MTW JANUARY 2022 Digital Magazine

Handling with Fingertip Sensitivity.
Handling with Fingertip Sensitivity.



The Finger Gripper OFG is Flexible, gentle and low-marking gripper for a wide
The Finger Gripper OFG is Flexible, gentle and low-marking gripper for a wide
range of tasks thanks to rounded design based on the human hand
range of tasks thanks to rounded design based on the human hand



WWW.SCHMALZ.COM/Schmalz Select
WWW.SCHMALZ.COM/Schmalz Select
T: 020 40725500
Schmalz India Pvt Ltd. EL 38, J Block, MIDC, Bhosari, Pune 411026. [email protected]
T: 020 40725500
Schmalz India Pvt Ltd. EL 38, J Block, MIDC, Bhosari, Pune 411026. [email protected]

MANUFACTURING INNOVATION 2022



Our world is changing rapidly, and so


too are consumer expectations




as aerospace, defence etc with optimised customer needs.
solutions suited to the needs of the With advanced technologies, such as
customer. IoT, AI being a part of the core strategy
Our staple entry level products comprise of organizations, innovations are driving
of the DX series (Turning Centre), and the industries to revolutionize and accelerate
PX/RX/RDX /Performance Series (C frame the digital transformation.
Machining centres). VTL series (Vertical We have found that the COVID-19
Turning). crisis drastically accelerated the
The high precision featured machines digitization process by three to four years
include the AX Series (Turn Mill), AT/ATM in the space of just a few months. This
series (Inverted spindle lathe), Tachyon means businesses must focus their efforts
Series (High speed drill-tap centre) on building better digital-first interactions
benchmarked against the best technology. with customers. Industry 4.0 is part
TS 120 (Twin Chucker) & DXG (linear of this process and are transforming
Mr. Himanshu Shaparia, tooling with gantry) for automation with manufacturing across the world.
VP Sales, Jyoti CNC Automation Ltd. turning. Under Vertical Machining Centres Jyoti CNC has launched 7thSENSE
umbrella we have K-Mill/ KX/K2X (bridge which is next gen Industry 4.0 tool which
n today’s dynamic business scenario, type VMC), NX Series (double column is one of the most versatile tools to initiate
the organizations that truly stand out VMC). Our Horizontal Machining Centre the digital journey as Productivity, Machine
Ifrom the pack today as clear leaders comprises of the HX and HSX Series with Health, and tool Life Management as the
within their industries, it would be clear various combinations. main features. 7th SENSE will redefine
that they all have one common factor: Our 5 Axis Machining Centres portfolio the conventional PPC to Plan-Produce-
they all embrace innovation. Hence comprises of MU Tech6, U Mill Series, Complete. The benefits and potential
manufacturing and innovation tango KX/KXG and MX 4 series. We have MTX return on investment are what is truly
together, enabling the organisation to Series, MX Series and TMX 200 (our range important.
GROW consistently, STAY RELEVANT, of Multi-Tasking Machines) which are 7th SENSE enhances the customer
and be a DIFFERENTIATOR to deliver developed indigenously by our Design experience, with automated track and
value to our customers. team which is an important milestone for
Team Jyoti.
Existing Product Portfolio.
Since we see ourselves as A One Stop New technology innovations
Solution provider, we have developed adopted.
a large product basket ranging from a Our world is changing rapidly, and so
turning chucker with linear tooling to too are consumer expectations.
Precision high speed multi axis / multi- Therefore, we must
tasking machines complimented with continue to add
automation solutions. Each of our products real value and
offer unique technological advantages solve customers’
with respect to Reliability, Productivity, problems, we
Accuracy, and Rigidity giving us a must rethink
competitive edge in the global market. our products
This bandwidth gives us the opportunity and services to
to serve large spectrum of industry take account of
segments including critical sectors such the huge shift in




48 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com



MANUFACTURING INNOVATION 2022































trace capabilities, you can quickly resolve Product Innovation results in are an avenue for growth since we do not
problems. In addition, product quality will Continued improvements on product substantial market share globally.
improve all this resulting in more profits. features and benefits, as well as new Backed by the government’s initiatives,
We have also developed PreciProtect product lines. such as Make in India and Atmanirbhar
which is a collision protection technology Operational Innovation helps products Bharat and sector specific policies and
comes under Artificial intelligence (AI) to develop faster, with more consistency, incentives, Indian manufacturing industry
give extra edge to metal cutting process and often at a lower cost. has been on a high growth trajectory.
with a complete virtualisation of your This would translate into opportunities
machine environment. This would pre- Improved Productivity - Improved for the machine tool sector as it is one of
empt any collisions during operations Efficiency – Low cost of ownership the critical drivers of the manufacturing
resulting in saving precious down time – Improved Profitability – Increased industry. India stands out as one such
as well as protect your asset from major Competitiveness are the power points country: a potential manufacturing
damages. of value /benefit to the end user powerhouse that has yet to realize its
As technology keeps on evolving, smart promise. However, the key challenges
machine tools will likely handle a greater Future of machine tools industry. of adapting technology, getting skilled
proportion of the work in manufacturing. The COVID-19 pandemic has profoundly manpower and India Machine tool
To stay competitive and equip your affected numerous industries and the industry has shed its traditional business
production lines for the future, the time Machine Tools industry was no exception. model and is emerging in a new avatar
to think about the next stage of your Amid the COVID-19 crisis, the global courtesy the advent of Digitalization
Industry 4.0 journey is now. market for Machine Tools estimated at and Industry 4.0. In the coming years,
US$67. growing at a CAGR of 3.7% over digitalization will completely transform
Benefits of innovation to end user the analysis period 2020-2027. Global the Machine tool industry and the merger
industries Machine Tools Market to Reach $87. 4 of these dynamic elements will result
Innovation is a challenge no matter what billion by 2027 as per reports. in process efficiency and productivity.
industry you’re in. On the demand side, The Indian Machine Tools Industry is The industry is witnessing innovative
the rapid changing technology than ever estimated to have an annual turnover technological solutions in every aspect of
before is resulting in constantly changing of approx. Rs 7,000 crore, according to the processes.
customer expectations. IMTMA’s recent annual report, (FY 19- Thus, 2022 also shall bring in a wave
Innovation enables problem-solving 20). Domestic consumption is at least of newer trends and applications of such
and provides creative insight that allows twice as much, meaning that imports technologies and it is exciting to see what
you to look from a different perspective, account for at least 50% or more – lies ahead of us. We are ready to be part
with the customer’ pain being the sole showing great scope for growth in the of these exciting times for India and the
focus of attention. Indian machine tool industry. Exports too Indian machine tool industry.




50 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com



MANUFACTURING INNOVATION 2022



We are taking a giant leap into the


digital future: Christian Müller, Grob Group




plants for electric motors and assembly GROB machining centers for production
lines for battery and fuel cell technology systems in the automotive industry are
are part of our product range. GROB being expanded with new developments
engineers are delivering solutions for the in the F-series in order to ideally machine
technology involved in spraying engine the new, large structural and housing
components, in cutting high-strength components for electromobility with
turbine housings and machining structural these machines. Since we forged ahead
and chassis components. By developing with these new developments at a very
GROB-NET4Industry, our proprietary early stage, we are now in a position to
industrial software for the digitalization respond comprehensively to all market
and networking of production systems, requirements with the two GROB
GROB is taking a giant leap into the digital core technologies of machining and
future. electromobility. Therefore, the GROB
group already received many prestigious
Q. What are the technological awards. In 2021 e.g. GROB was honored
innovations you have showcased by ZF with the Performance Award in the
Christian Müller, recently? Any recognition category “Operational Excellence for Non-
CSO & Member of the Board, received for your outstanding Production Material” for its achievements
GROB Group achievements? in a major project for “Electric Drive with
We have come a long way on our path of Hairpin Technology.”
Q. Could you give an overview of transformation, and have made excellent
your Group? technological progress. These successes Q. What are the smart
For more than 95 years, our company are apparent in our factory buildings manufacturing practices you
has been one of the global players in worldwide. We are able to provide all follow, backed by R & D?
the development and manufacturing technologies for the production of electric Since the market launch of our application
of machines and production lines. Our motors. In the field of batteries, we have software GROB-NET4Industry in 2015,
customers include the world`s most gained extensive experience in module the product portfolio has grown to a
prestigious car manufacturers, their and pack assembly. In the future, we will total of 14 software modules that can
suppliers and many other renowned be able to offer various technologies for be used according to the needs of the
companies from various industries. With battery cell production. We see massive customer. Our modular web applications
our production plants in Mindelheim long-term potential for our company in this allow them to network and digitalize their
(Germany), Bluffton, Ohio (USA), São area. In the traditional field of conventional production processes across all plants to
Paulo (Brazil), Dalian (China) and Turin machining, we have also fully aligned make manufacturing facility even more
(Italy), and worldwide service and sales ourselves to the new vehicle components efficient. From planning to engineering
subsidiaries, we are represented around with new machine concepts. But it is to maintenance, GROB-NET4Industry
the globe. The GROB Group generates not only in the area of electromobility combines relevant modules for increasing
worldwide revenue of over 1.1 billion that we have been able to successfully productivity and offers the all-round
euros with a workforce of about 7,000 position the GROB brand. Demand for package for modern production in the
employees. Our portfolio ranges from our 4- and 5-axis universal machining Industry 4.0 era.
universal machining centers to highly- centers is also developing very positively. In addition to the universal machining
complex manufacturing systems with own In combination with our GROB automation center market, GROB-NET4Industry is
automation function through to manual systems such as part storage and robot also gaining a foothold in the systems
assembly stations and to fully-automated cells, we are continuously expanding business and will enable the digitalization
assembly lines. Furthermore, production our market position. At the same time, of smaller GROB production lines in the




52 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com



MANUFACTURING INNOVATION 2022





demand for machinery and equipment
from the automotive and supplier
industries increased significantly from
September onwards and the market
situation improved solidly. We also
successfully continued production without
any major interruptions.

