mart march 2013

Volume 9 Issue 9 March 2013 Pages 60 `100

Tube and pipe welding preparation upto orbital

welding from ITW

“Our mission is to make Haas machine tools the most

reliable worldwide”Terrence Miranda

Managing Director, Haas Automation India Pvt Ltd

Choosing the Right Gouging Tool for a Weldable Edge

Orbital Tube to Tube Sheet Welding

Retention Policies of Employees in the Organisation

Commonly used Additive Manufacturing Technologies

Budget 2013 and the MSME sector

Dear Readers,

Budget and the concurrent economic reforms are the breaking news in the run-up to elections. Finance Minister in his budget proposal avows that the fiscal deficit will not be more than 5.3% of GDP in the current year and 4.8% in the next year. The debate going on is, how much the government is doing for the common man. The growth is at 10 years low which is quite alarming! However, on his sophisticated speech Mr. Chidambaram has soaked the rich, made a splash for women and most importantly sought to shore up investments. However, GAAR has been put off for the financial year 2015-16.

Budget impacts the bottom lines of industries like automobile, airlines, power, oil and gas, steel etc. Passenger and utility vehicle sales are expected to moderate to 8-10% in 2012-13. However, two-wheeler sales will witness an increase. Passenger traffic in the airlines has been hit by the economic slowdown and higher airfare. Proposal to develop a major port each in Sagar, West Bengal and Andhra Pradesh will add 100 million tonnes of freight capacity. In oil and gas sector, change in exploration policies and review of current national gas pricing policy are positive. Hit by the slowdown, domestic automobile sales is expected to grow at a subdued rate of 3-5 % in 2012-13. The proposed schemes providing a boost to the infrastructure and housing segments are likely to give a fillip to overall demands in the steel industry in the long run.

India must increase its productivity to reduce unit cost and to compete globally with the range of products. “Short term” has been the newest and bravest policy of the government. Encouraging high consumerism to fund the gap on the current financial deficit has to be stopped with immediate effect to stimulate manufacturing.

In this edition we are featuring the latest techniques and updates available in the welding industry. In Leader Speak we have interviewed Mr. IVS Ram, Country Manager of ITW Orbital Cutting and Welding along with Mr. Abhinav Sood, Sales Leader of Hypertherm India. Apart from our other regular columns we are featuring an exclusive interview with Mr. Terrence Miranda, Managing Director, Haas Automation India Pvt Ltd, one of the leading global machine tool manufacturers.

The changes we brought in our contents and look from the last edition was appreciated by a lot of our readers and it’s really encouraging. We look forward to your sincere feedback on the quality and quantity of MART. You can reach me at +91 8553012371 or email me at [email protected]. Your reviews help us to make MART, SMART!

Till then, Happy Reading!

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Volume 9 Issue 9 March 2013

Annual Subscription `1200 Member INS

Managing Editor Hari Shanker [email protected] +91 9743 181818

Associate Editor Hiya Chakrabarti [email protected] +91 85530 12371Editorial Advisory Board

Content Editor V Viswanath

Art & Creative Pradeep Jayaprakash

Accounts Suresh [email protected]

Manager Customer Prathibha Prakash Support +91 9964 181818

Sushama Prakash +91 8553012372

Circulation Officer Mamatha S Mallapur +91 8553012374

Regional Directors

Ahmedabad Narendra Vora +91 8734999636

Bangalore John Heston +91 98451 42405

Chennai Balu G +91 9840918972

Delhi Sujit Kumar +91 9871646163

Pune Jeetender M Daundkar +91 9822287560

Saravjit Singh

LD Bhakre

Manoj Kabre

Mahesh R P

P S Satish

Siji Nair

A S Shetty

J R Mahajan

Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Lotus Printers Private Limited, No:32/25, 2nd Main Road, Sir M V Industrial Town, WOC Road, Bangalore – 560 044 and Published from No: 217, 3B Main, OMBR Layout, Bangalore – 560 043.

Industrial Business Mart is a monthly journal published from Bangalore. Views and opinions expressed in the journal are not necessarily those of the Publishers.

Industrial Business Mart reserves the right to use the information published here in any manner whatsoever. While every effort has been made to ensure the accuracy of the information published in this edition, neither the Publisher no any of its employees accept any responsibilities for any errors or omissions.

© All Rights Reserved

Cover Feature

8 Choosing the Right Gouging Tool for a Weldable Edge

10 Orbital Tube to Tube Sheet Welding

14 Automation for Robotized Welding

16 Development of Nickel based TIGrods ...

Leader Speak

Articles

24 Laser Cladding Cost effective and accurate work with laser technology

30 Vertical turning machines for the high-yield production

environment

32 5-axis milling with additional capabilities

34 MultiCon = Meter + Controller + Recorder

+ HMI in one package

36 EPLAN speeds up the completion of coiling and winding

equipment projects by 30%

38 Advanced planning and scheduling software

Regular Columns

40 Managing a SME in IndiaP S Satish

42 Retention Policies of Employees in the Organisation

Venkatesh B Kabra

44 Commonly used Additive Manufacturing Technologies

L Jyothish Kumar

46 Budget 2013 and the MSME sector

V Viswanath

26 On Face

Terrence Miranda Managing Director

Haas Automation India Pvt Ltd

IVS Ram Country Manager India ITW Orbital Cutting & Welding

20 22Abhinav Sood

Sales LeaderHypertherm India

48 Event Scan 50 Corporate Mart

52 Mart Update

57 The Last LeafMediaMart InfotechNo:217, 3B Main, OMBR Layout Bangalore – 560 043Tel: +91 85530 12371 Email: [email protected] www.ibmart.in

Welding is the process of joining two pieces of metal together by heating the surfaces to the point of melting, and then uniting them by pressing or hammering. But before the parts can be welded together, excess, defective and worn metal must be removed. And very often, gouging is used to get rid of suchredundant material.

