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Editorial

July 2012 - MODERN MACHINE TOOLS 13

T

Solid State of Fluids

o a quirky question on doubting the relevance of ‘almost dedicating’ an edition on seemingly smooth operating metalworking fluids, our answer is precisely that!! ‘Smooth Operations’ is what it ensures and hence, the attention. Another reason is the all important factor, ‘cost’—which has become the anthem of survival.

Traditionally, metalworking fluids have been widely used in machining operations to increase cooling and lubricity, and, as a result, enhance the tool life, reduce process variability, etc. In short, assist and ensure smooth operations. However, over the last decade, it has become apparent that fluid-related decisions have all too frequently been based upon industrial folklore rather than knowledge-based quantitative evidence. But lately, there has been a change in this thought process…a change which could be attributed to the fact that costs associated with fluid use often constitutes between 7% and 17% of total production costs, as compared to 4% for tooling costs.

Fluid-related expenses include the cost of installing a fluid supply system, fluid purchase and system maintenance, and discarded fluid (waste) treatment. Fluid-related costs are large because high production manufacturing plants frequently utilise several cutting fluid reservoirs—each containing thousands of gallons of cutting fluid. Often, an entire reservoir is flushed to clean the system when quality issues arise. Certainly, reducing the amount of fluid employed can result in significant cost and waste savings.

Given the critical role it plays in smooth operations as well as cost optimisation, this monsoon, MMT is all drenched with key stats and facts about the demand that the metalworking fluids industry can expect, going forward. According to a report, the metalworking fluids market in North America, Asia and Europe is projected to grow at about 3% per annum, from 2.1 million metric tonne in 2010, to nearly 2.5 million tonne by 2015. Asia is the fastest growing market with 5% annual growth from 2010 to 2015. Over those five years, the projection says that the North American metalworking fluids market will grow at 2% and Europe’s by 1%, annually. The report focussed on North America (the US, Canada and Mexico), Asia and Europe, whose estimated metalworking fluid consumption totalled 2.1 million tonne, valued at $6.9 billion, in 2010. Since 2007, Asia’s metalworking fluid demand grew 3.3% annually, while Europe’s slipped 1.8% and North Americas’ fell 7.8%, per year.

With so much happening in this segment, the metalworking fluids industry has responded to the market demands by offering newer and wider variety of cutting fluids. Many new coolants have been developed to meet the needs of new materials, new cutting tools, and new coatings on cutting tools. All this, while keeping the goal of machining operations intact, which is to improve productivity and reduce costs. And this is accomplished by machining at the highest practical speed, while maintaining practical tool life, reducing scrap, and producing parts with the desired surface quality. In short, the key lies in proper selection and use of cutting fluids to achieve all of these goals.

Here’s to slick operations and flowing solutions!

EditorialAdvisory Board

Vikram SirurPresident, IMTMA & Executive Chairman,

Miven Machine Tools Ltd

L KrishnanVice President, IMTMA &

Managing Director, TaeguTec India P Ltd

Shailesh ShethMedia Chairman, IMTMA &

Past President, IMTMA

M Lokeswara RaoPast President, IMTMA & MD, Lokesh Machines Ltd

N K DhandPast President, IMTMA &

CMD, Micromatic Grinding Technologies Ltd

R SrinivasanPast President, IMTMA &

MD, RAS Transformation Technologies

Gautam DoshiAdvisor, IMTMA &

Consultant, Productivity & Quality Improvement Services

S N MishraPast President, IMTMA &

Vice Chairman, Bharat Fritz Werner LtdArchana [email protected]


NEXT EDITION HIGHLIGHTSSpecial Focus: Rapid Prototyping Insights & Outlook: Railway & Equipment Machining

Insights & Outlook Industry Snapshot ...............................................................

Construction Equipment Machining .................................

Machining Solutions ..........................................................

Compact Rebar Shop ..........................................................

Manufacturing Modules ....................................................

96

98

Contents

Special FocusIndustry Snapshot ...............................................................

MWF Projection ................................................................

Advances in MWFs ...........................................................

Occupational Hazards ........................................................

Mist Control .......................................................................

6C—Metalworking Fluid Management ............................

Cutting Fluid Costs ............................................................

One Q Many Views ...........................................................

Biodegradable Fluids ..........................................................

Maintenance & Filtration .................................................

MWF Additives .................................................................

Tips & Tricks .....................................................................

50

52

In Conversation With

Terrence Miranda

MD, HAAS Automation India Pvt Ltd .... 42

Editorial ...................................................................... 13

Sarathi Sutras .............................................................. 19

News, Views & Analysis .............................................. 20

Technology & Innovation ............................................ 40

Event List .................................................................. 120

Products .................................................................... 124

List of Products .........................................................170

List of Advertisers .....................................................178

Regular Sections

56

95

Cover illustration: Hemant Lambe

49

64

66

68

70

76

78

82

86

Geography WatchChennai ............................................................................. 32

SMEs@GlanceGrowth Enablers .................................................................. 38

Facility VisitHittco Tools Ltd ................................................................... 88

Energy ManagementUsing Energy Efficiently Can Boost Profitability ............... 108

Event ReportACMEE-2012 .................................................................... 116

Event PreviewAMTEX 2012 .................................................................... 118

Special Focus Metalworking Fluids

54

100

104

106

Looking For A Specific Product?Searching and sourcing products were never so easy.

Just type MMT (space) Product Name

and send it to 51818eg. MMT EDM and send it to 51818

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Insights & Outlook Construction Equipment

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What do Stuttgart in Germany, Shanghai in China,

Bilbao in Spain, Osaka in Japan and Taichung

in Taiwan, all have in common? Each one is

an industry paradigm, clusters that have been meticulously

fostered and developed by nations that have led the world in

the manufacture of machine tools. These clusters have evolved

as global hubs, concentrating in a cohesive geographical space,

the resources, institutions, knowledge, and capital required to

build the “mother machines that build all other machines”.

These concentrations symbolise a key, but often ignored,

‘sutra’ of this mother industry, the development of a machine

tool eco-system encompassing the

entire value chain.

Industrial clusters are a must for

manufacturing in any developing

nation, doubly so for a vertically

integrated and technology-driven

industry like machine tools. In

a global market, clusters offer

competitive advantages conducive

to growth, such as flexibility,

efficient logistics, information

exchange, and reduced transaction

costs. To illustrate these

advantages, Taiwan, the small

island nation that incredibly

ranks 6th in production and 4th in

exports, globally, has 72% of its

machine tool industry focussed in

Taichung! Over 490 enterprises

are clustered within a city that in a

few decades of planning and rapid

progress, has rightfully earned the tag, the world’s

first ‘Machine Tool Village’.

Such clusters are, essentially, little ecosystems

that bring together all the elements necessary for

the development of a sustainable machine tool

industry. In India, where 50% of the industry’s

output comes from clusters in the south, Bengaluru

is the best example of an evolved eco-system,

albeit leaps and bounds behind Taichung. Industrial clusters

develop in stages, from initiation to quantity expansion to

quality improvement to eruption. Each stage involves the

incorporation of key developmental elements as shown in

the figure. In order to achieve, by 2020, a 67% market share

for domestic manufacturers, a rise in exports to 20% and a

ranking within the top 10 machine tool producers globally,

every element of a machine tool ecosystem must be developed

in Bengaluru, Pune, Rajkot and Ludhiana. The integration

of large players in the industry with the hordes of smaller

manufacturers and ancillaries must be supported by visionary

government policies, investment in setting up of bridging

institutions such as machine

tool parks, common facility

centres, business and market

development support, and

technology institutes. Looking

at the Indian machine tool eco-

system, R&D development and

innovation seem to be elements

where Indian manufacturers

have particularly fallen behind,

in terms of initiative, access

and investment. Clusters

like Taichung have proved

how heavy investment in

R&D goes a long way in

ensuring the sustainability and

competitiveness of a machine tool

industry. Besides strengthening

CMTI and widening its

presence, manufacturers need to

indigenously develop high-class

products, and academia should be deeply entwined

with the industry, right from training to cutting-edge

innovation.

On the whole, it is pertinent that the machine tool

sector is perceived, not in isolation, but intrinsically

nurtured in an ecosystem. For Indian industry cluster,

the sutra is to muster strength to usher in an era of a

‘New Deal’, the need for which is greater now than

ever before.

Merchant of DreamsBy Shailesh Sheth

Shailesh Sheth, an eminent authority, shrewd analyser of trends, brilliant strategist and considered by the industry as a “Guru”, to us, he manifests as ‘Sarathi’, accomplishing his timely purpose in the ever evolving world.

The Machine Tool Eco-system

Machine Tool Manufacturers

Jobwork Companies

Consultants

IT Support Service

Providers

Trade Association

R&D + Academic

Institutions

Skill Development

& Training Institutes

Financial Institutions

Components Manufacturers

(Vendors)

Part Suppliers

MODERN MACHINE TOOLS - July 201220

News, Views & Analysis

Hypertherm Introduces Powermax105

Rittal bags innovation award

Hypertherm, a manufacturer of

advanced cutting products,

launched Powermax105 in

Asia at the 17th Beijing Essen Welding

& Cutting Fair, 2012. Powermax105

is a new 105-A air plasma system used

for hand-held and automated cutting

and gouging. The system is designed to

comfortably cut metals into 32-mm thick

pieces and sever metals by up to 50 mm.

The new system delivers faster cut speed,

improved cut quality and industry-leading

consumable life for better performance at

a lower operating cost.

Rittal India has won the best

innovation award for Liquid

Cooling Package (LCP). Rittal

RimatriX5 solves the problem of climate

control for high heat losses per rack with

LCP. Extremely high heat loads are

dissipated from the rack via the LCP air/

water heat exchanger. The system also

allows temperature-neutral expansion of

the data centre with pay as you grow

concept, in terms of scalability and

modularity.

The Indian subsidiary of

leading control system and

robot manufacturer, FANUC

Corporation, recently inaugurated its new

technology centre at Pune. The one-of-

its-kind facility saw a grand opening in

the presence of dignitaries from leading

companies in the machine tool & allied

industries, apart from dealers, customers

and the dynamic team of FANUC India

Pvt Ltd.

The event was graced by Sonali

Kulkarni, President & CEO, FANUC

India Pvt Ltd; Kazuhisa Otsuka,

Executive VP, FANUC India Pvt Ltd;

Katsuo Kohari, Manager, FA Overseas

Sales Joint Department Sales Division,

FANUC Corporation; and Nirmal

Bhogilal, Chairman & MD, Batliboi Ltd.

The facility has been designed in

such a way that no electricity is required

for lighting during day time, thereby

saving valuable energy. To make it more

environment friendly, the facility does

not use glass that prevent heat generation

inside the building, thus reducing the

energy consumption.

With the opening of this new

technology centre, the machine tool major

has reinforced its commitment to the

customers in the Indian market. It is being

equipped with training & seminar rooms

and solution gallery that are designed with

specific focus on customer requirements

during pre- and post-sales. Currently,

FANUC India has its Head Office at

Bengaluru and branch offices at Pune

and Delhi, along with a strong sales and

service network spread across the country.

Even amidst

e c o n o m i c

u n c e r t a i n t i e s

in India, Freudenberg

Group, a family-owned

German company,

expanded its reach

in the Indian market

through a new plant

at Mysore. Chem-

Trend Chemicals Co

Pvt Ltd and Klüber

Lubrication India Pvt

Ltd, headquartered

at Mysore, will

manufacture specialty

lubricants, release agents and maintenance

products. By 2016, Freudenberg expects

to invest around Rs 130 crore in the

new production plant, which is spread

across 40,000 m2. The two companies

supply to a wide range of customers

including the automotive, energy and

wind energy sectors.

“India is not just a low-cost

production centre for us. Almost 60% of

its GDP comprises local consumption

compared to only 40% in China. We

are here to serve the local market and

not to export. When we were facing

crisis in other parts of the world, we

showed 20% growth in India,” said Dr

Jörg Matthias Grossmann, Regional

Representative, Freudenberg India, and

Executive VP & CFO, Freudenberg

Chemical Specialties.

Apart from this, the Group, under

the brand, EagleBurgmann Pvt Ltd, is

expanding its R&D centre at Pune. It

will be a fully automated, computerised

state-of-the-art test centre for testing

seals for refineries, petrochemicals and

chemical plants. The facility will become

functional by the end of 2012.

FANUC Opens New State-of-the-art Facility in Pune

Freudenberg Expands Operations in Mysore and Pune

� Dr Jörg Matthias Grossmann (centre), Regional Representative, Freudenberg

Group, India, along with other Freudenberg off icials, addresses the press on

the Group’s major Indian investments.

FANUC’s Pune Centre� Will be used as a new training

centre

� Will help in providing total engineering solutions

� Will be treated as a live technical centre

� Will help to serve Pithampur, Rajkot and Mumbai regions, apart from Pune.

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Timken has awarded ‘2011

Foundation of Quality

Excellence’ Award to its bearing

plant at Chennai, India, during its

Asian Quality Conference in May 2012.

The awards are presented each year in

recognition of top quality performance

amongst its more than 50 plants around

the world, and the Chennai plant is one

of the two Asian plants recognised. The

facility produces single- and double-row

case-carburised tapered roller bearings,

including cups, cones and assemblies,

of 8 inches and above outside diameter.

Timken Chennai Wins ‘Foundation of Quality Excellence’ Award

IMTMA Seminar Calendar: July 2012Date Topic Venue

July 11, 2012 Seminar on Idle Time Reduction in Metal Cutting through Quick Changeover Techniques

Technology Centre, BIEC, Bengaluru

July 11, 2012 Seminar on Welding Technology in Auto Industry

Pune

July 12–13, 2012

Workshop on Process Capability—The Quality Route to Sustained Growth in Manufacturing


July 13, 2012 Seminar on Servo Technology for Industrial Motion Control

SKF College Campus, SKF India Ltd, Chinchwad, Pune

July 17–18, 2012

Training Programme on New Product Development on CNC Turning Centres


July, 17–18, 2012

Seminar on New Manufacturing Strategies using Multi-Tasking and 5-axis CNC Machines

Pune

July 20, 2012 Seminar on Lasers in Metalworking Technology Centre, BIEC, Bengaluru

July 20–21, 2012

Workshop on Measurement Systems Analysis Gurgaon

July 23–24, 2012

Seminar on Heat Treatment Process in Metalworking


July 24, 2012 Seminar on Design of Hydraulics, Pneumatics Coolant and Lubrication System

Gurgaon

July 24–25, 2012

Workshop on Workholding and Fixturing Techniques for Productivity Improvement on CNC Machines


July 25, 2012 Seminar on Right Selection of Linear Motion Guideways, Ball Screws & Servo Drives for Industrial Machinery

Gurgaon

July 27, 2012 Workshop on Calibration of CNC Machine Tools


CAPA, VIC to Promote Aerospace City in Bengaluru

Centre for Asia Pacific Aviation

(CAPA) India and Vittal

Innovation City (VIC) will

co-promote CAPA-VIC Aerospace City

in Bengaluru. The aerospace park will be

one of the industry clusters at VIC and

will spread over an area of 750 acre. VIC is

India’s first green technology & IPR safety

zone focussing on aerospace, defence &

electronics. CAPA, the region’s leading

specialist advisory, research & knowledge

practice, will bring together international

aerospace operators and manufacturers.

Nicolás Correa Received Orders of the Order of €5.5 million at the BIEMH

Nicolás Correa—the Spanish

company—received orders worth

multi-million pounds during the

27th edition of BIEMH (May 28–June 02,

2012, Bibao, Spain):

� One order was from Italy for a gantry

milling machine, with a mobile

sleeper, with X–Y–Z–W runs of

11,800 × 6,800 × 1,500 and 1,650,

respectively, for a total value of

€2 million. It will be used to machine

large components for the nuclear

sector.

Th e company provides milling solutions for:

� Equipment manufacturing

� Die and large mould

manufacturing

� Monolithic elements for

the aerospace, railway, and

energy, including turbines,

wind milss and general

mechanical sectors

� Another order, worth €1.5 million, was

from Chinese client Beyang Hanfen for

FPV-W 75 gantry milling machine, with

a mobile sleeper, with X–Y–Z–W runs

of 7,500 × 4800 × 1,500, and 1,650,

respectively.

� German client Zeisier bought a mobile

column floor-type machine from the Axia

family for €675,000.

� The company also sold fixed bench

machines in the UK and France to clients

CMS Cepcor and Robatel, respectively,

for a total sum of €650,000.


Leaders’ Views

Impact of Economic Slowdown on Machine Tools Industry

The current economic situation that the country is facing has definitely resulted in

a slowdown in capital investment. This does not augur well for the machine tool

industry. Coupled with this, the rising petroleum costs and the high inflation rate have

resulted in the overall slowdown of the manufacturing industry. Consequently, our customers

are deferring investments. We have to definitely look at the ways in which the input costs can

be reduced in areas such as the cost of the raw materials, labour, etc. In addition to this, the

government also has to look into the cost of imports in the import duty.

- N Gopinath, VP – Marketing, MMC Hardmetal India Pvt Ltd

The Indian machine tool industry is facing stiff competition from all over the world.

We, therefore, have to constantly innovate in terms of technology and processes

as well as value engineering. The missing links in the Indian industry are in the

areas of machine reliability and faster delivery. To achieve this, we need to create a strong

vendor base. However, this aspect of the industry is not very strong. We still do not have

reliable suppliers of auxiliary systems and critical machine components. The industry needs

to concentrate on strengthening the vendor base.

- Mohini Kelkar, MD, Grind Master Machines Pvt Ltd

Even as the Indian economy is rendered rudderless, with political leadership unable

to rise to the occasion, we are happy to note that our industry is full of optimism,

despite a weakened rupee, high interest rates and rising costs. All our customers are

geared to achieve 30% growth in 2012–13 amidst these major external handicaps.

- Sonali Kulkarni, President & CEO, FANUC India Pvt Ltd

The Indian machine tool industry has no option but to grow exponentially over the

next decade. Robust consumer-driven demand will accelerate progress in India

like never before, as it rises to become a powerful contributor to the international

supply chain. The current economic situation is probably not as exciting as we would like

it to be; however, it should hardly be interpreted as a situation that merits a critical or

desperate attitude. If we were to modestly forecast an average growth of 7.5% in GDP over

the next 5 years, we can arithmetically translate that, at the minimum, to a healthy 15%

growth per year in the machine tool industry.

- Satish Sadasivan, MD, SCHUNK Intec India Pvt Ltd



With the demand

slump in the

a u t o m o t i v e

industry, component

manufacturers are also

trimming down their output

to prevent inventory pile up.

The automakers this year

have seen a steep reduction

in demand pattern, which

led to downsizing the

production.

As vehicle sales dwindle

due to high interest rates

and petrol prices, many

automobile manufacturers in

India have planned to shut

down their plants temporarily

to reduce inventories. This

has directly affected the

component manufacturers

across the country. As

per Auto Component

Manufacturers Association

(ACMA) reports, the

components industry saw

a turnover of around $40

billion in 2010–11 and is

estimated to touch $66.3

billion in 2015–16. India’s

exports from the sector

stood at about $5.2 billion in

2010–11, expected to reach

$12.3 billion 2015–16.

Car sales in India grew

at the slowest pace in seven

months during May with

just 2.78% rise as high

interest rates, which are

hovering around 11-13%,

and petrol prices hit the

market.

JCB India,

the country’s

l a r g e s t

manufac tu re r

of construction

e q u i p m e n t

has launched

‘The All New

3DX’ Backhoe

Loader. With

the launch

of this new

equipment, the

company aims

to strengthen

its share of the

backhoe loader

market in India.

Speaking about the launch,

Vipin Sondhi, MD & CEO,

JCB India, said “We are

extremely delighted with the

launch of this

all new JCB

3DX Backhoe

Loader. The

benefits that

t h i s n e w

g e n e r a t i o n -

e q u i p m e n t

provides to its

customers are

immense. It

ensures 20%

lower fuel

consumpt ion

in excavation,

which wil l

result in fuel

savings worth `2.25 lakhs

per year at current diesel

prices. It is the best engine in

the construction and the

equipment industry.”

Component Firms Cut Output as Automakers Trim Production

JCB launches New 3DX Backhoe Loader in India

Advantages of 3DX Backhoe Loader� Will result in 20% lower fuel

consumption in excavation

� Will create 20% more cabin space

� Has twin ram steering facility for easy steering

� Has been provided with new brake linkage to ease the braking effort

� Has been fixed with new bonnet for easy maintenance

� Offers the best return on investment.


GEOGRAPHY WATCHChennai

Chennai’s automotive industry is moving forward at full throttle, and with this, the city encompasses in itself a cauldron of business opportunities for the machine tool builders of India. Debarati Basu throws light on the various lucrative options that Chennai offers...

The huge conglomerate of

automobile manufacturing

industry based in and around

Chennai has created a

thriving industrial ecosystem

for business to pour in. From the very

inception of the automotive industry

in the country, Tamil Nadu has been

providing the right environment to

optimise on the emerging opportunities.

Starting from Ford Motors, which

ventured here in 1995, to Hyundai,

BMW, Mitsubishi, Nissan and the

leading Indian companies such as Ashok

Leyland, TVS Group and M&M, almost

all major automakers have made Chennai

their home. Chennai hosts around 35%

of India’s auto ancillary units, and has

thus rightly gained the sobriquet ‘Detroit

of Asia’.

Building BusinessHowever, even with one of the biggest

auto clusters in place, Chennai could

never promote its own machine tools

setup. It either imports or outsources

most of its machine tool requirements

from various Indian cities. It procures its

machine tool requirements mainly from

Bengaluru and Coimbatore, which have

established their manufacturing base for

machine tool requirements. Syed Amjed,

Sr VP - Global Marketing, Bharat Fritz

Werner Ltd, explains, “Though we agree

that Chennai is an auto hub, Bengaluru’s

business is divided into categories

like automotive, aerospace & general

engineering.”

A setup for manufacturing

machine tools would need established

requirements for castings apart from

suppliers and sub-suppliers. For

Chennai’s auto industry, importing

machine tools or outsourcing its

requirements from other Indian cities

is more feasible than putting in the

investment for manufacturing the same

in Chennai.

Rama Bhatathi, Head Sales, South,

Hyundai WIA Pvt Ltd, says, “Over

the last 20–30 years when Chennai was

strengthening its automotive industry,

Bengaluru was simultaneously building

up its machine tools segment. And

now, both these cities have their own

matured market with established players.

Today, any global machine tool builder

entering the Indian industry would look

at Bengaluru just like any global auto

company will come to Chennai. This is

the ecology that has been traditionally

been created.”

This has given rise to an opportunity

for the Indian machine tool builders to

extract business opportunities from this

auto cluster. “Metal forming and metal

cutting form almost 60% of the total

manufacturing process of automotive

industry. Hence, the machine tools

industry has a huge role to play.

Bengaluru alone provides 55–65% of

the total national domestic consumption

followed by other Indian machine tool

clusters including Ludhiana, Rajkot and

Coimbatore,” says TK Ramesh, CEO,

Micromatic Machine Tools Pvt Ltd.

Machine tools industry is a

manpower-intensive industry that

requires volumes to justify the

investment. While the national

requirement for machines is around

15,000–20,000 machines per annum,

Chennai’s requirement is roughly

around 2,000–3,000 machines per

annum. While Chennai has some key

machine tool builders providing for the

auto industry’s requirements, it can also

explore this segment of manufacturing

as well.

“As the auto industry grows, the

machine and tool industry will also see a

rise, even though it may not be as huge

an industry as the automotive. The state

does have a few machining companies

and although they are not large in

number, they certainly produce quality

machine tools,” says Dilip Kumbhat,

CEO, K-Lite Industries, and Chairman,

Chennai Auto Ancillary Industrial

Infrastructure Upgradation Co.

Paving the WayIndia today has positioned itself as one of

the fastest growing auto markets in the

world. According to a CII Survey, the

Indian automotive industry is expected

to grow at the rate of about 13% per

annum over the next decade to reach a

size of around $165–175 billion by 2022.

At the rate at which the automotive

cluster is gearing up for the global race,

the machine tool industry definitely has

a lot to draw from Chennai.

[email protected]

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SMEs@GLANCEGrowth Enablers

At a time when the industry is on a full swing towards development, SMEs need to be strengthened to ensure consistent growth. However, while the big industries are growing even bigger, SMEs in India still have to fight for better benefits to explore its opportunities. Here is an insight into what SMEs really need. Debarati Basu reports…

The Small and Medium

Enterprises (SMEs) play

a vital role in the growth

of Indian economy. They

contribute over 45% of

industrial output, 40% of exports,

employ 60 million people, and more

importantly, have the potential to create

1.3 million jobs every year.

The contribution of the SMEs

towards the GDP in 2011-12 was

around 17% and studies predict that it

is likely to increase 22% by 2012-13.

According to a study, liberalisation and

deregulation in the industry would also

contribute to the sector’s growth. The

sector, which has grown at the rate of

35% in the last two years, is likely to

register 40% growth in the next five

years. However, with all the growth

projections, the Indian SMEs are still

grappling for support from government

and bigger companies alike.

Challenges EncounteredWith the potential that the Indian

SMEs possess, the segment can grow

manifold if given appropriate support

from all quarters. The growth of this

segment would result in the overall

growth in the production of the Indian

industry as well, and thereby the Indian

economy. However, the odds that

SMEs have to face have outweighed

their growth. This segment of the

industry is still grappling to own a

share of benefits from India’s growth

story. Here is a wish list of the Indian

SMEs and what they actually want:

� Availing easy finances: It goes

without saying that finance is a

major constraint that SMEs face.

The non-availability of credit

facilities and exorbitantly high

interest rates are some key issues

that all levels of the industry have

to grapple with. However, these

issues come down heavily, especially

on SMEs. Therefore, they need a

quicker and hassle-free procedure to

avail finances.

� Government aid: A helping attitude

of the Central Government and state

governments is the first requirement

of SMEs.

� Support to undertake R&D: SMEs

are the fountainhead of innovations

as they are the closest to the ground

realities of manufacturing. But, in a

desperate measure to cut down cost

to make profits, howsoever marginal,

the first thing that is usually struck

off from the list of expansion plans

is the investment in research and

development. Despite every effort,

most SMEs today have become

offloading units for mass production.

“Being an SME makes you a

puppet at the hands of the Original

Equipment Manufacturers (OEMs).

SMEs are usually trapped in the

cycle of scope, quality and schedule

and one of them is compromised

in the entire process. Although it

involves a lot of investment, every

SME should try to design its own

products and create a brand for

themselves in the market,” feels D

Ramamoorthy, Director, Applied

Engineering & Technologies Pvt

Ltd.

� Knowing the global requirements:

The world is growing at a rapid pace

and there is a dire need for SMEs

to keep themselves abreast with the

recent developments. The small

scale industries need to have a clear

understanding of what the global

customers need to manufacture

products that match the international

specifications. For this, the industry

needs to have a proper channel of

communication between the OEMs

and the entire gamut of SMEs.

Looking AheadGone are the days when SMEs

were synonymous with low-quality

manufacturing at less cost of production.

Today, they are trusted upon by OEMs

to produce quality-testified components

as per the standards of international

market. Various state governments have

started taking note of the potential that

SMEs hold and numerous industry

associations are also now coming

forward to help this segment. However,

SMEs still await a synergised effort

towards strengthening the backbone of

Indian machine tool industry.

Aiding small companies manufacture bigger wonders

[email protected]


High feed rates call for

powerful drive systems and

weights that are as low as

possible. On the other hand, a high

level of accuracy requires a high level of

rigidity, which also leads to large cross

sections, and hence, to large volumes

and weights where designs to cope with

force distribution are concerned.

Past reaction to the different

processing requirements relating to

rough and finishing machining was to

develop modular sub-assemblies. These

sub-assemblies were then combined

to adapt the machining level in the

best possible way. This meant that a

number of machines or process units

were necessary for complete machining

of the tool.

The concept of scissor dynamics

links the dynamics of a parallel structure

with the broad operational range

encompassed by scissor kinematics.

In contrast to other solutions, the

dynamic gain was deliberately set as

the limiting parameter because the

traversing movements of the serial axes

are accelerated within the range of the

required compensatory movements.

Through dynamic-oriented

utilisation of axial redundancy, it is

possible to achieve optimum adaptation

of the machine characteristics to the

relevant stage in the process. At the

same time, a considerable expansion of

the process scale is achieved because new

machining strategies are made possible

by the means of these improved and

controllable machine characteristics.

