COMPANY PROFILE
Aaroh Marketing:
Extending the horizon
stablished in the year 2013 at “AMC” serves to its clients for their
Pune, Aaroh Marketing Company, products and different business exercises
E“AMC” is a Premium product through the team of professionals, who
supplier in Die and mold industry actively have experience and knowledge in this
committed in distributing the range of domain.
Mold base and accessories of “DME” Our mentor, Mr. Chandrakant Chakwate
which is a part of “New Hellanbrand is instrumental in the success of this PRASHANT CHAKWATE
Group”, USA. domain. He is exceedingly motivational, Director-Sales & BD,
“AMC” started promoting “Laser Slat dynamic and enthusiastic towards his Aaroh Marketing Company
Cleaner” in Sheet Metal Industry from obligations and these things makes him a
“SIDEB”, Turkey. Looking at the current perfect pioneer for us. Following strengths have helped us to
need of industry, this product distribution meet our clients’ needs:
started for Indian market including East Industry we serve • Premium industrial product
Asian countries from 2022. • Die and Mold Industry • Specialized products as per customer
“AMC” is offering the complete range • Heavy Engineering Industry need
of products in Sheet Metal Industry like • Sheet Metal Industry • Wider range in every segment of
specialised CNC fiber Laser Cutting products
Machine, CNC Press Brake and CNC Why Us? • Ethical and transparent business policy
Tube/Pipe cutting machine in premium “AMC” takes pride in providing solution • Experienced and dedicated team
segment from Nukon, Turkey. in Premium product range of Mold base, • Competitive pricing in premium
“AMC” is also offering Eye bolt from accessories, slat cleaners and eye bolts segment
“Yoke”, Taiwan in premium segment in including Sheetmetal fabrication machine
material handling industry. of superior & specialized quality at very For more information,
Quality is the essential thing that affordable rates to Indian Market. www.aarohmarketingcompany.com
46 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
INDUSTRY FOCUS
Enhance Profitability & Productivity in
Die & Mold Industry with the
Right Toolholders
Companies that make dies and moulds expect high process and product expertise as
they are major contributor in making the final product as per the stringent specifications.
n order to increase the every die and Mold company
profitability and productivity can FOCUS and achieve
Iof the milling process in a die steep increase in its Overall
and mold industry, one has to Equipment Efficiency (OEE).
look beyond high-performance Please find few variants of
machining centers. Therefore, products and application area’s
its very critical to select the where they can be utilize for
right cutting tools and the its features and exhibit higher
toolholders along with the benefits and performance to
process. The tool holders can the user.
also lead to significant savings,
when you use JUST toolholders For more information,
MR. VIJAY CHOPDA for every application from array [email protected] MR. SANTOSH TIPALE
Founder & CEO, of products available in the marketing@ktaspindletoolings. Sales Director,
KTA Spindle Toolings market. This is exactly what com KTA Spindle Toolings
48 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
SUCCESS STORY
Advanced cutting tools to play a
significant role in the aviation industry
The aviation industry is constantly striving for latest technological solutions to the challenges it faces. A look
into the advanced tools and technology trends in the industry tells you that India is aggressively looking to carve
a role for itself as a global manufacturing hub as well as aiming big for infrastructure development. Cutting
tool industry, which derives its demand from across a wide spectrum of sectors, is looking forward to seize on
the opportunity. Adaptive as they are, Indian manufacturers are looking at challenges at hand in meeting the
expected demands and are constantly looking to address them through innovative technologies. Fortunately,
cross-sectoral demand for advanced cutting tool puts the industry well placed to capitalise on opportunities
emerging in a growing economy.
50 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
SUCCESS STORY
he end markets for drilling and It would be only appropriate in this the same time, innovations taking
boring tools for instance are context to take note of the Indian place in the field of hole making play
Thighly diverse and not confined government’s ambitious Rs 100 a substantive role in making very
to aerospace. As demand is driven by lakh crore (USD 1.3 trillion) plan for sophisticated pieces.
sectors as varied as general engineering, integrated infrastructure development The shopfloor faces myriad of
transportation, energy and aerospace to assess sectors driving the cutting tool challenges everyday such as process
market, the demand for advanced cutting industry. of changing drills leading to higher
tools will continue to shoot north in the Cutting tool industry is looking to find operation time and the setting of the
years to come. More so, because an a mentionable name for itself in the boring tools resulting in errors and
efficient use of cutting tools impacts the growth story. But like any other industry backlashes. Chip extraction, chip
overall cost of manufacturing. We are at any other time, it has challenges at jamming, chips spilling out of control,
very optimistic about the future and are hand. and improper evacuation of chips are
taking steps to capitalise on the potential Boring or drilling or deep hole drilling, some of the major challenges that
opportunities in these segments. each applications throws its own operators face with drilling. Vibration
Apart from aerospace, these challenge in selecting a suitable cutting and coolant starvation are some of the
segments include sectors like railways, tool. other aspects to be looked at.
defence, die and mould, and medical The most common among all the Consumers are getting forced to use
engineering for the sturdiness of the cutting tools, a drill, coming in various centre drills as a pre-drilling operation
growth. It particularly draws attention to shapes for varied types of applications, in long drilling applications which is
automotive industry and heavy and light is going through a major shift in terms another hurdle that leads to longer
engineering sectors for the “phenomenal of technology adoption for a myriad of operation time..
growth and technological advancements challenges that it places. Among the An expert makes particular mention of
in the industry”. most complex machining processes, the safety hazard as well as damage to
Infrastructure is another sector the drilling, deep hole drilling and boring has the workpiece on account of chip getting
industry has keen eyes on. Impressive witnessed introduction of a variety of out of control, especially while drilling
developments in infrastructure and solutions to challenges they pose. the super alloys or the stainless-steel
construction activities in the Asia Pacific “Hole making is considered to be workpieces.
region are also contributing factors in the one of the most difficult machining A very important aspect of safety is
growing demand for cutting tools. operations,” says the MMC MD. At a long, stringy chips getting wound up
52 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
SUCCESS STORY
around the drill body which could lead to addressed. There are various challenges a dog-eat-dog scenario, it is imperative
accident and damage to the workpiece. in searching for solutions and finding for businesses to create a strong value
Meanwhile, on the other hand, short answers through technology. differentiation for customers. “Adapting
chips generated during drilling of a According to a recent survey, it has emerging trends in cutting tools with
few varieties of cast iron or some been suggested that a lot of Indian innovation, refined manufacturing
alloy steels, may pose these problems manufacturers are adopting advanced processes, advanced surface treatments
because they do not get evacuated manufacturing practices more than and grades enable manufacturers
properly leading to breakage of tool and the manufacturers from some other to create that competitive value
sometime damaging the component or advanced countries. Manufacturers differentiation,” revealed the expert
the machine, too. Searching for suitable today embrace technology much faster who didn’t want to be named while
grades and coatings also need to be than ever before, says Ketan Shah, explaining the increasing integration of
Product Specialist – new technologies.
Hole Making for India However, since the industry serves
at Sandvik Coromant. a wide range of end-consumers, the
A market expert adoption rate of new technologies, of
stresses his point by course, varies according to the end
citing the rising ratio markets a manufacturer targets. Apart
of NPS (New Product from such individual variations, as the
Sales) in the market manufacturing industry continues to
which suggests that evolve, new technologies will also
the “rate at which continue to shape the future and cutting
customers and tools will definitely lead that future
manufacturers are charge.
adapting to changes
in the technologies is Arijit Nag is a freelance journalist who
increasing rapidly. In writes on current affairs and the economy.