Several metal gouging solutions exist in the market today, and selecting the right technology allows engineers to prepare metals for welding with greater ease. In India, carbon arc and plasma are the most widely used gouging technologies. And although carbon arc has long been seen as a sufficient gouging system for a variety of needs, plasma is fast-becoming the gouging solution of choice as technology improvements in recent years have made it easier to use and more productive.

Choosing the Right Gouging Tool for a Weldable EdgeSeveral metal gouging solutions exist in the market today, and selecting the right technology allows engineers to prepare metals for welding with greater ease. In India, carbon arc and plasma are the most widely used gouging technologies. And although carbon arc has long been seen as a sufficient gouging system for a variety of needs, plasma is fast-becoming the gouging solution of choice as technology improvements in recent years have made it easier to use and more productive.

Gouging Methods

In carbon arc gouging, an electric arc is generated at the tip of a carbon or graphite electrode. Heat generated then melts the metal, and themolten form is removed by a blast of air to form a groove. This process can be used on mild steel, cast iron, nickel alloys, copper, and aluminum, but is not suitable for stainless steel, which willcorrode if gouged using a carbon arc.

Plasma gouging involves blowing an inert gas out of a nozzle at a high speed. At the same time, current from a power supply forms an electric arc through the gas, turning some of it to plasma.

This process can gouge and cut any electrically conductive material, and is most frequently used on mild steel,

stainless steel and aluminum, giving plasma an advantage over carbon arc. Plasma systems can also gouge metals that are dirty, painted, or rusted.

With thisbasic knowledge about carbon arc and plasma, companies in India may be able to instantly decide on which gouging system to use based on their critical business needs. But for more specific factors such as ease-of-use, pollution, cost and productivity, this article explores the comparisons that companies should consider before deciding whether carbon arc or plasma is the best way forward.

Ease-of-Use & Gouge Quality

In recent years, the ease-of-use of technical processes has been gaining importance as a key decision factor in India, primarily because it minimizes training, improves safety, and ultimately increases profitability. And comparing carbon arc to plasma, operators are able to get used to the latter much more easily.

When using a carbon arc for gouging, it is difficult to control the electric arc. So, it is not uncommon to have too much metal removed or to wind up with extra carbon deposits on the base metal. This is the case even for experienced operators. Plasma, on the other hand, requires just some practice in order to achieve a smooth, clean, consistent gouge.Consequently, secondary operations, such as grinding, are not required to improve the gouge surface finish when plasma systems are employed.

Also, plasma is able to gouge a wider range of metals. It is suitable for both ferrous and non-ferrous material that is electrically conductive, as well as metal that is in any condition. Carbon arc gouging, however, can only be carried out on limited types

Erik Brine

technology.hypertherm @hypertherm.com

www.ibmart.in8 March 2013

Plasma is able to gouge a wider range of materials.

COVER FEATURE

Cost & Productivity

The initial capital cost of a carbon arc gouging system is generally lower than that of a plasma system. However, because plasma is typically able to gouge four times as fast as carbon arc is able to, the cost per part produced is much smaller. Also, consumables for plasma systems are able to last a longer time.Considering all these factors, plasma gouging becomes the more economically efficient option.

In addition, plasma systems can be used not just for gouging, but for cutting as well. End-usershave the potential to derive greater value from their equipment and may more rapidly realize a positive return on their investment in plasma.

Conclusion

In India, carbon arc and plasma gouging are both well-established processes for gouging metals. Each has its own advantages and challenges, and choosing between the two depends on companies’ specific business needs. Comparatively, plasma provides more benefits overall, such as greater ease of use, better gouge surface finish, reduced pollution, higher

productivity, and lower cost per part. These factors undeniably provide compelling reasons for plasma adoption over carbon arc in India’s rapidly-advancing economy.

Hypertherm designs and manufactures advanced metal cutting systems for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair. Its product line includes handheld and mechanized plasma systems, plasma and laser consumables, as well as CNC motion and height controls and cutting software. Hypertherm systems are trusted for performance and reliability that results in increased productivity and profitability for tens of thousands of businesses. The New Hampshire based company’s reputation for metal cutting innovation dates back more than 40 years, to 1968, with Hypertherm’s invention of water injection plasma cutting. The company, consistently named one of the best places to work in America, has more than 1,000 associates along with operations and partner representation worldwide.

The author Erik Brine is Product Manager, Manual Systems withHypertherm Inc. For more information, visit www.hypertherm.com.

of metals. This means that welders who utilize plasma systems need only to use a singleequipment to work on a variety of metals, while carbon arc users may have to switch between systems, depending on the material types they are working on.

Pollution

Providing a safe work environment is of increasing importance to manufacturers in India. And in this aspect, plasma gouging performs better than carbon arc.

For carbon arc gouging, the air blast often vaporizes molten metal into fine droplets, thus producing excessive fumes.These emissions may consist of metal vapor, carbon dust, and metallic by-products, which can cause health problems. With plasma gouging, on the other hand, liquefied metal is pushed out of the groove in a milder manner, so less fumes are produced.

In addition, carbon arc gouging, like mechanical gouging, is relatively loud. However, plasma is a quieter alternative that is typically a significant five to 10 decibels softer.

www.ibmart.in 9March 2013

Plasma systems can be used for gouging and cutting.


Orbital Tube to Tube Sheet Welding Compared to manual welding, the planning of the orbital tube to tube sheet welding requires some more specific atten-tion. The tubes have to be seamless (or without flattened weld), concentricity faults between the inner and the outer diameter must be limited to a minimum to allow the repeatability of the electrode positioning

Boilers and heat exchangers are used in all kinds of industries, whereas the heaviest equipment is found in the plants of the chemical or petrochemical industries and in electric power stations.