Potential for cost saving in crankshaft

manufacture and for enhancing the

quality of machining is offered by

the use of a high-precision dry machining

process instead of the previously used

machining process of grinding.

Consider, for instance, crankshaft

manufacture. Here, the precision turn

milling technology has the potential to

replace the grinding process. Grinding

process, as a machining process, requires the

use of cooling lubricants for geometrically

indeterminate cutting. The trend towards

machining using geometrically-determined

cuts and the subsequent achievement

of levels of precision of less than IT4

as well as form deviations smaller than

4 micrometers (previously achievable

exclusively by grinding) holds out the

promise of enormous potential for cost

saving, resulting not only from the use of

dry machining, but also from shortening

the process chain.

The p r e cond i t i on s f o r

economic and process-reliable

dry machining of the component

have been created by the development of

this new type of precision turn milling

machine, associated integrated studies of

the Work-Piece-Tool-Process-Machine

system, and new approaches to development

in respect of process, tool & coating and/or

lubricating principals.

To research thermal characteristics,

a rigid temperature management

is necessary to simulate various

operating conditions. One aim is to

determine the correlation between

temperature change and heat-dependent

shifts for the machine sub-assemblies,

which, to a major extent, determine the

working accuracy. Based on the knowledge

acquired relating to the heat sources and the

flow of heat, design measures can be derived

to reduce thermal deformations/shifts.

A further possibility is the correction

of the thermal shifts by direct/indirect

compensatory action. External thermal

influences are simulated by means of

conditioning the surrounding air and

base plate temperature for the thermo

cell to supplement conditions in practice.

Experimental tests may be carried out

during machine downtime, at idle

with the programme cycle and while

machining, in order to determine thermal

loads that have a disruptive effect on the

operational accuracy of the machine tool.

Over and above this, vertical or horizontal

temperature layers may be generated,

which may be used to render thermo-

neurological zones on the machine tool

identifiable by means of which workshop

conditions can be simulated.

Scissor Kinematics provides flexible machining strategies

Precision turn milling machine makes dry machining more efficient

Thermo cell simulates workshop conditions for machine analysis

Courtesy: Fraunhofer Institute for Machine Tool

and Forming Technology IWT

TECHNOLOGY & INNOVATION

42

IN CONVERSATION WITHTerrence Miranda


…and depreciation of the rupee and the situation in Europe is making overall business conditions uncertain. The industry wants the government to take certain policies and decisions much

faster,” says Terrence Miranda, MD, HAAS Automation India Pvt Ltd, a leading CNC

machine manufacturer, as he shares current trends and challenges that the industry is facing with Nishant Kashyap. Excerpts…

The machine tool companies in India are facing serious challenges…

Terrence Miranda


How has the machine tool industry responded to the increasing demand from customers for high speed and better productivity? In recent years, machining tasks have

become more complex. This means that

the machine technology has to become

more complex to provide cutting-edge

machining. The demand for quicker and

better productivity has naturally gone up.

Customers now want to increase their

productivity dramatically. At the same

time, they do not want to compromise

with the cost. Hence, to be in the business,

machine tool builders have to manufacture

products that are cost effective as well as

provide value for money. The increasing

demand for better productivity, efficiency

and speed would mean that we would need

faster machine tools that can efficiently

deal with complex machining.

On the other hand, from the user

industry’s perspective, faster machining

of components would require highly

specific tools tailored to the machining

process to maximise process speed. At the

same time, for higher productivity, the

product needs to be handled properly for

setting up the tools. Naturally, all these

additions to handle complex machining

will increase the cost. Hence, the industry

is continuously going through a cost–

quality tussle.

What are the current market trends?Currently, I see three major trends in

the industry. First is the extensive use of

automation. Loading/unloading of parts

with the help of robots, automatic pallet

systems or bar feeding systems is a clear

trend that is being seen in India. In this

ever-growing world, it is not just enough

to have CNC machine tools; customers

want to automate the entire process. This

would reduce dependence on manual

operation and also increase productivity.

The second trend is the growing

demand for 5-axis machining centres. As

the accuracy standards are going up, the

necessity to machine a part in a single setup

(i.e., 4–5-axis machining) is also growing.

This trend is seen in every machine shop,

big and small players alike. Companies

Q

Q

Which personality inspires you and

why?

If I was asked to name one person who

inspires me, I would say John Roth who

is the present Director of Production

at HAAS. He has been my mentor

and guide since I started working for

HAAS as a dealer and then as the

Country Manager for HAAS India.

What do you consider as a turning

point in your career?

The challenges that we faced in the

difficult years from 1998 to 2002

to bring the HAAS name to India

were the turning point for me. I truly

believe in the adage that adversity can

very often bring out the best in people.

multi-tasking machines that are affordable

for the mass market. I believe that multi-

tasking is a trend for the future.

What are the emerging sectors for machine tool builders? The construction equipment industry is

one of the fastest growing sectors and

it is definitely creating a lot of demand

for machine tools. One more sector to

look for is that of the aerospace industry,

which is growing at a fast pace in India.

Apart from these, medical, defence,

telecommunication, and other such

industries are also generating demand for

machine tools. The automobile and auto

component industries remain the biggest

customers of machine tools. I believe that

in the next two years, these industries

will provide an impetus to machine

tool builders and will demand the latest

generation of CNC machine tools.

What are your projections for the industry? In 2011–12, the sales in the metal

forming and metal cutting industry of

India were around $2.5 billion. In the

market in which we compete (where we

deal with machining centres and vertical,

horizontal & turning centres), we estimate

that a little over 14,000 machines—both

local and imported—were sold in India

in 2011–12, of which our market share

would be around 5%. The year 2012–13

has started on a slow note due to the

Eurozone crisis and high inflation. So I

think this financial year will also see a

similar number of CNC machines being

sold. We do expect to see stronger growth

in the 3rd and 4th quarters of 2012–13. In

this situation, the major challenge for us

is to increase our market share.

How is the adoption rate of CNC machines in India?The machine tool industry in India has

shown a double-digit growth rate over

the last several years and this trend should

continue. As large and small companies

in a diverse range of industries move

from conventional to CNC machines to

upgrade their productivity and meet their

own customer or product requirements,

personalUP CLOSE &

Q

Q

Q

are forced to adopt 5-axis machining.

The immediate cost of adopting a 5-axis

machine may be high, but in the longer

term, it will ensure increase in productivity

and reduced costs in manufacturing.

Currently, many cost-effective 5-axis

machines are available that can perform

almost all 5-axis operations other than very

high-end processes. Transitioning from

3-axis CNC machine to 4- and 5-axis

machines was not as easy as it is now.

The third trend is the use of

multi-tasking machines. Multi-tasking

machines combine various processes,

such as milling and turning, in a single

machine. These machines are growing in

importance as customers look to reduce

part handling and increase machine

versatility. Manufacturers are now

trying to combine more processes in a

single machine. Adopting multi-tasking

machines would improve productivity of

the machine and work space, as there will

be one machine for all these operations

instead of 2–3 different machines for each

operation. However, the challenge that

machine tool builders face today is the

way it has increased the complexity in

manufacturing operations. Many machine

tool builders are focussing on developing


Terrence Miranda

44

the demand for CNC machine tools will continue to go up.

Where does India stand in terms of R&D activities in the machine tool industry? R&D in the Indian machine tool industry is in its nascent

stage. But, there are many Indian machine tool builders who

are introducing indigenous products that are suitable for both

the domestic and global markets. However, the industry has not

seen many path-breaking technologies yet. The Indian industry

has a lot of opportunities for growth. Many Indian machine tool

builders are now showing the potential to develop products that

are unique and patented worldwide. But in terms of technology,

they have a long way to go. Products from Japan, Germany and

the US are technologically highly advanced as compared to the

products that are made in India.

What are the challenges you see in the industry today? The machine tool companies in India are facing challenges

similar to what other industries are facing. The depreciation

of rupee against all major currencies like dollar, pound and

yen is a major challenge. The situation in Europe is making

overall business conditions uncertain. The industry wants the

government to take certain policies and decisions much faster.

The current situation is not making India’s condition any better

as it is affecting the market sentiment and it is definitely not

helping capital investment. The machine tool industry is a

capital-intensive industry and anything that hurts capital

investment will hurt the machine tool industry.

India’s poor infrastructure is also a big cause of concern,

even though the country is making rapid progress. While power

and infrastructure represent huge opportunity areas, they are

also a bottleneck. As demand for better infrastructure increases,

it will call for a lot of machine tools. Whether it is power

generation or infrastructure, the equipment used in these

industries would require CNC machines for their manufacture.

Thus, we have both potential and opportunity in these sectors,

but the machine tool industry needs to gear up to meet these

requirements. Another challenge for us is to build value in the

product. Companies that can combine the need for higher

productivity and cost effectiveness will be successful.

What are your strategies to deal with the current situation?We are neither a low-cost machine tool manufacturer nor

do we make high-end or highly specific CNC machines.

Our focus will be on enhancing the value proposition for our

customers. When you combine productivity and efficiency

with cost, it becomes a value proposition. Any discounting

on these is a very short-term strategy, and it is not HAAS’

philosophy. We are instead trying to focus on providing value

for money. We have been very successful with this in the

past. In future also, our focus will be on adding value to the

product and satisfaction of our customers.

[email protected]

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50 Industry Snapshot Lubricating Industry Potential

52 MWF Projection Demand Drenched: 2.5 Million Tonne Annual Global Consumption 2015

54 Advances in MWFs Innovation & Efficiency, in Every Drop

56 Occupational Hazards Making Fluids Health-Friendly

64 Mist Control Techniques for Healthy Manufacturing

66 6C—Metalworking Fluid Management Spraying Edge to Manufacturing

68 Cutting Fluid Costs The Changing Costs of Coolants

70 One Q Many Views Is Cryogenic Cooling an Emerging Alternative to MWFs?

76 Biodegradable Fluids Vegetable Oils Turn MWFs Green

78 Maintenance & Filtration The Faultless Fluids

82 MWF Additives The Key to Cost Effectiveness

86 Tips & Tricks The Right MWF

METALWORKING FLUIDS

SPECIALFOCUS


SPECIAL FOCUSIndustry Snapshot


Global Industry Analysts (GIA), in a recent report, forecasts that the global market for functional fluids will reach $19.7 billion by the year 2017. With such a growth in demand, the opportunities in the market will be driven by innovations that meet the changing regulatory requirements and standards. Over the last year, the lubricating industry has seen burgeoning growth and expansion and promises greater potential for the future. Debarati Basu brings to the fore some of the latest happenings in this industry.

Lubricating Industry potential

[email protected]

Wrapping UpWith the increase in the

machining complexities,

the role of MWFs will

become more important

to ensure flawless

machining processes.

However, with the ever-

increasing competition in

this field, new products

need to stand out in

terms of technology and

performance. According to

a GIA report, biofluids are

expected to be seen as a

key area of expansion and

demand. Innovation in

lubricants and greases are

Fuchs opens a lubricant laboratory and technical centre in AustraliaUsing Australia’s position as a leading

lubricant industry development hub, Fuchs

Lubricants opened a world-class Regional

Lubricant Laboratory and Technical

Center. The new laboratory will be part

of the global research and development

as well as develop new products for the

market. It will also be responsible for

providing technical support to the region.

This is a step towards more research

and development and to set national

standards for lubricant product

development in Australia.

Greenbriar Equity Group acquire PetroChoiceGreenbriar Equity Group LLC—a

US-based company—acquired PetroChoice,

a leading, value-added distributor of

petroleum lubricant solutions. Greenbriar

acquired the company from KRG Capital

Partners. Headquartered in Riddlesburg,

Pennsylvania, PetroChoice is the largest

distributor of consumable commercial,

industrial, and passenger vehicle lubricants

in the Mid-Atlantic and Upper Midwest

regions of the US, providing its customers

with total fluid management for their

lubricant needs.

Hyundai Oilbank, Shell in a joint venture ( JV)Hyundai Oilbank, a South Korean

company, entered into the lubricant

base oil business by establishing a JV

with Shell Petroleum Co. With plans

to start production in the latter half

of 2014, the JV, named Hyundai and

Shell Base Oil Co, will break ground

in October this year for this new

venture.

Apache Oil with Houghton to distribute eco-friendly metalworking fluids (MWFs)Apache Oil, a Minneapolis-based

company, has partnered with Houghton

International—a world leader in high-

tech, metalworking, hydraulic fluids

and fluid management services—to

distribute Houghton’s premier line of

environment-friendly MWFs to the

customers.

Blaser Swisslube’s MWFs make titanium machining easyBlaser Swisslube’s expertise in

creating vegetable oil-based

MWFs led to a breakthrough

in the machining of titanium,

particularly in aerospace

applications, where stable and

safe working environments

are of paramount

importance.

Quaker becomes leading die casting lubricant provider in the USWith the acquisition of GW Smith & Sons, Inc—a leading manufacturer and

supplier of die cast lubricants—Quaker Chemical Corporation became the leading

die casting lubricant provider in the US. The acquired business has net sales

of approximately $14 million. GW Smith’s proprietary formulations of die cast

lubricants, metalworking lubricants and machining fluids are sold through direct

sales, distributors and agents in the US and international markets. GW

Smith now operates as a standalone subsidiary of Quaker.

required to match developments

in the equipment and machinery

industry. In future, while the

developing markets will drive

the lubricanting industry, the

industry will itself be volatile

to the demand trends of the

machining industry.

SPECIAL FOCUSMWF Projection


The impact of the recent

global economic recession

reverberated in markets

across the world, in

industries linked, directly

or indirectly, to the epicentre of

the collapse. The MWFs industry,

an integral part of manufacturing,

inevitably shuddered from these

reverberations, particularly in North

American and European markets. Yet,

the drop in demand was momentary,

although growth in Europe reduced to

1.8% CAGR post 2007, since major

regional markets, like in Asia, picked

up through the recession, growing at

3.3% CAGR.

Demand Driver: Asia & the Machine Tool SectorAsia, especially China, has by far the

biggest and fastest growing machine

tool industry globally. In the near future,

India is moving towards becoming one of

the top five consumers of machine tools.

As a direct result, MWFs are expected to

witness a surge in demand in the Asian

markets. With huge manufacturing hubs

established in Asia, the demand for

machine tools is bound to rise, resulting

in a surge in MWF consumption.

Supplementing this, modern machines

and processing equipment function

at higher speeds and temperatures,

demanding better performance, safety

and easy disposal for MWFs, all at lower

costs and volumes.

The largest markets that drove this

growth were Japan, India, China and

Korea, which undoubtedly indicates

that the future of the MWF industry

has shifted to Asia. But as economies

rebounded, major manufacturing

economies in Europe and North America

began recovering, buoyed by growth in the

transportation equipment and automotive

Little over a decade into the 21st century and consumption in the global Metalworking Fluids (MWFs) industry already finds itself driven by burgeoning automotive and transportation sectors. Moreover, the meteoric rise of Asian manufacturing and intraregional trade forecast a bustling 5% CAGR for the continent in MWF consumption leading up to 2015. By then, with over $6,500 million in value, the global MWF industry will see over 2.5 million tonne of lubricants flood the market. Tarun Tampi & Nishant Kashyap track the numbers, drop by drop…

Number Crunching

� Global CAGR through 2015: 3%

� Global expected consumption by 2015: 2.5 million metric tonne

� Removal fluids constitute 50% of total MWFs in use. Forming fluids, protecting fluids and treating fluids make up the rest in that order

� Two-third of total supply comes from 25 major suppliers

Asia-Pacific Region

� Growth rate (through 2010-2015): 5% (China fastest)

� Expected consumption in Asia by 2015: over one million metric tonne

� Largest clients/market sector: Transportation, followed by machinery

� Current total consumption: 891,330 tonne

� Current value: $3,160 million

MWF Projection


sectors. As of today, the global functional

fluids market is set to reach $18 billion,

with 2.5 million metric tonne of MWFs

to be consumed annually by 2015.

IndiaIf we consider India alone, the country

has several greenfield steel projects

underway, aggressive automobile and

aerospace sectors are expanding rapidly,

numerous global companies are entering

its markets, and capacity expansion

projects alongside heavy infrastructure

development are underway. As a side-

effect of this progress, the consumption

and application of MWFs and associated

technologies has been rising. Dr AK

Singh, Scientist Emeritus, Specialty

Product, IIP Dehradun, estimates,

“In India, consumption amounted to

nearly 115,830 metric tonne in 2010.

Of this, straight oil and soluble oils are

the major types of MWFs used.” This

growth is in spite of rising crude oil

prices, heavy import dependencies and

the emerging shift from petroleum-

based lubricants to biodegradable

vegetable oil-based lubricants. As the

manufacturing industry leans towards

the adoption of ‘green’ solutions on

their shop floors, the global demand

for ‘green’ fluids is expected to grow by

more than 30%, along with substantial

growth in the overall MWF demand.

M Krishna, MD, Master Fluid

Solutions (India) Pvt Ltd draws a line

through current consumption and the

demand projection, “300,000 drums

is a rough estimate of annual usage of

MWFs in India. Overall, consumption

is dominated by water-miscible MWFs,

amounting to about 70%, while neat

oil contributed about 30%. Within

water-miscible MWFs, soluble oils

and emulsion-based oils account for

about 70% of it, with the balance taken

up by the rising use of synthetic and

semi-synthetic MWFs. In the next five

years, consumption volume could grow

at a CAGR of 15%. With growing

demand and rapid changes in machine

tool requirements, there will be a shift

in the percentage of MWF usage,

especially for water-miscible MWFs.

Additionally, the semi-synthetic and

synthetic-based MWFs will increase

to at least 50% of the total volume of

water-miscible MWF.” All these factors

will provide great opportunities for

MWF manufacturers and distributors

in India, to double their sales and step-

up production.

[email protected]

[email protected]

Highlights from the Kline Report on MWFs Global Series 2010

Market Analysis and OpportunitiesThe MWF market in North America, Asia and Europe is projected to grow at about 3% per year, from 2.1 million metric tonne in 2010, to nearly 2.5 million tonne in 2015.

Asia is the fastest growing market with 5% annual growth from 2010 to 2015. Over these five years, the projection says that the North American MWF market will grow at 2% and that of Europe’s by 1%, annually.

The report focussed on North America (United States, Canada and Mexico), Asia and Europe, whose estimated MWF consumption totalled 2.1 million tonne, valued at $6.9 billion, in 2010.

Since 2007, Asia’s MWF demand, annually, grew 3.3%, while Europe’s slipped 1.8% and North Americas fell 7.8% per year.

North AmericaNorth America’s MWF market amounted to 613,000 tonne in 2010. The United States accounted for 83% of total consumption, Canada for 11% and Mexico 6%.

The North American MWF market had the top 10 suppliers accounting for just 55% of the market. Those were Houghton (12%); Quaker Chemical (10%); Henkel (7%); Fuchs (6%); BP Castrol Industrial (5%); ExxonMobil, Milacron and Metalworking Lubricants (each at 4%); Chemtool (2%); and Master Chem (1%).

AsiaAsia’s MWF market amounted to 891,000 tonne in 2010. In 2010, China accounted for 43% of MWF consumption in Asia, Japan, 24 %, India, 13% and Korea, 10%. Other important Asian markets include Thailand, Vietnam and Indonesia.

EuropeMWF consumption in Europe – including Western, Central and Eastern Europe and Russia – totalled 601,000 tonne in 2010, falling around 1.8% per year from 2007 to 2010.

The European MWF market weathered the storm largely because of Germany (21% of the region’s consumption in 2010) and Russia (23%).

Automotive ManufacturingGlobal automobile production increased from 71.7 million in 2007 to 75.2 million in 2010.

Consumption ASIA EUROPE (including Russia)

NORTH AMERICA

Volume (tonne)

Current (2010): Projection (2015)

891,330 over 1 million

601,100640,110

612,900680,500

Approx Market Value

(Million USD)

Current (2010): Projection (2015)

3,160 over ~3,900

1,550 1,650

1,850 2,043

SPECIAL FOCUSAdvances in MWFs


New Test Method to Detect Microbes in MWFsBacteria, fungi and other

microbial contaminants are

a perpetual problem as far as

implementing MWFs is concerned.

Apart from health risks to those working

with such fluids, microbes degrade the

quality of the fluid, reduce its components

in its composition, increase tool wear as

well as corrosion, and can lead to the

formation of biofilms, thus plugging

filters. Conventional dipslide tests to

detect microbial contamination take too

long and can, at best, detect only 0.01–1%

of microbes in the MWF. They are also

limited to samples tested in laboratories,

which may not provide the most

accurate measurement. Hence, a new

method that tests MWFs for microbial

contamination has been developed.

This method can be conducted within

minutes, accurately and on-site. The test

works by measuring the concentration

of Adenosine Triphosphate (ATP), the

main energy-carrying molecule in all

living things. However, before the ATP

is extracted and measured, the MWF

sample is filtered through a 10-micron

filter to isolate bacteria from fungi, and

then through a 0.7-micron filter to isolate

the ATP from the organic chemicals

that may be dissolved in the sample. The

concentration of ATP directly relates to

the level of microbial contamination

in soluble oils and synthetic & semi-

synthetic fluids.

Boron Nanotechnology-based Lubricant AdditiveConventional solid lubricants

are being revisited as the

proliferation of nanotechnology

has led to research looking to use

nano-sized particles as lubricant

additives. One such material is boric

acid whose particles, sized between 50

& 100 nanometers, have been found

to reduce the coefficient of friction to

between 0.02 & 0.1, nearly two-thirds,

for lubricants used on ceramic or

metallic surfaces. They are also easier

to disperse in mineral oil-based stocks

than larger micron-sized particles and

are compatible with most additives

used in making lubricants. Nano

boric acid, however, is susceptible

to agglomeration when exposed to

water, although the technology is

being improved to remedy this as

well. Potassium borate nanoparticles

used in an ester matrix as an additive

result in better lubrication, anti-wear

and extreme pressure performance.

The dispersion of potassium borate

nanoparticles in the ester does not

agglomerate in the presence of water

and is not adversely affected by other

contaminants. It remains stable for

The global decline in fluid sales in the past few years and the ever-widening web of environmental and safety regulations have led the industry to rethink the manufacturing and applicability of Metalworking Fluids (MWFs). Further, the costs of MWFs have increased to constitute almost 17% of a manufacturer’s overall costs, leading to an increase in the number of out-of-the-box innovations and specialised lubrication techniques. Tarun Tampi reports on the various emerging solutions in the MWF industry to improve tool life, reduce wear & costs, and minimise shopfloor and environmental mishaps.

Advances in MWFs


three to four years and results in a

coefficient of friction as low as 0.037.

Not only is the boron nanoparticle

containing lubricant additive better

in terms of replacing anti-wear and

extreme pressure additive packages, it

also exhibits some corrosion resistance,

thus allowing the concentration of

corrosion inhibitors to be reduced in the

lubricant mixture. The colour, viscosity

and tolerance to water are better and no

unpleasant odours are detected. Seen as

a replacement for chlorinated paraffin

additives, it can be used at one-third

the treat rate. A key application for

this nanoparticle containing boron

additive is in lithium greases, where it

has brought significant improvements

in the treat rate.

To Get More from Less…Over the last 20 years, the

disadvantages of metal-cutting

fluids and machining lubricants

have begun to weigh heavily against

the advantages. Reduced friction, wear

and corrosion were convincing positives

until MWFs were shown to pose serious

risks to health and environment. With

permissible exposure limits increasing

in their severity, along with the ever-

widening web of regulations, standards

and management practices, MWFs are

beginning to lose their lustre. At the

same time, in order to stay competitive,

manufacturers are looking to reduce

costs, of which MWFs form a growing

chunk, while simultaneously improving

productivity.

“From the machining perspective,

the MWF sector is at a nascent stage,

but growing at a rapid pace, moving

priorities from the ‘Need for Cost’ state

to ‘Need for Performance’ state. The

Indian industries growing globally,

feel the need for better productivity,

better process control beyond

machine parameters, better machine

maintenance and more advanced

machine tools. All these broaden the

spotlight on innovating and extract

better performance from MWFs,”

says M Krishna, MD, Master Fluid

Solutions (India) Pvt Ltd.

…by Dry Machining This has led to the increasing

prevalence of various machining

processes that are run ‘dry’,

without using MWFs. Although

the heat generated and questionable

surface finish were concerns in dry

machining, improved tool coatings

with impressive thermal properties, like

TiAlN, are making dry machining more

feasible. Milling and boring processes are

inherently more suited to dry machining,

whereas drilling, tapping and other

closed-face operations are still difficult to

perform dry due to chip removal issues.

Material has also been an issue for this

technique since several high-end alloys

and materials, like titanium, could only

be machined in the presence of cutting

fluids due to the quantity and temperature

of the heat generated. However, materials

that react with water, like magnesium,

can only be machined dry. Considering

all this, the use of dry machining is

becoming increasingly suitable if carefully

customised to the machining process, the

workpiece material and the tool.

…or Minimum Quantity Lubrication (MQL)Given that dry machining still

has some notable limitations,

near-dry machining or micro-

lubrication is a far more attractive

solution. If minimal quantities of oil-

based or vegetable oil-based coolant are

used, at flow rates around 50–500 ml/h,

and applied directly at specific points

between the tool and workpiece, then

huge savings in fluid, machining time

and costs can be made. Also known as

MQL, the aim is to maintain a thin

film of oil that will lubricate the cutting

surface, sometimes one drop at a time,

applied externally or through the spindle

and holes in the tool. For high-speed

carbide tools, MQL has been found to be

the most efficient method for lubrication

in terms of wear, tool life and accuracy.

The costs related to cutting fluids are

frequently higher than those related

to cutting tools. One study found that

Ford had reduced its costs by 13% when

MQL was implemented. The cutting

performance using MQL is far better

than when conventional flood-cutting

fluid supply is used since it reduces

the cutting temperature, improves

chip–tool interaction, reduces wear

and damage to the tool, and improves

dimensional accuracy in machining.

Moreover, most MQL lubricants

are biodegradable, thereby making

the technique environment friendly.

Globally, several companies, particularly

in Europe, retrofit MQL systems to

existing machining centres. HAAS

Automation also offers a Minimum Oil

Machining (MOM) as an option for its

machining centres.

Neat Oils, Emulsions & the EnvironmentMilky fluids are a factory

feature of the past. Synthetic

esters have long replaced mineral

oils and consequently increased sump

life. The same fluid can now be used for

over three years while extending tool life

and reducing corrosion. Tramp oil issues

have been largely dealt with as modern

day emulsions do not pick up tramp

oil, while still maintaining performance

and reliability. Further, environment

and regulatory measures have led to the

development of advanced emulsions, far

less prone to mist formation. Neat oils

are still most suitable for a variety of

low-speed applications, having become

lighter in colour, less prone to smoke,

odour and mist, and are inherently much

easier to recycle.

“Keeping environmental concerns,

improved performance, consistent

structure and characteristics in view,

there is a need to develop alternative

lubricants and emulsifier components

for soluble oils, which are biodegradable

and less toxic. Particularly those

developed from renewable sources,

like vegetable oil, show equivalent

performance properties to mineral

oil-based or synthetic lubricant-based

soluble oils. Biodegradable MWFs will

solve the disposal problem as well,”

says Dr AK Singh, Scientist Emeritus,

Specialty Product, IIP Dehradun.

[email protected]

SPECIAL FOCUSOccupational Hazards


Reduction of heat, friction

and removal of metal

pieces during machining

operations are the key

roles of Metalworking

Fluids (MWFs). They can be complex

mixtures of oils, emulsifiers, anti-weld

agents, and other additives. However,

the fluid gets compounded with the

contamination of substances from the

manufacturing process, such as tramp

oils and hydraulic fluids.

Water-based MWFs support

microbial growth, which introduces

biological contaminants and their

related biological byproducts, such as

endotoxins, in the fluids. A worker

is constantly exposed to the fluids by

breathing aerosols generated during

the machining process, or through skin

contact with them while handling the

tools and equipment.

Health Ailments Exposure to MWFs causes a range of

ailments, some of which are as follows:

Respiratory disorders: Hypersensitivity

pneumonitis, chronic bronchitis and

impaired lung function are some major

respiratory ailments caused by MWFs.

Work-related asthma is another most

prevalent occupational disorder. Water-

based MWFs are excellent sources

of bacteria and fungi, which cause

respiratory problems in the exposed

workers. A proper MWF system

management programme needs to be

maintained on shop floors which should

include fluid monitoring, record keeping

and maintenance, proper mist control

including close-capture ventilation,

machine enclosures and training

employees on the hazards and proper

use of MWFs.