54 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
2022
B 11
A revolutionary High Accuracy Mirror Finish CNC EDM By M/s DMNC, China
Leading No. 1 manufacturer in China.
Established in 1978 as Beijing Institute of
Electro Machining.
Exports to developed nations in USA,
Europe.
Production about 800 machines every
year.
Windows based controller.
Ra value of 0.08 microns.
Electrode wear less than 0.05%.
A Most Cost Effective Molybdenum CNC Wire EDM from M/s King Red, China
Leading No. 1 ISO manufacturer in
China.
High accuracy machine delivering
surface finish very close to brass wire
EDM.
Exports to more than 25 countries world
over.
Production about 500 machines every
year.
Windows based controller.
Controller compatible with CAD files.
Best finish in Multi cuts 0.8 Ra microns.
Low running cost.
Authorised Agents for DMNC, Kingred in India
M/s. Shreeda Enterprises
B-15, Kamal Pushp Society, Bandra Reclamation, Near Lilavati Hospital, Bandra (West), Mumbai - 400050
Tel. : 9819403977 E-mail : [email protected]
DRIVING
AUTOMOBILE INDUSTRY
12 DIE MOULD INDIA INTERNATIONAL EXHIBITION
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Get Ready To Explore, Engage, And Enhance Your Business Network
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27 – 30 APRIL, 2022
BOMBAY EXHIBITION CENTRE, GOREGAON (E), MUMBAI, INDIA REGISTER TODAY
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Visit the Die Mould India International Exhibition (12 Edition) and meet knowledge masters
from the tooling fraternity in one place to discover numerous ways to grow your automobile
manufacturing business.
INDUSTRIES BENEFITED :
Aerospace, Automobile, Auto Ancillary, Defence, Consumer Durables, Electrical, Electronics,
Engineering, Railways & Plastic Products
ONLINE REGISTRATION IS MANDATORY ORGANISED BY
SAFETY PROTOCOLS TO BE STRICTLY FOLLOWED
For more information, visit www.diemouldindia.org
TECH INNOVATION
Faccin Group:
Growing its metal
rolling solutions
ver the last few years, customer Faccin Group: an offering an extensive range of machines,
requirements for plate bending all-encompassing specialist thanks to its three brands: Faccin, Boldrini
Omachines have increased Faccin Group, has become a reference e Roundo. Each brand brings its own
considerably. Bending machines are point in metal forming technology, specific technical features, all having in
essential within factories and choosing common energy-efficient systems, state
the right model can make a huge of the art CNC controls and electronics
difference in production costs saving, and top of the range hydraulic set-ups.
especially in the current geopolitical As of today, Faccin Group has
situation. successfully installed more than 30,000
In response to new and more units worldwide and its machines are
demanding market requests, companies used to manufacture a wide variety of
have geared up with new machinery products, including pressure vessels,
to stay competitive, requesting the best heat exchangers, road and railway tanks,
product on the market to increasing natural gas pipelines and wind towers.
bending efficiency. Faccin Group, one
of the most important metal forming A wide range of plate rolling
machine manufacturers in the world, machines
has embraced this challenge and can Faccin products, especially plate rolls, are
propose to its customers tailored capable of bending steel sheets of different
cutting-edge products, for all market thicknesses, offering the highest precision
needs. Indeed, the Group has always tried and elevated productivity, with energy
to differentiate its offer and to satisfy efficiency. Most plate rolling machines can
multiple requirements, building energy- be divided into five major families, suitable
efficient machinery for different sectors. for different needs and situations:
60 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
TECH INNOVATION
• 2-Rolls model HCU: the ideal solution solution for
to roll thin plates thickness up to 3/16’’ automatic lines due
(5mm) and width up to 6 1/2’ (2000mm) to their high rolling
at a high speed from 180 to 300 pieces speed, extreme
per hour. precision, and
• 3-Rolls ASI (asymmetric): with tight tolerances
asymmetrical rollers and a single infeed, that together with
the ASI electromechanical plate roll is a series of ad hoc
suitable for basic production and rolling accessories like loading
of steel sheets up to 3/8” (10mm). devices, feeding tables,
• 3-Rolls 3HEL (Linear Guides) and and a powerful CNC, ensure
3HEP (Swing Arms): a perfect fit for all the full automation of plate
metal carpentry’s needs. rolling in the factory.
• 3-Rolls model HAV (Variable Besides plate rolls, it is also heavy-duty
Geometry): the most technologically important to consider, a key part of Faccin carpentry work.
advanced three-roll bending machines Group’s product offer, is profile benders,
available worldwide, they are perfect available in different sizes to meet the With the addition of the Boldrini brand
for medium and heavy-duty rolling different needs for bending structural products to its widely known Faccin
requirements from 1.6’’ (40mm) to over beams, profiles of different sections in Dished head production line, the Group
12’’ (300mm) thickness and specific steel, stainless steel, and aluminium. has widened the offer to become the
applications such as Pressure Vessels, Depending on the capacities and work absolute leader in solutions for the dished
Offshore Foundations for the Wind intensity required, the Group can offer: end manufacturers, either for those that
Industry, Offshore Platforms, Reactors • The Faccin RCMI series, are robust and fabricate and commercialize dished
and Heat Exchangers. precise, designed for bending profiles ends as their main activity or for those
• 4-Rolls 4HEL (Linear Guides) and 4HEP and angles with high flexion strength that fabricate heads for their internal
(Swing Arms): highly technological and modulus. production of pressure vessels, heat
innovative, it assures high productivity in • The Roundo R series, versatile and exchangers, industrial tanks, or truck
bending plates from less than 3’ (1mt) highly productive, adapted to handle a tanks. Customers can then choose either
and up to 33’ (10mts) with thickness great variety of bending jobs, being the or a combination of:
from 3/16’’ (5mm) to 6’’ (150mm). It is larger models optimized for bending • Boldrini dishing press, manipulator, and
the best solution for Tanks, Pressure beams the hard-way. flanging machines, designed to ensure
Vessels and Wind Tower production. • The Faccin Taurus model, with variable the fastest return of investment through
geometry, an oversized machine high productivity and energy efficient
4HEL Plate Rolls, are Faccin’s primary suitable for bending large beams and design.
• Faccin dishing press, manipulator and
flanging machines, high performance,
and reliability, to achieve the required
tolerances and lamination reduction.
Faccin Group’s catalogue also includes
special machines, built to the specific
requirements of different customers.
These tailored machines for a diverse
range of industries, are the Group’s
response to very challenging projects,
and designed by the company’s highly
experienced technical department.
For more information
Website: www.faccingroup.com
Email: [email protected]
62 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
TECH INNOVATION
Grob’s 4-Axis Machine Series
Precise, economical, future-oriented –
now also in a 4-axis version
With the development of the new 4-axis machine series, GROB provides the solution for the market demand for a
robust but also dynamic 4-axis horizontal machine. This series has been optimized for practically ideal static and
dynamic behavior with the aid of a multi-object simulation of the complete machine from the beginning, and will
perform with a high level of reliability, accuracy and dynamics in a highly competitive environment. The modular
configuration also allows the machines to be completely adapted to work with existing production systems, while
providing the freedom to break new ground.