Q. What’s your vision for the
coming fiscal to stay ahead,
braving the challenges posed to
GROB Technology & Application Centre for Electromobility in Mindelheim, Germany
the industry?
future. Currently, GROB-NET4Industry are increasing significantly. We expect In order to ensure constant capacity
applications can be used for the Siemens, to reach our capacity limits again very utilization at our production plants and to
Heidenhain, Fanuc and Beckhoff control quickly and return to a growth trajectory. meet the high demands of the industry,
systems. Even if machines have no As a result, new investments in hall GROB locations are being given a clear
control system or are very old, they can infrastructure will be made worldwide reorientation with a strategy that applies
be connected with the so-called IIoT kits in GROB Group. We recently laid the to all plants and subsidiaries. Subdivided
(Industrial Internet of Things). foundation for a second plant in Dalian, into the three areas of systems business,
Since GROB-NET4Industry has been China. New construction plans exist universal machining centers, and
successfully used in the machining sector for India near Bangalore, and there are electromobility with focus on e-motor and
for years, GROB has started digitalization expansion plans for our headquarters battery, clear targets were agreed. The
in electromobility as well: Complex in Mindelheim and our production plant implementation of these goals is discussed
processes and systems with a high output in Bluffton, Ohio. We have developed a weekly with the individual locations.
require different software solutions than clear vision for the future, creating a solid Since we have significantly expanded
machining, with a particular focus on the foundation for securing our leadership. our product portfolio and customer base,
digital recording of process and quality we have to plan much more precisely
data. GROB meets these requirements Q. How was the year that went by than in the past. Especially with the shift
and develops under high pressure new for your organisation? Were you to e-mobility, we are looking at new
software applications for electromobility forced to make any amendment in components, such as frame structural
systems to be used by both the customer your operating philosophy in the parts and battery housings. The newly
and for commissioning and quality wake of the pandemic? established GROB ‘Centers of Excellence’
assurance of our own production lines. In the course of the past year, capacity and the ‘Business Development’
utilization at our main plant in Mindelheim department team are providing additional
Q. What steps do you take to has improved continuously. Whereas in support for the change with their technical
maintain your leadership position? the first few months we still had major expertise. With this strategy and goal
We are happy to note that market gaps in our production program and in firmly in mind, we are well prepared for the
conditions are improving and requests some cases even a significant underload, challenges of the upcoming year.
















GROB Robot Cell (GRC)




54 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com



CASE STUDY




WEG starts its


WIND TURBINE DIVISION


& chooses FACCIN as its


trusted partner




ounded in 1961, in the city of
Jaraguá do Sul/SC, Brazil by Werner
FRicardo Voigt, Eggon João da Silva
and Geraldo Werninghaus, WEG started
initially producing electric motors and
then expanded its activities from the
1980s onwards, with the production
of electronic components, products
for industrial automation, power and
distribution transformers, liquid and
powder paints and electro-insulating
varnishes. The company has established
itself not only as a manufacturer of
engines, but as a supplier of complete
industrial electrical systems
WEG’s commitment is to develop
quality products and efficient solutions
that meet international quality standards
and transform into concrete actions and
public acknowledgement. The company
is today a multinational force with more
than 33.000 employees around the world, plate rolls have in the market, they approval by the appropriate management
branches in 36 countries, 12 factories and are considered high quality machines, committees. Finally, the matter is decided
a turnover of R$17,47 billion in 2020. offering reliability, robustness, technology by the board of directors. The most
And growth does not stop for WEG. and several resources that allow the important elements for decision making
The company decided to acquire heavy optimization of the plate forming process. were meeting the technical requirements,
duty equipment to meet the demand All this know-how and reliability in the Faccin’s know-how, as well as the budget
for rolling thick plates for the new WEG Faccin product, together with meeting the and a deadline meeting our needs.
wind turbine and also for other product requirements defined by WEG, led us to “The right solution was achieved
lines manufactured in its plant located in choose the equipment. If Faccin had not through an intense interaction between
Jaraguá do Sul – Santa Catarina, such as identified the correct solution for WEG, the technical and commercial teams of
components for hydraulic turbines and the project results might not have met our WEG and Faccin, and this took place
generators. expectations”, explained WEG through several meetings and exchanged
After analysing several solutions, and The selection and approval process for emails; this phase of the project lasted
due to the complexity of the project, the acquisition of this type of equipment around 2 months”, explained Mrs.
WEG decided to choose Faccin Group as within WEG follows a careful technical Gabriella Galoppini, Senior Sales Manager
its partner. “Seeking a Faccin solution analysis carried out by specialist of Faccin Group.
was due to the reputation that Faccin engineers, followed by submission and “The experience was very positive due




56 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com

Visit us at Imtex 2022
Stall No. 3A-B131






























No Filter Element-No Replacement Cost













APPLICATIONS

CNC/VMC Machines Grinding & Honing Thread Rolling Cold Forming Fastener Manufacturing
Heat Treatment Quenching Oil Hydraulic Oil
Gear Oil Test Bench Oil Furnace Oil Engine Oil

OTHER PRODUCTS
Tramp Oil Separator Oil Recovery Centrifuge Custom Built Machines for Oil Cleaning and Dispensing

CASE STUDY





to the openness and availability of both us to obtain a stable and accurate equipment allowed WEG greater
teams, who spared no effort to achieve process, improving our quality and autonomy in the sheet metal rolling
the defined goals. The final solution fully productivity levels. processes, significantly reducing its
met WEG’s expectations, the equipment This equipment was acquired for the dependence on external suppliers, as
was put into operation in just 2 weeks production of the new wind turbine, and, well as generating a modernization of our
after the start of the installation and it as it is a new production line, there is industrial park.
is operating as expected” added WEG no comparative history of productivity “Our experience with Faccin has been
Management. data; however WEG monitor all the very positive since the beginning of the
The main aspects of the equipment equipment’s operational data collection negotiations, availability and response
for guaranteeing the process that WEG through the MES system (Manufacturing time were differentials in this process.
performs are the accessories that this Execution System) which has provided The service provided by technicians
machine could be equipped with, such as us with very relevant information to during installation and start-up, who
vertical and lateral support, fundamental understand opportunities to increase spared no effort to meet deadlines and
in the thick plate forming process. In production. deliver the equipment in full production
addition, its Faccin’s CNC control allows As a result, the acquisition of this condition, were essential for the project’s
success” confirmed WEG management.
“The equipment’s performance also
fully met our expectations and has met
the technical requirements required for
the process. Without a doubt, it was a
good example of teamwork between
the Faccin and WEG teams, which
makes Faccin Group the trusted partner
to be considered for supplying future
projects”, added WEG management with
satisfaction.

The Company
Faccin Group is a leading global
metal forming machine producer that
manufactures and commercializes three
great brands, FACCIN, BOLDRINI and
ROUNDO, offering the widest range
of plate rolls, angle rolls, dished head
lines and special machines. The Group
have successfully installed over 30.000
machines worldwide.














For more information,
Website: www.faccingroup.com
Email : [email protected]




58 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com



TECH INNOVATION



Latest trends in Millturn technologies &


enhanced productivity




of 15kg. For shaft parts, a workpiece
diameter of 100mm and a workpiece
length of 300mm is possible.
WFL currently has over 20 different
MILLTURN models available: With turning
lengths from 1000 to 14000 mm and
turning diameters from 520 to 2000
mm, an extensive range of workpieces
can be machined completely. Almost
all MILLTURN models are also available
as counter spindle variants (with the
identification – G).