Dermatological disorder: A direct skin

contact with MWFs causes allergic and

irritant dermatitis. Folliculitis, oil acne,

keratoses and other allergic reactions are

some other dermatological disorders.

Most shop floors need to incorporate the

following preventive measures:

� Use of safe, less irritating and non-

allergenic additives or MWF

� Process modification and isolation

to limit the dispersal of MWFs

� Work practice and administrative

controls to assure the proper MWF

Cancer: Studies show that some MWFs

increase the risk of larynx, rectum,

pancreatic, skin, scrotum and bladder

cancers.

Measures to be Taken According to the National Institute

for Occupational Safety and Health,

exposures to MWF aerosols should be

limited to 0.4 milligram per cubic metre

of air (thoracic particulate mass) or 0.5

milligram per cubic metre of air (total

particulate mass), as a time-weighted

average concentration up to 10 hours

per day during a 40-hour workweek.

Some important measures that need

to be taken are as follows:

Fluid selection: The MWFs selected

should be non-irritating and non-

sensitising. Petroleum-containing

MWFs should be evaluated for potential

carcinogenicity. Water-miscible

MWFs should be checked for safe-use

guidelines. To minimise nitrosamine

formation, nitrate-containing materials

should not be added to MWFs

containing ethanolamines.

Fluid use and application: Mist

generation should be minimised. Most

machines today are incorporated with the

necessary mist controllers to minimise

mist dispension during the process.

Fluid maintenance: An MWF

management plan that includes

maintenance of the fluid chemistry,

fluid filtration and delivery systems

should be developed. MWFs should be

maintained at low temperatures to slow

down the growth of microorganisms,

reduces water loss and change in

viscosity, and reduce fire-hazard risks in

the case of straight oils.

Alternative FluidsGiven the various issues related to the

use of MWFs, most manufacturers

are accepting Minimum Quantity

Lubrication (MQL) as an option. MQL

is an environmentally viable technology

that helps in reducing manufacturing

costs. It is the process of applying a small

amount of a quality lubricant directly

into the cutting tool workpiece interface

and is effective in a wide variety of metal

cutting processes, including sawing,

turning, milling, drilling and tapping.

According to one study, the use of MQL

led to a 13% decrease in overall costs.

It also led to better cutting tool life,

a significant fluid reduction, reduced

costs of coolant handling, decreased

maintenance and an increase in machine

uptime. Most Indian manufacturers too

are focussing on the benefits of MQL in

manufacturing technology.

[email protected]

Making FluidsHealth-

FriendlyWhile metalworking fluids are one of the significant ingredients of smooth machining, they are also a source of various health ailments on the shop floor. Debarati Basu brings out the measures to curb health hazards…

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SPECIAL FOCUSMist Control


Metalworking fluids are

used to cool, lubricate

and remove metal chips

from tools & metal

parts during grinding,

cutting and boring operations. Straight

oils, water-based oils, synthetic and

semi-synthetic fluids are the most

commonly used MWFs. Except for the

straight oils, all other MWFs are mixed

with water before use. However, using

MWFs in the technological process of

metalworking often generates aerosols

by atomisation, and this mist stream

represents a significant hazard to the

workers and the environment.

MWFs are complex mixtures and

some of their ingredients can be toxic.

Without adequate precaution, bacteria

and fungi can start growing in these

mixtures, especially if the fluid has been

used for a long time. Heavy metals

can also build up and become highly

concentrated over time.

Health Risks and Preventive Techniques MWFs can cause adverse health effects

through skin contact with contaminated

materials, spray or mist and through

inhaling MWF mist or aerosol. The

severity of health problems caused by

MWFs depends on a variety of factors

such as the type of fluid, the degree and

type of contamination, and the level and

duration of the exposure.

Failure to control MWFs has long

been associated with work-related

health problems, such as work-related

asthma, bronchitis, irritation of the

respiratory tract and other breathing

difficulties. It can also cause extrinsic

allergic alveolitis following repeated

exposure, which can result in severe

breathing difficulties in recurrent

episodes. Exposure may also cause

irritation to the eyes, nose and throat.

Many companies are making

Metalworking Fluids (MWFs) can cause adverse health effects through skin contact with contaminated materials, spray or mist and through inhaling MWF mist or aerosol. Workers engaged in the manufacture of automobiles, farm equipment, aircraft, heavy machinery and other hardware are exposed to the harmful effects of machining fluids. This has forced companies to adopt various mist-control programmes at their shop floors. Here, Nishant Kashyap discusses the different methods that are used to control and prevent the formation of mist.

HEALTHY MANUFACTURING Techniques for

Mist Control


efforts to create greater awareness

about the problems as part of their

employee-safety programmes and are

actively targeting respiratory diseases

caused by inhaling MWF mists,

including bronchitis and asthma. To

achieve this end, many techniques

have been successfully implemented in

the industry. Some of the preventive

techniques are as follows:

� Use splash guards, where provided,

to control splashing and misting

� Minimise the production of mist and

vapours by controlling the volume

and rate of delivery of the fluid to

the cutting edge of the tool

� Use enclosures or ventilation to

remove or control any mist or vapour

produced

� Allow a time delay before opening

the doors of machine enclosures to

ensure that all mist and vapours have

been removed by ventilation

� Do not use compressed air to remove

excess MWFs from the machined

parts, plant or equipment.

However, mist- and vapour-control

programmes have not been properly

implemented in the small job shops;

they still lag far behind in applying the

required safety norms.

Mist-control ProgrammeVarious factors are responsible for

the formation of MWF mist in the

atmosphere of different manufacturing

industries. Some such factors are

high-speed dynamic forces involved

in machining operations, the chemical

composition of fresh fluids and

contaminants that enter fluids from

extrinsic machinery sources. The latter

considerations are important in the

design of devices for efficient removal

of mist from the workplace. M Krishna,

MD, Master Fluid Solutions (India) Pvt

Ltd, says, “In water-miscible cutting

fluids, the root cause of smoke and mist

on the shop floors is the high tramp

oil content in the coolant. Companies

need to ensure that the tramp oil level

in the coolant is maintained properly.

This can be done by reducing the tramp

oil contamination as much as possible in

the lubrication system leakages. Regular

cleaning of the MWF is also a good

measure to ensure that the coolant is

always cleaned. Our coolant recycling

equipment can help ensure that the

coolants in the machines are always as

good as new coolants.”

The role of tramp oil in the

formation of MWF mists in the

atmosphere of machining operations

is significant for all types of fluids.

Therefore, an effective mist-control

programme should include maintenance

measures to reduce the amount of fluid

leakage from machinery. Also, prudent

housekeeping, adequate ventilation and

mist enclosures can work together to

provide a comprehensive system of mist-

reduction practices. Proper utilisation of

chemicals and creating awareness among

the workers are some other mist-control

programmes.

Current TrendsWith greater emphasis on the reduction of

carbon footprints, several manufacturers

are experimenting with vegetable oil-

based coolants in their day-to-day

activities, as mineral oil and synthetic

alkanes are not appropriate to be used

as the base oil for environment-friendly

cutting fluid. This is because they have

poor biodegradability, and as a result,

they remain in the environment for a

long time causing pollution. Vegetable

oils and synthetic esters, on the other

hand, possess good biodegradability

and are thus safe. Pratap Marathe,

MD, Pratap Tex-Chem Pvt Ltd, says,

“Selection of base oils and additives to

ensure environmental aspects is a very

important factor, since it has become

absolutely necessary to take care of our

nature and deteriorating environment.

Therefore, we have to be constantly in

touch with the developments happening

in this field. For instance, the industry

is gradually implementing the usage of

esters and naphthenic base oils instead

of gum rosin and conventional base

oils, respectively, as they are easily

disposable and less harmful. The latest

advancement is the usage of synthetic

esters instead of mineral base oils

to save the reducing crude oil stocks.

Thus, we can divert these stocks towards

making fuel for vehicles, planes, etc.,

and buy time till we find an alternate

solution. Moreover, synthetic esters

have a single boiling point unlike

mineral oils that have variable boiling

points, and therefore, while machining

at elevated temperatures, they yield

excellent lubricity with less coolant

evaporation.”

Looking AheadIt is in the interest of industries to

provide a healthy environment to their

workers. In this regard, numerous

improvements have been made in

MWF products, engineering controls,

anti-misting technologies and industrial

hygiene procedures to reduce workplace

mists. It is noteworthy that many of

these advancements have been achieved

as a result of cooperative efforts between

MWF manufacturers and the end users.

As the science of MWF mist generation

is better understood, the industry can

expect more improvements in mist-

reduction technologies. At the same

time, we cannot employ similar methods

to control MWF mists and mineral oils,

as they are clearly different materials

and any considerations to pose limits

on them in a similar manner is neither

scientifically sound nor in the interest of

workers’ health.

[email protected]

How to Prevent Mist Generation

� Minimise the fluid delivery

pressure

� Match the fluid to the

application

� Use MWF formulations with

low-oil concentrations

� Avoid contamination with tramp

oils

� Minimise the fluid flow rate

� Cover the fluid reservoirs and

return systems wherever possible

� Maintain control of the fluid

chemistry.

SPECIAL FOCUS6C—Metalworking Fluid Management


If we perform a root cause

analysis for bad odour, skin

irritation, tool life, corrosion,

residue, paint peeling off, foam,

etc., from amongst the most

probable causes, such as concentration,

pH, water quality, tramp oil, filtration,

etc., we will find that there is a high

interaction among these variables. This

makes it difficult to pinpoint the root

cause. Hence, many times, a solution

to a specific problem in one company

may not yield the same result in another

company. In such scenarios, one of the

best proven and the most economic

methodologies in problem solving is to

have good preventive measures through

systematic approach to ‘Periodic Fluid

Management’ that will address all

the probable root causes within its

operational limits.

6C ConceptThe coolant management concept,

described here as ‘6C’, is a fundamental

and systematically choreographed

process for effectively managing

Metalworking Fluids (MWFs) and

holding the variables within

their operational limits, so that

productivity and performance

could be increased in all forms of

metalworking applications.

We start with the assumption

that the right coolant has been

selected for the application.

This is because the

coolant selection

p roce s s i s

‘ a p p l i c a t i o n –

m a n u f a c t u r e r ’

dependent. As the

process variables

are relatively

l a r g e a n d

highly interactive,

the same coolant may

not be necessarily suitable for

the same application across

different industry segments, or

sometimes, even within the same

industry at different locations.

Hence, coolant selection must

be done in conjunction with the

manufacturer. However, the 6C-MWF

management concept presented here is

generic and application–manufacturer

independent.

With these facts, let us now move to

individual ‘Cs’.

1C

Circulation

The method of mixing for circulation

forms an important process in the

coolant management cycle. ‘Premixed

coolant’ addition is generally the best

way to add new coolant in the machine.

This ensures homogeneity in the fluid.

Premix is done either through automatic

mixers or is mixed manually. While

handling emulsion products by hand,

one must ensure to add coolant OIL

(Oil In Last) in the agitated water to set

the fluid emulsion. This fluid emulsion

has small oil droplets suspended in

water phase that penetrate the point

of cut better and reduce carry off of

the fluid system. (Adding water to the

coolant oil will form reverse emulsion or

thick emulsion and is not what we want

to achieve!)

Thus, the 1st C of the

‘6C’ concept emphasises

the importance of having

good mixing and circulation

process, which form the

basis for realising effective

coolant value. It is generally

recommended to use an

automated mixer,

which could

be a low-end

venturi type

or high-end

proportional

pump, for

good mixing

and circulation.

2C

Controls

This ‘C’ is also the dashboard

of the Coolant Management

System (CMS). Therefore, most

of the coolant manufacturers or

service providers claiming to

provide coolant management

service focus only on this segment

The significance of Metalworking Fluids (MWF) is widely recognised, but very often treated only as a support function that is necessary, but not important. The average MWF cost in any industry lies approximately between 10% and 20% of the total production cost. Any lapse in fluid management, starting from the selection of right fluid, will result in failure in terms of quality issues and will also deteriorate the machine tool. To manage this important contributor, the industry must possess a robust management system.

Spraying Edge to Manufacturin

g 6C

CIRCULATION

CONTROLS

CONTAMINANTCLEANLINESS(SUMP)

CLEANING SCHEDULE

RECYCLING

6C—Metalworking Fluid Management


of the 6C concept. The ‘Control’ section

is critical to ensure that the machine

tool sump is monitored for coolant level,

coolant concentration and coolant pH.

As water constitutes anywhere between

85% to 95% of the end coolant, the

water quality parameters need to be

monitored at least weekly or with an

increased frequency, depending on the

water source being used.

This ‘C’ is only the beginning of

CMS, but, for many, it is also the end

of CMS. It is up to the end user or the

customer to impress with their CMS

providers to look and move beyond this

‘Control C’ to complete the coolant

management cycle.

3C

Contaminant

The most common reason for many

MWF failures is contamination, or

rather the ‘unattended contamination’.

The two major contaminants are tramp

oil and metal chips & fine particles. In

a machine tool, it is rather economical

to have some system to remove or

reduce contaminants than preventing

the contamination itself. The coolant

dynamics in the machine should

first be properly understood before

selecting appropriate automatic tramp

oil removal and metal chips removal

systems. It is suggested that the end

user, in conjunction with the coolant

manufacturer, should decide the most

suitable methodology for automatic

contaminant control and have the

system installed.

4C

Cleanliness (Sump)

The cleanliness requirement of the

sump is the most important factor but

is the least attended to, as the machine

will have to be taken down for a

considerable time for cleaning the sump.

Moreover, designers of machine tools

often overlook the necessity for a good

accessible sump design for cleaning.

In many cases, the sump is a ‘design

filler’ and takes all sorts of geometry

that cannot be accessed by humans.

Moreover, cleaning is undertaken only

when the machine is down, thereby

not giving enough time for justifiable

cleaning action.

For effective cleaning within

the available cleaning time, it is

recommended to use such sump cleaners

that could completely empty the sump,

clean particulate matter to, say, 50

micron (commonly used filter size), and

charge back again into the tank either

manually or automatically. In this way,

the automation system will be much

more effective and the complete cycle

for a 1,000-litre sump cleaning will be

anywhere between 20 and 30 minutes.

On the other hand, the manual method

would normally need more than 4–5

hours. In this way, cleanliness could

well be achieved with good returns on

investment.

5C

Cleaning Schedule

Along with good cleaning, a sustained

cleaning schedule that ensures cleanliness

of the sump on a continual basis is

also essential. This scheduling could

be a part of Preventive Maintenance

(PM) or Conditional Monitoring

(CM) schedules. The adherence to the

schedule should be driven from top-

down, otherwise this will become just

a cleaning activity. Thus, ‘cleanliness’

is an activity and ‘cleaning schedule’

is a commitment. This could be

implemented through TPM.

6C

Recycling

Recycling is a well-planned and

executed activity on a continual basis for

enhancing the performance of a coolant

by increasing its useful life, which, in

turn, enhances the machine-cutting

performance, finally contributing to

greener initiatives by reducing the

disposal of coolants. All these, of course,

give better returns to shareholders.

We need to understand that

recycling does not transform old

coolant into a new one; it merely

reconditions the used coolant by

removing solid particles, contaminants

and tramp oil through recycling and

adding the necessary additives to

control the microbes. Thus, we need

to understand that the coolant that has

lost its efficacy cannot be brought back

to life through recycling. Another myth

about recycling is that the coolant’s

life becomes infinite by continuous

recycling. This is not the case; a coolant

has a designed life expectancy and it has

to be disposed of at the end of its life.

The recycling will only ensure that we

get the designed life expectancy of the

coolant. ‘Recycling’ is not ‘reclaiming’

of coolants. Therefore, a well-planned

and scheduled management programme

is necessary for recycling.

Wrapping UpMost of the organisations execute

2nd C—‘Controls’, wherein a chart is

displayed by the service provider in terms

of three or four controllable factors and

updated daily. This is done religiously

and rigorously without failure, as any

slippage on this ‘C’ will directly affect

the production. The other Cs do not

directly affect the production, but do

affect productivity and performance,

and as a result, the profit. Hence, a true

CMS must focus on all the 6Cs.

It is necessary that any (new)

business concept or philosophy should

be a set of simple principles/activities

put together in a choreographed

sequence of processes to address the

3Ps of business—business productivity,

business performance and business

profitability. The ‘6C’ MWF

management addresses all the 3Ps of

business, both directly and indirectly.

In terms of production, availability,

performance and quality are considerably

improved, thereby improving overall

equipment effectiveness. In other

words, 6C is an important component

of TPM activity, contributing to

increased business sustenance.

M Krishna, MD, Master Fluid Solutions (India) Pvt Ltd. He has over 27 years of progressive business experience. He is also a ‘Six Sigma’ and ‘Lean’ exponent with over 12 years of hands on implementation and training expertise.

SPECIAL FOCUSCutting Fluid Costs


The costs of Metalworking

Fluids (MWFs) have risen

over the last few decades, and

today, account for 10–18%

of the total production costs.

This has become increasingly significant

given that fluid sales declined in 2009,

the variety of fluids available in the

market has decreased, and costs

of raw materials have increased

along with purchasing costs

for MWFs. Moreover, stricter

environment and health

regulations have also placed

a huge burden on MWF

manufacturers and users.

Worldwide, over 2 billion

litre of MWFs are being

used annually, and this is

after taking into account

only the concentrate

volumes (excluding

the volumes used after

dilution that could be 10

times more).

Understanding the CostsThe costs involved

in MWFs go far beyond

just the purchasing costs.

Purchasing costs vary depending on the

price and supply of base oil, additives

and emulsions, and these costs have

been rising due to continuous increase

in the cost of crude oil and fluctuations

in the global economy. Yet for end

users, MWFs have a far bigger financial

effect, apart from the cost

of purchasing, in

their Total Cost of

Ownership (TCO). This TCO involves

hidden costs and performance leverage.

The hidden costs can be attributed to

fluid management (from procurement

to implementation), shop floor

maintenance, performance monitoring,

waste treatment and disposal.

Performance leverage costs arise from

the efforts used to ensure optimal

functionality from MWFs, process

quality, tool life, scrapping, reworking

and rejecting parts. Syed Md Samim,

Marketing Manager, Quaker Chemical

India Ltd, explains, “There are many

components in considering overall fluid

usage costs. As MWF demands change

and costs increase, it is imperative for

plants to implement a fluid

management programme.

In today’s competitive

markets , cus tomers

must continuously seek

improvement in their processes

to raise productivity, lower

costs, maximise efficiency

and generate more income.

You want partners to help

deliver all of these”. “We

have repeatedly demonstrated the

fulfilment of these objectives. Day in

and day out, everywhere in the world,

Leonardo da Vinci was the first to use lubricants and lay down the importance of tribiology. Its importance has grown steadily over the centuries. With over 2 billion litre of lubricants being used worldwide annually, the need and consumption of metalworking fluids (MWFs) have been firmly established. However, the downside is that the costs of lubricants have risen exponentially. Tarun Tampi and Nishant Kashyap look at how effective fluid management, customer collaboration and innovations in MWF technology can help in halting the rise in cost.

Cutting Fluid Costs


we provide high-quality products, which

we incorporate into a unique offer of

teamwork, service, application know-

how and ongoing support. The result is

superior value for the customer, expressed

in lowered total cost, a combination

of chemical products, services and

technical expertise that help establish

sustainability, improve performance

& achieve a safe work environment,”

Samim adds.

Coolant Cost Vs Total Cost Per ComponentIn the recent years, there has been a

paradigm shift from coolant cost to total

cost per component and productivity

with MWFs, which is

significantly high and

more relevant in today’s

competitive market.

Manufacturers value and

acknowledge high-cutting

performance as the most

essential aspect of a

coolant. The industry is

focussing increasingly on

being more efficient in

every way. The cleaner

an MWF delivered to

the cutting zone is, the

greater the machining

performance and the

lower the cost per part

will be.

The main focus area for industry

has been to work on high cutting

performance with the help of better

lubricity in coolants and cutting oils.

It has been noticed that cutting-tool

cost is high as compared to the coolant

cost on all CNC machines, and hence,

focus on maximising tool performances

has increased. The net saving effect

can be higher as compared only to

the oil cost. Therefore, the focus for

continuous development in the coolant

industry will remain performance.

According to M Krishna, MD, Master

Fluid Solutions (India) Pvt Ltd,

“There are direct and indirect costs

involved in using MWFs. The direct

costs include coolant cost, tool cost

and rejection cost; while the indirect

costs include waste treatment, machine

downtime, maintenance cost, labour

cost and investment cost. Premium

quality coolants and proper coolant

management practices mean that the

coolant will perform better, will be

cleaner and its useful life will be longer.

A cleaner coolant will directly benefit

as it will have better lubricity, lesser

carry-off, better corrosion protection

and better dimensional accuracy &

repeatability. Other benefits that

contribute to increased profitability

arise from lesser consumption, lesser

disposal costs and improved machine

performance. Availability, performance

and quality will improve to get the user

a better overall equipment effectiveness

(OEE), and thus better capital and

capacity utilisation.”

Enhancing PerformanceA company needs to have an efficient

lubrication programme in place to

get maximum productivity from its

machines. A well-lubricated machine

constitutes an integral part of such a

programme. Without administering the

proper amount of lubricant at correct

intervals, a machine can experience

serious performance failures, resulting

in costly remedies. A centralised

lubrication system is a common tool

used in the industry to distribute a

precise amount of lubricant to specific

locations at a particular time by using

programmable timers, lubricant

pumps and lubricant injectors. Samim

highlights the need to have in-house

expertise for the customisation of MWFs

to suit a company’s requirements. “The

metalworking fluid specialist should

have the knowledge to grasp the unique

metalworking issues first, and then

identify areas where a change in fluid

could reduce the overall costs. MWF

manufacturer can then custom-engineer

fluids that enable the process to deliver

improved efficiencies with reduction in

total cost per unit, scrap/waste, operation

downtime and increment in productivity

and tool life,” Samim explains.

A company may use the best cutters

and the best coolant medium available,

but if the flood coolant is not

aimed precisely at the cutting

edge of each tool, it results

in the wastage of time and

money. “Metalworking fluid

manufacturers need to focus

on offering innovative products

that are cost effective and satisfy

customers’ changing needs. A

collaborative approach with

customers with increased focus

on research and development

and enhancing services would

go a long way to give a boost to

this market,” avers Samim.

Wrapping UpA host of eco-friendly solutions and

productivity-driven innovations have led

to the use of newer types of fluids, such

as macro-emulsions, semi-synthetics,

synthetics, biodegradable oils, etc., in

the the manufacturing sector. With

the growth of automotive, aerospace

and construction sectors in developing

countries, the demand for MWFs is

on the rise. Thus, it becomes all the

more important that end users reassess

their approach towards MWF usage,

i.e., they should be open to use semi-

synthetics, synthetics, etc., instead of

MWFs and work towards extracting

more with less while employing better

reuse and recycling methods to optimise

the material and investment.

[email protected]

[email protected]

Cutting Tools 4%

Coolant 8-16%

14% Coolant

EnergyPersonnel

Equipment

Disposal

Other

7%

7%

10%

40%

22%

Other Cost

� A break-up and distribution of coolant costs in manufacturing.

SPECIAL FOCUSOne Q Many Views


Cryogenic cooling, the latest in coolant technology, delivers liquid nitrogen through cutting inserts at -3210 F with a flow rate of 0.1 L/min per cutting edge. It dissipates heat like never before, extends tool life and increases material-removal rates. It provides a fresh, ‘cool’, approach to machining without liquid coolants, although like any other technology, it comes with a mixed bag of benefits and drawbacks. Tarun Tampi speaks to industry experts...

Cryogenic machining tests have achieved a 60% increase in speed

while milling Compacted Graphite Iron (CGI) with carbide,

and up to four times using Poly-Crystalline Diamond (PCD)

tooling. Additionally, with Minimum Quantity Lubrication

(MQL), we tripled speeds with carbide. We have focussed on

higher material removal rates, while keeping tool life equal to

what would be achieved with conventional wet coolants. This

technology dramatically improves the lifecycle cost for cutting

difficult-to-machine materials by reducing the required number

of machines and associated plant infrastructure, or possibly

increasing tool life beyond anything thought possible today.

It becomes even more competitive when you consider that it

is a ‘green’ technology. There is no coolant mist collection,

filtration, wet chips, contaminated workpieces or disposal cost,

and certainly less energy consumption without all the pumps,

fans and drives that go into handling coolant.

The limitations outweigh the benefits. First of all, obtaining

liquid nitrogen is a costly affair. Then, cryogenic cooling will end

up managing heat at the tool itself, instead of at the workpiece.

Hence, it results in comparatively high temperatures at the

surface of metal workpieces, thereby causing work hardening.

Further, the problem of corrosion on new metal surfaces will

not be resolved. Additionally, the issues of lubricity and chip

removal will also remain unresolved.

Eswari Prasad, President, MAG India

Dr AK Singh, Scientist Emeritus, Speciality Product, IIP Dehradun

an EMERGING ALTERNATIVE to MWFs?

It is an interesting concept,

but like other alternative

technologies (refrigeration

without using a compressor), it

needs to be proven, practically,

apart from the cost factor. The

question is if it can replace

not just cutting (lubricity and

cooling), but also non-cutting

functions of conventional

metalworking fluids (MFWs),

such as corrosion protection,

viscosity, oxidative and

hydrolytic stablising, etc.,

which go a long way in adding

to the quality of a machined

part. However, like any other

industry, MWFs will also

come out with options to

handle these innovations.

M Krishna, MD, Master Fluid Solutions Pvt Ltd, India

[email protected]

Verdict

Although cryogenic machining is not being seen

as a direct substitute for liquid MWFs, it could

still replace conventional coolants and lubricants

as a standard in several applications. With easy

retrofitting of existing machines becoming

possible, the benefits of cryogenic cooling (if

used along with MQL) like lower overall costs,

longer tool life, fewer health & environmental

risks, lower maintenance, etc., can be availed of

by any manufacturer.

MM

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SPECIAL FOCUSBiodegradable Fluids


The industry has long

been using mineral- and

petroleum-based oils as

the standard. However,

petroleum-based soluble oils

suffer from inherent limitations, such

as high toxicity to the environment,

poor biodegradability and inconsistent

characteristics with change in crude

oil composition. The disposal process

for such oils also adds an extra

financial burden to the users in the

manufacturing industry. As a result,

synthetic lubricants are increasingly

being used as an alternative to the

mineral- and petroleum-based oils.

Synthetic lubricants are especially

useful for use in extreme conditions of

temperature, pressure and radiation.

Some commonly used synthetic

lubricants are polyglycols, phosphate

esters, silicones, polyalpha olefins,

etc. However, synthetic lubricants can

also be toxic to the environment and

are not readily biodegradable, with

similar disadvantages to those found

in petroleum sulfonates and other

petroleum-based emulsifiers.

“In formulating eco-friendly

MWFs, the selection of the right

additives and components in the proper

ratio is a unique factor. Apart from

the vegetable oil base, emulsifiers and

additives should also be eco-friendly and

low cost. To strike a balance between

eco-friendliness, performance, cost,

availability in concentrated form, ease

of disposal and health issues, is not

easy task. This biodegradable MWF

is free from phosphorous, chlorine

and sulphur, with neem oil acting as

a natural fungicide. Emulsifiers are

obtained from natural products such as

oleates, sugar esters and rosin. Other

biodegradable MWFs are generally

based on synthetic esters, although this

increases the cost of MWFs,” says Dr

AK Singh, Scientist Emeritus, Specialty

Product, IIP Dehradun.

Biodegradability in MWFsThe biodegradability is primarily

determined by measuring the loss of

extractable hydrocarbon or complete

breakdown into CO2, H

2O, inorganic

salts and/or microbial biomass.

Vegetable oils are more prone to

microbial deterioration. This can be a

benefit when disposing of operationally

exhausted fluids, which can be

biocatalytically broken down by micro-

organisms using bioreactors.

Lubricating fluids usually have the

following composition:

� A base oil

� Emulsifier (if miscible)

� Extreme pressure (phosphorous and

sulphur compounds)

� Anti-wear and other additives,

which include corrosion inhibitors,

oil fog reducing additives, oxidation

inhibitors, etc.

For vegetable oil-based fluids, the

base oils often used are canola, rapeseed,

soybean and sunflower. They are used

in, more or less, the same application

areas as the conventional MWFs. They

are used as metal-removal fluids, metal-

protecting fluids and in conventional

hydraulic oils, gear oils, way oils, spindle

oils, and so on.