Mindelheim.
With the expansion of the product range by the 4-axis machine
series, GROB can meet the ever-increasing demands of all target
markets in addition to the 5-axis market segment. The modular
machine design and range of options allow the G440, G640 and
G840 4-axis machining centers to be configured in accordance
with specific customer requirements. As with the GROB 5-axis
universal machining centers, the 4-axis machine series impresses
with its compact design, high productivity and maximized
stability. In addition to being perfectly suited for the automobile
industry, is also ideal for the Mechanical Engineering, Bus &
Truck, Rail, Agricultural and Construction Machinery, and Fluid
Technologies sectors. The new 4-axis machine stands out among
its market competitors with its high loading weight, and high
thrust and acceleration capabilities of the main axes. provided as standard, all the way up to GROB-developed robot-
assisted part and pallet handling systems. With regard to part
Machine characteristics – over 95 years of machine clamping technologies, we can design and manufacture our own
tool experience systems. Flexible integration of new units into existing systems
To reduce the weight of the structural components and increase and automation systems is not a problem for GROB.
stability at the same time, the 4-axis machine series has been The tool magazines are installed next to the machine as separate,
designed with the aid of numerical methods such as topology independent modules, and can be easily replaced afterwards if
optimization and FEM simulations. The series is designed as a customers requirements change. The tool magazines’ capacities
moving column on a rigid machine bed with three fixator points. can scale to meet customer requirements. Large tool magazines
The rotary axis is powered by a dynamic torque motor and the holding 450 tools (HSK-A100) are available, rounding out the
linear axes by ball screw drives. For the G640 and G840 models, portfolio toward the top. Aside from control systems expertise,
the workspace can be expanded to a larger height configured for centralized tool magazines must also be integrated for flexible
the target segment, allowing the use of taller clamping units. manufacturing stations. Tools with tool lengths of up to 830 mm
can be inserted into the magazines directly at an ergonomically
GROB automation technology for the 4-axis series appropriate height manually during operation.
GROB amasses its competences for comprehensive automation The best way to get to know us is by planning your pending
technologies consultation in its Center of Excellence (CoE) production tasks together with us. Truly GROB – precise,
for automation and provides its customers with a balanced economical, and future-oriented.
automation solution designed with the aid of 3D planning
and process simulations under real-world conditions. Possible
implementation requests range from a pallet changer with For more information,
clamping units and sophisticated part clamping technologies Website: www.grobgroup.com
64 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
Visit US:
PRODUCT WORLD Hall - 1
Booth No. B15
April 27 - 30,
OF DIE AND MOULD 2022
BEC, Mumbai
PEACOCK
IGUANA
POWER LINE
Marketing and Business Development Office
ZECHA Precision Tools Limited
402, Vantage C, NDA Pashan Rd. Ram Nagar,
Bavdhan PUNE-411021 (INDIA) Tel.: +91 20 67467096
ZECHA Precision Tools Limited
F 2/2, MIDC Industrial Area, Chikalthana,
Aurangabad 431006 (INDIA) Tel.: +91 240 2482559
E-Mail: [email protected] · Website: www.zecha.in
TECH INNOVATION
Reducing cost of coolants, lubricants
and quenchants by automatic
proportioning with water
uge losses due to improper mixing of coolants / lubricants of quenching tank and desired
mixing of coolants / quenchants / quenchants with water, heat treatment characteristics
H/ lubricants with water are consistently and automatically. of induction hardened parts
experienced throughout industries. Mixing in correct dilution ratios
These include coolant spillage losses with water enables a number • Die casting and hot
of up to 5%, high evaporation losses of benefits in important forging lubrication: Correct
of coolants from sump, failure of heat operations like: mix of die lubricants with
treated parts due to improper quenchant • CNC / VMC operations: water enable optimal die
mixing, low die life or excessive lubricant Correct mix of cnc coolant life and ease of operations,
consumption in die casting, hot forging with water enables without job sticking
operations and low tool life in CNC/ reduced evaporation
VMC operations due to improper coolant losses, increased sump Accurate Proportioner
mixing with water. life of coolant, preventing automatically sucks pre-
Manual mixing methods followed in the bad odour from sump and set quantity of coolant
industry are always subjected to human increased tool life due to directly from coolant drum. It
error. Maintaining consistent, correct better lubricity emulsifies (mixes) the coolant
dilution ratio of concentrates with water with water and delivers the
is a challenge faced by metal-forming • Polymer quenching: diluted solution through the
industry. Correct mix of polymer outlet.
Steel Plant Specialities LLP, Mumbai, quenchant with water enables uniform The Accurate Proportioner operates
offers Accurate Proportioner for correct heat treatment of parts at all locations only on water connection. No electricity
connection and no complex softwares
or settings are required. As it works
on water pressure, the proportion will
always be accurate, as per the inlet of
water quantity.
Difference in water inlet water pressure
will not affect accuracy of proportioner.
Capacity of Accurate Proportioner is up to
350 litres per hour (concentrate + water)
Successful case studies and
certificates of appreciation from reputed
Organisations are available on request.
Complete support in installation of
equipment and training is offered by
Steel Plant Specialities LLP.
For more information,
Email: [email protected]
Website: www.steelplantspecialities.com
66 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
TECH INNOVATION
ISCAR expands the MILL-4-FEED
family of Fast Feed milling tools
he remarkable progress made in • A flat chipformer is available for insert
the area of rough milling over the sizes 09,12,17.
Tpast decades saw the introduction • 4 indexable reinforced cutting edges.
of fast feed milling (FF), also referred to • Increased corner radius for improved
as high feed milling (HFM). Rather than performance in near-to-wall machining
use the traditional high metal removal while maintaining the same tool
technique – milling with considerable diameter.
depths and widths of cut – users of the • Produced from ISCAR’s advanced
new approach continued to machine with SUMOTEC carbide grade for
similar width of cuts, although they used unsurpassed productivity.
a much smaller depth of cut and applied
much faster speeds with substantially The advanced geometrical design
increased feed per tooth. High feed combined with innovative carbide
milling enables much faster machining grades results in significantly improved
than conventional methods. Energy resistance to edge breakage and the revolutionary NEO-ITA for achieving
saving shallow-cut “fast” technology chipping, which guarantees better tool optimal machining results.
provides an excellent alternative to power life and enables highly productive fast
consuming deep-cut methods. feed milling, especially when cutting
ISCAR’s new FFQ4 SOMW... hard materials and when machining
insert features advanced capabilities non-continuous surfaces which results in
for increased milling productivity in interrupted cutting.
machining materials up to 60HRC which I would like to remind you to download For more information,
takes fast feed milling a giant step further. the ISCAR World app which features Website: www.iscar.in
68 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
TECH INNOVATION
Part one: Geometry Design and
Parameter Verification
very Endmill begins with design
and a well-designed geometry can
Emake a high performance Endmill.
There are many factors which will impact
the overall performance of an Endmill.
Four major ones that get cited are the
grade or quality of carbide material, the
cutting tool geometry design, the precision
manufacturing process or quality control
and the type of coating.
The hardness of an Endmill’s material,
usually carbide, will depend on the grade
of carbide in the matrix. Smaller grains
mean more substance versus binder, and
therefore a harder tool. Exotic coatings will
improve lifespan and cutting performance. High helix tools (over 35 really bite into the material.