The fusion of production hall and
M20 MILLTURN – Achieving maximum flexibility & performance with smart machining.
office
FL specializes in providing front of the machine. The working area With the new “iControl” process
complete machining solutions is perfectly illuminated, thanks to ultra- monitoring system, WFL gives the
Wand has developed its most efficient and bright LED lights. A clearly future machine operator a whole bundle
technologically advanced MILLTURN yet visible LED strip at the bottom of the of functions to ensure reliable and
that meets the demands of customers sliding door displays the machine status. economical production, particularly in
for fully-automated complete machining The M20 is available with a tailstock series production. On the one hand, the
solutions. The M20 MILLTURN is or counter spindle and features dynamic machine and tools should be used with
positioned at customer segments looking and powerful drives. The turning-boring- maximum productivity; on the other
for a compact and powerful complete milling unit with integrated spindle motor hand, the process should run as stably
machining solution to offer special and a B-axis with torque motor are entirely and reliably as possible. The software
technologies and features in addition to new features. The turning output of up package that WFL provides for this is
existing WFL machines. to 44kW means even hard-to-machine
materials can be handled with ease. The
Mllturn – Some Design Aspects milling spindle with up to 25kW and
The aim when developing the M20 was 20,000rpm is ideally equipped for all
to introduce a particularly robust machine machining tasks.
with the highest possible long-term Another key benefit of the machine is
accuracy. The machine frame is made the possibility of easily integrating a wide
from spheroidal graphite iron, ensuring range of automation options. Depending
optimal stability plus outstanding on the customer’s requirements,
damping properties. This also means articulated robots, gantry loaders or The iControl intelligent process
heavy roughing cuts can be made without an integrated production cell with the monitoring system from WFL protects
compromise. associated peripheral equipment can machines during autonomous
The most ground-breaking aspect, be implemented. The newly integrated production. Complex, intelligent
monitoring options offer comprehensive
however, is the machine’s new design. production cell ‘intCELL’ is fitted on the safety during production. iControl
The continuous toughened-glass front right-hand side of the machine. follows a multilevel monitoring logic to
features an integrated performance data The M20’s integrated loading feature is respond when collision limits or process
display and a touch panel for conveniently designed for chuck parts with a diameter limits are exceeded or if there are
operating the tool magazine from the of up to 300mm and a workpiece weight significant, rapid changes in force.




60 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com



TECH INNOVATION





extremely diverse and offers a suitable When the cycle is running, the friction
monitoring tool for practically every values of the axes and spindles, as well
processing situation. The up to 16 process as the temperature in the milling spindle
signals to be monitored are configured housing and the vibration or the rolling
by WFL at the factory according to bearing condition value of the front milling
the machine equipment and displayed spindle bearing are continuously recorded
live on the control screen. Important and stored on the control system. Using
process signals include the forces or Condition Monitoring Viewer, it is possible
torques of the NC axes and spindles in to select the data of the various Condition
combination with the respective actual Monitoring runs on the control system,
speed values, but also the signals from graphically overlay them and analyse
integrated sensors (vibration, pressure, them according to time in this way. This
flow, temperature, etc.). These are built allows for the early detection of possible
into machine components or tools and can malfunctions and minimises unplanned The dashboard overview of my WFL
be used for a wide variety of applications downtimes. Cockpit displays data such as machine
state, performance, operating modes
such as process control, optimisation or and override settings over time as well
monitoring. WFL Heavyweight machining: It all as operating hours, channel status,
comes down to the right machine active NC program and much more.
Operational data acquisition with design
my WFL Special needs demand special measures. premium quality standards and is based
The new operational data acquisition Gas and steam turbines or components on the many years of experience of the
system is myWFL Cockpit. Machine and for wind turbines, rollers, crankshafts and WFL machining specialists. Large masses
program states will be displayed according transmission parts in machine construction have a tendency to deform or change
to chronological order, productivity and – WFL can now machine large and, simply as a result of their net weight. The
technical availability. You can view this above all, heavy parts with workpieces sag of a turbine shaft weighing 60 tonnes
on a web browser via the control system, weighing up to 60 tonnes. What makes is so great that this needs to be taken into
either on a PC or a mobile device. This this extraordinary is that these types of account when clamping the workpiece.
means that the user can always be well- heavy components can be machined in This variable can be compensated with
informed about their machine productivity. just a few clamping operations and in a the correct design of the clamping device
Also new with myWFL Cockpit is single machine. A MILLTURN can even and clamping method. FEM calculation
the integration of the energy usage easily handle high-strength steel or HRSA (finite element method) can be used to
measurement device myWFL Energy material. Special-purpose machines, such precisely determine how the workpiece
which displays the current power and as those needed in multi-step production, can be correctly clamped and supported.
energy consumption data and that of each are a thing of the past. In this case, WFL uses a rolling or
workpiece. A MILLTURN eliminates the need for hydrostatic steady rest depending on
Another highlight of myWFL is the tedious changeover processes. Warpage- the characteristics of the workpiece.
integrated Condition Monitoring cycle. free and secure clamping is critical for This ensures optimal machining quality
and production. The accessibility to the
machine with folding grate elements and
tread plates also ensures the best possible
ergonomics.
The WFL M100 to M200 machine
assemblies provide ideal conditions for
creating a perfectly tailored machine for
every customer requirement.



For more information,
Test workpiece: gas turbine shaft with fir tree root, curved. Website: www.wfl.at




62 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com



TECH INNOVATION



Can forge shops be clean and hygienic?



by Srikar Shenoy, Director, Steel Plant Specialities LLP

ost forge shop owners
understand and appreciate
Mthe need for maintaining
cleanliness in their production zones.
Having a clean and healthy workshop
is a major milestone when it comes to
running a successful business. However,
most business owners take notice of
cleanliness issues only when they get
completely out of hand.
Audits like OHSAS, ISO 14001, ISO/
TS 16949, 5S and many others lay
down stringent rules for maintaining
cleanliness in production areas too. Dirty, oily forging machinery. Cleaned in minutes with O-CLEAN3
A number of overseas customers effectively and effortlessly
and reputed Indian automotive
manufacturers conduct their audits with
very high importance to cleanliness in
forge shops.
Hence, it is imperative to regularly
clean and maintain forge shops,
heat treat shops, machine shops and
assembly areas to ensure that your
employees are happy, healthy and
productive while it also leaves a good
impression on existing and potential
customers. create black deposits on dies, presses, used. These stains cannot be removed
forge shop floors and nearby locations. easily. Tramp oil getting leaked from
Challenges faced by a forging Maintenance of forging presses requires centralized lubrication areas increase the
organization in maintaining degreasing of parts, which is sometimes dirtiness in machine shops.
cleanliness done in kerosene or thinner based
Forge shops are pre-disposed to products. This is not advisable due to Small forged parts are often moved in
being dirty owing to factors such as various reasons. plastic bins that gather oil and dirt over a
use of various oils for fuel, machinery period of time. Due to oils, metallic burs
lubrication, rust prevention, use of Die shops face cleanliness issues due to get stuck in plastic bins. Such metallic
graphite as die lubricants, oil leakages handling and storing dirty dies covered burs create scratch marks and damages
during production and maintenance, in dense oil and graphite. Cleaning forgings that are carried in such dirty bins.
etc. Almost each area of a forge of dies consumes time and efforts. Areas that are used for applying rust-
shop presents its own challenge in Sometimes, dies are stored with layers of preventive on forgings are also prone to
maintaining cleanliness. Some of these oil and graphite present on them due to oil spillages and become very dirty and
are: previous production run. This also dirties oily over a period of time.
Forging presses: Oil and grease used for floors and nearby areas. To add to all the above problems of
centralized lubrication eventually spills cleanliness, the tyres of forklifts gather
on and around the forging machinery. CNC/ VMCs develop oil stains over a oil and graphite and deposit them all
Graphite based lubricants used for dies period of time due to the coolants being over the area during movement.




64 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com



TECH INNOVATION





Most problems of cleanliness in
forging organisations are due to oils and
graphite.