Global warming, limited oil reserves, environmental & industrial safety regulations, changing priorities in corporate ethics and government policies are driving the trend towards renewable lubricant technology, biodegradable metalworking fluids (MWFs) and other biomaterials. With IIP Dehradun indigenously developing a patented vegetable oil-based fluid, Tarun Tampi takes a look at the state of biodegradable fluids and what it means for India.

Vegetable Oils Turn

Biodegradable Fluids


Advantages and DisadvantagesBoth mineral oils and vegetable oils

have advantages as well as disadvantages.

They are:

� Lubricity

Mineral oils have poor lubricity

as compared to vegetable oils.

Moreover, they carry a slight polar

charge that draws the vegetable oil

molecule onto the metallic surface.

This bond is strong and protects

vegetable oils from being wiped off.

No such charge exists for mineral

oils, and therefore, they tend to

adhere less tightly to a metal surface.

� Flash point

The flash point for vegetable oils

is higher, which means that fluids

based on these oils are less prone to

smoke formation and have a lower

risk of fire.

� Oxidative stability

Mineral oils are far more stable

and less prone to oxidation than

vegetable oils. As a result, vegetable

oils tend to form sticky and thick

polymerised residues, and can be

hard to clean. Their viscosity and

lubricating ability can also change.

However, this disadvantage of

vegetable oils has been turned to

an advantage and has led to new

applications as grease for guideways,

trucks, machinery, and so on.

Under heat, both will oxidise, but

vegetable oils are more prone to

oxidation.

� Hydrolytic stability

Vegetable oils, which are composed

of triglycerides, tend to break into

fatty acids. These broken down

components act differently from

the original vegetable oil. However,

mineral oils are resistant to such

hydrolytic reactions. Nevertheless,

innovations in biotechnology have

led to the development of genetically

enhanced oilseeds that are naturally

stable and may eliminate such

problems. These stability problems

can also be overcome by using

additives, like antioxidants, or

by chemically modifying the

vegetable oils.

� Viscosity index (VI)

VI measures the viscosity of the

fluid. Mineral oils are fairly viscous.

Yet, vegetable oils have far better

viscosity, particularly at high

temperatures. For example, soybean

oil has VI of 223 as opposed to

90–100 for mineral oil.

As machining temperatures rise,

the viscosity of vegetable oils decreases

far slowly than that of mineral oils.

Similarly, as temperature falls, vegetable

oils remain more fluid than mineral

oils, resulting in quicker drainage

and removal of metal chips from the

workplace. The higher VI of vegetable

oils ensures that they will provide

more stable lubrication across a range

of operating temperatures. The high

viscosity also means that vegetable oils

can be used as lubricants for guideways

and gears in machine tools.

India and Biodegradable FluidsIn India, over 50,000 kilolitre of MWFs,

developed from mineral oil bases, are

consumed annually. The rising costs of

crude oil, costs of disposal, filtration,

recycling, etc., make the switch to

vegetable oil-based lubricants easier to

understand. However, vegetable oils

are costly, and until now, could not

penetrate the Indian market.

IIP Dehradun has developed a

non-edible vegetable oil-based fully

biodegradable MWF, under Indian

Patent No. IN244501, and transferred

the technology to Ecocare Bio Lube

India Pvt Ltd under product name

EBL-Cut 12. It has been developed

from rice bran oil to form a soluble oil

concentrate.

According to Dr Singh, “At

present, industries in the public sector

(railways, SAIL, BHEL, defence, etc.)

are importing biodegradable MWFs

at a very high cost from the Western

manufacturers, and the private sector

has no other choice, but to use low-cost

petroleum-based MWFs. Indigenous

manufacturing is limited to IOCL,

HP and Castrol, the main producers of

petroleum-based MWF. The remaining

MWFs, prevalent across industries,

are imported. The Government of

India is trying to replace and reduce

the use of mineral oils, and promote

the use of vegetable oils. Biodiesel

programmes have been launched.

Fundamentally, biodegradable MWFs

are being developed for the greater

goals of saving petroleum, reducing

energy consumption in metalworking

and saving the environment. Improved

R&D will lower the financial

burden and increase work quality in the

public sector, encouraging the private

sector to use this innovative and eco-

friendly product.”

Differences between Mineral Oil-based and Vegetable Oil-based Lubricants

Criteria Mineral Oil Based Vegetable Oil Based

Biodegradability Slow to degrade Quick to degrade

Renewability No Yes

Pour point -300 F 50 to 250 F

Misting Medium Low

Dermal sensitivity (depends on additives used)

Can be harmful; can cause dermatitis

Minimal dermal harm

Carcinogenic Yes; can be low if solvent refined or hydro treated

Naturally low

Cost Depleting resources and political instability leading to high prices; cost comparable today to vegetable oils

Used to be more expensive. But cultivation has increased; cost now comparable to mineral oils

[email protected]

SPECIAL FOCUSMaintenance & Filtration


Monitoring, maintenance

and optimisation of

MWFs are critical

aspects in the

implementation of

coolant systems in manufacturing.

The emphasis on reducing costs and

addressing environmental and health

concerns, while, at the same time,

maintaining or increasing productivity,

has increased over the last decade. Such

an emphasis arises from the obvious

benefits of maintaining and optimising

MWF usage. The service life of fluids

is extended, thereby saving on the

costs for purchase and disposal. Tool

life maximises and becomes consistent,

ensuring quality productivity. “MWF

manufacturers should use their industry

knowledge and process expertise to

understand specific issues related to

MWFs, solve particular problems, and

implement demonstrated solutions.

Trained on-site teams serve as your eyes

and ears, capturing data and analysing

results to provide detailed reports and

recommendations on how to reduce

costs and improve performance. As a

result, customers of machined parts

and other products experience vast

improvements in productivity, quality

and profitability, immediately as well as

in the future,” says Syed Md Samim,

Marketing Manager, Quaker Chemical

India Ltd.

Maintenance and monitoring

systems, along with strict shop floor

policies and procedures, improve

the health of machine operators and

reduce the impact of MWFs on the

environment. Moreover, it would also

protect companies from the risk of

prosecution whenever more stringent

health, safety and environment

regulations are enforced.

Maintenance MWFs are complicated mixtures

containing an array of additives in

various concentrations. There are four

basic MWFs used in the industry—

straight oils, soluble oils (emulsifiable),

synthetic oils and semi-synthetic oils.

Of these, straight and soluble oils have

been in usage for the longest time.

However, as non-mineral oil-based

fluids are being increasingly used,

synthetic oils (based on water) are also

being developed. Semi-synthetic oils use

both mineral oils and water. The most

THE FAULTLESS FLUIDSMaintenance and monitoring systems, along with strict shop floor policies and procedures, improve the health of machine operators and also reduce the impact of Metalworking Fluids (MWFs) on the environment. Moreover, it would protect companies from the risk of prosecution whenever more stringent health, safety and environment regulations are enforced. Tarun Tampi & Nishant Kashyap explain how, even in the world of MWFs, prevention is better than any cure.

Cou

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Maintenance & Filtration

important criteria in evaluating any

of these fluids over their lifetime are

performance and environmental impact.

The performance, of course, depends on

the application, the machining process

(broaching, grinding, milling, etc.) and

the metal being machined.

One of the biggest problems

faced in terms of performance is fluid

contamination, particularly microbial

contamination. The deteriorated

biomass impedes fluid flow, clogs filters

and reduces the ability of the fluid to

dissipate heat. Further, the numerous

additives deteriorate at different rates,

and therefore deplete at different levels.

The three major causes of failure that

prevent optimal use of any MWF are

biodeterioration, water quality (deioniser

and reverse osmosis systems) and other

contamination (metal particles, tramp

oil, swarf, dirt, etc.). In order to tackle

these issues, a common sense approach

involves using the following three main

steps in maintaining the quality of

MWFs:

� Monitoring the condition of the MWFs, especially their concentration

� Minimising contaminants

� Maintaining consistently high water quality and using deionised water to lower the mineral content.

Select biocides may be used to

reduce microbial growth to eliminate

corrosion, odour, filter plugging and to

extend fluid life.

MonitoringThe most important test is to measure

the concentration levels of a fluid.

Although these tests need to be

improved in terms of accuracy, precision,

output time and reliability, there are

several other tests, which if employed,

provide a good enough understanding

of the state of an MWF. To measure

concentration, a refractometer, which

measures the refractive index of a fluid,

is used. Alkalinity titration measures the

alkalinity of the MWF. Cationic titration

measures the anionic emulsifiers. Acid

split and wet chemical tests measure the

oil content in a fluid by reacting it with

mineral acids. A pH meter test is the

basic test to check fluid maintenance

as it measures the fluid pH, which

should be around nine for most MWFs.

Any deviation from this indicates

contamination. Instrument tests like

infrared analysis, X-ray fluorescence and

elemental analysis provide more specific

measurements of components in the

fluid. Then, there are a host of tests that

measure population density of microbes

in a fluid.

Filtration Filtration consists of the separation of

two phases using a physical barrier.

In the case of MWFs, this usually

involves the separation of chips.

Large oil droplets can be removed by

filtration, and depending on the affinity

of oil for the filter media, smaller oil

droplets can also be removed. There

are two kinds of filtration methods

that are generally used—membrane

filtration, which is used for bacterial

separation; and traditional filters used

in MWF recycling operation. When

the MWF enters the filter in the same

direction as it exits, it is called ‘dead-

end filtration’. In contrast, membrane

filtration typically operates with the

MWF entrance direction perpendicular

to the direction of filtration. This is

called ‘cross-flow filtration’.

A new MWF filtration technology

can help in achieving extended tool

life, improved component quality and

reduced maintenance & spare parts’

costs. Fluid Maintenance Solutions

Ltd has developed such a technology.

In fact, it was recently chosen as the

sole UK agent for its IFDR range of

advanced MWF filtration solutions for

machine tools and grinding systems.

Dead-end FiltrationDead-end filters can be disposable or

permanent. From the standpoint of

the environment, permanent filters

are preferred because disposable filters

present the problem of solid waste.

However, to the extent that in-plant

hazards and extension of MWF

life can be achieved using filtration,

disposable filters can be warranted from

the environmental perspective where

permanent filters are ineffective or

uneconomical.

Dead-end filtration operations

utilise gravity, pressure or vacuum as the

driving force. As filters clog, the driving

force required to maintain a given

filtration rate increases, otherwise the

filtration rate will decrease for a constant

driving force. After some time, demands

on driving force or declining filtration

rates become unacceptable. Disposable

media must be changed and permanent

media be cleaned. Permanent media

can be cleaned with high-pressure air

or MWF.

Cross-flow Membrane FiltrationMembrane filtration utilises a semi-

permeable barrier or a membrane

capable of separating feed stream

constituents according to their particle

size relative to the pore sizes of the

membrane. Membranes can separate

MWF ingredients from bacteria, tramp

oils and chips.

Membrane filtration is surface

filtration similar to that described

for the permanent filters. However,

membrane filters do not depend on a

cake layer for fine separation. Instead, a

porous membrane support is lined with

a thin skin where surface filtration takes

place. Pore sizes that have been used in

MWF recycling range from 0.01 to 0.1

μm (ultrafiltration) and 0.1 to 1.5 μm

(microfiltration).

Looking AheadThe industry should develop

quantitative guidelines with the help of

institutions like technical laboratories to

determine the useful life of an MWF as

well as parameters for when it should

be removed, such as reduction in tool

life, loss of surface finish, reduced

concentration, increased contaminants,

etc. This will help suppliers, maintenance

workers and end users work together to

optimise the use of MWFs.

[email protected]

[email protected]

SPECIAL FOCUS


MWF Additives

Metalworking fluids

(MWFs) are used in a

wide range of activities,

from simple grinding

and metal removal to

honing and broaching. Additives are

used both in water-soluble fluids and

in water-free neat oil formulations.

Over the years, many highly successful

additives have been developed that offer

formulators almost everything they

require. Syed Md Samim, Marketing

Manager, Quaker Chemical India Ltd,

says, “MWF manufacturers need to focus

on offering innovative products that

are cost effective and satisfy customers’

changing needs. A collaborative approach

with customers with increased focus on

R&D and enhancing services would go a

long way in giving boost to this market.”

Additives in Minimising WasteWaste minimisation has become one

of the biggest cost-cutting strategies.

It is an issue that affects the choice

of MWF additives when used in the

metal stamping process. Additives that

are stable to bacterial degradation and

hard-water salts, for example, are more

difficult to treat, but, at the same time,

promote longer tank life of MWFs,

thereby requiring less frequent disposal.

Metalworking lubricants are important

to the metal stamping process for

cleaning, stability, lubrication and

rust protection. MWFs evaluation is

often assessed by the amount of waste

disposal. The less waste produced, the

lower the disposal costs will be for

metalworking companies.

The waste disposal of MWFs is

a major issue that the metalworking

industry is facing. It is important to

find additives that are easy to treat

by most systems. This is the most

important element in minimising wastes

from MWFs. There are a number of

lubricants, corrosion inhibitors and

emulsifiers that can be evaluated for

their potential waste treatability. It is

important to be careful while deciding

the appropriate chemicals to use when

combining additives. This requires

thorough research and analysis.

Going ‘Green’Coolants are being increasingly utilised

to contain the heat generated during

machining. About two-third of all

coolant applications involve mineral

oil-based products, the rest utilise

Metalworking Fluids (MWFs) are a key production aid in the manufacturing of any kind of metal parts. They have come a long way from being just a coolant to becoming an ingredient for cost effectiveness and productivity. Many new additives are also being developed, which help in cost reduction and are also environment friendly. Nishant Kashyap provides insights on new additives and how they affect the overall industry dynamics.

The Key to Cost Effectiveness

Pho

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rate

ek S

ur

SPECIAL FOCUSMWF Additives


synthetic products, while only a few

use vegetable oil-based coolants. As

the manufacturing sector is adopting

green norms, and as this trend will only

increase in future, MWF industry will

witness huge demand for vegetable oil-

based coolants. M Krishna, MD, Master

Fluid Solutions (India) Pvt Ltd, says,

“Unfortunately, in the MWF sector,

the need for conserving environment is

at the ‘womb’ stage. Even some larger

multinationals seems to disregard the

need for better effluent treatment.

When the industry across developed

countries are running towards better

and stringent control mechanism,

India is learning to walk in these areas.

However, with global players setting

foot in India, the learning will become

faster for the Indian players.”

Choosing the Right Additives Choosing the right MWF for operations

is a Herculean and time-consuming task.

In order to select additives for a particular

application, both the advantages and

disadvantages of MWF products should

be compared through reviewing product

literature, supplier information and

usage history. Product performance

information shared by other machine

shops is another means of narrowing

choices. Ultimately, the best indicator

of fluid performance is through the

actual use.

While choosing fluids, it is

imperative that one should get value

for money. During fluid selection,

the benefits of fluids and their

versatility should be weighed against

its performance in each metalworking

application. Because of significant

improvements in fluid formulations,

fluids available today are capable of

handling a wide variety of machining

applications.

Usually, semi-synthetic coolants or

MWFs with Extreme Pressure (EP)

additives are used while machining

hard components made of titanium

and soft components like aluminium.

These EP additives help in reducing

friction between the tool and titanium

components, and provide proper finish.

It also strengthens aluminium, which

is comparably soft and melts even at

low temperatures. These EP additives

increase the chip welding property of

the coolant, thereby giving good finish

and ensuring fast removal of chips

from the tool that eventually increases

tool life. Machine shops that earlier

required several types of fluids may

now find that just one or two fluid

types meet their needs. Consolidating

the number of fluids used on the shop

floor simplifies fluid management.

Going Forward With emphasis on the reduction of

carbon footprints and adoption of

green process, several manufacturers

are experimenting with vegetable oil-

based coolants in their day-to-day

activities, as mineral oil and synthetic

alkanes are not appropriate to be

used as the base oil for environment-

friendly cutting fluids. This is because

mineral oils and synthetic alkanes are

poor at biodegradability, and remain

in water & soil for a long time,

causing pollution, whereas vegetable

oils and synthetic esters possess good

biodegradability properties. Since

the metalworking industry demands

environment-friendly and cost-effective

solutions, coolant industry constantly

needs to improve its products with

such additives that will reduce heat

generation and biocides to control the

bacterial growth and wastage, as well as

increase the tool life.

[email protected]

The World of Additives

� Boundary lubricity additives:

These are used to improve the

lubricity of the fluid by getting

adsorbed on the surface of the

metal to form a film, thereby

reducing metal-to-metal contact.

These additives generally have a

polar group that interfaces with

metal and a tail that is compatible

with mineral oil or water.

� Extreme pressure additives:

These are a special type of

boundary lubricity additives

that actually react with the

metal surface, instead of getting

adsorbed on the surface, to form

a metal-salt layer or a physical

barrier between the tool and

the workpiece under severe

metalworking conditions. They

contain molecular compounds

that react with metal surfaces

under extreme friction conditions,

producing a protective film that

prevents welding and surface

damage.

� Reserve alkalinity additives:

These are used for maintaining

the fluid’s corrosion by

neutralising acidic contaminants

and maintaining the pH in

a suitable range. It can also

form emulsifiers with other

components to stabilise the fluid.

� Stabilising oil-soluble additives:

These additives work in water-

dilutable MWFs by reducing

the interfacial tension between

incompatible components

by forming micelles (a sub-

microscopic aggregation of

molecules, as a droplet in a

colloidal system). These droplets

can then remain suspended in the

fluid. This is what happens when

we wash our hands.

MWF Additives

Syed Md Samim, Marketing Manager, Quaker Chemical India Ltd

MWF manufacturers need to focus on offering innovative products that are cost effective and satisfy customers’ changing needs.

M Krishna, MD, Master Fluid Solutions (India) Pvt Ltd

Unfortunately, in the MWF sector, the need for conserving environment is at the ‘womb’ stage.

TIPS & TRICKSThe Right MWF


Metalworking Fluids (MWFs) are crucial in the manufacturing and machining of metal products, from coins and wires to complex aerospace and medical parts. Apart from being a vital aid in producing high-quality finish, reducing tool wear and optimising machine performance, MWFs maintain a constant temperature and lubricity between the work piece and the tool, while simultaneously carrying metal chips away from the cutting area. Tarun Tampi reports...

Selecting the ‘PERFECT’ Cutting Fluid

[email protected]

Selecting an MWF for a particular machining operation requires an understanding of the basic types of MWFs and the

various compositions (additives, emulsions, etc.) they are available in. Although research is underway, there is no single

MWF that can be effectively used in every manufacturing facility, in every machining process and under every condition.

Some MWFs have better corrosion control, while others may lubricate better. Hence, an understanding of the benefits

and applications of each type of MWF along with corresponding machining processes are provided below.

Machining Process Synthetic Oil Semi-synthetic Soluble

Severity: Light milling, grinding (surface, double disk, rotary)

Rust inhibitors & cleaning agents only, no lubricants

Low oil content (5-10%), rust inhibitors

Severity: Moderate turning, grinding (tool room, internal, center and centreless)

Some polymeric lubricants High oil content (20-30%) High oil, esters & fats

Severity: Heavy drilling, sawing, tapping, reaming, gear cutting grinding (creep feed, form, thread & flute)

High level of polymeric lubricants + phosphate esters

High oil + EP lubricants High oil + EP lubricants

Excellent lubricity, rust control, long sump life, easy to manage

Expensive fill-up, excess heat generated, fire hazard, slip hazard, high mist formation

STRAIGHT OILS

Excellent physical lubricity, less heat generated, easy to manage

Heavy oil residues, affected by hard water, haze, mist and smoke formation

SOLUBLE OILS

Good heat reduction, physical lubricity, clean,

good rust control

May foam, affected by hard water

SEMI-SYNTHETICS

Very clean, excellent heat reduction, unaffected by

hard water, low foam, transparent mix

Poor physical lubricity, no oily protective films

SYNTHETICS


FACILITY VISITHittco Tools Ltd

H ittco Tools Ltd—a

B e n g a l u r u - b a s e d

company—started its

operations way back in

1974 as a High Speed

Steel (HSS) drills manufacturer, and

over the next four decades, it expanded

its portfolio to products like HSS taps

for threading operations. In 2008,

the company entered an entirely new

domain of carbide tools manufacturing.

“We took the decision to start

the carbide tool factory when most

people were wrapping up their business

activities due to recession. We had a

different perspective. When the market

is in full swing, manufacturers are so

busy executing the orders that they

do not observe the market trends. We

entered this segment during the deepest

recession, but when the market came

back to normalcy and orders started

to flow, we were ready to handle it,”

explains Rajib Ghosh Roy, Director -

Operations, Hittco Tools Ltd.

This segment of Hittco’s business

has grown by 80%, while the overall

growth of the company between 2008

and 2012 has been over 100%.

Keeping pace with the market

trends, Hittco Tools has found its

way to some of the major Indian

manufacturers in the automotive,

aerospace, railways, shipping, and

medical industries, among others.

Hittco now has experience and

theoretical knowledge in fields such

as tool material, tool geometry,

production process and quality

control. The company now has a pan-

India presence and its shop floor is

equipped with latest SPIBOMAT,

NORMAC, HERTLINE, WALTER

& ROLLOMATIC machines.

Business ModuleApart from being one of the key

suppliers to Indian companies, Hittco,

over the years, has been supplying to

various countries like Singapore, South

Korea, Philippines, Taiwan, Thailand,

Vietnam, Spain, Czech Republic,

Netherlands, West Asia, Turkey, South

Africa and the US.

“We are now working towards

making our global presence stronger

and bigger. The economic conditions

are confusing. And while the global

economic situation is difficult to

comprehend, the manufacturing is

shifting to Asia,” says Roy.

Hence, the company focusses on

manufacturing products to meet the

global demands. Roy further explains,

“Through our experience in various

countries and by understanding

their needs and demands, we have

Creating OPPORTUNITIES in Difficult Times

Sometimes, it is not the big investments but smart decisions that lead to success. From the 2008 recession to the precarious economic situation of the present time, Hittco Tools Ltd has learnt from its own experiences to widen its reach when others are going back into their shells. Debarati Basu finds out how a mid-sized company made the right moves during difficult times to strike the perfect equation of growth.

FACILITY VISITHittco Tools Ltd


Hittco Tools Ltd

continuously tried

to bring changes in our

products. The tool geometries

have to change

with the

c h a n g i n g

demands and we have been

introducing around five to six

new products every year in the

market.“

Given the vast

array of industries

that the company

caters to, the

tool dimensions

offered by it

range from

0.4 mm to 36 mm.

The company has also

caught the pulse of t h e

industry. Therefore,

despite being a mid-

sized organisation, it has

been successful in keeping the cost of its

products comparatively low.

“Today, the overall cost of

manufacturing has gone up right from

the cost of raw materials to the wages

of workers. Hence, every company

wants tools that can cut faster with

more precision and decrease the time of

manufacturing to increase productivity,”

says Roy.

To be in the competition with major

tool manufacturers, Hittco has been

consistently reducing the overhead costs

to bring down the cost of tools offered

to the market. “Bengaluru has some of

the major brands like Guhring, Seco,

Tagutec, Kennametal, etc., which means

that we have to provide tools that are at

par with international quality standards

to sustain ourselves in the market,”

says Roy.

The company, to bring down its

overhead cost, works on the ‘Just In

Time’ strategy, commonly called JIT.

Roy elaborates, “We never increase the

raw materials inventory level too high

and we have the kind of product mix

that sells off very quickly. This way, our

finished goods inventory is kept low,

which automatically keeps a check on

the bank interest from shooting too

high. Our raw material-buying pattern

also helps us to bring down the costs.

Reducing cost is a closed loop where

every entity of production has to be

taken care of.”

Quality Quotient Even though the cost of the tools offered

has to be kept low, in order to cater to

the global market, quality just cannot be

negotiated. Hittco has adopted a stringent

process of product inspection to reduce

the rate of rejection. “Apart from the

regular monitoring at every level, we have

inculcated a sense of ownership in every

operator where they check the products

themselves and implement immediate

steps of correction at the primary level

of manufacturing itself. Every employee

should have a sense of ownership and

take decisions in a way they would take

for their own company,” says Roy.

Challenges EncounteredSustaining in the market for a mid-

sized company has never been a

cakewalk. Also, the competition from

big manufacturers is just enormous.

Therefore, the challenges faced by

Hittco are huge.

“The main challenge that every SME

and MSME face today is that they do

not get the real price of the products

they sell. Many times, when the bigger

Indian players buy their supplies, the

optimum price is not given. The industry

needs to understand that the MSMEs

do not receive any government support

that they are entitled to and most of

them are neck deep in loans. On the

other hand, while the big companies

are growing by making huge profits,

the same profits are not shared with the

SMEs. If the country needs to grow, the

backbone of the country, comprising of

SMEs and MSMEs, needs to be taken

care of,” avers Roy.

Expansion PlansThe company already has over 150

employees at it two manufacturing units

designated for HSS and carbide tools. It

has had an annual turnover of `10 crore.

The company also has been diversifying

its portfolio and has recently entered

into manufacturing tool holders.

Now with the target to increase its

production, the company is planning

open branch offices in the USA and

Singapore. “Initially, we thought of

opening manufacturing units in these

countries, but our idea was to make India

the global manufacturer. This would be

our first extension outside India and the

offices will become operational by the

end of this year,” informs Roy.

With this expansion, the company

expects a growth of around 30%. Roy

positively affirms, “There is nothing like

a recession. It is the fear psychosis that

is making the bigger companies hold

back on the investment. How would the

market grow if money does not flow in

the market?”

The company is not just expanding

its business, but is also creating a

strong team that can make the brand

international.

Rajib Ghosh Roy, Director - Operations, Hittco Tools Ltd

The big companies, as they make money, need to share their profits with the SMEs and MSMEs. If the country wants to grow, the backbone of the country, comprising of SMEs and MSMEs, needs to be taken care of.

What is JIT?JIT or ‘Just in Time’ is a management

philosophy, a production strategy that

strives to improve a business return

on investment by reducing in-process

inventory and associated carrying

costs. This method is also called

the ‘Toyota Production System’. It

originally referred to the production

of goods to meet customer demand

exactly, within time, without failing

in quality and quantity. [email protected]

MM

T Ju

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96 Industry Snapshot Tracking the Growth

98 Construction Equipment Machining Creating an Era of Opportunity

100 Machining Solutions Offering Construction a Cutting Edge

104 Compact Rebar Shop Pumping Adrenaline into Process Efficiency

106 Manufacturing Modules Encountering Challenges in Construction

CONSTRUCTION EQUIPMENT

INSIGHTS & OUTLOOK



INSIGHTS & OUTLOOKIndustry Snapshot

The global construction equipment industry is experiencing robust development. While 2007 saw the growth of this industry at its peak, year 2008—09 saw a cumulative fall of 35.4%. However, it subsequently picked up, with skyrocketing momentum, and in 2011, its growth rate was approximately 26%, with the market value of roughly $190 billion. As the global construction equipment industry grows, India, too, is entering the league in a big way. Debarati Basu draws out the latest happenings in the construction equipment market from across the globe.

Caterpillar India sets up new manufacturing facility Construction and mining equipment maker, Caterpillar India, launched the

company’s new backhoe loader manufacturing facility at Thiruvallur near Chennai.

The new facility will strengthen the company’s presence in India and would

augment the distribution channel for earth-moving machines by bringing in

enhanced local production capabilities. This is the fourth manufacturing operation

in India. Caterpillar manufactures construction and mining equipment, diesel and

natural gas engines, industrial gas turbines and diesel-electric locomotives.

Isgec, Hitachi in joint venture ( JV)Isgec Heavy Engineering and

Hitachi Zosen Corporation,

Japan, joined hands to form Isgec

Hitachi Zosen to make specialised

and critical process equipment

with an investment of `100

crore. Isgec Heavy Engineering

is a leading global supplier of

process equipment and Hitachi

Zosen Corporation is a Japanese

engineering giant. The JV will

use one of the manufacturing

facilities of Isgec located at Dahej

in Gujarat. Isgec will hold 51%

stake in the new venture.

Hyundai Construction Equipment expands in Tamil NaduHyundai Construction Equipment India Pvt Ltd (HCEIPL), a subsidiary of

Hyundai Heavy Industries, opened a 3S facility at Puddukottai in Tamil Nadu

to cater to the needs of the fast-growing market in the South Indian state. It is

the fifth such facility, and along with Shristi Construction Equipment—a dealer

for HCEIPL—it will cover areas like Puddukottai, Tanjore, Sivagangai and

Tiruvarur. The expansion will help develop and expand operations in the Indian

excavator and backhoe loader business. Excavators in this region are employed

mainly for blue metal quarry (black stone) and granite quarry applications.