Specific requirements:

Compared to manual welding, the planning of the orbital tube to tube sheet welding requires some more specific attention. The tubes have to be seamless (or

without flattened weld), concentricity faults between the inner and the outer diameter must be limited to a minimum to allow the repeatability of the electrode positioning. With standard applications, (flush, protruding or recessed tubes - fig. 1) the torch is aligned at the inside of the tube whereas the welding is carried out at the external diameter. Concentricity faults would cause unacceptable variations of the distance between work piece and electrode and thus directly alter the arc length.

As with V-joints it is virtually impossible to ensure reliable melting of the base of the tube edge, especially in the vertically

down position (fusion defects are to be seen on macrographic sections), these joints have to be replaced by J-preparations (fig. 2).

Range of materials and tube dimensions:

Nearly all weldable metal and alloys are used in the field of tube to tube sheet applications, but the range of the tube dimensions is relatively restricted. Their diameter range covers 12.7 to 101.6 mm, the wall thicknesses are between 0.5 to 5 mm. Most of the

tube diameters measure between 19.04 mm (3/4”) and 31.1 mm (1,5”) with wall thicknesses between 1.65 and 3.4 mm.

Welding equipment:

In most cases, the welding equipment used for tube to tube sheet welding is strictly adapted to the kind of application and the desired level of automation:

1 - Welding equipment featuring three controlled axes (gas, current, rotation) is composed of a portable power source (fig. 3) and a closed welding head (fig. 4). This equipment allows for the execution of fusion welding without addition of filler wire.

2 - The welding equipment, including four controlled axes (gas, current, rotation, wire), is composed of a stationary installed power source - portable power sources are rarely used for these applications: there is no need for the machines to be carried - and an open welding head. The equipment is suitable for single pass welding; two passes must be welded in two separate steps.

3 - The welding equipment fitted with five controlled axes (gas, current, rotation,

wire, AVC) is composed of a power source (fig. 5) designed to control 6 axes and a welding head of the type TS 2000 or TS

8/75 with AVC configuration. The equipment allows the chaining of several passes with filler wire, the raising of the torch between the different passes can also be programmed and is carried out without interruption of the weld cycle.

COVER FEATURE

A B Kulkarni

ab.kulkarni@polysoude


4 - Welding equipment furnished with six controlled axes, (gas, current, rotation, wire, AVC, oscillation), comprises a PC

Power Source and a welding head of the type TIG 20/160. The equipment allows multi-pass welding (two or more passes); the torch can be displaced in radial direction.

Tube preparation:

In some cases, if a good thermal conduction is requested, the play between the tube and the bore must be eliminated by a slight expansion of the tube. Play is necessary for the assembly of the apparatus before the welds are carried out, but if clearances become too great, problems of repeatability may occur.

However, it is difficult to specify a

maximum amount of play; it depends on the demanded weld quality and the thickness of the tube.

Expert information:

To get optimised centring tools for the tube to tube sheet welding heads, each order must be accompanied by information about the depth of the expansion and the tube diameter at the expanded zone as well as the original diameter.

The contact zone between the tube and the tube sheet must be clean. Grease, oil or other residues from the tube manufacturing or machining can cause the formation of unacceptable blowholes, with outlets on the surface or enclosed in the welds.

A strong expansion of the tubes inside the tube sheet must never be carried out before automatic welding. A strong expansion (with or without longitudinal grooves in the bore) causes almost always explosive degassing effects which make automatic welding impossible.

Welding of flush tubes

Depending on the application, orbital welding of flush tubes with or without filler metal is possible. Different joint designs are shown below (fig. 8).

Welding of flush tubes without filler wire

Most often the type 1 preparation is carried out for the welding of flush tubes; rarely the type 4 is used. In case of tube diameters between 10 mm and 25 mm or 10 mm and 32 mm the use of especially developed welding heads, for these applications without filler wire, is recommended.

It is the operator’s task to position the welding head and to start the weld cycle. The complete sequence is carried out automatically; the operator is not needed


any longer at this machine. Thus, one operator can work simultaneously with several welding heads.

Typical application: Condensers of thermal-electric power plants. Here, the tubes with a wall thickness of about 1 mm are made of titanium whereas the tube sheet is designed and manufactured as titanium-cladded steel plate (fig. 9).

Welding of flush tubes with addition of filler wire

Welding equipment fitted with four or five controlled axes can be used for this application; the open tube to tube sheet welding head should be configured with devices adapted to the requirements:

• Integrated or external wire feeder • With or without AVC • With or without shielding gas chamber (for the welding of titanium or zirconium) • Torch angle of 0° or 15°.

Expert information: The AVC function is recommended especially for the welding of flush tubes

Generally, the tube end preparations are of the type 1, 2 or 3. If a preparation of the tube sheet is carried out, the V-joint can

be avoided. With this type of preparation, there is always the risk of incomplete

penetration of the root. A J-preparation (with or without radius) should be preferred, if the depth of the bevelled edge exceeds 1.5 mm, the tube end should be positioned at the half of it. The maximum value of the tube end to be recessed is 50 % of the tube thickness; the tube becomes flush by the weld.

Depending on the dimensions and the required weld thickness one or two passes are necessary. One tour of the torch is always applied in case of a pass for tightness; the layers for mechanical resistance often require a second tour.

Welding of protruding tubes

Protruding tubes are always welded with addition of filler wire, but in some cases the weld is beginning with a fusion pass. As shown below, different joint designs are possible (fig. 11).