Performance Proven Cleaning
Solution
Typically, cleaning is done by the use
of kerosene, thinner, saw dust, acids
and chemicals. Such strong chemicals
may be fast-cleaning. However, they
are neither safe nor eco-friendly or
economical. In many cases, acids and
such chemicals erode the lustrous
paint finish of expensive machinery
like presses and CNCs. If not used very Dirty, oily dies. Dipped in O-CLEAN3, wiped
carefully, kerosene, thinners and solvent
based cleaners pose fire hazards or skin Oils are made up of hydrocarbons. When In the case of concrete floors that have a
hazard to workmen’s hands. O-CLEAN3 is applied to oily machinery tendency to absorb oil, it is advisable to
In order to solve these problems of or surfaces, it breaks the bond apply O-CLEAN3 and leave it overnight
dirty machinery and shop floors, Steel between hydrogen and carbon, thereby to achieve a clean surface next day. In
Plant Specialities LLP, Mumbai, have eliminating the ‘greasiness’ or ‘oiliness’ in many cases, repeated applications are
developed an eco-friendly solution in oils. Once the oiliness is eliminated, the necessary to thoroughly clean such
the form of O-CLEAN3 water-based surface can be easily cleaned with water. surfaces where oil has seeped in since
oil-cleaning liquid which has proven to Time duration to be allowed after many months or years. Once cleaned,
be effective and safe in all the above application of O-CLEAN3 is crucial. In it becomes very easy to maintain
-mentioned challenging areas. the case of metallic surfaces, a reaction the surfaces oil-free by regular use
It is important to know the working time of 30 minutes to 45 minutes is of O-CLEAN3. Being eco-friendly,
and method of operation of any cleaning sufficient. After such time, the oily O-CLEAN3 is safe and comforting to use
product to enable appropriate cleaning. surface can be cleaned off effortlessly. even as hand-wash for workmen’s oily
hands.
Prior to epoxy coating of floors, to
ensure long life of epoxy coating, it
is very important to remove all oils
that may have seeped in the floor.
In such cases too, O-CLEAN3 and
its customized variants have proven
highly effective in cleaning oily floors
for surface preparation prior to epoxy
coating.
Documented demos of effective
cleaning are carried out in forge shops in
the following areas: Forging machinery
cleaning | Die cleaning | CNC cleaning |
Bin cleaning | Floor cleaning

Methodology
a. O-CLEAN3 eco-friendly oil cleaning
liquid was applied on the oily
Dirty, oily forging machinery and Cleaned in minutes with O-CLEAN3,
floors effectively and effortlessly machinery and floors. After 30




66 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com



TECH INNOVATION





For better results, soaking time may
be increased. Initial repeated cleaning
and planned frequent application of
O-CLEAN3 on cleaned surfaces will
enable in maintaining oil-free, clean
machinery, CNCs and shop floors.
• In the case of die cleaning, slight
agitation in the dipping tank will
give much better results. Heating of
dipping tank up to 80 deg. C., will also
give much better results. Both these
techniques, agitation and heating of
the liquid, may be tried out individually
and collectively to evaluate results.

Summary
minutes, it was simply wiped off with Images on the right are after the use of By the use of O-CLEAN3 eco-friendly,
wet cloth and water. O-CLEAN3 and effortless cleaning. water-based cleaning liquid, the forging
b. Oily, dirty forging dies were dipped in industry can achieve oil-free, clean and
O-CLEAN3 for 30 minutes. Observations: hygienic forge shops.
• 30 minutes soaking in O-CLEAN3 has
Photographs of the demos in various given all above results. Efforts required For more information,
applications are provided below. to clean oily surfaces are substantially Email: [email protected]
Images on the left are before cleaning. reduced by the use of O-CLEAN3. Website: www.steelplantspecialities.com













































68 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com



TECH INNOVATION




Innovations and Advancements in


Optical Emission Spectrometry



By Mukund Pant

ptical Emission Spectrometry – or Arc-Spark Optical /
Atomic Emission Spectrometry, to use it’s full and proper
Oname – is well over a century old. As far as its basics are
concerned, the technology as about as stable as it gets. Over time
though, the instruments used for this have not only evolved and
changed but done so dramatically. Indeed, the last five years have
arguably seen the most critical advances in the field – and these
advances have spanned across virtually every system that these
instruments are comprised of.

From single to dual – a massive leap in resolution
First up, there are the optics. As the name itself suggests, optics
lie at the heart of the Optical Emission Spectrometer (OES). For
over a century since the first instrument was made, designers of
OES relied upon a single and very large optical chamber in which
light was received, diffracted and then the individual elements
were analysed. This ‘single optics’ design however has now
become virtually obsolete, replaced almost entirely by the more
sophisticated ‘dual optics’ design.
The quest for every optics engineer is to enhance optical
resolution. Optical resolution depends on a number of parameters,
but most critical are the gratings’ groove densities and the focal
lengths. For a particular groove density, the only way to enhance Metavision-10008X features full spectral coverage from 120
to 800 nm with capability to analyze 60+ elements across
resolution would be to increase the focal length and for decades, all bases including C, S, P, N, O & H down to 1 ppm; Rapid
this was the path designers took. So much so, that it became analysis in 10 Seconds!
almost a given that the higher the focal length, the better the
spectrometer. As a result, every single modern OES is designed today with
With advances in grating manufacturing technology though, dual (or more) optics chamber. In these designs, an exceptionally
optics designers today have the option of using gratings with high-resolution UV optics using high groove-density gratings
50%-100% higher groove densities! The higher groove density is accompanied by a marginally lower-resolution Visible optics
results in a much larger spectral spread and brings into play chamber (which also uses a high groove-density grating). So,
the option of using a shorter focal length to generate the same if you want to understand how modern or state-of-the-art
resolution or using the same focal length to deliver much greater the technology of your spectrometer is, the optical setup is an
resolution. As with everything though, this does come at a certain excellent place to start!
cost. In this case, the cost is that the spectral spread becomes
so wide as to eliminate the option of using a single optical Neither purged nor a vacuum – hermetically sealed!
chamber. So wide and high-resolution is the dispersion that it is Another big change on the optics has been the continued move
geometrically impossible to accommodate in a single chamber. away from the inefficiency of vacuum optics. The early days of
Nonetheless, so significant are the benefits of higher resolution this shift saw designers move towards a purged optical chamber
on the ultra-violet (UV) and deep ultra-violet (DUV) sides of the – where Argon gas was constantly purged through the optics
spectrum that the use of a dual-optics design is well worth the chamber to ensure inertness. Purging however is also not perfect
investment. and ‘as near as possible to perfect’ really is what any good




70 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com

STEEL

PHARMA

AUTOMOTIVE

TEXTILE

































Digitized automation for a changing world
Ideal Solution to Excellent Power Quality & 100
High Efficiency 95


THDi PF
5% Harmonic Filtering 0.99 Reactive Power Compensation 75
Improves equipment reliability Enhanced power efficiency and avoid power factor penalty
Reduces electromagnetic interference Precise compensation to release extra capacity for the transformer
Load Balance 25
Protects power cable from worn out to prevents fire accident Reduces electromagnetic interference
5

0
www.deltaelectronicsindia.com I [email protected]





Machine tools world
Tuesday, January 18, 2022 1:17:25 PM

TECH INNOVATION





designer or manufacturer always aims for. Enter hermetic sealing. Integration – be aware, everywhere!
The most advanced spectrometers today are designed with The move to Industry 4.0 and the ubiquitous demand for
hermetically sealed optical chambers that are filled with Argon seamless integration and connectivity has left no field untouched.
and also fitted with a repurification system. This ensures that the Spectrometry is no exception to this. Indeed, being so critical to an
optics are always completely inert and achieve stability as soon organization’s quality and operations, the more easily, seamlessly
as the temperature stabilizes and also results in the spectrometer and immediately data outputs from spectrometers are available to
consuming far less Argon than any purged optics system while those that matter, the better. For decades though, the reality has
also not consuming any of the energy that is required by a been that if you wanted to see the outputs from the instrument,
vacuum optics design. you had to walk over to it – or at best, you could connect a remote
transmission station to it, but would require this station to be
The rise of CMOS within line-of-sight of the instrument itself. For someone used
Detector technology has changed thrice since detectors and to such setups, the truly modern OES of today will seem almost
computers replaced photographic plates. The first, of course unrecognizable!
was the usage of PMT (Photomultiplier Tube) detectors. In the For starters, the OES of today is smarter even at the
second change, linear-array CCD (Charge Coupled Device) workstation itself. Today’s modern OES come equipped with
detectors replaced PMTs – offering the benefit of much better integrated touch screens that constantly show users the health
wavelength coverage, much smaller footprints and also, lower status of the unit, self-diagnose, proactively update users about
costs. In the latest change, high-end CMOS (Complementary impending failures / maintenance requirements and even provide
Metal Oxide Semiconductor) detectors have replaced CCDs as alerts regarding operator oversight. The instruments also leverage
well. CMOS detectors offer all the benefits of CCDs, and add cloud infrastructure and various communication modes and can
some more, namely far greater sensitivity, far higher speeds, and deliver real-time reports and updates onto the mobile phones of
also immediate digitization of data, making them by far the most users even thousands of miles away. Needless to say, integrating
optimal detectors for high-end applications including gaseous these units with foundry management systems, different
element analysis, time-resolved spectroscopy, ultra-trace level databases and other IT tools is simplicity itself!
analysis and a lot more!
In conclusion - old horses have learned a ton of new
tricks!
The innovations mentioned above are merely the tip of the
iceberg. There are multiple other advancements too that have
been made ‘under the hood’. The data rates, redundancies, and
ease of operating as well as servicing spectrometers have seen
quantum leaps in the last decade. These though, remain largely
invisible to users – who merely see the dramatically improved
performance levels and the sudden emergence of spectrometers
that not only analyse routine elements, but even ones that used to
be considered “impossible” a mere five years ago.
From Oxygen to Mercury and from Potassium to Hydrogen,
there is virtually no stable naturally-occurring element in the
world that today’s modern OES can’t analyse – and analyse down
to ppm levels. Evidence, if any were needed, that the age of a
technology is no bar to innovation and proof that when it comes
to the world of technology, old horses not only can, but indeed do
learn the newest of tricks!



