

Ceratizit India Pvt Ltd 97

T: +91-33-24947146


W: www.ceratizit.com

Chamunda Equipments 139

T: +91-79-27522437


W: www.chamundaequip.com

Cosmos Impex (India) Pvt Ltd Booklet

T: +91-265-3927000


W: www.cosmos.in

Crane-Bel International Pvt Ltd 18

T: +91-120-3263281


W: www.crane-bel.com

Crane-Bel International Pvt Ltd 20

T: +91-120-3263281


W: www.crane-bel.com

Creaform India 133

T: +91-11-65022218


W: www.creaform3d.com

Dees Hydraulic Industrial Co Ltd 146

T: +886-2-2601-8661


W: www.spc.com.tw

Dijet Industrial Co Ltd 58

T: +91-22-40121231


W: www.dijet.co.jp

Doosan Infracore India Pvt Ltd 14

T: +91-80-42660122


W: www.doosaninfracore.com

Dowel Machinery Pvt Ltd 145

T: +91-281-2362465


W: www.thedowel.com

Drake Manufacturing 77

T: +330-847-7291

W: www.drakemfg.com

Durga Bearing Pvt Ltd 55

T: +91-22-6876073


W: www.durgabearings.com

EFD Induction Ltd 65

T: +91-80-7820404

E: [email protected].