Tracking the GROWTH

Industry Snapshot


The Future TrendsLooking at the global business

environment in the construction

equipment market, we can say that the

Indian industry is well placed to enter

this market with with new developments

that meet the global requirements and

quality standards.

Ashok Leyland, John Deere enter into JVHinduja Group flagship Ashok Leyland

entered the construction equipment

business, along with American company

John Deere, with the launch of the 435

backhoe loader. Backhoe loader was

the first product to roll out the 50:50

JV. Around `200 crore was invested

in the first phase of the 435 backhoe

loader. The product will be sold under

the ‘Leyland Deere’ branding and

manufactured at a greenfield facility at

Gummidipoondi, near Chennai.

Volvo Rents acquires Action Equipment RentalVolvo Rents, a worldwide

provider of small to medium-sized

construction equipment, announces

the expansion of its operations in

New Mexico with the acquisition

of Action Equipment Rental,

a three-location construction

equipment rental company with

stores in Alamogordo, Las Cruces

and Silver City. With these

acquisitions, Volvo Rents now

has 120 outlets in North America,

including four in New Mexico.

Hitachi Construction expects record sales this yearHitachi Construction Machinery Co,

the world’s biggest maker of giant

excavators, expects its global sales of

mining equipment to reach a record

this year. The company won an order

from Vale SA (VALE5) to supply

excavators and dump trucks for an iron

ore project in Africa and has secured a

contract for gold mining equipment in

Turkey. Sales from mining companies

may surge by a third to ¥ 200 billion

($2.5 billion) in the year to March.

Volvo goes green with construction equipment To reduce greenhouse gas emissions, save resources, lower costs and help

protect the environment, Volvo Construction Equipment (Volvo CE) is offering

customers a range of revitalised components with its Volvo Reman programme.

In view of environmental care and cost effectiveness, more and more people are

willing to recycle, reuse and make the best use of limited resources. Volvo CE is

imbibing the same in the construction industry—evidenced by the Volvo Reman

programme, arguably one of the company’s most resource-friendly initiatives.

Chinese equipment maker acquires German concrete pump makerSANY, a fast-expanding Chinese construction equipment producer, in January

this year, acquired German concrete pump maker, Putzmeister Holding GmbH

for €525 million, making it one of the biggest purchases of a niche German

business by Chinese company. SANY intends to use its German acquisition to

reach new markets in the Western world, as well as to accelerate development of

its own technology and design.

SANY Heavy Industry starts crawler crane production in India SANY Heavy Industry India, subsidiary of one of China’s fastest-growing

manufacturing companies, SANY Group, started its first integrated crawler crane

production line at Chakan near Pune. The plant will substitute the import of

crawler cranes from China and cater to India’s growing needs. Earlier, the cranes

were imported from SANY China as per customer requirements. However, looking

at the constant growth of crane market and products receiving higher appreciation

by Indian customers, SANY has taken this step to start the production of cranes

at its manufacturing centre in India.

Hitachi unveils $15 million project in ZambiaTaking advantage of the Multi

-Facility Economic Zones of Zambian

economy, Hitachi Construction

Machinery Zambia Co Ltd recently

announced its re-manufacturing

factory project. The $15-million

project is the first-ever investment in

the Zambian manufacturing sector

by the Japanese company. Hitachi

is one of the largest manufacturers

of construction, mining and earth-

moving equipment in the world.

The plant will have value addition

activities through the provision and

repair of processing equipment.

[email protected]


INSIGHTS & OUTLOOKConstruction Equipment Machining

Infrastructure is an important

component for industrial and

overall economic development

of a nation. It is considered

as the yardstick to measure

the investment viability of a nation.

However, in India, there is a wide

gap between the potential demand for

infrastructure and its available supply.

To minimise this gap,

an investment

of around

$445 billion is required over the next

five years, which will directly affect the

overall business dynamics of construction

equipment manufacturers. The industry

will also have to grow at a Compounded

Annual Growth Rate (CAGR) of 15%

over the next five years to support the

growing requirements of every sector of

the economy.

Indian Construction Industry Considering the present industrial

growth, industries working for railways,

power sector, and construction

machinery, among others, are doing

extremely well. Companies like BHEL,

L&T–MHI and Siemens are finding

it difficult to cope with the orders

in hand. To cater to these demands,

they are investing in new technologies

to reduce the machining time of the

components, leading to an increase in

production.

According to market research firm

RNCOS, the Indian construction

equipment industry has been witnessing

a consistent double-digit growth over

the past few years. Though the economic

slowdown had a moderating effect on

the industry, it regained momentum

in 2010, showing a stupendous growth

that is expected to continue in the years

to come. The earth-moving segment, in

particular, has been driving the overall

construction equipment industry in

India, with strong demand emanating

from the government-backed

infrastructure projects. The

segment is poised

to register

a remarkable CAGR of around 21%

during 2011–2015, as per estimates.

According to Ramesh Chandak,

MD & CEO, KEC International Ltd,

“The Indian machine tool industry and

automation providers have an important

role to play in the infrastructure

sector. They can develop solutions to

achieve better quality with better safety

standards. Higher accuracy and better

interfaces, along with intelligence and

remote diagnostics that automation

processes offer today, are the trends

that can help India. This must not only

be restricted to large manufacturers,

but must be used by medium and small

units as well. Today, the availability

of skilled manpower is a constraint in

the construction segment and if better

technologies and automation requiring

lesser manpower can be developed, it

would be useful.”

In India, market penetration for

construction equipment used to be

very low. But growth in the Indian

construction industry has picked up

quite significantly over the past few

years. This industry is estimated to be

of around $12–14 billion by 2015. The

rapid pace of industrial development

in India is driving up demand for the

use of process automation to improve

manufacturing processes, especially for

high value-added applications. Indian

tooling firms have an important role to

play in helping manufacturers achieve

cost optimisation, enhanced productivity

and improved product quality by

introducing the latest automated

solutions in the market.

Creating an Era of Opportunity With the government projecting a whopping $1 trillion investment in the infrastructure sector during the 12th Plan Period (2012–17), several foreign firms are planning to enter the Indian market. This will certainly make the Indian machine tool builders more competitive and adopt international standards in their production process. Nishant Kashyap tracks the opportunities for machine tool builders in the construction equipment industry.

Construction Equipment Machining


Technology Trends Globalisation has forced companies to

use modern manufacturing methods.

Technology has increasingly altered the

manufacturing process of construction

equipment. While equipments

are being produced at faster rates,

manufacturers must continue to

balance increased productivity and

efficiency with quality & innovation.

Some modern technologies that can

boost manufacturing in the automotive

industry are programmable machines

& tools, industrial robots, data

management, supercomputing, virtual

manufacturing & complex visualisation

and advanced forging techniques.

G Devraj, MD, IMT Exim

India (P) Ltd, says, “Some of the

technologies, such as milling machine,

moving column, 5-axis machine,

double column and VMCs, are

mostly used for construction

equipment manufacturing. The size

of the machines ranges from 5–10 m.

But I feel that Indian machine tools

companies still need to work on their

technology to cater to the construction

equipment industry.”

Machine tools builders are constantly

developing new tool geometries and

technologies. Various tool geometries

are available to address the varied nature

of composite materials.

Metalworking OpportunityThe increasing number of infrastructure

projects in the country has created huge

demands for machine tool builders.

The construction sector is growing by

leaps and bound and so is the demand

for automated machines by the Indian

companies. The requirement in this

segment—in terms of volume—is also

increasing. As far as the competition

from the other Asian countries are

concerned, industry experts believe that

Indian machine builders can compete

with them in terms of technology and

knowledge, easily manufacture cost-

effective products and also provide

good service. “Because of infrastructure

development, the demand is picking up

for the construction equipment, which

will also positively impact the machine

tool industry. As of now, Indian

companies are only able to fill 20–30%

of the total infrastructure requirement.

Machine tool builders have a huge

opportunity in construction equipment

industry,” feels Devraj.

The machine tools manufacturers

in India produce general purpose

machinery of international standards in

terms of quality, precision and reliability.

However, they lag behind in design and

engineering capability. As a result, they

are not able to manufacture very-high-

precision CNC machines.

Future TrendsAs of now, Indian machine tool sector is

not very demanding. However, growth

in construction equipment, including

small component manufacturers who

are sub-suppliers to major infrastructure

projects, will create huge demand for

machine tools. Moreover, India is

gradually becoming a manufacturing

hub for all the major industries

worldwide. This will also lead to an

increased demand creation in the Indian

machine tool sector in the near future.

As a result, it becomes important

that Indian manufacturers invest in

sophisticated and flexible multi-purpose

machines for better productivity and

quality in manufacturing in order to

meet stringent international standards.

The Indian machine tool industry is all

set to leverage this demand. Going by

the statistics and recent developments,

the construction equipment industry

seems to be the next big focus for Indian

machine tool industry.

[email protected]

Infrastructure: Deficit and Eleventh Plan Physical Targets

Sector Deficit Eleventh Plan Targets

Roads/Highways 65,590 km of NH comprise only 2% of the network; carry 40% of traffic; the 12% four-laned; 50% two-laned; and 38% single-laned

Six-lane 6,500 km in Golden Quadilateral; four-lane 6,736 km NS-EW; four-lane 20,000 km; two-lane 20,000 km; 1,000 km Expressway

Ports Inadequate berths and rail/road connectivity New capacity: 485 m MT in major ports; 345 m MT in minor ports

Airports Inadequate runways, aircraft-handling capacity, parking space and terminal buildings

Modernise four metro and 35 non-metro airports; three greenfield in NER; seven other greenfield airports

Railways Old technology; saturated routes; slow speed (freight: 22 kmph; passengers: 50 kmph); low payload to tare ratio (2.5)

8,132 km new rail; 7,148 km gauge conversion; modernise 22 stations; dedicated freight corridors

Power 13.8% peaking deficit; 9.6% energy shortage; 40% transmission and distribution losses; absence of competition

Add 78,577 MW; access to all rural households

Source: Eleventh Five Year Plan, Government of India


INSIGHTS & OUTLOOKMachining Solutions

Welding Technology The Construction

equipment industry

is one of the biggest

customers of welding

equipments. Some of the

commonly used welding

processes are S h i e l d e d

Metal Arc Welding

(SMAW), Gas Metal

Arc Welding (GMAW),

Flux-Cored Arc Welding

(FCAW) and Gas

Tungsten Arc Welding

(GTAW). SMAW is the most common

type of welding. It is fairly inexpensive,

and can be used both on the shop floor

and out in the field. GMAW has a higher

welding speed than SMAW. FCAW

has an even higher welding speed, along

with better metal penetration. GTAW

is used when a weld is very important,

such as in aircraft applications. Some

other features of these welding processes

are discussed below:

� SMAW: It is defined as an arc

welding process in which metals

are coalesced with the help of heat

produced from an electric arc. This

arc is maintained between the tip

of a flux-covered electrode and the

surface of the base metal in the

joint being welded. This process

is commonly referred to as ‘stick

welding’. SMAW is one of the most

widely used welding processes in

the construction industry. The cost

is low and the equipment can be

portable. It can also be used in areas

of limited access in all positions, and

is a viable process for joining most

metals and alloys.

� GMAW: It is used to weld all

commercially important metals,

including steel, aluminium, copper

and stainless steel. It can be used

to weld metals in any position,

including flat, vertical, horizontal and

overhead. It is usually connected to

use direct current electrode positive

(DCEP). It is an arc welding process

that incorporates the automatic

feeding of a continuous, consumable

electrode that is shielded by an

externally supplied gas.

� FCAW: This welding process is

widely used on ferrous metals. The

consumable electrode can have an

interior flux or a mix of flux and

metal powder and has a tubular

form. The process can use DCEP

or DCEN (direct current electrode

negative) polarity, and is suitable for

all welding positions with the correct

filler metal selection, depending on

the flux composition.

� GTAW: It is versatile and can be

used both on ferrous and non-ferrous

metals and, depending on the base

metal, in all welding positions. The

process can be used to weld thin or

thick materials with or without a

filler metal.

Robotics Application Automated and semi-

automated means of

production have already

been introduced in the

construction industry,

and are being widely

used to manufacture

excavators, bulldozers,

draglines, etc. The automobile and

aerospace industries are widely using

Robotics systems. Robots used in the

manufacture of construction goods,

whether it is I-beams or insulation,

are becoming more advanced and are

gaining popularity. In the manufacturing

sector, robots are stationary while

product moves along the assembly

line. Therefore, automation is easier

to incorporate because each product is

identical with respective tasks done over

and over. However, construction robots

Employing new-generation cutting-edge technologies in the construction machinery manufacturing industry will greatly improve the state of our infrastructure, which, in turn, will stimulate revenue growth. It will also generate a huge demand for machine tools and better machining techniques. Nishant Kashyap discusses some new technologies that are being used in the machining field.


Machining Solutions

face different demands than conventional

industrial robots. These robots are

mostly used for welding, cutting and

material handling operations. Therefore,

they have to be specialised for their

respective functions. Such specialised

robots have the potential to raise

productivity by doing repetitive tasks

efficiently. They also improve working

conditions by working in areas that are

hazardous for humans.

Metal-cutting MethodsDue to high cost, less

speed and adverse side

effects of traditional

metal-cutting methods,

technologies such as

chip-less machining

processes automation,

Numeric Control

(NC) technique, electro discharge,

waterjet, plasma cutting system and

laser machining techniques have been

developed. Many equipment in the

construction industry have complex

shapes, and therefore, techniques, such

as multi-axis machining, which can be

used for manufacturing complex shapes

that are required. The use of computers

has also increased the precision and

efficiency of metal- cutting tools.

Nowadays, NC controls have become

more sophisticated as the concern

for environment has increased in the

manufacturing sector. However, new

metal cutting advancements are gaining

acceptance and applicability in the

industry. These advances could again

bring significant changes in the methods

employed to cut metal.

Lathe Machines A metal lathe or

metalworking lathe is

a large class of lathes

designed for precisely

machining relatively hard

materials. These rigid

machine tools remove

material from a rotating

workpiece via the (typically linear)

movements of various cutting tools,

such as tool bits and drill bits. “Turning

machines can be classified into various

categories like CNC lathes, which are

now replacing the older lathes due to

their ease in setting and operation. These

are designed to utilise modern tooling

and fully used modern processes. These

processes have been widely accepted in

the construction equipment industry

for sheet metal cutting operation,” says

Tom Sangho Shin, GM – Overseas

Sales Team, Machine Tools & FA BG,

Doosan Infracore Co Ltd. The part may

be designed, the tool paths programmed,

and the resulting file is uploaded to the

machine. Once it is set, the machine

will continue to turn out parts under the

occasional supervision of an operator.

On the other hand, for work requiring

extreme accuracy, a Swiss-style lathe is

often used.

Shin elaborates, “The collet sits

behind the guide bushing, while the

tools sit in front of it, holding stationary

on the Z-axis. The rigidity of the tool

makes it ideal for slender workpieces. To

cut lengthwise along the part, the tools

will move in and the material itself will

move back and forth along the Z-axis.”

Waterjet TechnologyIn the current scenario, where saving

the planet has become the most popular

mantra, companies are

adopting technologies

that are more

environment friendly. As

one of the most valuable

and extensive green

manufacturing methods

of metal-cutting process,

waterjet technology is gradually gaining

acceptance in the construction equipment

manufacturing. This technology has

proven to be a highly effective method

for cutting any flat material, including

stainless steel and aluminium. Waterjet

tool has parameters to define minimum

and maximum cutting lengths, and the

simulation checks for errors such as jet

cutting through multiple sections of

the workpiece, cutting through fixtures

when it should not, and cutting either

too close or too far from the jet nozzle.

It can cut large pieces of reusable scrap

material and prevent unnecessary waste

that gets creative from using traditional

cutting methods. It uses no chemicals,

gases or harmful liquids. It is a very

clean process and does not produce

any by product and wastewater. Thus,

waterjet technology provides a much

safer working environment.

Plasma CuttingSpeed, accuracy and the range of

materials that plasma cutting system

can cut have made it a

useful technology for

automobile and steel

companies to utilise

on a large scale. At the

same time, the demand

for this technology

is also increasing in

the construction equipment industry.

Plasma arc cutting is faster and cheaper

than oxyfuels, especially for cutting steel

up to 2-inch thick.

It also provides greater speed than

laser cutting systems for thickness over

0.125 inch. The plasma cutter has many

advantages:

� It is equipped with the latest

techniques to cut metal.

� It prevents the warping and paint

damage that occur while cutting.

� It is faster and cost effective than

other equipment.

� It cuts the metal accurately.

These aspects make plasma cutting

one of the best options in the industry

for cutting metals.

Looking AheadAs our economy is growing, it will create

new challenges and opportunities for

construction equipment manufacturers.

Moreover, as the Indian companies are

now working in a highly competitive

global environment, it becomes all

the more important that they employ

cutting-edge technologies. Such

technologies will not only help them

become quality conscious and cost

effective, but will also improve India’s

infrastructure, thereby contributing to

India’s growth story.

[email protected]


INSIGHTS & OUTLOOKCompact Rebar Shop

Economic pressures and the

huge opportunities lying

unclaimed in developing

markets have forced the

construction and associated

equipment industry to embrace advanced

technologies and concepts more readily.

Symptomatic of this shift is the gradual

rise in the implementation of automated

equipment for the processing and

handling of rebar. The Compact Rebar

Shop incorporates the latest equipment

for the cutting, bending and handling

of reinforcing bars, and all this, off-site.

Reassessing RebarThe common practice is to cut, bend

and process rebar on-site with the use

of large manpower. The process is

inefficient, expensive, time consuming

and results in unnecessary wastage of

steel, sometimes upto 5–7% of the total

volume. Improvements in productivity at

construction sites mean that one can build

a structure in 12 months as opposed to

two or three years, while simultaneously

supplying multiple projects from a rebar

shop. Aditya Mehta, Director, Jaypee

India Ltd, points out, “Site fabrication of

rebar, though effective in terms of instant

modifications or last-minute changes,

requires a detailed planning schedule

and highly skilled fabricators. In the

event of improper planning or unskilled

fabricators, it can result in an increase

in the wastage of steel by as much as

6%. Efficient off-site fabrication can

eliminate these costs.” One of the major

obstacles is the touch time involved

in the transportation and handling of

materials, using cranes, forklifts and

other lifting equipment involving manual

labour. Addressing the need to reduce

the touch time and minimise the use of

manual labour, Mehta explains, “With

rising costs of manpower and shortages

in the supply of skilled labour at job sites,

most construction companies find it

difficult to get enough skilled manpower

to execute large requirements in rebar

fabrication, thus, the need to have more

efficient equipment, which can fabricate

a higher tonnage of rebar, with the use

minimal manpower.”

Compact Rebar Shop: Who and How?The concept of the Compact Rebar Shop

was developed by KRB Machinery, US,

a company founded in 1986 that today

controls 70% of the market in the US and

is among the four largest manufacturers

of such equipment in the world. The

modular rebar shop concept is highly

specific to the optimal processing of

fabricated rebar with minimal touch

time. KRB tied up with the pioneers of

this technology in India, Jaypee India

Ltd, to commission two centralised

Pumping Adrenaline

In this era of rapid urbanisation, industrialisation and infrastructure development in the developing countries, the construction equipment industry is a rather volatile business, dependent on the fluctuations of unstable material costs and labour issues. Yet, the onus is on the industry to build faster and quicker, to squeeze phenomenal productivity from less and less. With technology, Tarun Tampi observes, this task is becoming increasingly possible. Nowhere is this more evident than in the Compact Rebar Shop, an innovative solution for rebar fabrication that pumps adrenaline into process efficiency.

into Process Efficiency

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Compact Rebar Shop


steel service centres in the country.

Established in 1982, the company

has led the industry in manufacturing

bar-bending and cutting equipment in

India. Jaymac, an iconic brand in rebar

processing equipment from Jaypee

India Ltd, is ubiquitous in the industry,

wherever rebar is processed. Therefore,

it was only natural that the two

companies would collaborate together

in introducing the technology in India,

thereby bringing the best and most

efficient international-standard

automatic equipment to the nation’s

construction industry. Reflecting

on the opportunities that this tie-

up provides to the Indian market,

Mehta observers, “The concept of

centralised rebar fabrication shops

is a budding concept across the

country, wherein many sectors of the

industry have found cost advantages

in the automatic method. The use

of highly efficient control systems,

in order to maintain the accuracy of

the final product, is very important

in these machines, and as a result,

had kept domestic manufacturers at

bay, considering the high costs of

developing the systems.” Therefore,

it was expensive and difficult to

develop such technology in a purely

indigenous fashion but that is where such

collaborations help. “Both international

collaborations and technology transfers

have a significant role in the growth of

the manufacturing sector in India. Such

collaborations give long-drawn technical

and commercial support to the home

industry. Also, such automated concepts

would not be practically feasible in India

since high-end electronics, drive systems

and requisite software are not currently

available here.”

Inside the ShopIt all begins when rebar arrives as raw

material at the facility. It needs to

be handled and transported from the

suppliers’ flatbed truck or railcar to a

storage or inventory space. Overhead

cranes then lift the rebar, as required,

onto processing machines. Till this

point, the efficiency cannot be improved

unless an excess of modern technology

devices and controls are used. One

of the first processing equipment

implemented in the compact rebar

shop is the AutoShakeout machine that

does the work equivalent to two men

in separating the required number of

bars for processing. The cutting system

is optimised to ensure a cutting strategy

that minimises scrap material, with

in-built controllers, logging scrap and

reducing inventory.

The bars are then fed, via walking

bins that index the bars, into automatic

double headed bending machines like the

MagnaBend (which can cut 25–40 tonne

of rebar in a single shift) or single headed

ones like the DuraBend. It is interesting

to note that so far, only one operator is

required to cut as much as 50 tonne of

rebar (depending on the size and shift)

with parametes fed in directly, say, by

scanning. Both the bending machines

required only one operator, aided by

user-friendly touch screen computer

controls that make the need for trial

and error bending redundant. The

ServoForm allows for the bending of any

other configurations that the other two

machines cannot handle, like stirrups and

ties. This again is completely automated,

with electromechanical servo motors and

pneumatic cylinders. Overall, the compact

rebar shop reduces the total manpower

required for the processing and handling

of rebar by 1/10th to 1/20th, resulting

in just three to four men operation—a

process whose output is virtually the

same as a full fledged factory. Illustrating

its benefits, Mehta says, “Being fully

automated with no dependence on

labour efficiency and productivity, even

our lowest capacity rebar processing

equipment outputs about 0.8 tonne per

hour of finished product, with variations

of approximately 0.1% from quoted

values, whereas in manually driven

processing, the variation could be as

high as 7–8% at minimum. Wastage

incurred in automated rebar shops

is approximately 2% at best, thus

the productivity increase would be

near about cent per cent. On site,

with manual operation, the wastage

could go as high as 7–8% of total

production.”

The Market OutsideImplementing the compact

rebar shop requires a thorough

understanding of how the system

works, what quantities and types of

rebar are required to be processed,

and what the total cost of ownership

involves. Jaypee experienced this first

hand while dealing with large and small

clients in India for the compact rebar

shop. Mehta charts the response from

the market, particularly in convincing

potential customers of the initial

investment, “The whole concept came in

India with much fanfare with many shops

being set up in a very short span of time.

No sooner did the companies realise that

the cost dynamics of this shop are much

more complicated than they assumed it

to be, which led to a slowdown in new

shops being set up. But the market has

matured since then, and the industry is

now looking at the process with a much

warmer perspective.”

As labour costs rise and automated

technology becomes cheaper and

easier to implement, the Compact

Rebar Shop is a natural solution to

increase productivity in a sustainable

and reliable manner.

[email protected]

� Aditya Mehta, Director, Jaypee India Ltd, next to the Multi-

Form 1016M that automates the bending and shearing of

deformed straight or coiled rebar.

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INSIGHTS & OUTLOOKManufacturing Modules

Since the process of selection

is closely associated with

the factors that influence

the quality of end products,

selection of methods, tools and

processes becomes extremely important

in manufacturing any product. Some

key factors that should be taken into

account before opting for a specific

selection process are the type and size

of equipment, efficiency, working

conditions, job type and operator’s

experience. Many new developments

have taken place in construction

equipment manufacturing, such as

using new materials & machines and

increasing use of automated systems

like robots and Product Lifecycle

Management (PLM) systems, among

others. Moreover, many new materials,

such as alloys, coatings, etc., are being

developed for use in construction

equipment manufacturing. These new

materials are not only corrosion free, but

are also very strong.

Significance of MetalsThere is no simple definition for ‘metal’;

any chemical element having ‘metallic

properties’ is classified as a ‘metal’. Some

of these metallic properties include

sheen or shiny metallic appearance, good

electrical & thermal conductivity, the

potential of being permanently deformed

or shaped at room temperature and

malleability & ductility. Metal is used as

a structural framework for large buildings

such as skyscrapers, or as an external

surface covering and in manufacturing

earth-moving equipment such as loaders,

cranes, etc. Metals are also used for

building construction equipment such as

titanium, chrome, gold or silver.

An example of alloy that finds

extensive use in construction equipment

manufacturing is steel. It is a metal

alloy whose major component is iron

and is the most common choice for

structural building materials because of

its strength, versatility, durability and

economic value. Among its most popular

uses today are standing seam metal roofs;

it is also 100% recyclable. Earlier, A7

grade steel was used in the construction

equipment industry. However, A7’s

successor—A36/A36M, the standard

specification for carbon structural

steel—is now widely used in riveted,

bolted or welded construction of bridges

& buildings and for general structural

purposes. As corrosion can harm steel

quality, ultimately contributing to

product failure, protection against rust

and corrosion is critical to the life-span

of steel and its continued use in various

applications and products. Therefore,

steel is protected by a number of

methods ranging from internal alloying

to metallic coatings.

Though these new materials and

alloys provide efficiency and durability

to the construction equipment industry,

they need special attention in machining.

Some of these materials with complex

geometries require multi-axis machining

and tools. They also need high-tech

welding systems.

Machining Technologies In the construction industry, the metals

used for manufacturing the parts change

as per the project and geography.

Often, to manufacture the same kind

of product, two different categories of

metals are required, which call for using

different machining techniques. For

instance, to cut a metal into 3-cm thin

strips, depending on the type of metal,

waterjet or laser cutting technique is

used.

New technologies are continuously

being developed in the construction

industry. They involve special tool

materials & tool geometries and specific

tool design, matching the uniqueness of

operations that are indispensible for the

Construction equipment as a segment faces some fundamental challenges in tool selection, use of materials, operation & maintenance and replacement of equipment components. Nishant Kashyap looks into some of the critical factors that affect the overall dynamics of construction equipment manufacturing.

Manufacturing Modules


future growth of the tooling industry.

Methods like laser, plasma, Electrical

Discharge Machining (EDM), waterjet,

etc., are used as per the job specification

and requirements, resulting in better

productivity, speed and reduction in the

cost of machining.

The key to producing quality

work and making wise investment in

equipment is having information on the

type of cutting method that would be

most suitable for a particular application.

While waterjet cutting is perceived as

competing with laser, plasma and EDM,

many shops view these processes as

complementary to each other and use

more than one method.

Advantages of PLMPLM system helps manage product

data and integrate & automate business

processes. Thus, it helps in improving

efficiency, which consequently enables

companies to develop more new

products, shorten time to market, reduce

costs, increase productivity and improve

the quality of products & procedures.

As a result, all major construction

equipment manufacturers have adopted

the PLM solution.

Vivek Marwaha, Director –

Marketing, Siemens PLM Software,

explains, “Three application areas of

PLM have evolved—traditional design

mechanical automation (CAD/CAM/

CAE), digital life-cycle management

and digital manufacturing solution (this

is all about simulation and manipulating

processes, before putting the product

for the actual manufacturing). In an

ideal solution, with the use of digital

manufacturing, a company should

be able to simulate the entire plant/

factory they plan to set up and arrive

at the most optimum architecture for

their new plant/factory.” Huge demand

from the customers and the need to

deliver products in time have made

these companies realise the importance

of using the latest technology to grab

maximum market share. All these

factors have forced PLM solution

providers to offer affordable solutions to

these companies.