The author, Mukund Pant is Director at
The Metavision-1008i3 features ultra-high resolution dual Metal Power Analytical Pvt. Ltd.
optics, employs the latest generation CMOS detectors and He is contactable on his e-mail ID:
custom-developed optical components. Nitrogen analysis
from 8 ppm & Oxygen analysis from 10 ppm. [email protected]




72 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com



TECH INNOVATION



Handling with precision:


The FINGER GRIPPER OFG












































ith the finger gripper OFG, of silicone. When the pressure inside and stability during transfer. While the
Schmalz has a new gripper the gripper is increased, the finger “Basic” control unit implements opening
Win its product range that bends to create a form fit. If the pressure and closing via vacuum and pressure,
grips in a tight-fitting and gentle manner. decreases, it retracts. This allows the OFG the “Controlled” control unit allows
Delicate food products such as doughnuts, to place delicate products carefully and parameters to be configured via USB or a
chocolate kisses, fruit, and vegetables are precisely into adjacent trays. serial interface. Users can also integrate
packaged safely and kept intact. The main body and control unit satisfy a robot controller and continuously adjust
Automated processes bring efficiency specific requirements. The FDA-compliant the opening angle and gripping force.
and safety to the food processing version is ideal for applications in the The OFG operates in a pressure range
industry. Gripping and handling hygiene sector. Its main body is made of from –0.8 to a maximum of 1.6 bar. It
equipment is essential for this. It has PET-P (polyethylene terephthalate) and has a repeatability of ±0.06 millimetres
direct contact with products that later designed to be particularly easy to clean. at a gripper speed of 0.05 seconds. The
end up on plates and must therefore Alternatively, the finger gripper comes finger gripper is heat-resistant up to 200
be transported hygienically and gently. with a main body made of aluminum. degrees Celsius and protected against
J. Schmalz GmbH now offers the new This model is suitable for applications water and dust in accordance with
finger gripper OFG to handle unpacked in industrial environments, e.g. in protection class IP68.
food products automatically. Its four warehouse logistics or as an assembly
slender and rounded bending fingers aid. A centrally positioned bellows suction For more information,
imitate the human hand and are made cup can optionally increase gripping force Website: www.schmalz.com




74 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com

More Precision



Precise laser scanners Inductive sensors (eddy current)
for 2D/3D profile measurements for displacement, distance & position






Oil gap Expansion
Radial run-out




Ideal for precise measurement and
evaluation of profiles on any surface
scanCONTROL eddyNCDT
ƒ Powerful laser scanners with integrated profile evaluation: ƒ Non-contact measurement of displacement, distance & position
no external controller required on all metals
ƒ Patented Blue Laser Technology for red-hot glowing metals ƒ High frequency response for dynamic measurement tasks
& transparent objects ƒ Highest accuracy & stability
ƒ Comprehensive software offers easy solution of multiple ƒ Robust designs for difficult ambient conditions
measurement tasks (oil, dirt, high temperatures, pressure up to 2000 bar)

+91 20 2674 1009 | [email protected] | www.micro-epsilon.in

TECH INNOVATION



Mastercam Multiaxis Machining


Improves Productivity




ultiaxis machining can dramatically increase a shop’s Cutting now provides control of climb or
competitiveness. Mastercam Multiaxis is an add- conventional cutting while working with
Mon for Mastercam Mill 3D, Router 3D, Mill-Turn, surfaces that may require using both
and Mastercam for SOLIDWORKS®. It improves sides of a tool. It was previously
productivity with simultaneous 4- and 5-axis impossible to maintain this
machining capability for Mastercam. Mastercam while cutting a curved shape that
Multiaxis offers a wide range of multiaxis machining would require the use of both sides of the
strategies, both basic and advanced. These tool.
toolpaths are also useful for advanced control of Swarf Milling toolpath enhancements include the
3-axis machines. Drop tool to floor option which controls whether Mastercam will
The new Multiaxis Unified toolpath allows drop the toolpath down to a floor or retract to the bottom of swarf
you to select multiple pieces of input geometry surfaces. The new Sorting Spiral Multi Cuts option allows multiple
to generate the toolpath pattern. Using those slices to be output as a spiral instead of single slices, providing a
geometry choices, the toolpath picks the best better finish across the part.
algorithm to calculate the path. This single toolpath gives Rotary Advanced toolpath enhancements include the Axis
you access to all the surface-based toolpaths, as well as the offset option which allows you to shift the tool off-center to
geodesic toolpath options, in a single interface. maintain a better contact point, which extends tool life and
New Deburr toolpath enhancements include a new option, improves the machining quality. The new Smoothing options
Number of cuts along edges, which allows users to add multiple round sharp corners using a perfect of the stepover.
cuts to the Deburr toolpath, rounding or flattening edges, to Mastercam continues to expand the critical machine simulation
create a quality edge on deburred parts. Additionally, the new Tilt needed for optimal multiaxis programming with Mastercam
Range options allow you to limit tilt when machining type is set to Simulator which includes the new Smart Measure feature that
5-axis (simultaneous) or 3+2 axis. allows you to measure distances quickly and accurately in the
Maintaining climb and conventional machining is critical for graphics window during simulation. Simulator now processes
surface finish and tool life. Controlling Climb and Conventional standard 3-axis and 5-axis operations faster when backplotting,
verifying, or simulating, and now lists all collisions, proximity
alerts, and axis overruns in the new Report pane.

Additional enhancements to Mastercam Multiaxis
include:
• Maintaining a single tool axis orientation with Accelerated
Finishing tools, providing optimal tool axis control to minimize
or eliminate extra multiaxis movement.
• The new Point tool to rotary axis option allows you to rotate a
toolpath around an offset point instead of the toolpath being
fixed to the axis itself, which leads to a better tool contact point.
• The new Automatic arc lead-in type creates automatic arcs in
locations where it can be difficult to determine the correct arc to
fit and makes it easier to add arcs to linking moves.
• New Apply filtering for conversion generates a more efficient
toolpath by filtering incoming toolpaths to reduce size & noise.

For more information,
www.mastercam.com/solutions/multiaxis/.




76 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com



TECH INNOVATION


High precision in ROBOTICS




APPLICATIONS






























Robot axes must be calibrated at regular intervals.
Micro-Epsilon’s induSENSOR (LVDT) displacement
sensors carry out this task. Mounted on robot axes,
these gauges detect the zero point via a probe tip
when the axis is turning.


Robot technology has been booming for years now and the market is growing enormously. Modern industries
all over the world are increasingly relying on more intelligent robots that operate at high precision and 100%
reliability. Operators benefit from increased flexibility in production processes as well as higher quality, reduced
material and cost savings. When discussing smart robot technology, innovative sensors that act as interfaces
between the robot and its environment are of vital importance.

he demands on intelligent robotics are becoming higher. that ensure the correct operation of the robot. These must
Absolute accuracy down to the micron range, longevity, determine the status data of the robot, e.g. its orientation in the
Thigh flexibility, higher speeds and lower costs are just room, calibration, speed measurement or recognition of rotating
some of the fundamental requirements. Modern sensors play a movements. An example of this application is the calibration of
major role when it comes to fulfilling these specifications. Camera the robot axes carried out by induSENSOR LVDT displacement
systems perceive the environment, temperature sensors detect sensors from Micro-Epsilon. These robot axes must be adjusted
hot spots and bodies, and laser triangulation sensors determine during commissioning and at regular intervals within the context
micrometer-precise positions and distances. They help integrate of quality assurance. The measuring gauges are mounted on the
the robot into its environment. To carry out its tasks, the robot robot axes and detect the zero point during the rotation of the
requires information about the position of tools and the position axis using a feeler gauge. The integrated electronics evaluates the
or nature of production goods. Reliable operation is particularly feeler gauge and transmits a switch signal to the robot control.
important with collaborative robots that involve human-machine Using this procedure, the robot is adjusted reliably, independent
interaction. of the operator. As the measurement is carried out at high
With sensors for robotic applications, two different possibilities speed and fed into the control system automatically, downtime
are distinguished. On the one hand, there are internal sensors is also avoided. The gauges are perfectly suitable due to their