• torches with an angle of 15° are preferentially used in case of thin-walled tubes (1.6 mm to 2.11 mm), thus melting the inside can be avoided • torches with an angle of 30° are applied for thick-

walled tubes (from 2.5 mm onwards) if there is sufficient space with regard to the tubes around

(reduced pitch).

In any case, to avoid melting down the tube edge, the tube length measured from the ground of the groove must exceed at least

5 mm.

Expert Information: If equipment fitted with five controlled axes is used, the AVC has to be operated in the relative height mode. Thus it is possible to adjust the distance between electrode and tube plate to get the best result; independently of the torch position

Special attention must be paid to the training of the operators; differently to orbital tube-to-tube welding, where the mechanical adjustments of torch and wire guide are carried out in the same plane,

tube to tube sheet welding requires three-dimensional operation (fig. 14).

Welding of recessed tubes

Different joint designs are shown below (fig. 15) :

Welding equipment fitted with four or five controlled

axes and an open tube to tube sheet welding head can be used for the application D, E and F.

The preparation of the type G is frequently used in the petrochemical industry; welding equipment with six controlled axes and a TIG 20/160 welding head with separate clamping device have to be used. This type of application generally requires a specific project to study the best adaptation of clamping tools and welding procedures

Expert information: Different to those applications with protruding tubes, in the case of recessed tubes a V preparation of the tube plate is possible. If joint preparations of the type E or F are applied, the tubes may protrude slightly from the


base of the groove.

Depending on the dimensions, and the required weld thickness, one or two passes are necessary. One tour of the torch is always applied on the first pass for tightness; layers needed for mechanical strength and wear resistance will often require a second tour.

Particular application: Welding behind the tube plate of a double-walled collector for air-cooling or fluid condensation. The AVC operation is indispensable to make the weld in this application.

Internal bore welding behind the tube sheet

To avoid gap corrosion between the tube and the tube sheet, gapless joints are welded from the inside of the tubes at the backside of the plate. This type of application requires extended accuracy of the workpiece preparation and welding. Some possible joint designs are shown below (fig. 18):

A joint preparation of the type X is not recommended: the greater mass difference between the tube and the plate excludes

the possibility to achieve a sufficient penetration.

The joint preparation of the type Y overcomes the penetration problem by creating a welding zone with a better balanced mass of the tube and the plate.

For three reasons, by the joint preparation of the type Z the weld conditions become quite similar to those of a standard orbital tube-to-tube weld operation:

• By the recess the tube is aligned on the bore. • Melting down the collar offers some additional metal which increases the mechanical strength of the weld. • The concave form of the weld is reduced.

Expert information: Unlike classic tube to tube sheet applications, the internal bore welding operations behind the tube sheet require a gas protection of the root, (at the outside of the tube). Only with a preparation of the type X, where the tube end is positioned sufficiently deep in the bore (e.g. half of the tube wall thickness), a root protection is not necessary. The protection can be provided by flooding the entire apparatus with inert gas or, if the backside of the plate is accessible, by a local protection applied tube after tube.

With a tube I.D. of more than about 35 mm, the use of welding tools with filler metal is possible.

If relatively thick walled tubes of 3 mm to 3.6 mm, (depending on the base material), are to be welded, a horizontal weld position with the plate at the bottom with the Weld Head also horizontally positioned, is recommended.

The distance from the face of the plate to the welding joint must be very precise, (close tolerance). The operator cannot see

the torch position inside the tube, he has no possibility of adjustment and he cannot watch the welding process.

Welding equipment fitted with three or four controlled axes can be used for this application, in the case of a joint preparation of the type X, five

controlled axes are necessary. The welding heads must be equipped with a particular lance for internal bore welding

Similar application: If nipples have to be welded on a collector, (this is typical application in the field of power plant equipment construction), identical base materials are used, and the joint preparation and the precautions to be taken are similar to those of internal bore

welding behind the tube sheet.

Conclusions:

At the end of this article, it remains to underline once again the importance of orbital TIG (GTAW) welding if sophisticated applications require reliable outstanding joint quality. For several decades, the French company Polysoude has developed and manufactured appropriate gear and can offer a wide range of standard machines or adapt it for specific demands. The modular design of the devices, i.e. welding heads and power sources, allows the proposal of tailor-made solutions to exigent customers, always taking into consideration the special constraints of the particular project.

Finally, due to the confidence of the clients and hence the shared experience of solving technical problems, Polysoude has become the market leader in mechanised and automated TIG welding equipment. The sales department, the engineering and the application service would highly appreciate participating in your welding activities.

For further information do write to A B Kulkarni, Head Of Representations, Polysoude India, Shri Shanta Durga Niwas, Plot no. 7, Shivaji Co-op. Hos. Soc., Off Senapati Bapat Marg, Pune-411 016 Tel: +91 20 40035931, Mob: +91 9890529923.


Automation for Robotized WeldingColombo Filippetti of Italy, masters of mechanical cam-based automation, have added another dimension to robotic welding. They have provided automation to material handling in the welding of the 2-wheeler chassis, so that there is almost zero time loss in the manufacturing cycle for welding.

The normal requirements of such welding are:-

1. Manual loading of the 2-halves of the chassis together between the fixtures. 2. Clamping of the fixtures. 3. Approach of the robotic welding head carrying the electrode. 4. Beginning of the welding cycle. 5. End of the welding cycle. 6. Retraction of the robotic head. 7. Unclamping of the fixtures. 8. Unloading of the welded chassis manually from the fixtures.

Colombo Filippetti has developed a 2-station oscillating indexing table for this purpose. After the workpiece has been clamped, and the push-button pressed, the indexing table rotates clockwise and stops at 180 degrees, opposite to the loading station. There it remains stopped, for as long as needed by the welding cycle, controlled by the PLC.