Future Trends The current trend in the construction

industry is to minimise the cycle time

& quality variance, and achieve these

objectives with optimum cost by keeping

the effective cost/component as low as

possible. This trend has posed challenges

to metalworking and allied industries

to provide better and cost-effective

solutions to the construction equipment

manufacturers. With the government

determined to increase the contribution

of the infrastructure sector to the national

GDP, the sector will provide immense

opportunities for the metalworking

industry, PLM solution suppliers and

automated (CAD/CAM) solution

providers & material vendors in the form

of simple trading and sourcing, setting up

partnerships, wholly-owned subsidiaries,

manufacturing units and in exploring

technology collaborations in India.

[email protected]


INSIGHTS & OUTLOOKEnergy Magement

The increase in energy costs has made the efficient use of kilowatts more important than ever. European firms have long known this, as energy costs are much higher in Europe than in North America. Although some retrofitting of older equipment may be helpful, newer equipment is designed and built to use less energy than machines put in service only five years ago.

Motors, drives, controls

and machine design

improvements can save

operating cost, thereby

reducing overhead

costs. Some of these advancements are

reviewed below.

Electric Feedback in All Drives Power source regeneration uses the

concept that motors act as generators

whenever they decelerate, which is

about as often as they accelerate. Turret

indexing motors on Index and Traub

machines, for example, are also used

to drive rotating tools, and therefore,

decelerate frequently. With modern

machine tools, it is possible to recover

power from both the axis and spindle

motors.

Regenerative drives on advanced

machines convert the motion energy of

all braking operations on spindles and

axis drives directly into electrical energy

and feed it back to the supply network.

This reduces energy consumption on a

sustainable basis and reduces the heat

emission in the proximity of the machine.

Drives capable of power source

regeneration can redirect it and return it

to the power supply through intelligent

power modules. The result, it has

been estimated, is that power-source

regeneration can cut net energy use by

as much as 40%.

Power source regeneration yields

the best returns for applications with

high speeds and frequent changes in

acceleration. Multi-tasking machines

with multiple tool changes in a cycle

and only one second between cuts means

that the spindle motor has to decelerate

from 8,000 rpm to zero almost instantly.

As the motor decelerates or brakes, a lot

of energy is released. Capturing it and

returning it to the power supply is a

great example of efficiency.

Use of Synchronous Motors Properly sized motors and drives also

add savings. Alternating current (AC)

motors feature a rotor spinning with

coils passing magnets at the same rate

as the AC and resulting magnetic field

that drives it, avoiding energy-wasting

slip under most operating conditions.

They operate synchronously with line

frequency. An induction motor, on the

other hand, slips in order to produce

torque. Synchronous motors are a

highly efficient means of converting

AC energy to work. They are typically

used in positioning machine axes where

high precision and constant speed are

required. Most European builders are

prepared to provide power consumption

details because of the required energy

tags (CE) mandated in Europe.

Reduce Energy Also, there are clever mechanical

designs are also appearing, which reduce

the weight of the axis components in

the machine tool, thus requiring less

USING ENERGY EFFICIENTLYCan Boost Profi tability

ENERGY MANAGEMENTDrives & Motors


Drives & Motors

energy to move them. The turret slides

of an Index automatic lathe move in the

‘X’ and ‘Z’ directions on a single slide,

plate-type slide system. This system,

unique to Index, permits rapids as much

as 60 m/min and accelerations as much

as 1 G while maintaining rigidity. Using

this plate-type guideway for the turret

slides also means that turrets glide

directly on the machine bed, resulting

in high stiffness and dampening, longer

tool life and better surface finish while

reducing energy consumption.

Saving through Shorter Cycle Times As machines use energy when they are

switched on and even more while they

are cutting, the two most cost-effective

options for reducing consumption

are to optimise machine usage and

minimise run time. An idle machine

can use several hundred watts simply at

rest. Properly sized motors and servos

relative to the mechanical weight and

structure of the machine can also save

energy, potentially reducing peak-

power requirements. Plus, they respond

quicker, and therefore, can help reduce

cycle times. Compared with a less well-

designed machine system, it has been

estimated that a machine designed

with this type of efficiency in mind can

save 1 to 2 kW an hour per machine,

per shift.

Reduced Consumption If a machine has some scheduled stops

during the shift or at the end of an

unmanned job, the controller should be

able to turn off affected parts of the

machine—as any PC does. Turning

off motors, such as those running fans,

pumps and chip conveyors, can save a

lot of energy, and while the spindle is

not turning, it may also be powered

down. Adjusting the cycle of the chip

conveyor can contribute to meaningful

energy savings, particularly when

combined with turning it off completely

at the end of production. The automatic

shutdown function of machines today

automatically shuts down all high energy

consuming units after a user-defined

time elapses following an unplanned

production interruption (standby mode).

Centrally Controlled Machine Cooling System Older Direct Current (DC) motors and

some large Variable Frequency Drives

(VFDs) include resistors on top of the

control cabinet to dissipate the heat

directly into the shop. Smaller VFDs,

however, include bleeder resistors inside

the drive housing, which means the heat

is retained inside the cabinet.

In these cases, a larger air conditioner

is installed on the cabinet to protect the

electronics inside. But this arrangement

results in an energy efficiency loss, plus

the electricity to cool the cabinet and/or

the shop costs money.

The cooling concept from Index Corp

cools the spindles, hydraulics and control

cabinet constantly and the captured heat

can be fed to another useful application

via a ‘water interface,’ for example, for

service water heating or as process heat

for other manufacturing steps.

The cold water interface provides

the ability to dissipate heat in a climate-

neutral manner if the machine waste

heat stored in the cooling medium

cannot otherwise be used. The cooling

unit can, with the aid of the water

interface, be used outside the shop as

well as centrally across several machines.

This offers considerable potential energy

savings for shop cooling/climate control,

and/or increased efficiency, as a result of

centralised heat disposal.

Targeted Heat Dissipation All high-loss heat sources of advanced

machines can be cooled directly with

different cooling media via multiple

fluid circuits. In addition to the cooling

circuits for the main spindle, counter

spindle and milling spindles, the

hydraulic system and control cabinet

also have a separate cooling circuit. The

lost heat energy is absorbed directly

in the fluid and conducted from the

machine to a central location.

Offline Simulation Techniques Programme simulation offers a

major opportunity to optimise a

machine’s operation, and therefore,

reduce wasteful, energy-using motion

even before the machine’s power

switch is turned on. Machining

programmes can be created, checked

and optimised on a PC before they

are loaded into the control with 3D

simulation. Optimised cycles permit

field-oriented applications, tested and

reliable operation, maximum flexibility,

shortest possible machining times and

optimum machine usage.

As machines become more

complicated, simulation becomes more

helpful in saving setup time—potentially

50% to 75%—because users do not have

to tool and run the machine to complete a

setup. Machine time is very expensive and

if users can save 50% on setup time, they

can get that much more production out

of a 24-hour day, avoiding machine idle

time and maximising productive time.

Wrapping UpCost savings are where you find them,

and these are only some of the ways

that machine builders are responding to

the demand for more energy-efficient

machine tools. The quest is on, and it’s

delivering tangible results.

� In addition to more energy-eff icient electronics,

such as axis drive and spindle motors,

mechanical designs using less mass are being

incorporated to reduce energy requirements for

motion without sacrif icing rigidity. Courtesy: MMS Magazine

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REPORTACMEE-2012

The year 2012 has been an

excellent one for Tamil

Nadu in striking the best

investment deals. Yet the

amount of investment

trickling in is just the beginning of what

the state has to offer. The 10th edition of

the biennial international machine tools

exhibition, ACMEE-2012, is being

held at just the right time.

Organised by Ambattur Industrial

Estate Manufacturers Association

(AIEMA), the event is the ideal tool for

Chennai to advertise its potential to the

world. ACMEE-2012, was inaugurated

on June 14, 2012, at Chennai Trade

Centre amidst the august presence of

Thiru MC Sampath, Hon’ble Minister

of Rural Industries and Nutritious Noon

Meal. Dr Niranjan Mardi, Principal

Secretary, MSME Department, presided

over the event. Other luminaries who

graced the inauguration ceremony

included Thiru Hans Raj Varma, CMD,

TANSIDCO; P Sriram, Chairman,

CIT; Satish Sadasivan, MD, Schunk

India; John Donlon, Executive VP,

HURCO; Brijesh Agarwal, COO,

Indiamart.com; P Ramdas, MD, ACE;

RSS Satish Babu, Chairman ATC; and

K Ayyappan, President, AIEMA, among

others.

Commenting on the importance of

ACMEE at the inaugural ceremony,

MV Robert, Chairman, ACMEE,

said, “The Government of Tamil

Nadu recently announced its Vision

2023, which focusses on two main

strategic initiatives for upgradation of

manufacturing technology and MSME

development. ACMEE is working

towards this.”

Talking about the extensive growth

in the Ambattur Industrial Estate,

Sampath elaborated that Ambattur,

being one of the oldest industrial

estates in the small and medium sectors,

offers direct and indirect employment

to nearly 2,80,000 people. It has a

turnover of nearly `8,000 crore. He

added, “AIEMA has been established

to champion the cause of the small and

medium sectors, to help voice their

grievances and other difficulties in their

business operations to the government,

and collaborate with the state & central

government agencies to provide suitable

solutions.” ACMEE-2012 saw heavy

participation from overseas delegates,

as well as from companies from all

over India.

Visitors to ACMEE-2012 witnessed

a variety of technologies including

abrasives, automotive component parts

& supplies, bearings, CAD/CAM

solutions, power tools, and low-cost

automation solutions, among others.

Expanding Global ReachThe exhibition has grown exponentially

through each of its 10 editions so far.

This edition had over 430 exhibitors

(both national and international) who

participated in the exhibition. A host of

Tamil Nadu, over the years, has developed the perfect ecology for manufacturing, metalworking and automotive industries. But is that enough? With the exponential growth of the global industry, coupled with rising demands and challenges, the state has to go beyond the conventional to prove itself as an enviable investment destination. Promising to be a platform to upgrade, build technology awareness and foster business prospects, ACMEE-2012 opened its doors for investment to pour in. MMT reports…

Thiru MC Sampath, Minister of Rural Industries and Nutritious Noon Meal

Exhibitions like ACMEE will strengthen the rapid progress and industrialisation in the state and help usher in economic development, not only for the people of Tamil Nadu, but the whole country as well. Trade shows like these also help in extending the benefits of the local industry to various overseas participants.

Broadening the Scope of Opportunities

ACMEE-2012


Photos by Prateek Sur

countries participated in the exhibition,

with special pavilions for companies

from Taiwan and South Korea. In-Ho

Shin, President, Korea Machine Tool

Manufacturers’ Association (KOMMA),

expressed, “We had earlier taken part in

the expo held in Bengaluru and realised

that Chennai too is a potential market.

This is the first time we are here with

seven Korean companies.”

He added, “India is the 7th largest

consumer in the world and is one of the

fastest growing industry. Being a major

automotive hub of the country, Chennai

has a huge potential for machine tool

builders. All these make it important

for Korean companies to showcase their

expertise in India.”

Thiru Hans Raj Varma, CMD, Tamilnadu Small Industries Development Corporation Ltd (TANSIDCO)

Dr Niranjan Mardi, Principal Secretary, MSME Department

I congratulate ACMEE-2012 for the overwhelming response that it has received. As a part of the recently released Vision 2023 document for Tamil Nadu, the initiatives taken by government include the allotment of `50 crore for the development of district industrial centres in 32 districts, implementation of common facilitation centres for 20 industrial clusters and programme to encourage first-generation entrepreneurs. The Department acts as a catalyst for the development of the medium-scale industries.

We have been working towards the promotion and development of the MSME industry in Tamil Nadu. We have taken up skill-development initiatives, best technology and management practices for which we are seeking proactive partnership from the industries. We will be further working towards making the MSME industry proactive. Further to this, I complement ACMEE for taking up this initiative of encouraging business in the state.

� Thiru MC Sampath, Hon’ble Minister of

Rural Industries and Nutritious Noon Meal,

Government of Tamil Nadu, inaugurates

ACMEE-2012 by lighting the traditional

lamp in the presence of eminent dignitaries.

� Thiru MC Sampath, Hon’ble Minister of

Rural Industries and Nutritious Noon Meal,

Government of Tamil Nadu, witnesses a live

demonstration at the FANUC stall after the

inauguration.

This was the first time that we exhibited in ACMEE. This exhibition is a way for us to increase our exposure and reach in Chennai. We are the only company exhibiting fully-automated products. Since we displayed our machines and demonstrated the process, the visitors could touch, feel and know the machines better.

The quality of the exhibition has significantly gone up both in the number of participants and the quality of exhibits. My main purpose is to understand the new trends in the market & promote parts & components of my company to the exhibitors here.

The range of exhibits this year is wonderful and I could meet many companies of my interest. I am into valves manufacturing and this exhibition has broadened my knowledge in this segment. The wide range of companies also gives opportunities to strike good deals.

AV Srinivasan, CEO, Meiban Engineering Technologies Pvt Ltd

KS Srinivasan, GM - Marketing, Star Circlips & Engineering Ltd

S Raghuram, Director - Operations, Oliver Valves India Pvt Ltd

We have been regularly participating in ACMEE and have been in association with this show since its 2005 edition. ACMEE is more of a platform to propagate our brand and create awareness about our products among the visitors. We have had a good response and many of the visitors have also shown serious business interest in our products.

Satyanarayanan A, GM - Regional Sales, UCAM Pvt Ltd

Exhibitors’ Views

Visitors’ Views

Taiwan participated with more

than 13 machine and tool companies

in the exhibition. Henry Chen, Chief

Executive, Evergreat Yota Machine Co

Ltd, who participated in this event for

the first time, said, “I was mainly looking

for dealers in India and have already met

some potential clients. Next time, we

would come with bigger stalls and more

machinery to display at the event.”

Other countries present at the

expo included Austria, Australia,

Brazil, China, France, Germany, Italy,

Malaysia, Norway, Russia, Singapore,

Spain, Switzerland, Thailand, Turkey,

the UAE, the USA and the UK.


EVENT PREVIEWAMTEX 2012

The Asian Machine Tools

Exhibition (AMTEX)

has grown by 300% since

its inception 12 years

ago, and has now become

one of the largest shows of machine

tools, machineries and manufacturing

technologies in Asia. It is working

towards creating a platform where

all relevant sectors and technologies

could interact. It offers the exhibitors

an opportunity to present brand new

approaches to enhance productivity by

optimising the production process. Here,

the key industrial sectors can display

their individual strengths, and, at the

same time, engage in interdisciplinary

knowledge transfer.

An International EventThe 8th Indiamart AMTEX 2012, as

in the past editions, will provide its

visitors with technological solutions

to enhance their competitiveness. A

large proportion of visitors from the

metalworking, automobile, aerospace,

industrial automation and general

engineering industries are expected

to visit the exhibition in search of

innovative solutions. It will present the

visitors a unique cross section of key

metalworking technologies.

The grand event would witness

representation from 16 countries

including Germany, Italy, Switzerland,

Czechoslovakia, the US, Sweden,

Belgium, Spain, Israel, Turkey, Japan,

China, Korea, Malaysia, Sri Lanka

and Singapore. Exclusive Chinese,

Taiwanese and Korean pavilions will be

the principal attraction.

Opportunities GaloreAMTEX 2012 will be a splendid

spectacle of the latest advances in

machine tools and manufacturing

solutions. More than 1,600 exhibitors,

sprawled in Hall Nos. 2A, 8, 10, 11,

12 and 15, will be participating in the

event and will put their efficiency and

innovative power to test before eager

national and international visitors.

Terrence Miranda, MD, HAAS

India Pvt Ltd, says, “AMTEX promises

to be a key exhibition for us this year,

which is why we opted to be one of

its sponsors. The events in Europe,

currency fluctuations and global

economic uncertainty are all combining

to create tough trading conditions,

especially for importers like HAAS.

However, irrespective of where a small-

to mid-sized machine shop is based,

they all share the need for reliable,

high-productivity, well-supported and

affordable machine tools.”

Triune Exhibitors Pvt Ltd, India’s leading organiser of industrial exhibitions, is all set to host the 8th

Indiamart AMTEX 2012 at Pragati Maidan, New Delhi, India, from July 27–30, 2012. The exhibition will offer a superlative stage for showcasing the latest in machine tools, be it product service or new-age applications. It facilitates interaction between manufacturers, suppliers and users of the growing Indian market on one platform. Nishant Kashyap reports…

A Gateway to Exciting Opportunities

Exhibitors’ Profile

� Lathes & CNCs

� Machining centres

� Electric Discharge Machines

� Hydraulic, mechanical &

pneumatic presses

� Shearing and bending machines

� Metal-forming machine tools

� Drilling and boring machines

� Milling and grinding machines

� Gear-cutting and finishing

machines

� Assembling systems & industrial

robots

� Sawing and cutting machines

� Measuring and testing

instruments

(This list is only illustrative and features only a

limited number of profiles.)

[email protected]

Event List - National


AMTEX 2012AMTEX (Asian Machine Tools Exhibition)

has constantly strengthened its position as

one of the largest shows of machine tools,

machineries and manufacturing technologies

in Asia. The event will showcase the latest

advances in machine tools and manufacturing

solutions; July 27-30, 2012; Pragati Maidan,

New Delhi.

For details, contact:

Triune Exhibitors Pvt Ltd

25, 3rd Floor, 8th Main Road

Vasanthnagar, Bangalore 560 052

Tel: +91 80 4330 7474

Fax: +91 80 2235 2772


Web: www.triuneexhibitors.com

Automation 2012The event will showcase the power of

collaboration between solution providers,

ie, vendors, engineering companies

and actual users of the technology. The

conference held during the course of the

event also provides an excellent insight in

the latest practices; September 7–10, 2012,

Bombay Exhibition Centre, Mumbai


IED Communications Ltd,

243, Shiv Shakti Industrial Estate,

Marol, Andheri Kurla Road,

Opp Mittal Estate, Andheri (E)

Mumbai 400059

Tel: 28505138/ 28514673

India Manufacturing Show 2012 The exhibition is an ideal platform of

all Indian and global manufacturing,

engineering and other ancillary industries

including Public Sector Undertakings

(PSUs), especially for the micro, small and

medium enterprises; September 27-30,

2012; Bangalore International Centre,

Bengaluru.


IMS Foundation

#15/47, 47th A Cross, 8th Block, Jayanagar

Near Gelli Apartments, Bengaluru

Tel: 80 2665 1234/4171 6085


Web: www.indiamanufacturingshow.com

CeMAT India 2012One-stop shop for the automotive and

transport, infrastructure, manufacturing,

pharmaceuticals, dry ports, steel and food

processing sectors; November 21-24, 2012;

India Expo Centre, Delhi.


Hannover Milano Fairs India Pvt Ltd

No 13/16, Vatika Business Centre

Wing B, 7th Floor, Supreme Business

Park, Hiranandani Gardens,

Powai, Mumbai 400076

Tel: 91 22 40050681/82

Fax: 91 22 40050683


Web: www.cemat-india.com

Industrial Automation India 2012International trade fair for process &

production, automation and industrial

building automation; November 21-24,

2012; India Expo Center, Delhi.


Hannover Milano Fairs India Pvt Ltd

No 13/16, Vatika Business Centre

Wing B, 7th Floor, Supreme Business

Park, Hiranandani Gardens,

Powai, Mumbai 400076

Tel: 91 22 40050681/82

Fax: 91 22 40050683


Web: www.ia-india.com

IMTEX 2013The 16th Indian Metal-cutting Machine Tool

Exhibition, with international participation,

will showcase the exhaustive range of

innovations and technological refinements

in the complete product segment of metal-

cutting machine tools and manufacturing

solutions.

The concurrent event—Tooltech 2011—

the international exhibition of cutting tools,

tooling systems, machine tool accessories,

metrology and CAD/CAM, will feature

the latest trends in cutting tools and tooling

systems from across the globe; January

24-30, 2013; at Bangalore International

Exhibition Centre (BIEC), Bengaluru.


Indian Machine Tool Manufacturers’

Association

Bangalore International Exhibition

Centre, 10th Mile, Tumkur Road

Madavara Post, Bengaluru

Tel: 080 6624 6600

Fax: 080 6624 6661


Web: www.imtex.in

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

Electronics, Material Handling and Safety Equipment.

For details

Infomedia18 Ltd, Ruby House, 1st Floor, JK Sawant Marg, Dadar (W), Mumbai 400 028.

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

• Web: www.engg-expo.com

LUDHIANAPunjab

Dec 21-24, 2012

AHMEDABADGujarat

Oct 5-8, 2012

CHENNAITamil Nadu

Nov 22-25, 2012

PUNEMaharastra

Nov 2-5, 2012

INDOREMadhya Pradesh

Jan 11-14, 2013

AURANGABADMaharastra

Feb 1-4, 2013

RUDRAPURUttarakhand

Feb 23-26, 2013

Event List - International


MTA VIETNAM 2012 The 10th exhibition will serve as a platform to

network with pioneers from machine tools,

precision engineering and metalworking

technology sector; July 3–6, 2012; Saigon

Exhibition & Convention Centre, Ho Chi

Minh City, Vietnam.


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,

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

AsiaMold 2012Innovative technologies, informative

events and increasing business

opportunities make the exhibition the

most distinguished mould-making and

tooling design exhibition; September

19-21, 2012; Guangzhou Poly World

Trade Center, China.


DEMAT GmbH

Carl-von-Noorden-Platz 5

60596 Frankfurt/Main

Tel: +49/69/27 40 03-0


Web: www.asiamold.de

BI-MUThe 28th international event will

showcase latest in metal-forming

& metal-cutting machines, robots,

automation and auxiliary technologies;

October 2-6, 2012; Fiera Milano, Italy.


BI-MU c/o

CEU-CENTRO ESPOSIZIONI

UCIMU SPA

viale Fulvio Testi 128

20092 Cinisello Balsamo MI, Italy

Tel: +39 0226 255 234/860

Fax: +39 0226 255 897


Web: www.bimu-sfortec.com

METALEX Vietnam 2012 The international exhibition will be

the all-under-one-roof meeting centre

for new machine tools, metalworking

technologies; October 4-6, 2012; Saigon

Exhibition & Convention Center

(SECC), Vietnam.


32nd floor, Sathorn Nakorn Tower,

North Sathon Road, Silom, Bangrak

Bangkok, Thailand

Tel: +66 2686 7299, Fax: +66 2686 7288


Web: www.reedtradex.com

EuroBLECH 2012The world’s largest International Sheet

Metal Working Technology Exhibition

will emphasise on energy-efficient

technology, environment-friendly

manufacturing processes and intelligent

use of material; October 23 -27, 2012;

Hanover, Germany.


Mack Brooks Exhibitions

Romeland House, Romeland Hill

St Albans, Herts AL3 4ET, UK

Tel: +44 0 1727 814400

Fax: +44 0 1727 814401


Web: www.euroblech.com

JIMTOFThe 26th Japan International Machine

Tool Fair will contribute to the

promotion of industry and trade through

increased international transactions and

technical exchanges of machine tools

and their related equipment; November

1-6, 2012; Tokyo Big Sight (Tokyo

International Exhibition Center), Japan.


JIMTOF Fair Management

(Tokyo Big Sight Inc.)

3-11-1 Ariake Koto Tokyo,

JAPAN 135-0063

Tel: 03 5530 1333 (Direct dialing)

Fax: 03 5530 1222

Web: www.jimtof.org

EuroMold 2012International trade fair for Moldmaking

and Tooling, Design and Application

Development; November 27-30, 2012;

Frankfurt, Germany.


DEMAT GmbH

Carl-von-Noorden-Platz 5

60596 Frankfurt am Main

Germany

Tel: +49 69 27 40 03 - 0

Fax: +49 69 27 40 03 - 40


Web: www.euromold.com

Th e information published in this section is as per the

details furnished by the respective organisers.

In any case, it does not represent the views of

Tenders


Latest Popular Tenders brought to you by www.tendersinfo.com

Org: Organisation’s name, TRN: Tendersinfo Ref No, Desc: Description, DSLD: Doc Sale Last Date, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type.

INFORMATION COURTESY: TENDERSINFO.COM1, Arch Gold, Next to MTNL Exchange, Poisar, S.V. Road, Kandivali (W), Mumbai - 400067, Maharashtra, India

Tel: +91-22-28666134 • Fax: +91-22-28013817 • Email: [email protected]

CNC MACHINING CENTRE

Org : Ordnance Factory Board

TRN : 11519333

Desc : Tenders are invited for supply of CNC Machining Centre for 03 Nos.

BOD : July 17, 2012

LOC : India

BT : Tender

SB CNC TURNING CENTRE

Org : Ordnance Factory Katni

TRN : 11495402

Desc : Tenders are invited for supply of double-ended pedestel grinding machine.

BOD : July 18, 2012

LOC : India

BT : Tender

2000 MM LATHE MACHINE

Org : Ministry of Defence

TRN : 11481955

Desc : Tenders are invited for supply of 02 Nos of 2000 mm Lathe Machine

BOD : July 10, 2012

LOC : India

BT : Tender

TOOLED UP CNC CYLINDRICAL GRINDING MACHINE

Org : Rifle Factory

TRN : 11463998

Desc : Tenders are invited for supply of tooled up CNC Cylindrical Grinding Machine for grinding operation of barrel of 5.56 mm Insas Rifle, 0.315” Sporting Rifle & 30.06 Sporting Rifle

BOD : July 31, 2012

LOC : India

BT : Tender

CNC LASE CUTTING MACHINE BELLOWS

Org : Diesel Locomotive Works

TRN : 11419450

Desc : Tenders are invited for supply of spare parts for CNC laser cutting machine bellows with

installtion and commissioning

BOD : July 2, 2012

LOC : India

BT : Tender

UNIVERSAL AXLE JOURNAL TURNING & BUMISHING LATHE

Org : Central Organisation For Modernsation Of Works (Indian Railways)

TRN : 11434696

Desc : Tenders are invited for Universal Axle Journal Turning & Bumishing Lathe (BG).

BOD : July 26, 2012

LOC : India

BT : Tender

CNC POLISHING MACHINE

Org : Opto Electronics Factory

TRN : 11287027

Desc : Tenders are invited for supply, erection, commissioning & proving of CNC polishing machine.

BOD : July 2, 2012

LOC : India

BT : Tender

CNC BILLET CUTTING MACHINE

Org : Hindustan Aeronautics Limited

TRN : 11174699

Desc : Tenders are invited for CNC Billet Cutting Machine with accessories.

BOD : July 4, 2012

LOC : India

BT : Tender

DEVELOP A MANUFACTURING GROWTH CENTRE FOR INCLUDING A SWITCHGEAR UNIT AND ANOTHER TO MAKE PRECISION TOOLS, DIES AND COMPONENTS FOR THE AVIATION INDUSTRY

Org : Larsen & Toubro Limited

LOC : India

Contact : Larsen & Toubro Limited, L&T House, Ballard Estate, Tel: 91 22 22685656 Fax: 91 22 22685858, Mumbai, Maharashtra 400001, India

Products - National


This section gives information about the national and international products available in the market




CNC swiss machineThis CNC lathe features heavily ribbed cast-iron construction to dampen cutting vibration for enhanced productivity, superior surface finish and improved tool life. A 10-HP Mitsubishi spindle motor drives the powerful 6,000-RPM spindle. Both the main and sub spindle use 32mm Traub A-32 collets for easy part transfer and complete “done-in-one” machining efficiency, including all radial, end-working, and Y-axis live tooling work on both the front and backside of the part. It weighs over 7800 pounds, making it the heaviest machine in its class.

Ganesh Machinery, Inc

New Delhi

Tel: 818-3499166

Mob: +91-9810133968


Website: www.ganeshmachinery.com

Solid state relaysThese solid state relays features 5mm wide pluggable/PCB mountable single-in-line AC and DC output SSRs, single channel DRS series sockets for CN series SSRs, and DIN rail mounted CNseries SSR/socket assemblies. These relays meet industry standard pin out configurations for both solid state and electromechanical relays and are designed for plugging into Crydom DRSCN series sockets or soldering into printed circuit boards. The marker strips for the sockets are also offered to allow easy circuit function identification for each socket.

CST Sensors India Pvt Ltd

Bengaluru - Karnataka

Tel: +91-080-41132204


Website: www.cstsensors.com

Flange facer The electro-mechanical flange facer is offered for ID clamping or OD clamps or face clamping, depending upon the job requirement. The flange facer consists of a rotary drive unit, horizontal arm, electrical control panel & operator’s console. Powered quill mechanism is optionally offered for depth of cut setting and for boring operations. The spindle (rotary drive shaft) is supported by a

pair of heavy duty taper roller bearings in the front and by a pair of ball bearings in the other end. Bearings are lubricated for life with molybdenum sulfide grease. The rotary movement ranges from 2 to 20 rpm in a step-less range through vector VFD. The spindle is made of EN-24, hardened and ground. The box type ram and the ram housing are made of high grade CI.