78 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com



TECH INNOVATION



compact size, which enables their integration into extremely small
installation spaces. Furthermore, they provide switch signals at
high speed and high repeatability. Their robust housing ensures a
long service life. In cooperation with a worldwide leading supplier
of robotics, Micro-Epsilon has developed the induSENSOR for
robot axis calibration.
On the other hand, there are external sensors that provide
data and measurement values about the robot’s environment.
They recognize the position of the workpiece within the room,
but also enable tactile perceptions. The requirements on the
sensor technology used are extremely high as precision, high
speed, stability, direct communication, full integrity, real-time
measurements, longevity and wear-free reliability are all Laser scanners from Micro-Epsilon enable
critical factors. Optical sensors from Micro-Epsilon fulfill these measurements on almost all industrial materials,
demands. Laser point and laser line sensors of the optoNCDT and largely independent of the surface reflection.
scanCONTROL series are used.
and functionality of the vehicle must be achieved using as little
Absolute precision in automotive production material as possible. For these tasks, robots are perfectly suitable
The automotive industry is the sector where most industrial robots as they work continuously and reliably without psychological and
are used. Therefore, the requirements regarding cycle time, degree physiological impairments, while operating quickly and accurately.
of automation and repeatability are increasing. In production and Furthermore, they also take over many tasks that previously
joining processes from the shock absorber to the front spoiler and would have involved heavy manual labor for employees. Laser
the lights, many steps must be carried out during which different sensors and laser scanners from Micro-Epsilon are used in these
parts are joined. Previously, the production processes were rigid. applications for intelligent robotics. They detect measurement
Now, these are controlled in real-time by state-of-the-art sensor values in real time and can directly transmit these to the PLC.
technologies. Meanwhile, the tolerances of the gap sizes have The result is improved quality control based on extremely high
halved and are now between 0.5mm to 2mm. In order to achieve accuracy, process optimization, cost savings and material savings.
these tolerances, all working steps must be carried out accurately.
The joining processes in production automation for example Marriage of engine and car body
require precise assembly. This is why robots have now taken optoNCDT laser point sensors, for example, monitor the “marriage”
over most of these processes. In addition to the optical-visual of the car body and the engine. Car body and engine, i.e. the
impression, the correct and long-life function of all parts must entire drive train, are joined together in so-called marriage lines.
be ensured. Squeaking doors are not acceptable and windows Therefore, the drive train is moved into the production line on
must be tight and installed flush. In parallel, perfect appearance a frame. At this point, the car body is suspended from a device
and is swiveled from above by a robot in such a way that the car
body is above the drive train, which is then lowered onto it. Laser
triangulation sensors mounted on the device measure the distance
between the car body and the engine. Now, the car body must be
placed exactly onto the drive train and fastened accordingly.

High precision cockpit positioning
The cockpit in the car includes hundreds of individual parts and
weighs up to 100kg. During its installation into the vehicle, it
must be positioned precisely. Therefore, a rectangular frame of
metal struts with two grippers is mounted on the outsides on
a robot arm. The gripper grabs the cockpit on both sides and
moves it horizontally in the direction of the vehicle, which is fed
into the assembly line on a conveyor belt. Shortly before reaching
the vehicle, the robot inclines the cockpit side to be mounted
Micro-Epsilon’s laser scanners accurately position the vehicle. slightly downwards. In this position, the cockpit is swiveled into




80 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com



TECH INNOVATION



range of red and blue laser scanners covers measuring ranges
from 2mm to 1000mm and measuring rates from 2kHz to
49.14kHz with resolutions down to 0.03µm. High precision laser
sensors from Micro-Epsilon are used in high-tech areas such as
automotive industry and 3D printing, where aircraft components
are also produced.

Car windows
In the automotive industry, measurement tasks in which the
simultaneous detection of multiple measurement values and three-
dimensional detection of measurement objects within short cycle
times are required. For example, when installing the windshield, a
scanCONTROL laser line sensor detects detailed distance values
in all axes. In the installation process, the sensor is mounted
In the automotive industry, there are measurement onto the robot, which fits the window into the vehicle. When the
tasks which require simultaneous detection of several windshield is placed on the car, the scanner detects the complete
measurement values or three-dimensional detection of profile and vicinity of the windshield while all necessary values are
measurement objects within short cycle times. For example, determined with a single run in quick time. It can be determined
when assembling the windshield, a scanCONTROL laser line whether the windshield is placed straight and centered or whether
sensor is used to detect detailed distance values.
it fits perfectly in every plane. The results, which are in this case
the passenger compartment over the robot through the opening, the gap and flushness, are directly generated in the sensor head
which is intended for the driver door and then turned horizontally and output to the PLC.
again. Typically, four optoNCDT laser sensors are used for this Another measurement task concerns the adhesive, which is
measurement task which are installed in the four corners of the already applied before the windshield is fitted into the chassis and
metal frame respectively. They are fixed both on the top and also detected by a laser scanner. Therefore, the scanner is directly
the bottom, i.e. in the four corners of the metal frame, which is mounted onto the robot that applies the adhesive beading. Here,
equipped with the grippers. The sensors measure reference points the sensor moves along the adhesive bead to create a 3D image.
in the vehicle interior in real time. These can be prominences and It reveals whether the adhesive quantity is sufficient, whether it
depressions. The four sensors ensure that the cockpit is properly is applied evenly and whether the bead is applied in the correct
aligned in all directions (x-, y- and z-axes). When all sensors have places. All detected measurement values are stored separately.
detected their respective reference marks, the robot is stopped If an error occurs in the process at a later point in time, these
in order to move the cockpit forward into exactly this position measurement values can be used for analysis purposes.
relative to the car body, to dock it on and to fix it in place. For the
entire process including the fitting of the cockpit, an extremely Gap inspection
short cycle time of less than one minute is required. Furthermore, When assembling a vehicle, numerous gap and flushness
the sensors must operate independently of the surfaces, as measurements are necessary. This includes, among other things,
different reflections occur due to the multitude of different surface the position inspection of airbag stitching. The scanner detects
paints used – from dark to bright colors and from mat to shiny the contour of the stitching while being guided by a robot arm
appearances. and evaluates several features synchronously. The laser scanner
continuously inspects the distance between the stitching and
Strengths of the laser point sensors the separating point between the single stitches and outputs
Considered as one of the best in their class, optoNCDT laser the evaluation directly as 0 (NOK) or 1 (OK) via the Ethernet
point sensors are used for displacement, distance and thickness interface. Beyond that, the height difference between two single
measurements. The Real-Time Surface Compensation feature components is directly inspected in order to immediately recognize
(RTSC) enables the sensors to operate regardless of materials and any faulty assemblies that might impair the safety.
colors. The extremely small measurement spot size also enables Another measurement task involves gap monitoring in car
the measurement of very small objects, while simultaneously interiors. Important parameters of quality are homogeneous gap
providing high accuracy measurements down to the micrometer sizes of cockpit elements and the center console. Depending
range. Measurement data is generally available in real time and so on the inspection situation, a single scanner applied on a robot
can be used to automatically correct and control the production arm can measure different gaps in a static or dynamic mode;
process. Depending on the model, Micro-Epsilon’s wide product alternatively, a special frame on the robot arm is used that enables



82 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com



TECH INNOVATION



the scanner to detect a number of different gaps in the interior
in static mode within fractions of a second. The sensor evaluates
these measurement values and sends a signal to the control
system if the values measured lie within the tolerances defined by
the customer. Other gap inspections also concern the car body, e.g.
when measuring gaps in doors or when assembling body trims.

Strengths of laser line triangulation
The strengths of scanCONTROL laser scanners include its
compact design, which enables its integration in restricted
installation spaces. The entire electronics is housed in the sensor
head, which simplifies installation of the sensor on the robot.
Robot-suitable cabling enables extreme twists and torsion
movements on the robot arm. In addition, the laser scanners are
equipped with an integrated, highly sensitive receiving matrix
that enables measurements on almost all industrial materials,
largely independent of the surface reflection. The laser scanner
recognizes large measuring ranges in a single operation. One
relative movement between sensor and measurement object
enables the scanner to fully detect even three-dimensional profiles
or images of surfaces down to the micrometer range. Real-time Important parameters of quality are homogeneous gap sizes
quality control enables immediate intervention in production of cockpit elements and the center console. Depending on the
control. Micro-Epsilon offers laser scanners with either red or blue inspection scenario, a single scanner applied on a robot arm
laser diode, which is usually only used when the red laser light is can measure different gaps in static or dynamic mode.
operating at its limits, e.g. with organic materials, wood, semi-
transparent materials or red-hot glowing metals. An Ethernet interface with GigE Vision enables connection to
The blue laser light can be more sharply focused on certain a PC. In order to simplify the integration into a customer’s own
surfaces where it provides high precision measurement results. software, Micro-Epsilon offers libraries for C, C++ and C#, as well
Set up and configuration of the laser scanner is carried out via the as LabVIEW drivers. Integration into Linux environments is not
Configuration Tools PC software, which enables, for example, the a problem either due to corresponding libraries. For applications
measurement of steps, angles and grooves. Parameter sets are in harsh environments, Micro-Epsilon offers special accessories
recorded in the sensor. It is possible to output OK/NOK signals to protect the scanner. For example, a special housing with
and to directly feed the measured values into the PLC. If the user exchangeable windows is available for welding applications.
wishes to evaluate the profile data externally, the laser profile A special compressed-air purge system protects the optical
scanner can also output all raw profiles of the sensor matrix. components from dust. The laser scanner can be inserted into a
cooling jacket for use in high ambient temperatures.
In addition to the sensor technology, the customer’s application
is also a decisive factor when selecting the appropriate sensor.
Micro-Epsilon offers specialist advice and industry expertise based
on 50 years of technology experience. From the initial discussions
to the installation of the sensors, the customer is always supported
by a strong partner when solving individual measurement tasks.
Micro-Epsilon concentrates on the development of customer-
specific solutions while offering a broad range of innovative
Considered one of the best in their class, products that also allow for standard sensors to be adapted to
these laser point sensors are used in customer-specific requirements.
displacement, distance and thickness
measurements. Due to the RTSC real- For more information,
time surface compensation feature, the Email: [email protected]
laser-optical measuring system operates
almost regardless of material and color. Website: www.micro-epsilon.com