Quality control means a workshop can get degrees) have long been On the contrary, low
a consistent result. popular for their strength helix tools are less likely to
But geometry has an outsized role, and fast feed and swarf chatter and typically perform
one that highlights the blend of art and removal rates. While they better in soft materials. Their
engineering – and for a long time, trial have these advantages over disadvantage is the lower
and error – involved in creating the ideal low helix Endmills for hard feedrates and hence lower
Endmill. This begins with design. Some materials, they are also the material removal rates. Our
of the important factors in Endmill design more prone of the two to understanding of how to
include the combination of both variable chatter. Some of the trial mitigate chatter has come
helix and index flute geometry design, core and error to combat this has been around a long way and involves no guesswork
geometry design, the OD clearance angles variable helixes and pitches and trying nowadays. The geometry and design are
eccentric versus facet reliefs design, to better balance tools. This has led to purely based on material to be cut whether
endface design with wiper flats and pad “weird” Endmills, with higher geometrical it is soft or hard.
grinding or end dubbing etc. each time levels of complexity. In high helix tools the Variable helix end mills with variable
from a set of Endmills. cutting forces are directed more vertically index are considered state of the art
As I have written elsewhere, the and less horizontally, which reduces tool these days. The idea is to vary the helix
progress of the industry has seen Endmills deflection and results in quick and efficient along the flute length or from flute-to-
grow increasingly “weird” as toolmakers chip evacuation. flute. The aim of the variable helix is to
have sought high material removal rates More positive axial rake lowers cutting fight chatter. Since chatter is a resonance
while avoiding “chatter”. forces which helps to increase feedrates. effect, anything we can do to break up the
Regenerative chatter happens when the The core of the tool is thicker due to the resonance of the flutes beating against
harmonics between a tool and workpiece shape of the helix and the tool is stronger. the workpiece will reduce chatter. The tool
are at different frequencies. The two High helix Endmills are typically used in balancing capabilities in the RN34 release
self-excited objects will hit against each tougher harder materials because they of ANCA’s ToolRoom software is the
other, which is a negative for surface finish wear better, although they can also be perfect solution to combat chatter.
and dimensional accuracy, as well as the used in softer materials like aluminium.
lifespan of the tool and machinery. It is a One disadvantage of high helix Endmills For more information,
drain on productivity and profits. is the tendency to chatter more, and they Website: www.anca.com
70 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
TECH INNOVATION
INTEGRATED OR SEPARATE?
Safe Control Technology on Smaller Machinery
Safety controllers are becoming increasingly popular as an alternative to relay modules, even on smaller
machinery. The designer can opt for one of two concepts: some designers favour integration of safety into the
automation PLC, but a separate (small) safety controller offers clear benefits.
Safety integrated’ or ‘safety separated’:
should machine safety be integrated
‘into the PLC or implemented separately
using separate hardware and software?
This is the question that every machinery
designer needs to ask today.
Replacing relay modules
The question is especially important in Fig. 1: Developed for
the case of smaller machinery with a applications with a
manageable number of safety functions manageable number of
and switchgear devices. There is a safety switchgear devices
noticeable trend favouring replacing – the parametrisable
multiple safety relay modules with one compact safety controller
small safety controller or with a PLC with Protect Select.
integrated safety functions.
There is good reasoning behind this
trend. In the first instance, machinery machinery productivity. With a safety- application as it can be realised in wide-
is becoming increasingly complex. It focused control system, machinery ranging areas through parametrisation
features additional and differentiated builders can create the prerequisite and programming.
safety functions, in some cases offering for bringing only part of a machine
interaction with the operator. Examples to a halt in the event of irregularities. Integrated or separate?
include setup with touch mode or Additionally, safety functions can be To return to the original question: should
troubleshooting. This does, however, linked together, which can also lead to the machinery builder accomplish these
presuppose that these options can be increased productivity and avoidance of benefits with an integrated or separated
mapped and monitored in the safety- unscheduled downtime. The enhanced solution for the safety of machinery?
focused control system. Additionally, the diagnosis options when compared to At first glance, there is more than one
requirements on the safety of machinery safety relay modules enable more rapid argument in favour of integration – the
are becoming increasingly stringent, localisation of fault causes in the event of fact, for example, that modern PLCs cover
partly due to growing awareness of malfunctions. safety of machinery tasks and that users
hazards and partly due to increasing With traditional relay modules, the can save on costs as well as space in the
differentiation of general and machinery- effort required for wiring, documentation control cabinet. Plus, it’s for good reason
specific standards. and validation of the module solution that integration has become a popular
becomes disproportionately large concept in automation and digitisation.
Productivity and availability when the safety functions reach a In theory at least, integrated solutions
Equally important is the fact certain complexity. With safety control promise robust coordination of functions
that differentiated, needs-based systems, the wiring effort is reduced. The and simple infrastructure with reduced
implementation of safety requirements configuration is also simpler and enables hardware effort.
can also enhance user operability and better adaptation to the individual In practice, there are clear benefits of a
72 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
TECH INNOVATION
separated solution One of the positives of based on a safety integrated solution, developed for this very application.
standalone safety infrastructure is the fact machinery and subsystems that operate The user does not have to program the
that a safety concept can be accomplished in standalone mode can often only be controller but can choose from pre-
independently of the automation solution operated in a rudimental manner. On the configured programs and only has to
and, therefore, independently of the other hand, a compact safety controller like enter the corresponding parameters.
manufacturer of the functional control the Protect PSC1 from Schmersal offers These applications cover a wide range
system that may be specified by the a simple and flexible option by means of possible use cases. Additionally, the
machinery builder. Consequently, even of integrated safety protocols (Profisafe user can also activate special features
when customer-specific automation PLCs and FSoE) to operate such machinery such as free allocation of feedback circuits
are used, a standardised safety concept encapsulated and, if required, to integrate (EDM), start-up tests, cyclical testing and
can be accomplished on an always them into fail-safe fieldbus architectures auto-start with every program. Additional
identical component and hardware basis. without having to make changes to the functions and operating modes (setup
Another benefit is that you do not need safety application. mode, process monitoring) can also be
to be a PLC specialist to program the accomplished.
safety functions – the range of language Compact and complete
is manageable when compared to Manufacturers of smaller machines Modular compact safety controller
automation control systems. in particular are increasingly having If a higher level of customisation and
to confront more stringent safety adaptability is required, the Protect PSC1
Integration option requirements. In addition, the expectations safety PLC could be an option. Thanks
Opting for separate safety does not of end customers in terms of diagnosis to its modular design, it is easy to adapt
mean that integration is impossible. options and ease of maintenance are to user requirements, irrespective of
Quite the opposite in fact. Bus protocols also on the increase in this segment. This whether the signals from emergency-stop
enable integration into higher-level requirements profile can be mapped easily control devices, electromechanical safety
control systems, something which might and cost-effectively with a small safety switchgear, tactile protective devices,
be required when production systems controller. Depending on the application, safety sensors or optical protective
comprising multiple subsystems from standard automation can also be realised devices need to be evaluated. A number
different providers need to be integrated. with the small controller, and integration of modules are available for fail-safe
In that case, the safety solutions of the can be achieved ‘in the opposite direction’. drive monitoring, which reliably monitor
individual system must be connected The Schmersal Group offers two options parameters including position, speed and
in order to implement a higher-level to help achieve a safety separated concept increment.
emergency-stop function, for example. on smaller machinery. The Protect Select Additionally, the controller can also
If the higher-level safety concept is small safety controller has been specially be supplemented with a universal
communication interface, where the
user simply selects and sets various bus
protocols such as Profinet, Ethercat,
Ethernet/IP, Profibus or CANopen using
software. The interface also allows
safety remote I/O communication and the
simultaneous connection of up to four
systems via safety cross communication
via Ethernet. An OPC UA server can
also be integrated. In summary, a
safety separated safety concept can
offer significant benefits in terms of
standardisation, operating convenience
and flexibility.