Shenoy Engineering Pvt Ltd


Tel: +91-080-28361767


Website: www.spm-india.com

Radial drilling machineThis machine is used for radial drilling. It has 16 steps of spindle speed & feed which brings about economic & high-efficiency cutting. All mechanical & electrical controls are centralized on headstock. Clamping for assemblies & speed change of spindles is done by hydraulic power. Maximum drilling diameter is 50 and range of spindle speeds lie between 25-2000 r/min.

Macht Exim LLP.

Ahmedabad - Gujarat

Tel: +91-79-40087600

Mob: 9925700006


Website: www.machtexim.com

Peening machineThe machine consists of robustly built and sturdy blast cabinet having servo driven rotary turn table. A six-axis robot with controller unit with teach pendant is stationed inside the cabinet having arm provided with sand blasting hose pipe with boron carbide long nozzle for peening application. The media recovery system consists of vacuum recovery unit with double chamber pressure blaster for continuous shot peening operation. Online spiral separator is provided for removing broken shots, hollow shots & shot with sharp edge. The cartridge type dust collector is provided for ventilating blast cabinet. The movement of robotic arm is pre-

Products - National


programmed as per job requirement for peening application. The quantity of shots to air ratio is precisely monitored by magna valve provided at the outlet of bottom chamber.

Surface Finishing Equipment Co

Jodhpur - Rajasthan

Tel: +91-0291-2740128,+91-291-5120021


Website: www.sfecindia.net

Junction boxesThe output junction box has t r a n s m i s s i o n range up to 50 to 60 meters for indoor application and 1.2 km for outdoor application. Its working band of frequency is 2.4 GHz. It accepts 24 V DC as a supply voltage. It has a very wide application in the field of machine to machine communication. It accepts M12 socket connection of sensor / input.

Katlax Enterprises Pvt Ltd

Gandhinagar - Gujarat

Tel: +91-2764-286784

Mob: 09724506614


Website: www.katlax.com

Products - National


Digital readoutIt can be used to replace many models of competitive digital readout displays. It accepts 5v quadrature encoder feedback (TTL) and is compatible with many models of Acu-Rite, Anilam, Mitutoyo, Fagor linear encoders as well as several others. Adapter cables are available for many models. Topaz Digital is available in 2 and 3 axis variants and is also available for Mill and Lathe applications. They are available in two versions, SA100 and SA100-R, where SA100-R is the rotary version of the SA100.

CST Sensors India Pvt Ltd


Tel: +91-080-41132204


Website: www.cstsensors.com

CNC LatheThis twin spindle CNC lathe is equipped with 2 Strong headstock and spindles assembled with angular contact bearings for more powerful cutting. Spindle speed is 300-3000 RPM. Spindles can be either mounted with Colet system or pneumatic or hydraulic type. Two main motors provided for more speed range to complete various turning and machining, even powerful cross drilling or milling head can be provided for turn milling option. Machines can be provided with either single CNC system or Double CNC system. This machine will be very useful for manufacturing auto parts, textile parts and motor parts.

Arrow Machine Tools

Chennai - Tamil Nadu

Tel: 044-2658 2694,09840236534


Website: www.arrowmachinetool.com`

Treated fresh air unitsThe DRI TFA is manufactured in accordance with the best technology in casing manufacturing. It offers all the prerequisites for creating a ventilation system with the lowest running costs possible to suit retail application with the added advantage of Energy Recovery which cuts down the aircon costs. The FlexAir Treated Fresh Air Units with Eco-Fresh Molecular Sieve Coated Heat Wheel inside provides a complete solution for IAQ and Energy Saving in a single unit, with the option to add modules for cooling, heating, humidification, high efficiency filtration, mixing, sound

Products - National


attenuation, etc. The FlexAir Series TFA from DRI is designed in accordance with European Standard for leakage Class B. All functions like coils, heat exchangers etc. are optimized to give lowest possible pressure drop in proportion to highest possible efficiency resulting in very low LCC. Deep folded bag filters with big filter areas and good sealing. The good tightness ensures clean air supply to the room is of high quality.

Desiccant Rotors International Pvt Ltd

Gurgaon - Haryana

Tel: 91-0124-4188888


Website: www.drirotors.com

Heavy- duty lathe machineThis extra h e a v y duty lathe m a c h i n e VEH is o f f e r e d

with height of centre up to 1066 mm, length of bed ranging up to 12000 mm, between centres up to 11000 mm, main spindle hollow ranging 150 mm and main spindle nose is A2-12 type. Dynamically balanced spindle enable the spindle run at vibration free motion. The spindle carries the 10 T job weight. The norton gear box is able to cut the any of metric, modules and pitch. The bed is made from graded cast iron. Also offered are face plate, carrier plate, steady rest, follow rest, motorised coolant pump with tank and fittings, rear tool post, quick change tool post. The machine is maintenance free and is easy to use.

Vinit Engineering Works

Rajkot - Gujarat

Tel: 0281-2311734 ,09879022052


Website: www.balajilathe.com

affordable media blasting to clean, peen, deburr, or finish parts. The larger enclosure (50” x 39” x 43” tall) accepts powered turntables. The suction blast cabinet come with a unique pilot actuated air logic system to maximise airflow to the blast gun.

Prism Surface Coatings (P) Ltd


Tel: +91-8110-417999,09844400285


Website: www.prismsurface.com

Website: www.prismsurface.com

Abrasive blasting machinesThese air-powered blasting machines are used to clean, deburr, shot peen and to remove coatings. The 4,500 litre capacity unit supports four blasters and is widely used for long duration of blasting in

ship building industry and on site structures and large f abr i c a t ions . The BNP 220 pressure blast cabinets deliver e f f i c i e n t ,

Products - National


HMC MachineHorizontal machine center machine H630B incorporates the optimum machine structure design and the latest technology with versatile features to suit different applications from heavy duty die mold application to feather weight aluminum auto component without bottleneck; H630B extended its strength for flexible manufacturing needs with programmed six pallets changer with the user friendly software that enhances scheduling efficiency, reduces non cutting time and boosting high productivity. The integrated built-in-high precision spindle is powered by 30 KW for zero vibration cutting, the entire axis are equipped with high performance digital servo to match the speed with very little power.

S&T Engineers Pvt Ltd

Coimbatore - Tamil Nadu

Tel: +91-0422-2590810, Mob: 9489079060


Website: www.stengineers.com

SoftwareThis EPLAN software keeps users flexible in the process and the new update macros function makes sure that all data is updated to the most current state, either individually or automatically. Partial circuits can been inserted and can be updated effortlessly. Macro master data changes can easily be adopted into currently active specific projects. These high-quality templates gives consistent quality in the project and a standardised engineering process. The check run messages highlighted in message management can be synchronised with the opened navigators. The user can apply check routines specifically to newly entered corrections during a project edit.

Rittal India Pvt Ltd


Tel: +91-080-41515497


Website: www.eplan.in

Corrosion protectionThe ECP (Enhanced Corrosion Protection) has been established which can provide an improved rust resistance over 120 hours in salt spray atmosphere. It has a zinc coating with black passivation for valve component parts in steel and cast iron, black opaque anodizing for aluminium caps, electronic boxes and protection and natural gloss light grey anodizing for aluminium name plates. It also provides black plastic encapsulation (Rynite) for other coils and for coil’s nut rings

ATOS SPA


Tel: +91-80-23613840

Email: [email protected], Website: www.atos.com

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Products - National


Machine oilSpecialized “Electrical Discharge Machining” (EDM) Oil is highly refined mineral oil with low viscosity which is free from aromatics and unsaturated hydrocarbons especially applicable for “Spark Erosion Metal Working Operations”. It is colourless and odourless, making it operator-friendly. This oil, which is neutral and pure, can substantially reduce the chance of effects on skin of the operators. Its lower viscosity improves flushing and fast particle settling and both of these contribute to faster machining rates and fine surface finishes. Also low aromatic content eliminates smoking during machining and higher flash point ensures safety of the environment. It has exceptional long service life due to stability towards thermal oxidation. It is used in as Dielectric fluid in finish-cut electrical discharge (spark erosion) machining operations. It is also used in manufacture of electronics, extrusions, air-craft components, hardware, tools, fasteners, silver-ware, cutlery, valves and regulators etc.

Eastern Petroleum Pvt Ltd

Mumbai - Maharashtra

Tel: 022-2529 9990,09821531709

Email: off [email protected]

Website: www.easternpetroleum.in

Products - National


Lathe chuckThe Rota-S plus lathe chuck has an optimized wedge bar drive system and an improved lubricant system ensure consistently high clamping forces from the new lathe chuck. Since higher speeds and cutting speeds are possible, users can apply more efficient cutting materials, which shorten the manufacturing time. An optimized drive allows fast, comfortable, and repeat accurate jaw changes. This lathe chuck is fully compatible, and already existing base jaws can be used in it. Its unique three-fold jaw safety device prevents operating errors. It has located an indicator pin at the chuck circumference, which displays the individual clamping status. Protection sleeve system and expansion arbor are categorized as additional equipments.

Schunk Intec India Pvt Ltd


Tel: +91-080-40538999

Mob: 09741211766


Website: www.in.schunk.com

Auto tool settersThese TM26 auto tool setters are direct acting type, specially designed for CNC machining centres with IP67 Protection. Basically it is used for length detection of tools such as drills,

BP Bharti,

Managing Director,

Rightvision (India) Private Limited

I am glad to share with the readers that advertisements in SEARCH

have fetched us a contract of €3 million from the Indian markets. I

really would like to thank them for the support and my best wishes

to them.

Products - National


end mills, and cutters mounted on machining centres, drilling machines, milling machines, and boring machines. It can detect tool wear while accommodating the thermal expansion of the machine for the compensation. The operating speed is 100~200 mm/min, parallelism of contact is 0.01 / 12 mm, stroke is 5 mm & contact rating is DC24V 20mA(max).

Metrol Corporation India


Tel: +91-080-42105031


Website: http://www.metrol.co.jp/en/

lightweight Lathe chuckCompared with conventional power chucks, the weight of the ROTA NCL in steel version is reduced by 35%, in aluminum by 54%, and in carbon by 62%. Only the steel chuck is in series production. The patent pending double cylinder version of the base jaws ensures that the forces are optimally distributed on the chuck body. For fully maintaining clamping force, rigidity, and precision, every

Products - National


component which is in the direct flux of force are made of extremely resistant hardened steel. The chuck bodies themselves are completely made of steel, aluminum or CFK.

Schunk Intec India Pvt Ltd


Tel: +91-080-40538999

Mob: 09741211766


Website: www.in.schunk.com

AC drivesThe Vacon 20 series incorporates a built-in programmable logic controller(PLC) functionality which conforms to the IEC61131-3 standard. In addition, the functionality can be extended via optional modules, including field bus cards and tools for easy parameter copying from one unit to another. Efficient volume manufacturing is possible as they are fast to install and easy to set up. Also, the products can be modified and tailored to the needs of the customer.

Vacon Drives & Controls Pvt Ltd


Tel: +91-044-24490024


Website: www.vacon.com

Back artwork

Front artwork

Products - National


Buffing & polishing machineThis machine is used for mirror finishing of stainless steel, aluminum pots & pans, pressure cookers, water filter, mixer jars & hollowware in general. The job to be polished is held by specially developed vacuum chucking system. The machine is operated pneumatically and controlled by relay logic (optional PLC). Automatic buff wear compensation ensures consistent finish and high productivity. The buffing can be done by unskilled operator.

Grind Master Machines Pvt Ltd

Aurangabad - Maharashtra

Tel: +91-240-2376262


Website: www.grindmaster.co.in

Surface grinding machineThe surface grinding machine ranges are 150 x 450 to 1600 x 6000mm with various types of machines. The main spindle is cartridge type which ensures the spindle run out with in 2μ and completely sealed and lubricated for high durability and accuracy. The base is one piece design and having good rigidity, the movement and durable accuracy, the hydraulic pumps are vane pumps and having the high precision direction control valves

Products - National


Hydrogen gas detection systemThis hydrogen gas detection system is used for detection of hydrogen gas. It uses a 3-status technology which displays in terms of low/medium/high concentration. It has selectable slide switch for audio & visual built-in solid state buzzer. The system has the facility to function five gas detectors with independent alarm latching facility, potential free N.O/N.C contact, and recorder output. The system is equipped with 4-wire technology and maturity timer.

Subtronics (India) Pvt Ltd


Tel: 022-2422 4461


Website: www.subtronicsindia.com

and cross feed driven by ball screw with higher cost can obtain a grinding effect of more smooth and high precision and maintain longer life.

S&T Engineers Pvt Ltd


Tel: +91-0422-2590810,+91-0422-2593487

Mob: 9489079060


Website: www.stengineers.com

Ashok Kumar Gupta,

Chairman, Crane-Bel

Hydraulics

We are pleased to share with the readers that SEARCH has helped us to reach out to our customers with the new launch of the high performance product range of EATON VICKERS. We have been able to achieve it through advertisements and product profiles, which have been continuously published in this excellent magazine having a good reach in the industry, especially in the widely spread industrial areas such as Uttar Pradesh and Uttarakhand.

We have been able to promote the exclusive range of EATON VICKERS Hydraulic products in our target sectors of whole U P and Uttarakhand to our entire satisfaction and able to increase our turnover to a big extent.

Products - National


Breath analyser with printerIt detects alcohol in the breath and gives an audio-visual indication. It has 3-status technology which includes bright graphic display, easy & quick testing, reading latching, non-volatile memory, password protected critical menu settings, subject sample blow indicator, print readings with data & time, user selectable multiple number of prints for evidential record documentation etc. The instrument is housed in a robust plastic enclosure.

Subtronics (India) Pvt Ltd


Tel: 022-2422 4461


Website: www.subtronicsindia.com

Honing machineThis ML-2000 power stroked honing machine has twice the power and more speed than older style honing machines. It has fast & easy setup. Complete setup is handled from the front of the machine without raising a cover. It has unique roll-out coolant cart for easy maintenance and coolant changeover. It can be used with sunnen’s turbo hone multi-stone mandrels for fast stock removal. It is built to be durable with a rigid machine base constructed of reinforced structural steel and cast iron. It offers lifetime application service with every machine purchase. The diameter range depends on manual stroking, power stroking & automatic sizing. It has a stroke length of 6 to 170 mm.

Omira Marketing Pvt. Ltd.


Tel: +91-22-26400791, 91-22-26165032


Website: www.omira.co.in

Grinding / Polishing MachinesThese Direct Drive Tool Post Grinding / Polishing Machines are specially designed for use on lathes, shapers, and planer machine etc. for operations like cylindrical external grinding, face / radius / surface grinding. It has a heavy duty direct drive head complete with motor, bearing loaded spindle, sturdy guard & mounting plate. Direct Drive Grinders

are available in 1 HP & 2 HP, 2800 RPM,200 diam. & 25 mm width whereas Direct Drive Polishers are available in 2 HP & 3 HP, 2800 RPM, 300 diam. & 50mm.

Prem Brothers

New Delhi

Tel: 011 28117456, 28117464, 45595068

Email: [email protected], Website: www.powermaster-india.com

Products - National


Conical nozzle torchThese conical nozzle torches of duramax are available for five more plasma cutting systems: Powermax600, Powermax800, Powermax900, MAX42, and MAX43. Duramax series of torches, provide more reliable arc starting. They also enable consumables to last up to six times longer.

Hypertherm (India) Thermal Cutting Pvt Ltd


Tel: +91-044-28345361

Email: [email protected], Website: www.hypertherm.com

Bandsaw machinesThe bandsaw machines use linear motion (LM) guides and bearings instead of conventional hard chrome plated columns and bushes for sliding of cutting arm. With the use of LM guides the up-down movements of cutting arm is very smooth leading to productivity. The steel enclosure is provided to prevent coolant from splashing and spillage.

ITL Industries Ltd

Indore - Madhya Pradesh

Tel: +91-0731-3044400

Email: [email protected], Website: www.itl.co.in

Pankaj Dhingra,

Properiter

Prem Brothers

Advertisement of our products in Modern Machine Tools (MMT) has increased our exposure to prospective customers, helping us enhance our reach to clients all over India.

The quality and presentation of the magazine is appealing at the first look, inducing readers and subscribers to go through its informative articles and product advertisements.

A truly modern magazine having useful articles on the latest innovations and technologies.

Products - National


Panel Air ConditionerPanel Air Conditioners are used to dissipate heat generated by AC/DC drives, Electrical/Electronic components inside a control panel. In industries environment is hot and to avoid entry of dust, dirt and moisture inside the panel use of ambient air is refrained and a closed loop air conditioner is used to maintain desired temperature.

Reliance Engineering Company


Tel: 91-0422-6538340, Mob: 09244420143


Website: www.relianceengineeringcompany.com

Variable speed polishing machinesThese machines are specially designed for flexible operation of polishing by varying R.P.M on the same machine. Different finish can be obtained using the same buff at different R.P.M. It is a robust design double ended machine 7.5 KW of 10 HP, has a variable RPM stepless of 500-3500 max. It has dust covers with dust collector electro-magnetic brake for instant stopping.

Prem Brothers

New Delhi – 110 064

Tel : 011 28117456, 28117464, 45595068

Email: [email protected], Website: www.powermaster-india.com

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Products - National


Energy recovery ventilatorThey are capable of recovering upto 80% of sensible and latent energy from the stale exhaust air and transferring it to the fresh outside air. The heart of the ERV is the Eco-Fresh desiccant coated energy recovery wheel, which slowly rotates between its two sections. The stale air is passed through the wheel, and exhausted to the atmosphere. The wheel absorbs sensible and latent energy from the conditioned air, which is used to pre-condition the incoming fresh air in the other section, during the second half of its rotation cycle. The rotating wheel transfers the sensible and latent energy between the counter flowing exhaust and supply air and in the process preconditions (cool/ heat/ dehumidify/ humidify) the fresh air.

Desiccant Rotors International Pvt Ltd

Gurgaon - Haryana

Tel: 91-0124-4188888


Website: www.drirotors.com

Power cuttersThe Nile pneumatic Nipper can cut metallic wires, aluminium cables, piano wires, gold, steel wires up to diam. 6 mm, Copper up to diam. 7 mm, Soft plastic up to diam. 13 mm, and hard plastics up to diam. 4.5 mm. Just by changing the blades, several

Products - National


manufacturing applications are possible with same types of tools. They are of light weight & have long life.

Arhan Technologies Pvt Ltd

Pune - Maharashtra

Tel: +91-20-65603200


Website: www.arhan.co.in

CirclipsThe circlips are used for restraining axial movement of components of shafts and where there are space restrictions. They are also applicable in small mechanism. They are manufactured from suitable high carbon steel, such as C80 of IS: 1570-19621 or EN42J. They are hardened and tempered. They are also available in SS-304 materials of construction.

R K Engineering Company


Tel: +91-022-22671141


Website: www.rkengineeringco.com

Products - National


Mini Jewel Foot SwitchIt has a 3 Terminal Micro Switch, 1 Common Change Over to NO/NC & Foot Switch is Powder Coated in Black Structure Coating. These are available in current range of 10A/250VAC, 15A/250VAC & 10A/500VAC. Dimension is 95X70X25 & Weight is 300gms. Two core 2 meter wires provided with the Switch free.

Precision switchgear industries


Tel.: 02522 – 645770, Mobile: 09225100895.

Email: [email protected], Website: www.footswitch.co.in

Induction cap sealerThe water cooled Fluxosealer AFX3000 is a heavy duty induction cap sealer for high speed sealing and special applications. Bottles with neck diameters ranging from 10mm to 150mm can be sealed with ease. Standard features include no foil detection system which consists of sensors to detect induction seal inside the cap, easy line relocation & plug & play system. Enclosure is of MS Powder coated/SS304.

Arshad Electronics Pvt Ltd


Tel: +91-022-24451709

Email: [email protected], Website: www.arshadelectronics.in

Products - National


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


VLT drivesThe D-Frame VLT® drives are among the smallest in its class and designed to support any automation application. Its back-channel cooling concept keeps electronics safely within optimal operation temperatures, the advantage being the system installation and operating costs are reduced dramatically. For robust protection, all drives come with coated printed circuit boards. Using a ducted back-channel, air is allowed to pass over the unit’s heat sink with minimal air passing through the electronics area.

Danfoss Industries Pvt Ltd


Tel.: 044-5550 1555

Fax: 044-5500 1444


Website: www.danfoss.com

Products - International


Cable and hose carrierIt was developed specifically for use in environments with heavy contamination from chips and dirt. The all-round closed structure effectively prevents the intrusion of foreign bodies into the cable space, and allows for reliable protection right up to the connection area. The covers can be opened and removed easily on the inside or outside to load the cable carriers. The interior can be modularly partitioned with various divider solutions for even cable distribution. The optimised geometry and a triple encapsulated stroke system allow it to span extensive unsupported sections. The integrated gliding surfaces make the cable carrier the ideal solution for long travel lengths. Integrated noise damping ensures that the cable carrier is running silently and with low vibration at all times.

Kabelschlepp India Pvt Ltd (Subsidary of Kabelschlepp GmbH)


Tel: 080-4115 8997


Website: www.kabelschlepp.com CNC graphite machining centerThis closed bridge type-high speed CNC Graphite Machining Center has patent design on its structure, as its super structural rigidity is combined with advanced technologies. It has a 30000 RPM high speed spindle, resulting in high quality graphite electrode performance. The Graphite Dust Suction & Filtration

implements high-speed, high-precision machining by reading 200 blocks in advance for acceleration/deceleration control. It has a synchronous built-in servo motor installed. The number of blocks to be read in advance can be increased, thereby enabling up to 1,000 blocks to be read in advance for acceleration/deceleration control. This enables high-speed, high precision machining without feedrate variations even for a program consisting of super-minute line segments. Additional 1-axis control can be added to enable simultaneous contour control of up to 4 axes. Spindle is directly coupled with its motor. Least maintenance due to grease sealed bearings. The high speed and high precision ball bearing is used for the high-speed spindle.

GE Fanuc Automation Europe SA

Germany

Tel: +49-352-7279 79213


Website: www.fanucrobotics.com

RobodrillIt is a small machining center with spindle taper size No. 30 for milling, boring, drilling and tapping. This machine is characterized by Nano CNC system, HRV control, AI contour control which



Steel barsThese bars are processed with center-less grinding & hard chrome plating after cold drawn. The bar is abrasion-proof & corrosion-proof. These are hard chrome coated where thickness is minimum 20 microns. Standard length of mass product is 3000 mm-6000 mm.

Fu-Long Metal Industrial Co., Ltd.

Taoyuan Hsien - Taiwan

Telephone: 886-3-4852858; Fax: 886-3-4787597

Website: www.flweb.com.tw

System (GDSFS) results up to 99% dust disposal efficiency. The Dry Type GDSFS is implied here. It has high efficiency dust-collecting equipment & incorporates zero wear-out draught fan function.

Hsiu Fong Machinery Co Ltd

Taichung City - Taiwan

Tel: 886-4-22792121


Website: www.surefirst.com

Vertical machining centreThe model VM-2 vertical machining centre is designed for mould industries. It is a high-performance machine with a 30” x 20” x 20” work cube, 36” x 18” table, 12000 rpm inline direct-drive spindle and high-speed control with full look-ahead. High-precision linear guides on all axes further increase

Laser cutting systemThe Sirius automation-ready flying optics laser cutting system is used for fast, efficient sheet metal processing. This system is designed to provide efficient processing of parts at optimal speeds and accelerations to suit the part geometry, offering reliable cutting performance at an affordable price-performance ratio. It is optimised with additional features and automation capabilities and provides quick and precise positioning and consistently accurate laser processing. The combination of a dynamic machine with an excellent laser beam quality allows high-speed laser cutting.

LVD Company NV

Gullegem - Belgium

Tel: +32-56-430511


Website: www.lvdgroup.com



rigidity and stiffness, while providing a low coefficient of friction and long-term reliability. High-speed brushless servos, combined with fine-pitch ball screws and high-resolution digital encoders, ensure ultra-precise positioning and extreme repeatability.

Haas Automation, Inc

California - USA

Tel: +1-805-2781800


Website: www.haascnc.com

Boring headsA wide range of rough and finish boring heads producing diameters from 8 mm up to 500 mm plus all different couplings and accessories are offered. There are 3 basic boring heads, viz, micro boring heads fitting indexable boring bars with carbide insert pockets; finish boring heads; and rough boring heads with a synchronised adjustment. All the boring heads are radially adjustable for boring different diameters. The first two models feature a micrometer adjustment with 0.002 mm increments.

Pinzbohr Boring System

Barcelona - Spain

Tel: +34-93-5720873


Website: www.pinzbohr.com



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


RobocutThis machine has high-performance CNC coupled with digital servo technology. It has a high-rigidity casting and a thermal insulation structure. It is incorporated with Twin-servo wire tension control, advanced AWF2 enabling safe unmanned operation, customised Fanuc PC FAPT Cut programming software & Servo water level control for stable cutting. It comes with a 15-inch LCD touch panel & an USB I/O. For high precision, it has an upgraded AI pulse controls 2 & finish cutting generator.

GE Fanuc Automation Europe SA

Germany

Tel: +49-352-7279 79213


NC servo slideThe major material used here is FC30 casting, which is for long life usage. Position accuracy could achievable in ?m grade. It is controlled by C5 ball screw and it could have less friction but raise efficiency to keep in stable precision with fully support. RH series is u Specifications are: Width: 200,250,300mm; length: 400,640,520,760,1000mm.

Hann Kuen Machinery & Hardware Co Ltd

Taiwan

Tel: +886-4-2486 0602


Milling heads unitsThe gears and axis are all made from SCM415, and have heat-treatment and precise girded to JIS 1 level. Most of components are lubricated by auto-pump and auto-injection. High Precision, low noise and vibration free, each model has different speed for machining and some models also could be used for drilling. These milling heads most equipped on Plano milling machine for vertical and horizontal milling or the retrofit work shop.