W: www.efd-induction.com

Emuge India Pvt Ltd 98

T: +91-20-39310000


W: www.emugeindia.com

Ermaksan Sheet Metal Working Machinery 48

T: +90-224-2947500


W: www.ermaksan.com.tr

Erwin Junker 46

T: +91-20-26053896


W: www.junker.in

Essor International Inc 153

W: www.essor.com.tw

Everising Machine Co. 163

T: +886-4-2359-3178


W: www.everising.com

Femco India 143

T: +91-20-40147870


W: www.femco.com.tw

Festo Controls Ltd 67

T: +91-80-22894100


W: www.festo.com

Flow Asia Corporation 160

T: +91-9343-340-001


W: www.flowasia.com

Fong Ho Machinery Industry Co., Ltd 148

T: +886-4-2406-6769


W: www.fongho.com.tw

Fullton Machinery Co., Ltd 26

T: +86-411-82767678


W: www.fulltontech.com

G W Precision Tools India Pvt Ltd 59

T: +91-80-40431252


W: www.gwindia.in

Ganro Industrial Corp 152

T: +886-4-2537-6266


W: www.ganro.com.tw

Gentiger Machinery Industrial Co Ltd 119

T: +886-4-2683-6919


W: www.gentiger.com.tw

Goindustry (Uk) Ltd 115

T: +44-20-70983700


W: www.go-dove.com

GSK CNC Equipment Co. Ltd 29

T: +91-9886835186


W: www.gsk.com.cn

Guang Dar Mangnet Industrial Ltd 150

T: +886-4-2436-0757


W: www.guangdar.com

Guhring India Pvt Ltd FIC

T: +91-80-40322500


W: www.guhring.in

Haas Automation India Pvt Ltd 7

T: +91-20-32935433


W: www.HaasCNC.com

Haimer India Pvt Ltd 109

T: +91-9890153568


W: www.haimer.com

Heidenhain Optics & Electronics (I) BIC

T: +91-44-30234000


W: www.heidenhain.in


List of Advertisers


HG Technology Co Ltd 154

T: +886-4-7362-725


W: www.hgt.com.tw

Hong Ji Precision Machinery Ltd. 37

T: +886-4-2422-1095


W: www.hong-ji.com.tw

Hwacheon Asia Pacific Pte Ltd 144

T: +91-20-30429140


W: www.hwacheaon.com

Hyundai Wia 141

T: +91-9940653703


W: www.hyundai-wia.com

Igus India Pvt Ltd 142

T: +91-80-39127800


W: www.igus.in

Indiam Machine Tools Manf - AMTTF 22

T: +91-80-22731625


W: www.amttf.in

Indiam Machine Tools Manf - Finishing School 96

T: +91-80-66246600


W: www.imtma.in

Indiam Machine Tools Manf - MMS 16

T: +91-80-66246600


W: www.mmsinfo.in

Indiam Machine Tools Manf -

Productivity Summit 44

T: +91-80-66246600


W: www.imtma.in

Indian Tool Manufacturers 122

T: +91-22-25852559


W: www.indiantool.com

ISGEC Heavy Engineering Ltd 61

T: +91-120-3301 001


W: www.isgec.com

Jagdeep Foundry (Regd.) 148

T: +91-1871-242750


W: www.jagdeepfoundry.in

Jainnher Machine Co., Ltd 156

T: +886-4-2358-5299


W: www.jainnher.com.tw

Jin Year Precision Co Ltd 150

T: +886-4-2523-2817


W: www.jinyear.com.tw

Jyoti CNC Automation Pvt Ltd 99

T: +91-2827-287081


W: www.jyoti.co.in

Kabel Schlepp India Pvt Ltd 129

T: +91-80-41158997


W: www.kabelschlepp.com

Kim Union Industrial Co. Ltd 159

T: +886-4-2533-1131


W: www.threadrolling.com.tw

Komet Precision Tool India Pvt Ltd 81

T: +91-80-280780000


Korber Schleifring Gmbh 111

T: +91-80-41554601


W: www.schleifring.in

Korloy Inc. 123

T: +82-2-2522-3181


W: www.korloy.com

Larsen & Toubro Ltd 91, 161-162

T: +91-22-67051093


W: www.larsentoubro.com

Macpower CNC Machinery Pvt Ltd 107

T: +91-2827-287930


W: www.macpowercnc.com

Marox Tools Industrial Co Ltd 158

T: +886-4-2278-0167


W: www.marox.com.tw

Metrol Corporation India Branch Off 58

T: +91-80-42105031


W: www.toolsensor.com

Micromatic Grinding Technologies Ltd 11

T: +91-120-2712137


W: www.micromaticgrinding.com

Milltronics CNC Machines 53

T: +91-98-45902876


W: www.milltronics.net

Mitsubishi Heavy Industries India Pvt Ltd COC

T: +91-11-41021234


W: www.mhiindia.com

Mitutoyo South Asia Pvt Ltd 25

T: +91-11-26372090


W: www.mitutoyoindia.com

Montfort Shanghai Co Ltd 35-36

T: +860-21/52136600


MTE Industries Pvt Ltd 73

T: +91-40-23777571


W: www.mteindustries.com

Neri Engineering 89

T: +91-80-28374885


W: www.nerigroup.in

Neway CNC Equipment (Suzhou) Co., Ltd 39

T: +91-281-276-7100


W: www.newaycnc.com

Nikon India Pvt Ltd 147

T: +91-124-4688 500