For more information,
Fig. 2: The Protect PSC1 safety controller enables the realisation of ‘safety
separated’ solutions. It also enables integration into higher-level infrastructure. Website: www.schmersal.in
74 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
TECH INNOVATION
Sensor solutions for the reliable
inspection of wind turbines
Due to safety and cost reasons, wind turbines require 24/7 monitoring. Lightning, defective rotor blades or
tower movements due to localized storms can have serious consequences until the wind turbine finally collapses.
Precision sensor technology from Micro-Epsilon is already used during production as well as in the real-time
monitoring of active plants. The sensors enable the plant operator to intervene early during production or to
switch off the running wind turbine early enough to avoid danger or damage. Targeted monitoring using modern
sensor technology reduces the costs of maintenance and servicing.
Due to safety and cost reasons, wind turbines require 24/7 monitoring. Precision sensor technology from Micro-Epsilon is
already used during production as well as in the real-time monitoring of active plants.
arnessing the power of wind time of day or night. Due to wear and operation. Wear of parts or deviations in
has been used over many years, the complexity of plants, in addition to production should be recognized before
Hfor example, to power windmills environmental influences, there are also catastrophic damage occurs. Therefore,
and sailing ships. Today, generating a number of possible problems such as it is possible to intervene long before the
power is the most important use of wind shaft issues, gear faults, gear wheel wear, parts fail or tools begin to wear out. Not
energy. Wind turbines are used onshore material fatigue, imbalance, temperature only can current states be documented,
and offshore for power generation. The differences, lubrication faults and bearing but trends and changes in measurement
rotor towers of these major plants weigh clearances, which do not only impede data can be analyzed and evaluated.
dozens of tons and reach up into the sky. smooth operation but might also involve Maintenance becomes predictable and
Their average rotor diameter is approx. other subsequent or secondary damage. sudden failure or downtime of these
110m, the average hub height is approx. Predictive Maintenance plays an essential large plants is reduced to a minimum.
130m. If such equipment fails, a high role here. Proactive monitoring based on This is how productivity can be increased
financial cost is incurred. Cranes and precision sensor technology has already while efficiently using resources & saving
other machines are normally unavailable begun to be used in the production money.
at short notice. Particularly offshore process and continues in test benches Modern and innovative sensor
farms are not easily accessible at any and real-time monitoring during turbine solutions from Micro-Epsilon enable
76 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
TECH INNOVATION
3001 and 3005 sensors offer high
accuracy and temperature stability,
making them particularly well suited
to continuous operation in industrial
environments. The sensors can be rapidly
exchanged due to, amongst others, their
M12 housing. They are robust, protected
to IP67 and their compact design allows
them to be integrated into the smallest
of installation spaces. The sensors are
therefore ideal for predictive wear and
condition monitoring tasks. Compared
to inductive switches and sensors, these
models provide a higher bandwidth and
so are suitable for exact detection of high
speed movements.
In a wind turbine, the offset of the coupling ring, gap measurement of the plain
bearing, temperature monitoring of the generator and air gap monitoring in the Gap measurements in plain
generator are, amongst other things, critical factors. bearings
Hydrostatic bearings are used in large
reliable measurements and targeted and tangential axes. The eddyNCDT plant and machinery such as stone mills,
evaluation of a considerable amount of 3001 and 3005 eddy current sensors telescopic installations and also wind
critical data. In a wind turbine, the offset are temperature-compensated and turbines. The task is to monitor the gap
of the coupling ring, gap measurement of so offer high stability, even in strongly size between the bearing surface and the
the plain bearing, temperature monitoring fluctuating ambient temperatures. They shaft. In the lubricating gap is an oil film
of the generator and air gap monitoring in are factory-calibrated for ferromagnetic which prevents direct contact between
the generator are, amongst other things, and non-ferromagnetic materials, which the bearing surface and the shaft. In the
critical factors. eliminates the need for field calibration of case of a malfunction in the hydraulics,
the sensor. the oil pressure can rise and, in extreme
Offset measurement of the Due to factory calibration, eddyNCDT cases, the gap will close. This would lead
coupling ring
Above 100 meters, enormous wind loads
act on the rotor blades, housing and
tower. Therefore, gearbox and generator
have an elastic bearing. This is why
couplings in wind turbines must balance
the relative movement of the gearbox
and generator. When measuring the
offset of the coupling ring, eddy current
sensors determine the distance, while
measuring onto the metallic coupling
ring. This leads to the determination
of the load profile. Monitoring the
measured values is required in order to
avoid unnecessary wear of couplings,
bearings and shaft seals or, in extreme
cases, serious damage to the wind In the case of a malfunction in the hydraulics, the oil pressure can rise and, in
turbine. The measurement is carried out extreme cases, the gap will close. The sensor measures through the oil film and the
in different directions – in the axial, radial plain bearing directly onto the shaft.
www.mtwmag.com APRIL 2022 MACHINE TOOLS WORLD 77
TECH INNOVATION
to damage of the bearing and in turn to calibration and linearization procedures.
a possible plant failure. Therefore, the Not only in wind turbines but in almost
sensor is mounted horizontally to the any application in diverse industries,
bearing shoe. It measures through the innovative sensor technology prevents
oil film and the plain bearing directly repairs, reduces failures, helps to predict
onto the shaft. Here, eddyNCDT 3001 maintenance cycles and reduces costs.
and 3005 non-contact eddy current Compared to manual inspection where
displacement sensors are used. They differences can depend on the person’s
stand out due to a robust, compact tiredness and changing mood, sensors
design with integral controller. Eddy provide high precision, reliable and
current sensors from Micro-Epsilon are repeatable measurement results. Micro-
often used in applications where harsh Inductive sensors from Micro-Epsilon Epsilon is a leader in high precision
ambient conditions are present and based on the eddy current principle are measurement technology. The product
where maximum precision is required. often used in applications where harsh range comprises inductive, confocal
Immunity to pressure, lubricants and ambient conditions are present and chromatic and capacitive sensors,
where high precision is required.
extreme temperature are distinctive together with laser, eddy current, draw-
features of eddy current sensors. Other optical & capacitive sensors are used wire and temperature sensors, including
requirements with respect to the sensor to measure the distance between the inspection and measurement systems,
technology are fast commissioning and stator and rotor and to monitor the rotor e.g. for modern 3D surface inspection.
the possibility to retrofit to existing plant. gap whilst the motor is in operation. The The sensor solutions, which are
Due to the worldwide use of these plants, sensor technology is based on capacitive customer-specific in most cases, are from
the sensor should be easy to replace. sensors with a measuring range of 0 to a single source. The sensor manufacturer
8mm. develops, produces and distributes
Air gap monitoring in the Capacitive sensors from Micro- the technology. More precision,
generator Epsilon are designed for non-contact miniaturization and easy integration into
With very large generators and electric measurement of displacement, distance machines as well as data transmission via
motors, it is important to determine and position. They stand out due to long- state-of-the art interfaces are key factors.
the radial run out of the rotor inside term stability, reliability and temperature With 25 subsidiaries at home and
the motor compared to the stator. Due stability. During air gap monitoring in abroad, the company bundles long-term
to imbalances during operation which a generator, the average temperature knowledge of high precision metrology
could be due to wear caused by extreme is approx. 120 °C. However, modern and offers a worldwide unique product
wind and weather conditions, the rotor and innovative Micro-Epsilon sensor range of cutting-edge technologies for
might touch the stator. This could lead technology enables highly precise future industry requirements.
to catastrophic failure. This is why measurements under extreme conditions.