Para Mill Precision Machinery Co Ltd

Taichung City - Taiwan

Tel: 886-4-26800678


Website: www.paramill.com

List of Products


Product Pg No Product Pg No Product Pg No

Abrasive belt grinder .................................. 166

Abrasive blast cleaning ....................................152

AC gear motor ..................................................22

AC servo motor ................................................22

Acoustic rooms ................................................152

Adaptor ...........................................................130

Advance cutting materials .................................25

Aerosol multispray ............................................63

Air gun ............................................................134

Air pollution control .......................................152

Airline fluid .......................................................63

Aluminum extrusion .......................................142

AMTEX 2012 ................................................148

Angle encoders ...............................................BIC

Assembly & high temperature grease ...............63

Automation .........................................37, 51, 132

Automation products ......................................123

Bags bailing press ...................................... 151

Ball bearing ...............................................81, 155

Bar feeder ..........................................................33

Bars .................................................................145

Bearing ......................................................12, 155

Belt grinder .....................................................163

Bench grinder cum polisher ............................166

Bench grinding machine .................................163

Boring ................................................................60

Boring and milling machines ............................74

Boring bars ........................................................35

Boring mill ......................................................142

Buffing powder .................................................35

Building automation .......................................132

Cabinet ..................................................... 112

Cable carrier ......................................................12

Cable conduits ...................................................29

Cable connector ................................................12

CAD/CAM software ........................................16

CAM followers ...............................................158

Carbide ............................................................130

Carbide endmill tool ............................... 137, BC

Carbide rods ....................................................153

Carbide tools .....................................91, 130, 159

Centre drill ......................................................130

Centreless grinding machine ............125, 179,138

Ceramic ...........................................................181

Cermets ...........................................................181

Chain .................................................................12

Chain oil ...........................................................63

Chillers ............................................................168

Chrome bars/ shafts ........................................145

Chuck ..............................................................130

Clamping tool ......................................... 137, BC

Cleaners ...........................................................143

Close frame hydraulic press ............................151

CMM ..............................................................177

CNC......................................................5, 73, 154

CNC controller .................................................37

CNC cutting machines ...................................132

CNC cylindrical external grinding machine ...179

CNC double column machining centre ............10

CNC engraving machines ...............................145

CNC equipment ...............................................31

CNC external grinding machine ....................179

CNC horizontal borer .......................................83

CNC horizontal boring & milling machine .....10

CNC horizontal machining centre ...................10

CNC horizontal turning centre ........................10

CNC internal grinding machine .....................179

CNC laser cutting machine ............................132

CNC lathe ................................ 11, 45, 58, 74, 83

CNC machine tool .........................................133

CNC machines ..............................6, 73, 111,154

CNC machining center ...............................14, 73

CNC milling machine ......................................45

CNC multi-tasking centre ................................10

CNC oxy fuel cutting machine .......................132

CNC plasma cutting machines .......................132

CNC precision lathe .........................................36

CNC small machining center ...........................14

CNC tool holders ...........................................171

CNC tools ..................................................51,130

CNC turning center ............................11, 73, 154

CNC turn-mill centre .......................................10

CNC vertical machining center ...........10,73, 154

CNC vertical turning lathe ...............................10

CO2 laser marker series ..................................157

Coating machines ............................................132

Coating plants .................................................132

Coating systems ..............................................132

Collets ........................................................94,130

Collets chuck .....................................36, 130, 171

Column hydraulic press ..................................151

Compressor oil ..................................................63

Connector ....................................................12, 41

Control cabinet .................................................41

Control panel ....................................................41

Control system ..................................................41

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

Conventional precision lathe .............................58

Conveyor lubricators ........................................87

Coolant ..............................................................71

Coolant pump .................................................166

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

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

Corrosion preventive .......................................143

Countersink ................................................FIC, 8




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

List of Products


Coupling regulator ..........................................134

Crush blade .................................................46, 47

Customised tooling solution .............................94

Cutting fluids ..................................................143

Cutting machines ............................................132

Cutting oil ...................................................35, 71

Cutting tool ........................39, 46, 47,91,113,153

Cutting tools carbide metal working tool .......181

Cylindrical grinding machine .....................30,125

Dampers ......................................................93

Desktop printer .................................................72

Diamond cutting & processing systems .........139

Diamond tool .............................................8, FIC

Didactic equipment for training .......................41

Die coater ....................................................46, 47

Diode end pumped laser marker .....................157

Diode side pumped laser marker ....................157

Disc couplings ...................................................93

Drawing & forming compound ......................143

Drill chuck arbor .............................................130

Drill mill .........................................................130

Drilling machine .............................................103

Drilling tool .............. FIC,8, 39, 91,113, 137,BC

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

Dust collectors .................................................163

EDM sinker machines ............................... 145

Element shrink disc ........................................158

End mills .........................................................130

Exhaust brake system parts ...............................94

Exhibition- AMTEX 2013 .............................128

Exhibition-Engineering Expo .........................156

Exhibitions ......................................................101

Expandable mono block-reamers ......................59

Exposed linear encoders .................................BIC

Factory automation .................................... 132

Ferrous casting ................................................142

Fiber laser marker ...........................................157

Flexible shaft grinder ......................................166

Floor automation .............................................114

Forged components .........................................142

Form measurement ...........................................23

Freewheel-one-way-clutches ...........................158

Fuel injection system .......................................94

Fuel injection system parts ................................94

Gantry automation..................................... 114

Gantry machining center ................................142

Gap frame press ..............................................152

Gauges .............................................................147

Gear box ............................................................90

Gear milling solution .......................................79

Gold purity (xrf) systems ................................139


List of Products


Gomet bearings .................................................81

Grease ................................................................63

Grinding machine ..............30, 115, 125, 179,163

Grinding tool for hard material ......................115

Grinding wheels ................................................35

Grooving & parting tools ...............................153

Guide rods .......................................................145

Gun drill.................................................... FIC, 8

Handling system module ..............................41

Handy probe ...................................................159

Handy scan ......................................................159

Hard chrome plating bars ...............................145

Heat exchanger machines ...............................103

Heavy duty cycling duical bearing ....................81

Heavy duty lathe machine ................................30

Helical gear box ................................................90

High performance spindles ..............................61

High power ups system ...................................167

High precision machining services ...................94

High precision tool holders ..............................21

High precision wire cut EDM machine .........145

High speed drill tap centres ..............................83

High speed machining center ...........................73

HMC ..............................................................103

Hold back ........................................................158

Holders ..............................................................35

Hole making .....................................................25

Hole making tools .......................................46, 47

Horizontal CNC machines .............................154

Horizontal hydraulic press ..............................151

Horizontal machining center ...........5,73, 83, 154

Horizontal spindle rotary table surface grinder 179

Hose ................................................................134

Hydraulic & gear oil .........................................63

Hydraulic accessories .......................................134

Hydraulic centerless grinding ..........................125

Hydraulic chucks ...............................................94

Hydraulic cylinder ...........................................162

Hydraulic cylindrical grinding machine ..125, 179

Hydraulic machine ............................................33

Hydraulic press ........................................151, 152

Hydraulic shearing machine............................152

Hydraulic valve housing ....................................94

Hypercad ...........................................................16

Imaging & vision systems .......................... 132

IMTMA - AMTTF .......................................160

IMTMA - Finishing School Summit ............136

Indexable cutting tools ......................................35

Inductive proximity switches .............................29

Industrial robots ..............................................169

Integrated shot blasting rooms .......................152

Internal grinding machine...............................125

Iron & steel parts ........................................46, 47

Jewellery polisher ....................................... 166

Keyless transmission element ..................... 158

Lamp pumped laser marker ........................ 157

Large part drilling machines ...........................103

Laser cutting machine .....................................157

Laser cutting system........................................139

Laser engraving machine ................................157

Laser exhibition ...............................................101

Laser marking - engraving system ..................139

Laser marking machine ...................................157

Laser medical ..................................................139

Laser micro machining ...................................139

Laser robotic welding ......................................139

Laser shaping ..................................................115

Laser welding system ............................... 139,157

Lathe ...................................................................5

Lathe machine...................................................30

LED ..................................................................29

Length gauges ................................................BIC

Lens mould .................................................46, 47

Light duty lathe machine ..................................30

Linear rods ......................................................145

Lm shafts ........................................................145

Load break switches ..........................................29

Locking elements ..............................................93

Lubes .................................................................71

Machine & tools lubricators .........................87

Machine measurement ...................................BIC

Machine taps .....................................................35

Machine tools ....................................................51

Machined castings .............................................94

Machined components ....................................142

Machining & grinding fluid ...........................143

Machining centre ..............................................83

Magnescale technology ...................................131

Magnetic modular encoders ...........................BIC

Material handling ............................................127

Material testing .................................................23

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

Measurement equipment...................................23

Medium duty lathe machine .............................30

Metal bellow couplings .....................................93

Metal cutting tool .............................................57

Metal scrape baling press ................................151

Metal spray booths ..........................................152

Metrascan ........................................................159

Metrology equipment ........................................23

Metrology instrument & solutions .................177

Micron drills................................................46, 47

Milling ....................................... 25, 39, 113, BIC

Milling centres ....................................................5

Milling cutter .....................................FIC, 8, 153

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

Milling machine ........................................45, 103

Milling tool ............................. 46,47,91, 137, BC

Mobile cylinder hydraulic press ......................151

Modular tooling system .............................FIC, 8

Mold components .......................................46, 47


List of Products


Motor ................................................................90

Motor protection circuit breaker .......................29

Multi function turret .........................................33

Multi functional tools .....................................153

Needle roller bearings ..................................81

Oil coolers ................................................. 168

Optical measurement ........................................23

Paint booths .............................................. 152

Panel coolers ...................................................168

PCB drills....................................................46, 47

PCD & carbide reamers ...................................59

PCD & CBN tool ..........................................181

Pedestal grinder ...............................................166

Pedistar buffer .................................................166

Peening ............................................................152

Photonic exhibition .........................................101

Pillar type hydraulic press ...............................151

Pilot lights .........................................................29

Piston bars .......................................................145

Planning machine ............................................138

Plano-millers ...................................................138

Plant lubrication systems ...................................87

PLC operated hydraulic press .........................151

Plugs and sockets ..............................................29

Pneumatic accessories......................................134

Pneumatic tools ...............................................134

Polishing machines .........................................163

Post processor ....................................................16

Power press .....................................................152

Power sources ..................................................109

Precision measuring instruments ....................147

Precision steel ..................................................115

Precision switches single & multiple ................29

Precision universal cylindrical machine ...........125

Press brake machine ........................................152

Pressure sensor for wet packaging application ..135

Printing system .................................................72

Process automation and control equipment ......41

Product assemblies ..........................................142

Programmable logic controllers.......................123

Pull stud ..........................................................130

Push buttons .....................................................29

PVC flexible braided hose ..............................134

Rack .......................................................... 112

Reamer ...............................................FIC, 8, 130

Rear cylinder hydraulic press brake ................152

Robotic automation .........................................114

Roller bearing ..................................................155

Rolling oils ......................................................143

Rotary ..................................................................5

Rotary encoders ..............................................BIC

Rotary switches .................................................29

Rust preventing ...............................................143

Safety protection devices ..............................29

Screw machine ..................................................45

Sealed linear encoders ....................................BIC

Servo-drives .....................................................123

Servo-insert couplings .......................................93

Shafts ...............................................................145

Shearing machine ............................................152

Sheet metal working machinery ........................48

Shrink fit adaptors ............................................94

Shrink fit technology ........................................35

Side lock adaptor .............................................130

Single limit switches .........................................29

Sinking EDM .................................................181

Slant / flat bed ..................................................83

Sleeve bearings ..................................................81

Small size ball bearings .....................................81

Solar cell scribing system ................................139

Solid carbide drill ........................................57, 59

Solid carbide drill with ic ..................................57

Solid carbide mill ..............................................57

Solid carbide reamer..........................................57

Solid carbide reamer with ic .............................57

Solid carbide special drill ..................................57

Solid carbide special mill ..................................57

Solid carbide special reamer ..............................57

Solid mono block reamers .................................59

Solid rotating tools ............................................35

Solid state laser cutter .....................................157

Special boring bars ............................................59

Special fine boring tools ....................................59

Special induction hardening machine .............109

Special line boring tools ....................................59

Special reamer ...................................................59

Special tools.....................................................130

Speciality oils .....................................................35

Spindle nose tooling ........................................153

Standard fine boring tools.................................59

Standard induction hardening machine ..........109

Straightening machines ...................................138

Super precision bearings ...................................81

Surface grinding machine ...........................30, 83

Surface preparation solutions ..........................152

Tapping systems ........................................ 171

Taps .......................................................8,FIC, 34

Tensioner nut ..................................................158

Thread mill .......................................................79

Thread mill cutters ............................................35

Thread milling cutters & taps holders ..............34

Threading tool ................................... 59, 137,BC

Thrush ball bearings .........................................81

Tool holders ......................................................94

Tool holding systems ........................................35

Tooling system ..................................25, 137, BC

Tools ...............................................................130

Touch probes .................................................BIC

Track rollers ....................................................158

Trade show ......................................................101

Transparent gel .................................................63

List of Products


Product Pg No Product Pg No Product Pg No

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

Inside Cover BGF - Back Gate Fold BC - Back Cover

Travelling column milling machines .................60

Tubing accessory ...............................................41

Turbo charger parts ...........................................94

Turned components ........................................142

Turning ..................................... 25, 39, 113, BIC

Turning holders ..............................................153

Turning tool ................................46, 47, 137, BC

Twist drills ......................................................130

Ultra high pressure apparatus ................. 46, 47

Vacuum /pneumatic recovery and

conveying system ....................................... 152

Vacuum chuck ...................................................33

Valve ..........................................................41, 134

Valve terminal ...................................................41

Vehicle lubricators .............................................87

Ventilation .......................................................152

Vertical and horizontal machining centres .......74

Vertical machining center ...................................5

Vertical machining centres-single /

double column ...................................................83

Vertical turning lathe ......................................142

Vertical turret lathe ...........................................24

Wear parts ................................................. 153

Wear resistant tools ....................................46, 47

Wire cut EDM ...............................................181

INTERNATIONAL

Associations .................................................18

Brass wire .................................................. 161

Carbide ball end mills ..................................62

Carbide drills .....................................................62

Carbide end mills ..............................................62

Carbide reamers ................................................62

Carbide spotting drills.......................................62

Cast iron cutting .............................................119

Centerless ..........................................................44

Centerless grinding machines ...........................27

Centralized lubrication systems.......................126

Chuck ..............................................................166

Circular cold saw .............................................162

CNC angular cylindrical grinding machines ....27

CNC cylindrical roll grinder ...........................150

CNC lathes .....................................................141

CNC plunge/angular cylindrical grinder ........150

CNC rotary tables ...........................................146

Coordinate measuring machine ......................129

Copper anode ..................................................161

Cutting tools ...................................................165

Cylindrical .........................................................44

Diamond grinding wheels for LCD glasses . 157

Diamond scribers for sapphires.......................157

Diamond tools for semiconductors .................157

Diamond tools for silica tile industry .............157

EDM wire ................................................. 161

Electro magnetic chuck ...................................166

End mills .........................................................165

EUROBLECH 2012 ........................................85

Fine-pole permanent magnetic chuck ......... 166

For precision grinding wheels .........................157

Free cutting brass rod & wire .........................161

Fully automatic circular sawing machine ........162

Fully automatic tungsten carbide

sawing machine ...............................................162

Grinding machine ........................................44

High-speed centerless grinding machines .....27

Horizontal band ..............................................140

Horizontal machinery center ..........................107

Hydraulic angle lock vise ................................137

Hydraulic automatic type aluminum copper ...162

Hydraulic automatic type metal sawing machine ..162

Hydraulic machinery .......................................158

Hydraulic press ................................................158

Hydraulic press brakes ....................................158

Hydraulic punch presses .................................158

Internal grinding machines .................... 27, 44

Lathes-automatic ....................................... 141

Magnetic block unit ................................... 166

Manufacturing equipment ...............................158

Measurement systems .....................................129

Measuring gauge .............................................129

Measuring machine .........................................129

Measuring tools ...............................................129

Metal circular pipe / bar stock end chamfering

machine ...........................................................162

Metal forming .................................................158

Mold changing systems ...................................149

Natural/polycrystalline/single crystal

diamond dies ............................................. 157

NC cylindrical grinder ....................................150

Nickel silver wire .............................................161

Permanent magnetic chuck ........................ 166

Phosphor bronze wire .....................................161

Precision cutting wheels ..................................157

Press brake ......................................................158

Quick die change system ............................ 149

Quick mold change system .............................149

Rolling machine ........................................ 140

Rotary permanent magnetic chuck .................166

Sawing machines........................................ 140

Saws .................................................................140

Shafts ...............................................................140

Shear series ......................................................158

Shearing machines ..........................................158

Sheet metal working technology exhibition ......85

Silicon bronze wire ..........................................161

Special form cutting tools .................................62

Spindles ...........................................................125

Standard (powerful) magnetic base .................166

Standard (powerful) permanent magnetic chuck .. 166

Thread ...................................................... 140

Traditional cylindrical grinder ........................150

Twin-spindle compound grinding machines ....27

Universal .....................................................44

Universal cylindrical grinder ...........................150

Universal cylindrical grinding machines ...........27

Vertical machinery center ........................... 107

Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No

List of Advertisers


Accut Machinery Co. Ltd. 142

T: +86-411-84804589

E: [email protected]

W: www.accutmachinetools.com

ACE Micromatic Group 11

T: +91-80-22186700


W: www.acedesigners.co.in

Atul Machine Tools 30

T: +91-281-2360227


W: www.atulmachine.com

Austin Engineering Company Ltd 155


W: www.aec-bearings.com

Autotech Machine Tools Sales & Services 6

T: +91-20-25690044


W: www.autotechcnc.com

Baker Gauges India Ltd 147

T: +91-20-66093800


W: www.bakergauges.com

Big Daishowa Seiki Co. Ltd 21

T: +81-729-828277

W: www.big-daishowa.com

Birla Precision Technologies Ltd 94

T: +91-22-67933000


W: www.indiantool.com

Blaser Swisslube India Pvt. Ltd. 71

T: +91-124-4994000


W: www.blaser.com

Cenlub Industries Ltd 87

T: +91-129-4113701


W: www.cenlub.in

Ceratizit India Pvt Ltd 153

T: +91-33-24947146


W: www.ceratizit.com

Champkraft Machine Tools 179

T: +91-2752-241881


W: www.solcogrinder.com

Changhua Chen Ying Oil Machine Co., Ltd. 126

T: +886-4-2639-3751


W: www.chenying.com.tw

Coatec India 132

T: +91-172-5063436


W: www.coatecindia.com

Creaform India 159T: +91-11-65022218E: [email protected]: www.creaform3d.com

Dees Hydraulic Industrial Co. Ltd. 158T: +886-2-2601-8661E: [email protected]: www.spc.com.tw

Doosan Infracore India Pvt Ltd 10T: +91-80-42660122E: [email protected]: www.doosaninfracore.com

Dowel Machinery Pvt Ltd 151T: +91-281-2362465E: [email protected]: www.thedowel.com

Durga Bearing Pvt Ltd 81T: +91-22-6876073E: [email protected]: www.durgabearings.com

EFD Induction Limited 109T: +91-80-7820404E: [email protected]. W: www.efd-induction.com

Electromech Material Handling Sys P 127T: +91-20-66542222E: [email protected]: www.emech.in

Emuge India Pvt Ltd 34T: +91-20-39310000E: [email protected]: www.emugeindia.com

Engineering Expo 156T: +91-9819552270E: [email protected]: www.engg-expo.com

Ermaksan Sheet Metal Working Machinery 48T: +90-224-2947500E: [email protected]: www.ermaksan.com.tr

ESA Eppinger Gmbh 161T: +91-9900588559E: [email protected]: www.eppinger.de

Essor International Inc 164W: www.essor.com.tw

Euroblech 2012 85W: www.euroblech.com

Everising Machine Co. 140T: +886-4-2359-3178E: [email protected] W: www.everising.com

Festo Controls Ltd 41T: +91-80-22894100E: [email protected]: www.festo.com

Finechrome Shafts Pvt Ltd 145T: +91-22-29204209E: [email protected]

Fong Ho Machinery Industry Co., Ltd. 162

T: +886-4-2406-6769


W: www.fongho.com.tw

Forwell Precision Machinery Co., Ltd. 149

T: +886-4-8345-1960


W: www.forwell.com

Freeze Tech Equipments Pvt Ltd 168

T: +91-44-42152387


W: www.freezetechequip.com

Fullton Machinery Co Ltd 24

T: +86-411-82767678


W: www.fulltontech.com

G W Precision Tools India Pvt Ltd 57

T: +91-80-40431252


W: www.gwindia.in

Ganesh Techmachinery Pvt Ltd 45

T: +91-11-41612203


W: www.ganeshmachinery.com

Ganro Industrial Corp. 146

T: +886-4-2537-6266


W: www.ganro.com.tw

Greenleaf Corp 119


W: http://www.wexper.com

GSK Cnc Equipment Co. Ltd 31

T: +91-9886835186


W: www.gsk.com.cn

Guang Dar Mangnet Industrial Ltd. 166

T: +886-4-2436-0757


W: www.guangdar.com

Gudel India Pvt Ltd 114

T: +91-20-25459531


W: www.gudel.com

Guhring India Private Limited FIC

T: +91-80-40322500


W: www.guhring.in

Haas Automation India Pvt Ltd 5

T: +91-22-61392800


W: www.haascnc.com

Heattrans Equipments Pvt. Ltd. 142

T: +91-79-25840105


W: www.heattrans.com


List of Advertisers


Heidenhain Optics & Electronics (I) BIC

T: +91-44-30234000


W: www.heidenhain.in

HG Technology Co., Ltd. 165

T: +886-4-7362-725


W: www.hgt.com.tw

Hyundai Wia India Pvt. Ltd 133

T: +91-9940653703


W: www.hyundai-wia.com

IFM Electronics India Pvt Ltd 135

T: +91-2312672770


W: www.ifm-electronic.in

Igus India Pvt Ltd 12

T: +91-80-39127800


W: www.igus.in

Indian Machine Tool Mfgr’S Association 128

T: +91-80-66246600


W: www.imtex.in

Indian Machine Tool Mfgr’s Association 160

T: +91-80-22731625


W: www.amttf.in

Indian Machine Tool Mfgr’s Association 136

T: +91-80-66246600


W: www.imtma.in

Isgec Heavy Engineering Ltd 83

T: +91-120-3301001


W: www.isgec.com

Jainnher Machine Co.,Ltd. 150

T: +886-4-2358-5299


W: www.jainnher.com.tw

Jin Year Precision Co., Ltd. 137

T: +886-4-2523-2817


W: www.jinyear.com.tw

Jyoti Cnc Automation Pvt. Ltd. 73

T: +91-2827-287081


W: www.jyoti.co.in

Kabel Schlepp India Pvt. Ltd., 137

T: +91-80-27839111


W: www.taegutec-india.com

Kao Fong Machinery Co. Ltd. 107

T: +886-4-2566-2116


W: www.kafo.com.tw

Kim Union Industrial Co., Ltd. 140

T: +886-4-2533-1131


W: www.threadrolling.com.tw

Komet Precision Tool India Pvt Ltd 59

T: +91-80-280780000


Korloy India Tooling Pvt. Ltd. 113

T: +91-124-4930080


W: www.korloy.com

Larsen & Toubro Limited 91

T: +91-22-67051093


W: www.larsentoubro.com

Larsen & Toubro Ltd 123

T: +1800-2335858


W: www.larsentoubro.com

Lexis Tooling Systems 171

T: +91-422-3052110


W: www.lexisindia.com

Lico Machinery Co., Ltd. 141

T: +886-4-2563-0950


W: www.licomachinery.com

Macpower Cnc Machines Pvt Ltd 154

T: +91-2827-287930


W: www.macpowercnc.com

Mehta Cad Cam Systems Pvt Ltd 157

T: +91-79-26840551


W: www.mehtaindia.com

Metrol Corporation India Branch Off 14

T: +91-80-42105031


W: www.toolsensor.com

Mitutoyo South Asia Pvt Ltd 23

T: +91-11-26372090


W: www.mitutoyoindia.com

MMI India Pvt Ltd 101

T: +91-9811090046


W: www.photonicsindia.net

Montfort Shanghai Co Ltd 75

T: +86(0)21/52136600


Neway Cnc Equipment (Suzhou)Co., Ltd 74T: +(281)276-7100E: [email protected]: http://www.newaycnc.com

Nicolas Correa S.A. 60T: +91-20-25654891E: [email protected]: www.correanayak.es

Nikon India Pvt Ltd 177T: +91-124-4688 500 E: [email protected]: www.nikon-instruments.jp/eng/

Nmtg Mechtrans Techniques Pvt Ltd. 158T: +91-79-22821527E: [email protected]: www.nmtgindia.com

Objet Ap Ltd 72T: +852-2174-0111 E: [email protected]: www.objet.com

Openmind Cadcam Technologies (I) Pvt Ltd 16T: +91-80-30504647E: [email protected]: www.openmind-tech.com

Optical Gaging (S) Pte Ltd. 129T: +65-6741-8880E: [email protected]: www.smartscope.com.sg

P R Sales Corporation Pvt Ltd 33T: +91-20-25437591E: [email protected]: www.prsales.in

Palmary Machinery Co., Ltd. 44T: +886-4-2492-9799E: [email protected]: www.grinding.com.tw

Paragon Machinery Co., Ltd. 27T: +886-4-2539-5678E: [email protected]: www.paragoncnc.com

Pitroda Utility Industries 125T: +91-2752-243795E: [email protected]: www.pitrodautilityindia.com

Pramet Tools India Pvt Ltd 39T: +91-124-4703825E: [email protected]: www.pramet.com

Precihole Machine Tools Pvt Ltd 22T: +886-3-329-9968E: [email protected]: www.peei.com.tw

Precimac Solutions 61T: +91-20-32538701E: [email protected]: www.precimac.com


List of Advertisers


Ou

r co

nsi

sten

t ad

vert

iser

s

FGF - Front Gate Fold FIC - Front Inside Cover BIC - Back Inside Cover BGF - Back Gate Fold BC - Back Cover

Prem Brothers 163T: +91-11-28117456E: [email protected]: www.powermaster-india.com

Quaker Chemical India Ltd 143T: +91-33-22822181E: [email protected]: www.quakerchem.com

Quattro Engineering India Limited 51T: +91-80-25585439E: [email protected]: www.quattroengg.com

Quickmill Inc. 103T: +705-745-2961E: [email protected]: www.quickmill.com

R S Electro Alloys Pvt Ltd 145T: +91-11-25280488E: [email protected]: www.rselectro.com

Raj Petro Specialities Private Limited 63T: +91-44-42288900E: [email protected]: www.rajgrp.com

Riat Brothers (India) 138T: +91-161-2530805E: [email protected]: www.riatbrothers.com

Ringfeder Power Transmission India Pvt. Ltd 93T: +91-44-26791411E: [email protected]: www.ringfeder.com

Robin Precision Products Pvt Ltd. 130T: +91-2827-287631E: [email protected]: www.bloodtools.com

Rotomotive Powerdrives India Ltd. 90T: +91-2692-230430E: [email protected]: www.rotomotive.com

Royal Precision Tools Corporation 125T: +886-4-2338-2068E: [email protected]: www.royal-spindles.com.tw

Sahajanand Laser Technology Ltd 139T: +91-79-23287461E: [email protected]: www.sahajanandlaser.com

Samkrish 131T: +91-44-23612310E: [email protected]: www.samkrish.com

Samkrish Machine Tools 111T: +91-44-23612310E: [email protected]: www.samkrishmachinetools.com

Sandvik Coromant India FGFT: +91-20-27104800E: [email protected]: www.sandvik.coromant.com/in

Seco Tools India Pvt Ltd 25T: +91-2137- 667300E: [email protected]: www.secotools.com/in

Shailesh Sales Corporation 152T: +91-281-2461102E: [email protected]: www.shaileshmachines.com

Shuter Enterprises India Pvt. Ltd. 112T: +91-44-32407116E: [email protected]: www.shuter.in

Siemens Ltd 37E: [email protected]: www.siemens.com/industry

Synco Industries Ltd 152

T: +91-9214407024E: [email protected]: www.synco.co.in

Taegutec India Ltd BCT: +91-80-27839111E: [email protected]: www.taegutec-india.com

Taiwan Diamond Industrial Co., Ltd. 157

T: +886-3-363-6971E: [email protected]: www.taiwandiamond.com

Taiwan Machine Tool & Accessory Builders’

Association 18

T: +886-4-2350-7586E: [email protected]: www.tmba.org.tw

Takamatsu Machinery Co Ltd 36T: +81-76-2741403E: [email protected]: www.takamaz.co.jp

Teknic 29T: +91-22-26592392E: [email protected]: www.tecknic.co.in

Trident Products Pvt Ltd 162

T: +91-124-4300626E: [email protected]

Trigon Tooling Solutions Pvt. Ltd. 35T: +91-124-2370250 E: [email protected]: www.trigontools.com

Triune Exhibitors Pvt Ltd. 148

T: ‘+91-80-43307474E: [email protected]: www.amtex2012.com

Tungaloy India Pvt Ltd 46, 47T: +91-22-61248888E: [email protected]: www.tungaloy.co.jp.in

Tussor Machine Tools Ind P Ltd 58T: +91-422-3200183E: [email protected]: www.pinachoindia.com

Tyrolit India Superabrasive Pvt. Ltd 115T: +91-80-40953259E: [email protected]: www.tylolit.com

Uniline Energy Systems Pvt Ltd 167T: +91-11-46661111E: [email protected]: www.unilineindia.com

Universal Corporation 134T: +91-22-23422238E: [email protected]: www.samson-grp.com

Vargus Limited 79T: +91-9730028248E: [email protected]: www.vargus.com

Vijay Machine Tools Pvt Ltd 166T: +91-22-24950886E: [email protected] W: www.elmacovijay.com

Wexper India Ltd 181T: +91-124-2210020E: [email protected]: www.wexper.com

Yaskawa Robotics India Ltd 169T: +91-124-4758534E: [email protected]: www.motoman.com

YG Cutting Tools Corporation Pvt Ltd. 8T: +91-80-43543636E: [email protected]: www.yg1.co.kr

Yuang Hsian Metal Industrial Corp. 161T: +886-4-761-3688E: [email protected]: www.yhm.com.tw

Zen Wu Zheng Sun Tool Co., Ltd. 62T: +886-7-352-5743E: [email protected]: www.jsk-tools.com.tw

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modern machine tools - july 2012

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