84 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com

INDIA’S LEADING MONTHLY MAGAZINE

ON MACHINE TOOLS &


ALLIED INDUSTRY




Connect with

the industry





For advertising
opportunity contact:
[email protected]






www.mtwmag.com

TECH INNOVATION




AA3000 series: Servomotor alternative for energy-intensive
pneumatic cylinders

Electric cylinders combine power


and dynamics with the advantages of


servo technology



The electric cylinders from the AA3000 series are ideally suited as direct drives for linear applications with high
process forces and speeds. The advantages with regard to force, dynamics and compactness meet the advantages
of servo technology such as controlled positioning, safe holding at a standstill and high energy efficiency.























The electric cylinders from the
AA3000 series of can replace
energy-intensive pneumatic cylinders
while taking advantage of the
dynamics, precision and functionality
of a servomotor.

he integrated mechanism of precise continuous force and 0.5 m/s maximum technology particularly easy. In addition
roller bearings, ball screw and speed or to the high resolution, the safe 24-bit
Tguide provides for a backlash-free, • with 6,250 N peak force, 1,850 N multiturn encoder installed offers the
purely translatory motion. Furthermore, continuous force and 1.0 m/s maximum advantages of the One Cable Technology
this results in very compact dimensions. At speed. (OCT) and the electronic identification
the shaft end of the spindle is an external plate for fast and simple commissioning.
thread on which conventional adapters Pneumatic compatibility and high In addition, the electric cylinder enables
such as ball heads or clamping hooks from functionality uncomplicated access to process data,
the pneumatic/hydraulic range can be The flange size of the electric cylinder which can be used to optimize process
mounted. is based on ISO 15552 and has bolting performance quickly and easily. Other
The first product of the new series is the points on both sides in case, for example, spindle pitches or a backlash-free holding
AA3033 electric cylinder, which is offered an application requires a swivel bolt brake are available as options.
in two variants: connection. This compatibility makes the
• with 12,500 N peak force, 3,700 N conversion from pneumatic to electric drive Website: www.beckhoff.com/aa3000




86 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com



TECH INNOVATION







ANCA’s newest


Smart Factory


tool, LaserUltra,


is 70% FASTER



MEASURING


TOOLS




























NCA leads the market in and advanced profile geometry cutting
inventing, developing, and tools is revolutionising the Die and Mold
Aoffering its customers the latest and Aerospace machining industries.
technology to realise the benefits of ANCA’s LaserUltra tool measurement
automation and lights out manufacturing. system together with RN34 software
LaserUltra is the next generation of the gives tool manufacturers all they need
highly popular LaserPlus, an in-process to manufacture complex profile endmills
measurement technology only available productively to outstanding accuracy.”
with ANCA that gave customers the
power to operate unmanned overnight LaserUltra offers:
with confidence they could retrieve • A cycle time that is approximately 70%
their finished tools the next day within faster than LaserPlus in normal tool
specification. measurements.
Pat Boland, ANCA Co-Founder • Greater accuracy due to a new Analog
said: “The intersection of 5 axis milling continuous edge scan rather than a
machines, advanced CAD/CAM software number of digital points.




88 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com

TECH INNOVATION





• Several new ToolTypes like Barrel
shape cutters and Lens shapes.
• New operations like runout
compensation and enhanced functions.
• Larger working envelop means larger
diameters and length of tools can be
measured.
• Eliminates errors caused by manual
compensation process.
• Flexibility to service multiple markets,
supporting a large range of cutting tool
applications. Offering versatility in grinding minimum set-up time.
with the MX7 and FX5 Linear
Thomson Mathew, ANCA Software The FX5 Linear has the latest in features AR300 is ANCA’s designed and
Product Manager said: “Gone are the for increased productivity and is ideal for built auto tool loading solution
days of manual or external measurement everything from light manufacturing, to Using the latest control technology
and compensation for critical dimensions regrinding and full production. It has a from ANCA Motion the AR300 loader
or profile forms due to wheel wear or wheel spindle power of 12 kW and an provides quick, affordable, and automated
other grinding factors, as LaserUltra can automatic two station wheel changer tool loading for ANCA ‘s CPX blank
measure and compensate within a couple for an increased range of wheels and preparation machine and FX Linear
of microns. All this is done in-process tool types. With the optional automatic machines. The tool is passed directly
without taking the tools out of the headstock clamping, it can provide from the pallet to the collect in a single
machine. Measurements are displayed unmanned operation and the flexibility gripping action. The AR300 has a tool
at various locations to give customers to handle small volumes and mixed load or unload cycle time of 15 seconds
complete visibility and trust in their batches of tools. and is intuitive and easy to use.
grinding process.” The MX7 Linear grinding machine is
LaserUltra is an automatic OD, profile packed with features to meet the needs
measurement and compensating system of tool manufacturers seeking both
for ANCA’s TX, MX and FX machines. It maximum output and flexibility for high
is ideal for measuring and compensating precision production grinding. Cylindrical
tools to maintain tight tolerances linear motors offer higher accuracy and
(0.002mm) in unmanned production performance. Its unique features enable For more information,
grinding. it to handle varied batch sizes with Website: www.anca.com






























www.mtwmag.com JANUARY 2022 MACHINE TOOLS WORLD 89





TECH INNOVATION



GALAXY SERIES: The Revolutionary


Welding System



-By Mehta Cad Cam Systems Private Limited

























s you all know welding is the (Please refer the table below for three
most important and integral models, their power supply and their
Apart of metal forming industries different thickness welding capacities).
and fiber laser technology has made Another major advantage of Mehta’s
revolution about how welding is done. Galaxy Fiber Laser welding system is that
Fiber laser technology it saves upto 2 to 10 times
is becoming popular in of your time than any other
India as well as throughout conventional MIG and TIG
the world because of its welding.
advantages like absolutely The process of grinding for
trouble and maintenance removing excess material in
free machine, long life conventional methods can materials was always a headache, but
fiber laser source, no be completely eliminated welding with Mehta’s Galaxy Series Hand
special skills requirement by this fiber laser hand held Held Welding system it is no more an
to operate, anyone can do welding system resulting in issue.
welding with Mehta’s fiber saving of manpower, time, Moreover, the traditional systems of
laser gun. and money every time giving MIG or TIG welding are hazardous to
Mehta’s Galaxy Hand most aesthetic look to the health which is not the case with this
Held Fiber Laser Welding welded item. technology.
machine is available in three Welding on aluminium or Mehta’s Galaxy hand held fiber laser
models, with 1kW, 1.5kW welding on a metal as thin as welding machine is not just easy to use
and 2Kw power supply. 0.5 mm or welding dissimilar but is also very affordable making is
easier for industries to shift to this new
THICKNESS and better technology.
MODEL SS MS ALUMINIUM
For more information,
1 kW Upto 3mm Upto 2 mm Upto 1mm Mr. Axay on +91 72290 93988
1.5 kW Upto 4-5 mm Upto 3-4 mm Upto 1.5-2 mm Email: [email protected].