The sensors used are specially adapted
to measurements in a generator. They are
resistant to vibration and are protected
by a special housing. Their unique,
triaxial design enables flush installation
into electrically conductive materials as
the guard ring electrode and grounding
are also located on the front edge of
the sensor alongside the measurement
electrode. Capacitive sensors from Author:
Capacitive sensors from Micro- Micro-Epsilon stand out due to their Michael Kuran
Epsilon are designed for non-contact high electromagnetic compatibility. Beratung & Vertrieb Sensorik
measurement of displacement, distance Exchanging the sensors does not require Micro-Epsilon Messtechnik
and position. They stand out due to any new recalibration whilst conventional [email protected]
long-term stability, reliability and
temperature stability. systems were subject to complex www.micro-epsilon.de
78 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
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TECH INNOVATION
MOLD MAINTENANCE:
The Hidden Value of a Spotting Press
As mold complexity increases, so too does the complexity of maintenance, which advances the role of
spotting in mold validation.
n the highly competitive plastics but people often forget about the resources into high-precision machining,
industry great emphasis is placed on importance of completing the mold yet tests its molds using an overhead
Iprecision, efficiency and productivity, process. If a mold builder invests crane, how can he assure his customers
80 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
TECH INNOVATION
that the molds are properly validated? where the upper platen withholds the brings the two halves together with
With a high-precision spotting press, capability of flipping 180 degrees and precision. This technology features
a mold builder can say, “This is how the lower platen rolls out, then tilts 70 four electronic measurement devices,
we know the mold is accurate.” This degrees to either the left or right. This which continuously check the press’
validation not only completes the allows workers to ergonomically adjust upper plate position and parallel-ism
mold process, it also provides the both platens with the benefit of working while comparing it with the lower plate.
quality assurance of a premiere mold on the same side. Encoders are located diagonally in the
manufacturer. four external corners of the upper plate
As molds become more and more Productivity: Some shops use with the columns. The measurements
complicated, so does the checking production molding presses to adjust are displayed on a touch panel for
and maintenance process. In turn, a mold. This method is dangerous. It the entire stroke. If the preset limit
technology advances and so does the is difficult for technician to work on parameters are exceeded, the stroke’s
role of a spotting press to validate a it. Molding machines need to be in movement is immediately disabled and
mold. Having a high-precision spotting production continuously utilizing molding the error is displayed. Parameters can
press provides a shop owner several machine for spotting or mainte-nance of be exceeded when hydraulic cylinders
advantages. Mold is net loss of Production Time. not being retracted or tools are being
The features available on Spotting left in the mold (for example, scrapers,
Safety: The first criteria in the design press helps operator to finish the grinders, slip gauges and hammers).
and manufacture of a spotting press work faster with better quality which Some presses use optic scales to ensure
should be safety. A high-precision is impossible when you use Molding the upper plate’s movement is even,
spotting press minimizes dangerous Machine for spotting. while the lower platen is locked into
mold handling associated with cranes, Considering increased complexity of position.
forklift trucks and other lifting equipment. molds (for example, multi-shot molds),a
Different from the mechanical multi-hole built-in rotational table on a high- User friendly Control Spotting
or toothed bar system, a high-precision precision spotting press allows shops operations of a high-precision press
spotting press has a safety device that to simulate mold production instead of are intuitively controlled through a
prevents the press ram from falling, in taking up precious molding machine control touch panel that makes press
case the hydraulic system fails. Safety time. All in one setup, two-shot molds functions clear, straightforward and
devices are externally connected and can be tested, adjusted and checked in a simple. Additionally, the diagnostic
always locked, which adds an extra safe and simple manner, saving time and program immediately reports on the
safety measure. money. display any anomalies that occur during
Ergonomics: A high-precision spotting
press is designed intrinsically with
the maintenance crew in mind. Both
platens should have the ability to tilt
at varying angles, which helps avoid
stressful maneuvers when performing Accuracy: High-precision spotting operation. Each movement of the press
mold maintenance, by making the molds presses have high repeatability and is represented by a specific pictogram.
easily accessible. Some presses have accuracy. Trials can be further improved In case of a malfunction, the relevant
a compact design that allows the mold by testing hydraulic slides, auxiliary point is shown on the specific page for
maintenance technician to approach cylinders and ejectors. Thanks to a a quick solution. This helps minimize
the mold from a variety of angles with parallelism control system which can downtime, quickens troubleshooting and
a simple tap of a control touch panel. gauge the upper plate’s position to reduces service costs, especially after
For example, a press with the upper ensure an even stroke. Today there is a the warranty period.
platen rotating 360 degrees and the lot of focus on mold accuracy, as many
lower platen rolling out and then tilting companies cut to net shape and negative
75 degrees. This same approach can stock on their cores and cavities. This For more information,
be applied to medium and large molds parallelism control unit accurately Website: www.millutensil.com
www.mtwmag.com APRIL 2022 MACHINE TOOLS WORLD 81
TECH INNOVATION
Breaking It Down Chip by Chip
Five Things To Know About Chip Formation in Machining
hether examining how tool selection is impacting
chips, how coolant plays a role in chip evacuation or
Wlooking at the size and shape of chips, chip formation
says a lot about the application being run. Knowing what differ-
ent chip details indicate allows machinists to better manage chip
formation, make adjustments and prevent tool failure. Because
when it comes down to it, better chip formation means a more
successful application.
Shape & Size The thickness of the chip formed decides how the chip will frac-
When looking at chip formation, a key indicator of a good chip ture, but this is also dependent on the material being machined.
is the shape. The preferred outcome for any application is chips At the same time, changing the speed impacts the chip thickness;
shaped as sixes and nines or a single conical shape. These small, the higher the speed of the tool, the more heat generated in the
manageable chips are essential for efficient, predictable drilling. cut, which makes the material more elastic. So a balance between
Nevertheless, it is important to be aware of what chips in other speeds and feeds is necessary. With many materials, a thicker chip
shapes and sizes can indicate. For example, a straight, flat chip is a means there is a greater chance of exceeding the elastic limit of
result of elasticity. If the chip is a continuous ribbon, then there are the materials, which increases the likelihood of chip fracture; on the
likely many adjustments that need to be made in order to achieve other hand, thinner chips are more elastic and, thus, farther away
ideal chips. from the elastic limit necessary to fracture the chip.