Then it rotates anticlockwise, to bring the welded chassis back to the original station. This whole process is flawless, smooth, and vibration-free. There are no pneumatics or hydraulics involved in this rotary motion.

The cam based system brings it always

COVER FEATURE

to the same spot. The cam inside has a double-track, with 2 sets of followers; so, that here is no back-lash and the contact is continuous between the mating elements.

Time is saved by the fact that while loading and unloading is taking place at one station, automatic robotic welding is going on at the station opposite. So, nothing has to wait. One loaded chassis is carried in the clockwise direction, and the next one in the anticlockwise direction, to exactly the same point across. This goes on cycle after cycle, shift after shift.

The indexing table is provided with a through-hole in its centre, enabling the passage of the cables, or of the pneumatic pipes needed for the clamping operation.

The purpose of the cyclic oscillation is specifically to prevent the twisting of these cables and tubes, which would have been caused, had the motion been unidirectional (only indexing).

Colombo Filippetti produces indexing or oscillating tables suitable for various load

categories, for static load of up to 2 tons. These being high-precision machine elements, with no loose components, can be mounted as vertical or horizontal. The application described above has been employed by a reputed Indian 2-wheeler manufacturer for the last several years.

Colombo Filippetti SpA designs and manufactures cams and cam mechanisms for every sector that requires automation and transfer motions, which are precise and repetitive.

Colombo Filippetti can produce other than cams to customer’s drawings and specifications many other mechanisms: Indexing and Oscillating drives, Globoidal and Indexing rotary tables, Linear and Rotary Manipulators, Tandem parallel shafts, Complete Tool Changers with or without storage magazines, Pallet changing cam systems, Output overload clutches. Offering customers the best support possible in application engineering, design and development

For further details write to PI-TECH Services, 108, Aashirwad, Green Park (Main), New Delhi - 110016. Tel: +91 11 26513704/ 26561687 Visit www.pitechservices.in

Surendra Kumar [email protected]


Development of Nickel based TIGrods containing Tantalum for overcoming severe corrosion problem of the chemical and other process industriesThe need for corrosion-resistant material is continuing to grow as engineers push their existing processes harder to gain more efficient production. These processes push conventional materials, specially nickel-based alloys beyond their limits creating a strong need for new material solution

The common nickel based alloys used in chemical, power, petroleum, marine, process, oil and gas are Inconel alloy 625, alloy 825, alloy 256 Mo, Inconel 622, alloy 276, alloy 686, alloy 686 CPT, alloy 59, alloy C-22, alloy C-4 etc.

In order to improve corrosion resistance properties, specially in highly corrosive media, moderately at high temperature, addition of Tantalum metal was studied and new nickel based alloy having designation (UNS No 6210) Alloy T-21 has been developed. The alloy has Ni-19Cr-19Mo-1.8Ta and has excellent resistance to localized corrosion attack crevice corrosion attack etc.

The tigrods are having almost similar composition Ni-19 Cr-19Mo-1.8 Ta and have PRE 81.1. These tig rods find increasing application in many industries particularly chemical, process, petrochemical, off-shore, salt manufacturing industries etc.

Various corrosion tests were conducted with newly developed alloy and were found that it has excellent corrosion resistance properties.

1.0 Use of Nickel base alloys in highly corrosive chemical and process plants.

Depending upon corrosive nature of the liquids used in chemical process plants, Nickel base alloys are used. Usually these alloys have alloying elements such as Ni, Cr, Mo and W. Each alloy has different PRE (pitting resistance equivalent no). Higher the no, better is corrosion resistance properties, specially resistance to crevice corrosion at room and higher

COVER FEATURE

temperatures. Table 1 gives information about common grades of Nickel base alloys used in highly corrosive media to have better resistance to corrosion properties.

PRE = Cr% + 3.3 (Mo% + 0.5 W%) + 16N Even though these alloys find applications in chemical industries handling corrosive acids at high temperatures& still for more severe applications these alloys are not able to resist corrosion attack specially at high temperatures. One of the application is salt manufacturing units are not satisfied with the present Nickel base alloys because of corrosion problem.

2.0 Addition of Tantalum in Nickel base alloys

Tantalum metal is famous for its outstanding resistance to corrosion properties by acids. Tantalum is almost completely immune to corrosion by Aqua-regia.

Due to resistance to attack by body fluids, tantalum provides an excellent material for medical devices (surgical implants and instruments).

2.1Three experimental alloys with different percentage of Tantalum were made. The composition of these alloys are given in Table -2.

Table – 2

Chemical composition of Nickel base alloys with different level of Tantalum

3.0 Beneficial effect of Tantalum

3.0 Beneficial effect of Tantalum in Nickel base alloys was studied through corrosion tests.

Corrosion tests were performed for pitting as well as for crevice corrosion attack. For corrosion tests various commercial grades of Nickel base alloys and experimental Ni-Cr-Mo alloys with different levels of Tantalum were used.

2.20 Critical pitting temperature test

The solution used for Critical temperature test was as under:

11.5% H2S04 + 1.2% HCl +1% CuCl2 + 1% FeCl3

M P [email protected]


Critical pitting temperature was much above 150 degree centigrade.

For T 21 alloy even at 150 degree centigrade there was no corrosion attack observed.

2.30 Different levels of Tantalum.

Crevice corrosion test (attack) Solution used for the test was 11.5% H2S04 + 1.2% HCl +1% CuCl2 + 1% FeCl3

Duration of the test was 50 Hrs.

Even after 50 Hrs, no corrosion was observed even at temperature of 150 degree centigrade whereas even alloy 686 could not withstand the test above 135 degree centigrade.

Higher PRE no, resistance to crevice

corrosion at high temperature is better.