92 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com

TECH INNOVATION





Robotic Solutions for Metal


Cutting and Welding by Mehta



ehta Cad Cam group is always solutions can also help to weld on complex
aggressive and ahead in shapes with precision and allows mass
Minnovation and new development production.
in the field of laser and CNC technology. Mehta’s robotics welding solutions
They have very well understood the need have successfully accomplished various
of Robotics for accurate precision and complicated welding applications which
mass production and that is the reason were almost impossible till now. They
they have tie up with provide different wattage solutions for
renowned Taiwanese different welding thickness.
robot manufacturer. Mehta’s robotic solutions for MIG
Mehta have launched welding MIG welding, TIG welding is
very robust, stable the most important area in sheet
and high speed robots for different metal fabrications. As per their
applications in the engineering field. study, 60 percent of
With the vast experience in manufacturing businesses who are using
of Fiber Laser cutting machine for sheet MIG welding for their
forming industries; they are offering fiber job of mass production
laser cutting system, fiber laser welding needs robots. Despite
system, MIG welding system with Mehta’s this, still many are not
Robot and provide unique solution as aware of robotic solutions or
per the need of customers. even though they are they are
Robotic solutions of fiber laser afraid of adopting it thinking
cutting of metal is highly of its complicated operations,
suggested for 2D and 3D or high investment.
cutting which cannot be Mehta’s Robots have
done with Fiber laser cutting solutions for both these
machine available in the market. obstacles. They claim that
It is widely use to cut certain even a layman can use robot for
design after the forming of the mass production and that to in
metal sheet. most cost effective way.
Mehta Cad Cam is very confident They invite customers to visit
that their robotic solution for cutting and experience the ease of working
and welding can resolve lots of issues with Mehta’s robots for all their applications
related to intricate cutting on complex in their state-of-art manufacturing facility
shapes of sheet metal. Mehta’s robots are established at Ahmedabad. They also
available with different wattage of power welcome customer’s samples for free trial
source to cut different thickness of various and testing.
material.
Mehta’s robotic solutions for fiber laser
welding We all have truly understood the For more information,
advantages and power of Fiber Laser Website: www.mehtaindia.com
Welding Technology against the traditional Mr. Axay on +91 72290 93988
methods of MIG and TIG welding. Robotics Email : [email protected].




www.mtwmag.com JANUARY 2022 MACHINE TOOLS WORLD 93

PRODUCT SHOWCASE




Chip Briquetting Machine from Oilmax


Metal Chip Briquetting Machine presses • Compacted bricks can directly be fed into
the metal waste under high pressure into a the furnace; hence there will be low power
briquette form. Normally it is used to reduce consumption in foundries
the storage cost and enhance the conversion
ratio in the furnace for metal recycling. Reduction in melting time which
Oilmax has supplied Chip Briquetting increases furnace utilization.
Machine to one of the leading manufacturers Also fumes and blasts are
of shock absorbers for the machining avoided in the furnace
process. The customer is reportedly very
happy with the performance of the machine. Performance:
• No. of bricks produced:
Benefits derived: 3,73,885 (Weight = 730
• Hygienic chip storage with reduction of grams/brick)
storage space by 75 or 85% • Total weight of bricks i.e. chips
• Accountability of chips for monitoring compacted: 261 Tonnes
• Reduction in transportation cost To conclude this product offers some major
• High selling cost of scrap as it is dried to benefits including a convenient method of For Product Enquiry Contact
achieve high recycle yield storage of chips unlike the conventional Oilmax Systems Pvt. Ltd
• Almost 90% of the oil has been recovered method, thereby also making it cost-effective 38/2/12, Narhe Dhayari Road
Narhe, PUNE 411 041
and reused which otherwise goes along for the users in many ways. It also contributes Phone: 020-2543 1052 /
with the scrap towards eco-friendliness by reducing the 093260 74504
• Less surface area to oxidize & become slag impacts of industrial waste. Email: [email protected]
www.centrifugaloilcleaner.com


Plates cut quicker and more accurately

with sliding table panel saw



A sliding table panel company’s busy factory.
saw has been well Vesconite stores manager Martin Nyathi
utilised since it was informs that a large number of plates and
installed late last strips have been accurately cut on the
year at Vesconite machine and expects the saw to be a great
Bearings’ warehouse asset in 2022.
in Johannesburg. The machine can cut lengths up to 3,700
The saw has mm long and 1,500 mm wide to an accuracy
mainly been used to of ±0.25 mm, so it can accurately and swiftly
cut Vesconite and cut the most-frequently-ordered plates that
Ultrablack wear plates Vesconite Bearings produces.
that are used in a
Vesconite stores manager range of wear applications.
Martin Nyathi expects a The introduction of the machine means
sliding table panel saw to the Johannesburg warehouse can dispatch
be a great asset in 2022 cut-to-size orders quickly, reducing the For Product Enquiry Contact
Martin Nyathi
longer lead times of having plates cut at the +27 11 616 1111






94 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com

PRODUCT SHOWCASE





Poly Cotton Knitted Seamless


Features & Benefits
Poly Cotton Knitted Gloves are mainly made
from mixed fibers or recycled
materials to make it more cost
effective. But the wearing comfort &
features are same as 100% Cotton.
These gloves are more popular in
Shell Colours like Natural, Black, Navy
Blue, Grey & white. The color options
are also be developed/ available for
bulk orders. There are various weight
options available.

Application:
• General Purpose/ Maintenance
For Product Enquiry Contact • Shipping & receiving
Marvel Gloves Industries • Warehousing
[email protected] • Assembly
www.marvelgloves.com • Packaging & Stacking.






High Speed All Geared Lathe


STANDARD ACCESSORIES :
• 3 - Jaw Self Centering True Chuck,
• Steady Rest
• Follow Rest,
• Face Plate,
• Fool Brake,
• Coolant System.
• Machine Lamp,
• Centre Sleeve,
• Centre,
• Driving Plate,
• Oil Gun,
• lnstruction Manual


OPTIONAL ACCESSORIES :
• 4 -Jaw Independent Dog Chuck, • Key Way Milling Attachment,
• 2 -Axis DRO (Digital Read Out), • Tool Post Grinder,
• Rear Splash Guard, • Revolving Centre,
• Quiek Change Tool Post • Pipe Centre, For Product Enquiry Contact
• Taper Turning Altachment, • Anti Vibration Pad. Bhavya Machine Tools
www.bhavyamachinetools.com




www.mtwmag.com JANUARY 2022 MACHINE TOOLS WORLD 95

AD INDEX




PG. PG. PG.
COMPANY NAME COMPANY NAME COMPANY NAME
NO. NO. NO.
A K PROFESSIONAL ENGINEERING 69

ACCUSHARP CUTTING 35
TOOLS PVT. LTD. KHUSHBU HONING 41 Q

AMBIONICS 63 KTA SPINDLE TOOLINGS 61 QVI INDIA PVT. LTD. 39

AMRUTA THERMAL 85 L R
EQUIPMENTS
LAWAS LUBE – SPECIALITIES 83 R. S. IMPEX 51
ANCA MACHINE TOOLS 1
PRIVATE LTD
LOKESH MACHINES LIMITED 19 S
ATQ METRO 9
M SCHMALZ INDIA PVT. LTD. 47
B
M.S. TOOLS & MANUFACTURING SEW-EURODRIVE INDIA
COMPANY PVT. LTD. 3 PRIVATE LIMITED 73
BECKHOFF AUTOMATION 5
PVT. LTD.
MASTER FLUID SOLUTIONS 7 SIDBI 23
BHAGYASHREE ACCESSORIES
PVT. LTD., PUNE (INDIA) 67 MASTERCAM INDIA 33 SPRAYMET SURFACE 59
TECHNOLOGIES PVT. LTD.
BHAVYA MACHINE TOOLS 43 MEHTA CAD CAM 45
SYSTEMS PVT. LTD. STEEL PLANT 77, 79,
SPECIALITIES LLP 81
D METAL POWER ANALYTICAL
(INDIA) PVT. LTD. 55 SURYA MANUFACTURING 65
DELTA ELECTRONICS COMPANY
INDIA PVT. LTD. 71 MICRO-EPSILON INDIA
PRIVATE LIMITED 75 T
E
MICROMATIC MACHINE BACK TRUCUT PRECISION FALSE
TOOLS PVT. LTD. PAGE
EPPINGER TOOLING 90 - 91 TOOLS PVT. LTD. COVER
ASIA PVT. LTD.
MMC HARDMETAL INSIDE U
FRONT
F INDIA PVT. LTD. COVER
UCAM PVT. LTD. 21
FACCIN S. P. A. 25 N
UNITED GRINDING INDIA 13
G N. P. BEARINGS INDIA 75
V
GROB MACHINE TOOLS 37 NICOLAS CORREA, S. A. 15
INDIA PVT. LTD.
V M TRADERS 87
O
I
VENTURA ALLOY AND
OCTAGON MANUFACTURING STEELS PVT. LTD. 53
INSIDE 83
ISCAR INDIA LIMITED FALSE TECHNOLOGY
COVER W
OILMAX SYSTEMS PVT. LTD. 57
J WOHLHAUPTER /
OKUMA INDIA PVT LTD 11 ALLIED MACHINE & 31
ENGINEERING COMPANY
JAGAT ENTERPRISE 49
P
Y
INSIDE
JYOTI CNC AUTOMATION LTD. BACK PATSON MACHINES
COVER PRIVATE LIMITED 29 YASKAWA INDIA PVT. LTD. 27




96 MACHINE TOOLS WORLD JANUARY 2022 www.mtwmag.com