The size of the chips impacts evacuation as well. There are two Soft, gummy materials like soft carbon steels, 300 series stain-
major factors that impact the size of chips in drilling tools: chip less steel or pure titanium have a high elastic limit—so much
breakers, also known as chip splitters, and lip geometry. With chip so that increasing chip thickness has a negative effect on chip
breakers, the width of the chip is thinned to allow for easier evacu- formation. Materials like these require specific lip geometries to
ation; the wider the chip the easier it is to get it to roll onto itself potentially create an acceptable chip. Nevertheless, it is key to look
and break. Lip geometry acts as a mechanical chip breaker to frac- at the chip deformation ratio of materials to better understand chip
ture a chip by curling the chip on top of itself or by impacting the thickness. Chip deformation ratio can be defined as the ratio of
chip forming with the backside of the lip radius. Although harder deformed chip thickness over the undeformed chip thickness (feed
materials will curl a chip on top of itself to create chip fracture, rate). For most steels, this ratio is typically 2-3:1; however, it can
gummier materials often skip over the lip radius and only fracture be as high as 5-10:1 for those soft, gummy materials. Ultimately,
after impacting the back of the lip radius. Still, the purpose of the though, this measurement is an indicator of chip form and elastic-
combined chip breakers and positive lip geometry is to break off ity in the material being cut, and the higher the deformation, the
the chip so that it is narrow enough to easily evacuate. more difficult chip formation will be.
Chip fracturing can also occur naturally due to the velocity dif-
ferential between the outside and inside of a chip, which creates a Coolant
cone-shaped chip that curls on itself and fractures. Because larger When it comes to coolant, through-tool coolant when paired with
diameter inserts have a higher velocity differential than smaller the right drill geometry is critical for the best chip formation and
diameter inserts, it is easier to fracture chips i.e., the larger the chip evacuation. Additionally, changing coolant type, pressure and
breaker spacing the more chip fracturing that will occur. Smaller volume influence the thermal shocking of chips. This can change
diameter inserts are limited to the velocity differential available the properties of the chips and make them more or less likely
due to the restriction on the chip width required to easily evacuate to break into manageable segments. For example, coolants can
chips through the holder gullet. decrease material elasticity due to the strain hardening that occurs
as coolant quickly cools hot, elastic chips. The cooling of elastic,
Thickness continuous chip formation embrittles chips to the point of fracture
The thickness of the chip varies with the feed rate; heavier feed by reducing their elastic limit.
rates form thicker chips while lighter feed rates form thinner chips. For chip evacuation, coolant pressure and volume are important.
82 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
MGM-Pubblicità(210x297)_Layout 1 08/04/13 10.33 Pagina 1
MGM-Pubblicità(210x297)_Layout 1 08/04/13 10.33 Pagina 1
HIGH QUALITY FOR YOUR
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• AC 3-ph brake (no rectifier) or DC brake on request
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• RD helical gearboxes: 50 to 2300 Nm. Two and three stages.
• TEFC 3-ph asynchronous brake motor (0.09kW-130kW) • RS-RT worm gearboxes: 28 to 150 mm centres.
reduced maintenance
• AC 3-ph brake (no rectifier) or DC brake on request One stage worm, helical/worm and double worm.
• RN parallel shaft gearboxes: 180 to 3300 Nm. Two and three stages.
• Oversized brake disc for higher brake torque, longer life and • RD helical gearboxes: 50 to 2300 Nm. Two and three stages.
• Fine and easy brake torque adjustment (as standard)
• RO-RV bevel/helical gearboxes: 180 to 3300 Nm. Three stages.
• Very quick brake r
• RG precision planetary gearboxes: 10 to 230 Nm.
reduced maintenanceeaction time • RN parallel shaft gearboxes: 180 to 3300 Nm. Two and three stages.
• Frequent START/STOP cycle applications
One and two stages.
• Fine and easy brake torque adjustment (as standard) • RO-RV bevel/helical gearboxes: 180 to 3300 Nm. Three stages.
• Very quick brake reaction time • RG precision planetary gearboxes: 10 to 230 Nm.
• Manual brake release (as standard)
• VR dry friction speed variators: IEC63 to IEC90
• Frequent START/STOP cycle applications One and two stages.
• Hexagonal hole on non drive end of the shaft for manual rotation
1 to 5 stepless speed range, 300 to 1500 rpm.
• VS planetary speed variators: IEC71 to IEC112
• Manual brake release (as standard) • VR dry friction speed variators: IEC63 to IEC90
• Single speed or two speeds motors
• All motors designed for inverter duty
• Hexagonal hole on non drive end of the shaft for manual rotation 1 to 5 stepless speed range, 300 to 1500 rpm.
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• Single speed or two speeds motors • VS planetary speed variators: IEC71 to IEC112
• All motors designed for inverter duty 1 to 5 stepless speed range, 200 to 1000 rpm.
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Ware House No. G3 and G4 • Ground Floor • Indus Valley's Logistic Park • Unit 3 • Mel Ayanambakkam • Vellala Street
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TECH INNOVATION
To evacuate a set volume of chips, a set amount of kinetic energy chip forming in front of the cutting edge. For both material proper-
is provided by the coolant volume. Drilling can occur uninterrupted ties and running parameters, the angle varies; however, it should
from the top of the hole to the bottom as long as enough coolant always be a goal to make the shear plane angle more vertical
volume is available, which will be evident during the application because the steeper the shear plane the better chip formation.
with a steady load meter reading while drilling. With an insufficient Chip thickness comes into play here as well. The more elastic a
coolant volume, an unsteady load meter will be detected when material is the steeper the shear plane angle will be, resulting in a
drilling into the hole. Although this does not mean that drilling with thinner chip. Conversely, the harder the material is is the flatter the
insufficient coolant is not possible, it does demonstrate that the shear plane angle will be, which means a thicker chip is formed.
drill must be altered to fit the environment. All in all, more rake angle means more shear angle, which means
Pressure on the other hand is the force behind the coolant that better chips, but balance is key here as well. A really sharp cutting
provides a fixed volume of coolant through a given diameter. edge will make great chips but will fail and break due to a smaller
As coolant pressure is increased through a fixed coolant orifice cutting edge cross section and weaker cutting edge, so find bal-
diameter, the coolant volume will increase. When drilling small ance in the rake angle—one that is aggressive but not overly so.
diameters, high coolant pressure is needed in order to provide suf-
ficient coolant volume, but as drill diameters increase, high coolant Changes in Chip Formation
volume becomes more necessary than high coolant pressure. In A final thing to look for when examining chips is any changes in
high-production drilling—especially deep hole drilling—through chip formation. If chip formation is altered during an application, it
the tool coolant is critical because it provides an upward force on could be caused by a myriad of elements: wear on the tool, built
the chip to aid in flushing the chips through the drill flutes and out up edge on the tool (BUE) or changes in the environment like
of the hole. Although flood coolant can be used alternatively to coolant or material changes. In new applications, it may be best
through-tool coolant in short drilling applica- to drill shallow test holes and take a look at
tions under two times diameter, in deeper the chips to make sure they are small and
holes flood does not promote good heat segmented. Being conservative in the begin-
transfer and can also push chips back into the ning with speeds and feeds could also aid in
hole, which can cause chip packing. better understanding chip formation and what
Through-tool coolant is also important adjustments need to be made.
when factoring in heat because it provides Awareness of any changes in chip forma-
coolant right to the cutting edge where it is tion is key, though. Poor chip formation can
needed to cool the tool. When machining, cause major problems in drilling applications.