2.40 Effect of Tantalum additions

Presence of Tantalum in Ni-Cr-Mo alloy enhance the passivation

Tantalum forms a very strong and tenacious film on the surface of the alloy which is exposed (outer surface). Tantalum increases stability of passive film which in turn improves resistance to corrosion.

The alloy has outstanding resistance to pitting and crevice corrosion.

Positioning of MAT-21 alloy

The alloy has outstanding resistance to pitting and crevice corrosion

MAT 21 > Alloy 22> Alloy C-276

Deposited weld metal using MAT 21 tig rods has very high corrosion resistance properties.

2.50 Highest Mo containing alloy /weld metal in existing Ni-Cr-Mo alloy.

Typical Mo content in MAT-21 alloy or weld metal is 19% which is highest in comparison to alloy 22, alloy C276. Therefore it has excellent corrosion resistance properties specially in reductive type of corrosive liquids.

2.70 Corrosion test of the weld metal

For comparison purpose weld metal was deposited as per followings:

1) Alloy 21 weld metal deposited on Alloy T-21 base metal plate.

2) Alloy 22 weld metal was deposited on alloy 22 and base metal plate.

3) Alloy C-276 weld metal was deposited on Alloy C-276 base metal plate.

4) Alloy T-21 weld metal was deposited on Alloy T-21 base metal plate.

These welded plates were immersed in highly corrosive boiling solution of 11.5% H2S04 + 1.2% HCl +1% CuCl2 + 1% FeCl3 for the period of of 10 days (240 Hours).

After completion of corrosion test, welded pads were taken out and were examined for corrosion attack.

Following observations were noted:

1) Alloy T-21 weld metal was intact. There was absolutely no corrosion

2) Alloy C-276 weld deposit has corroded maximum even though parent metal was unaffected at the end of the test.

3) Alloy 22 weld deposits on alloy 22 parent metal was having pitting corrosion mark but Alloy 22 parent metal was free from corrosion.

2.80 100 Hours corrosion test of the weld metal.

Weld metal of different alloys were deposited including experimental Tantalum alloy composition such as 1Ta, 1.8 Ta, 3 Ta.


Duration of the test was 100 Hours/

Solution used for the corrosion test was

same as per previous experiment.

11.5% H2S04 + 1.2% HCl +1% CuCl2 + 1% FeCl3

The test was conducted at two different

temperatures i.e. at 135 and 145 degree

centigrade.

Observations:

All alloys except 1.8% Ta and 3.0 Ta showed

sign of corrosion.

When Ta was increased to 3.0% there was

no added advantage. The corrosion results

were same for 1.8 Ta alloy and 3.0 Ta alloy.

2.90 Corrosion resistance properties of

different alloys including 316L grade of

stainless steel.

Behavior of resistance to corrosion of

different alloys was studied in different

corrosive solution.

Corrosion attack on the weld metal was

calculated in mm/year.

It was observed that corrosion attack on

MAT – 21 was very low in comparison to

other Alloys.

It was maximum in case of 316L. Infact

in 40% H2S04, the entire weld metal was

eaten away.

3.0 Weldability MAT-21 alloy.

MAT – 21 alloy can be easily welded by TIG

and MIG process for which filler metal in

various diameters are available. Usually the

sizes of filler metal used are 1.6mm, 2,4mm

and 3.20mm.

Recommended welding parameters are as

under:

For thin sheet welding, square butt joint

with 0 to 1.0mm gap.

For thicker plates, bevel angle is 40 degree

( Included angle 80 degree) with about 1.0mm root face and 1 to 2mm root gap.

Recommended shielding gas is Argon (high purity)

For shielding, gas flow rate is 10-15 L/m

For shielding gas flow rate is 5 – 10 L/m min.

Interpass temp: 150 degree maximum.

3.10 All-weld assemblies were prepared on

the basis of AWS/SF 5.14 specification.

All-weld tensile test was conducted at

various temperatures such as Room

temperature, 250 degree Centigrade,

500 degree Centigrade and 750 degree

Centigrade.

The results of the tensile test are tabulated

in the following table:

3.20 Corrosion resistance of all-weld metal

Corrosion resistance properties – corrosion

rates were studied in different corrosive

solution.

3.30 From the above results, filler wire

used MAT-21 (Ni-19Cr-19Mo-1.8 Ta) has

given satisfactory results.

4.0 Conclusion:

1) Nickel base alloys which are

available in the market do not satisfy need

of highly corrosive chemical and process

plants such as salt manufacturing plants.

2) Tantalum metal has exceptional

corrosive resistance properties in highly

corrosive media.

3) Three different Nickel base alloys

were developed with different levels of Ta

such as 1 Ta, 1.8 Ta, 3.0 Ta.

4) Corrosion test such as pitting

corrosion test and crevice corrosion tests

have shown that Ni-19Cr-19Mo-1.8 Ta

alloy has exceptional corrosion resistance

properties.

5) The alloy

can be welded

using TIG and

MIG process

for which

filler metal

having similar

composition are

available.

6) The weld metal was subjected

to mechanical test which gave satisfactory

results meeting requirements of the parent

metal.

The author M P

Dhanuka is working

with GEE Limited

as Executive

Director (Technical

& Marketing). After

Post graduation,

Mr. Dhanuka joined

Advani-Oerlikon

Ltd. in their R&D

department.

Thereafter he

was deputed

to Switzerland,

Germany and other

European countries for specialized training

and was with Advani-Oerlikon Ltd for 34

years. For further details

visit www.geelimited.com


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The guidance and support of the experienced industry

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the industry as an utility.