W: www.nikon-instruments.jp/eng/

NMTG Mechtrans Techniques Pvt Ltd 146

T: +91-79-22821527


W: www.nmtgindia.com

NN Combined Engineering Agencies Pvt Ltd BGF

T: +91-40-27844279


W: www.nncea.com

Objet Ap Ltd 70

T: +852-2174 0111


W: www.objet.com

OM Manufactures 151

T: +91-281-2384444


W: www.ommanufacturers.com

Openmind Cadcam Technologies (I) Pvt Ltd 10

T: +91-80-30504647


W: www.openmind-tech.com

OSG India Pvt Ltd 87

T: +91-20-66304407

W: www.osg-india.com

P R Sales Corporation 112

T: +91-20-25437591


W: www.prsales.in

Palmary Machinery Co., Ltd 159

T: +886-4-2492-9799


W: www.grinding.com.tw


List of Advertisers


Para Mill Precision Machinery Co Ltd 155

T: +886-4-2680-0678


W: www.paramill.com

Pinnacle Engineering Enterprise 155

T: +91-2752-230552


W: www.pinnaclegrinder.com

Pitroda Utility Industries 149

T: +91-2752-243795


W: www.pitrodautilityindia.com

Pramet Tools India Pvt Ltd 31

T: +91-124-4703825


W: www.pramet.com

Precihole Machine Tools Pvt Ltd 24

T: +91-22-25836780


W: www.precihole.co.in

Precision Industrial Co. 163

T: +91-22-23436717


Prem Brothers 124

T: +91-11-28117456


W: www.powermaster-india.com

Premier Ltd 79

T: +91-22-61179009


W: www.premier.co.in

Progressive Engineers 151, 153

T: +91-22-32944289


W: www.hangsterfers.com

Quickmil 125

T: +705-745-2961


W: www.quickmill.com

Riat Brothers (India) 157

T: +91-161-2530805


W: www.riatbrothers.com

Robin Precision Products Pvt Ltd 138

T: +91-2827-287631


W: www.bloodtools.com

Rockwell Automation Pvt Ltd 113

T: +91-120-4671694


W: www.rockwellautomation.com

Royal Precision Tools Corporation 139

T: +886-4-2338-2068


W: www.royal-spindles.com.tw

S&T Engineers 88

T: +91-422-2590810


W: www.stengineers.com

Samkrish 121

T: +91-44-23612310


W: www.samkrish.com

Samkrish Machine Tools 71

T: +91-44-23612310


W: www.samkrishmachinetools.com

Sandvik Coromant India FGF

T: +91-20-27104725


W: www.sandvik.coromant.com/in

Sarabsukh Machine Tools 140

T: +91-1871-223893


W: www.sarabsukhmachines.com

Schunk Intec India Pvt Ltd 60

T: +91-80-41277361


W: www.schunk.com

Seco Tools India Pvt Ltd 21

T: +91-2137-667300


W: www.secotools.com/in

Shanghai Reed Exhibition Co Ltd. Beijing Office 68

T: +86-10-5933-9080


W: www.cimes.net.cn

Shuter Enterprises 72

T: +91-44-32407116


W: www.shuter.in

SLN Technologies Pvt Ltd 140

T: +91-80-26651659


W: www.slntechnologies.com

Taegutec India Ltd BC

T: +91-80-27839111


W: www.taegutec-india.com

Taiwan Diamond Industrial Co., Ltd 138

T: +886-3-363-6971


W: www.taiwandiamond.com

Takamatsu Machinery Co Ltd 41

T: +81-76-2741403


W: www.takamaz.co.jp

Teknic 27

T: +91-22-26592392


W: www.tecknic.co.in

Tungaloy India Pvt Ltd 45

T: +91-22-61248888


W: www.tungaloy.co.jp.in

Tussor Machine Tools India Pvt Ltd 100

T: +91-422-3200183


W: www.pinachoindia.com

Vargus Ltd 93

T: +91-9730028248


W: www.vargus.com

Vijay Machine Tools Pvt Ltd 157

T: +91-22-24950886


W: www.elmacovijay.com

Weizmann Engineering Ltd 82

T: +91-44-22280595


W: www.weizmann.in

Wexper India Ltd 169

T: +91-124-2210020


W: www.wexper.com

YG Cutting Tools Corporation Pvt Ltd 12-13

T: +91-80-43543636


W: www.yg1.co.kr Ou

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MODERN MACHINE TOOLSA

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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 1ST & 2ND Of Every Month / English & Monthly. Date Of Publication: 28th of Every Month

MODERN MACHINE TOOLS - Supplement April 20122 MODERN MACHINE TOOLS - Supplement April 20122

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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 1ST & 2ND Of Every Month / English & Monthly. Date Of Publication: 28th of Every Month

modern machine tools - april 2012

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import dependence

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