60% of the heat generated in the plastic Long, continuous chips are difficult to evacu-
deformation of the material remains with the ate and can become packed in the drill flutes,
chip formed while the other 40% remains damaging the drill or even causing drill failure.
with the tool and workpiece. This portion These long chips could also become wrapped
that stays with the tool must be evacuated by coolant in order to around the drill body and again cause tool failure. Lastly, poor chip
have sufficient tool life. Clearly, when more coolant pressure and formation impacts the hole quality. If chips are dragging or packing
volume can go through the tool, the cooler the tool will run. This in the flutes, there will be poor hole finish. Noticing any changes
then means that there will be greater tool life and that the tool can in chip formation is important not only for tool life and hole quality
potentially be run faster. but also for the overall success of the application.
Knowing more about the chips formed in any metal cutting
Tool Selection application enables machinists to better control the outcome and
Chip formation can also indicate whether the best tool is being success of drilling operations. While it is necessary to examine
used. If the chip formation is not meeting the standard, a change chip size, shape and thickness, it is just as important to know how
to tool geometry may be needed in order to improve the situation. coolant, tool selection and changes in chip formation tie into the
Clearly, the geometry of a cutting tool has a significant impact on application as well. So take a look at the chips being created and
the chip formed. Specifically, increases in rake angles can improve break it down chip by chip because both proper chip formation
chip formation, yet this does come at a cost because the greater and chip evacuation are required for successful high-production
the rake angle the weaker the cutting edge. drilling.
Rake angle also highly influences the value of the shear plane
angle, which is the angle formed by the pure plastic deformation For more information,
of the workpiece material. Here, the material starts deforming or www.alliedmachine.com
84 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
PRODUCTS
SHOWCASE Scan for more Products
High Speed All Geared Lathe
STANDARD ACCESSORIES : • Rear Splash
• 3 - Jaw Self Centering True Chuck, Guard,
• Steady Rest • Quiek Change
• Follow Rest, Tool Post
• Face Plate, • Taper Turning
• Coolant System. Altachment,
• Machine Lamp, • Key Way Milling
• Centre Sleeve, Attachment,
• Centre, • Tool Post
• Oil Gun, Grinder,
• lnstruction Manual • Driving Plate,
• Revolving
OPTIONAL ACCESSORIES : Centre, For Product Enquiry Contact
• 4 -Jaw Independent Dog Chuck, • Pipe Centre, Bhavya Machine Tools
• 2 -Axis DRO (Digital Read Out), • Anti Vibration Pad. www.bhavyamachinetools.com
Nylon / Polyamide Knitted Seamless
Features & Benefits • Paint Shop
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comfort & soft feel. The Nylon offers more • Automotive Assembly
sensitivity & ease at finger tips & less lint • Pharmaceutical.
reduces the chance of contamination of
material handled. The gloves in 13 & 15
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These gloves are available in different colours
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For Product Enquiry Contact Application:
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Chaitali Davangeri
Portfolio Director
E: [email protected]
M: + 91 98921 65683
AD INDEX
PG. PG. PG.
COMPANY NAME COMPANY NAME COMPANY NAME
NO. NO. NO.
A GLOBE-TECH ENGINEERING 85 PRECISION PUNCHES
EXPO - 2022 & DIES 61
AAROH MARKETING 63
COMPANY GROB MACHINE TOOLS 13 PROFESSIONAL
INDIA PVT. LTD. ENGINEERING 35
ACCUSHARP CUTTING
TOOLS PVT. LTD. 29 I PROSTARM INFO 27
SYSTEMS LTD
ACE MANUFACTURING BACK INTEC - 2022 79
SYSTEMS LTD. PAGE Q
INSIDE
ADDLIFE COATING 3 ISCAR INDIA LIMITED FALSE
SYSTEMS PVT. LTD. COVER QVI INDIA PVT. LTD. 31
AMTEX - 2022 87 J S
ANCA MACHINE TOOLS 1 JYOTI CNC INSIDE SHREEDA ENTERPRISES 57
PRIVATE LTD AUTOMATION LTD. BACK
COVER
ATQ METRO 67 SHREEJI MOULDS PVT. LTD. 69
K
AUTOMAC SERVICES 55 SINUTECH MACHINE TOOLS 33
KALYANI MOULD 59
BASE PVT LTD
B STEEL PLANT 71, 73
SPECIALITIES LLP
KTA SPINDLE TOOLINGS 49
BHAVYA MACHINE TOOLS 25
L T
BLUM-NOVOTEST
MEASURING & TESTING 21 LAKSHMI MACHINE TOPSOLID 43
TECHNOLOGY PVT LTD 5
WORKS LIMITED
TRUCUT PRECISION FALSE
C
LIBESH ENGINEERING 69 TOOLS PVT. LTD. COVER
COSMOS IMPEX 11 M
INDIA PVT. LTD. U
D MASTERCAM INDIA 15 UCAM PVT. LTD. 9
MATRIX MACHINE TOOL
DIEMOULD INDIA - 2022 58 (COVENTRY) LIMITED 23 USBCO STEELS PVT. LTD. 51
DOWEL ENGINEERING MAX MOULD 41 V
WORKS 75
MGM-VARVEL POWER 83
TRANSMISSION PVT LTD VENTURA ALLOY AND 47
E STEELS PVT. LTD.
MILLUTENSIL SRL 45
ELTEC ENGINEERING 53 Y
INSIDE
MMC HARDMETAL
F INDIA PVT. LTD. FRONT FRONT
COVER
YESKOLUBE INDIA PVT. LTD. GATE
FACCIN S. P. A. 17 MMMM EXPO - 2022 56 FOLD
G P Z
GLEASON WORKS (INDIA) PRECISION MOTION ZECHA PRECISION 65
PRIVATE LIMITED 7 INDUSTRIES, INC. ( PMI ) 37 TOOLS LTD
88 MACHINE TOOLS WORLD APRIL 2022 www.mtwmag.com
RDX Series
Vertical Machining Center
VMC Series
Vertical Machining Center
VMC Series
Vertical Machining Centre
Performance Large Series
T-Base Vertical Machining Center
K Mill Series
Bridge Type Machining Center
KX Five Series
Five Axis Machining Center
visit us @
Jyoti Pavilion
540V 740V
Die & Mould 850V 1060V
1580V 1260V
Machining Solution
Tyre Mould Cavity
Mouse Mould Connecting Rod Mould
Th e Adv an tag e
Teeth Mould Bottle Mould
Best in class machines offering high quality and productivity, well
suited to meet the requirements of job shop, tool rooms, auto
component dies, rubber dies, injection moulds and Sheet metal dies
• Rigid structure with compact footprint
• Direct drive spindle
• Available in three different Control System options
Mobile back (Fanuc, Seimens, Mitsubishi)
*- The v alues ment ioned are optional f eatures.
Machine H i gh ligh ts
Roller guide ways on all axis Close surface profile and good accuracy
High metal removal rate High Rapid rates for Better cycle time
Handling intricate geometry Direct drive high speed spindle in 6000/8000/10000 rpm
AL L Y O U NEE D IN M A CHININ G acemic romati c.net