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“Complete solutions for tube and pipe welding preparation upto orbital welding” E.H. Wachs is well known as the premier manufacturer of portable pipe cutting and bevelling machine tools for weld preparation. Orbitalum Tools is a very distinguished manufacturer of orbital welding systems using latest technology in the market. Bringing these world class products under one roof, ITW is sure to give customers a varied choice for their cutting and welding requirements. Excerpts from a small conversation with IVS Ram, Country Manager India of ITW Orbital Cutting & Welding:-

Can you brief about Orbital Cutting and Welding. Which are the potential markets you have in India?

E. H. Wachs - USA and Orbitalum Tools GmbH, Germany (ITW companies, Illinois Tool Works), have joined forces. The two companies will now be identified as the ITW Orbital Cutting & Welding group with the same great products, built to the highest standards in the United States and Germany. The idea is to provide complete solutions for tube and pipe welding preparation up to orbital welding - all from

one source that will give customers the most comprehensive assortment of weld preparation equipment and orbital welding systems in the market.

The end markets for these products include process plants (high purity applications - semiconductor, electronics, pharmaceutical and biotechnology; chemical, food and beverage industry, dairy, water treatment ; Anti-Corrosion applications (Chemical, aviation and aerospace technology, shipbuilding); energy plants (power plants, refineries, oil, gas and petrochemical industry).

Two market leaders Orbitalum and Wachs under one umbrella “ITW Orbital Cutting & Welding”. Can you put some light on each brand and the umbrella one?

Orbitalum Tools develops and produces portable tube saws, tube facing machines, pipe end preparation machines, computer controlled orbital welding power sources as well as closed and open weld heads while E.H. Wachs is well known as the premier manufacturer of portable pipe cutting and bevelling machine tools for

weld preparation.

Together, EH Wachs and Orbitalum cutting tools and orbital welding systems are the perfect complement to each other, as a precision weld preparation is the key ingredient to a successful welding program. EH Wachs and Orbitalum range of cutting, beveling and facing machines deliver a perfect prep so you can produce a perfect weld.

Building on decades of expertise in the field and responding to market interest in a unified equipment supplier, the two companies have come together under the ITW umbrella.

The Orbitalum orbital welding system includes Orbimat power supply/controllers; Orbiweld enclosed welding heads, OEM accessories and consumables plus the segment leading Orbitwin switching unit.

These products match the best features of other systems while delivering a unique user experience to produce repeatable, precision welds on tube and piping systems.

LEADER SPEAK


What are the advantages the industry has, to get these two brands under one division?

E.H. Wachs is well known as the premier manufacturer of portable pipe cutting and bevelling machine tools for weld preparation. Orbitalum Tools is a very distinguished manufacturer of orbital welding systems using latest technology in the market. Bringing these world class products under one roof is sure to give customers a varied choice for their cutting and welding requirements.

The challenges “ITW Orbital Cutting & Welding” has in India and your

opportunities?

We have a large inventory of Orbitalum welding and EH Wachs cutting products in stock ready for immediate delivery from our Hyderabad facility. This will help our customers have a first-hand experience of our products and see for themselves the product suitability and quality. Our aim is to offer an inspiring customer service – you can measure us against this promise. We also offer technical support in the form of

• Repairs and maintenance • On-site service

• Service training for our customers • Cost-effective lease devices on request • Product demo and Training • Calibration of machines

Besides these we also provide Rental/used machine service • Comprehensive rental pool • Long-term rental • Hire purchase

Your take on Weld India 2013?

The Exhibition is a good platform as it brings together customers and companies. It is a great way to showcase our product-line and also to acquaint oneself of the latest in the market.

How many engineering industries in India are ready to modernize their welding manufacturing facilities?

Mechanised or orbital welding is now used widely as it can yield fairly accurate results. It is reliable, consistent and guarantees a high standard performance. This results in increased productivity with assured quality control processes in place. The weld quality is also excellent. It can also be used in fairly difficult working environment. These benefits certainly favour the need to modernize welding manufacturing facilities.


“Hypertherm continues to invest in enlarging our local infrastructure, as part of our long-term commitment to Indian market”World Plasma Leader Hypertherm enjoys a dominant leadership position in the Indian market with their local exper-tise. Hypertherm provides local channel partners with capable after-sales support, and world-class cutting technolo-gies. Despite the current economic situation, Hypertherm continues to view India as a market with huge growth po-tential. We had a detailed discussion with Abhinav Sood, Sales Leader, Hypertherm India about their plans, excerpts.

LEADER SPEAK

Can you brief us about Hypertherm India’s offerings to the Indian Manufacturing industry?

All of Hypertherm’s mechanized and handheld plasma systemsand consumables, as well as computer numeric (CNC)controls, torch height controls and CAM solutions, are available within the India market.

In order to meet the needs of various local end-users, Hypertherm recently launched the MAXPRO200® for mechanized& handheldapplications, Powermax105®air plasma system and HDi technology for stainless steel applications.

MAXPRO200 is a 200-amp cutting and gouging plasma system, which has proven to be able to production pierce 32mm mild steel and sever 75mm plates of the metal. In addition, the technology has an impressive capability to produce virtually dross-free cuts even on 20mm mild steel.

Powermax105 is currently the toughest and most versatile air plasma system in the market, and features a remarkable ability to comfortably cut 32mm-thick metals, and to sever metals up to 50mm-thick.

As one of Hypertherm’s latest innovations, theHDi technology applies Hypertherm’s

vented nozzle process to thin stainless steel cutting, bringing true HyDefinition quality to stainless steel plates that are between 3mm and 6mm thick. HDi technology is available to all HPRXD end-users, simply with the purchase of a new consumable set.

How do you rate the current manufacturing growth of India?

The global economic slowdown has had an impact on many countries’ manufacturing output, and India’s is no exception. Despite the current situation, Hypertherm continues to view India as a market with huge growth potential. As one of the BRIC nations, India possesses many traits that make it a rapidly developing emerging economy. The country is becoming a preferred manufacturing base within Asia for international companies, and this has inevitably led togreater adoption of technology, such as plasma cutting, in order to increase productivity and lower manufacturing costs. At the same time, growing of domestic consumption will help increase manufacturing output.

The markets you target in India and the challenges?

Over the past few years, Hypertherm has seen strong growth within the construction, infrastructure, railway, vessel manufacturing and shipbuilding sectors. These industries have continued to exhibit great developments, which is why Hypertherm has maintained its focus on these areas, and supportedeach industry with technology upgrades and new product offerings.

Although we have witnessed some slowdown in the

manufacturing sector in recent months, Hypertherm continues to invest in enlarging ourlocal infrastructure, as part of our long-term commitment to India market. In the third quarter of 2012, we inaugurated our first cutting technology centerin New Delhi, which has solidified our commitment to training channel partners and their employees. At the same time, we continue to maintain close contact with end-users in order to better understand their requirements.

How do you compete with the Indian and Global manufacturers?

Hypertherm enjoys a dominant leadership position in India market and continues to be the World Plasma Leader with Local Expertise. In essence, this means that Hypertherm provides local channel partners with capable after-sales support, andworld-class cutting technologies.

As a company, Hypertherm recently celebrated its 100th plasma technology patent. Our emphasis on research and development has allowed us to create leading edge solutions that uphold our mission to “cut the cost of cutting metal” while improving cut quality.This has truly

In 2012, Hypertherm inaugurated its first cutting technology center in India.


Hypertherm acquires AccuStreamset us apart from local and international competition.

Hypertherm also pays a lot of attention to maintaining strong local support through in-region technical and sales associates. In addition, we work closely with our channel partners to ensure that their employees are well-trained in both technical and sales skills, in orderto assist end-users in their troubleshooting and maintenance needs.

Hypertherm recently acquired US-based Accustream, a manufacturer ofwaterjet cutting systems. When will you be introducing the waterjet cutting machines in India, and what are the opportunities?

Hypertherm is in the process of integration with Accustream at the moment.Once this has been finalized, we will share our plans to introduce waterjet cutting systems technologies intothe different markets. But of course, we hope to bring Accustream’s technologiesinto India as soon as we can.

With this acquisition, Hypertherm will be able to provide an even more comprehensive range of cutting solutions, which can be used in a greater number of applications. Waterjet allows manufacturers to achievecutting with no heat-affected zone as this is a cold cutting process, and complements our OEM and system integrators’ current array of cutting solutions.Considering these, as well as the market’s familiarity with the technology, we will be able to boost Hypertherm’s customer base in India.

Your take on Weld India 2013?

We successfully showcased our latest technology at Weld India 2013, and visitors showed much interest in three of Hypertherm’s most recent innovations – Powermax105, MAXPRO200, and in particular, the HDi technology. We conducted live demonstrationsto exhibitHDi’s industry-leading thin stainless steel cutting performance and exceptional stainless steel piercing capability.

At the same time, wewere able to reinforce Hypertherm’s commitment to the India market, and connect with end-users to better understand their needs.

The show provided a conducive platform for us to educate professionals fromthe industry about plasma, and its benefits over conventional cutting and gouging technologies, such as oxyacetylene and carbon arc gouging.

Hypertherm, a U.S. based manufacturer of advanced cutting systems, announced the acquisition of AccuStream, a Minnesota based manufacturer of waterjet cutting products.

The acquisition will advance Hypertherm’s strategy of providing customers with the optimum cutting technology—whether plasma, laser, or waterjet—for their particular cutting application, supported by the company’s control and software

products for increased performance and ease of use. At the same time, AccuStream and its customers will receive access to Hypertherm’s substantial engineering resources and global infrastructure.

“AccuStream’s core values and focus on building reliable, highly precise cutting products makes the company a perfect fit for Hypertherm,” said Hypertherm founder and CEO Dick Couch. “We believe waterjet cutting is an excellent complement to Hypertherm’s existing plasma and fiber laser technologies and look forward to working together to advance the capabilities of waterjet technology.”

“Hypertherm’s worldwide sales and service infrastructure is ideally suited to expanding the availability and support of our waterjet products,” said Eric Chalmers, AccuStream’s co-founder and president. “I am also excited about joining a company with such

a high level of commitment to its team, and focus on developing market-leading technology.”

Hypertherm does not plan any major changes to AccuStream’s operations. All positions including manufacturing will remain in New Brighton, Minnesota and no workforce reductions or consolidations are planned. In addition, Hypertherm plans to provide AccuStream associates with the full complement of Hypertherm

benefits, including profit sharing and full participation in its employee stock ownership plan.

The transaction was structured as a purchase of substantially all of the assets and assumption of certain liabilities of Accustream Inc. Financial terms of the transaction are undisclosed.

AccuStream Inc. specializes in the quality engineering, manufacturing and sales of high-pressure waterjet components and replacement parts designed to optimize performance and lower costs for users. The AccuStream A and AS Series of waterjet intensifier pumps, featuring the company’s exclusive Advanced Intensifier Technology™ (AIT), are widely recognized for their outstanding reliability and cost-effective performance. AccuStream replacement parts are known for their quality and are available for all major brands of waterjet cutting machines.

www.ibmart.in 23


Laser Cladding – Cost effective and accurate work with laser technologyLaser Cladding is the process wherein the metal (powder/ wire) is deposited on to another metal using a laser as heat source. It’s an alternative to traditional welding and thermal spray.

This technology is similar to thermal spray in that it has an energy source to melt the feed stock that is being applied to a substrate. Where it differs is that it uses a concentrated laser beam as the heat source and it melts the substrate that the feed stock is being applied to.

This results in a metallurgical bond that has superior bond strength over thermal spray. Additionally the resulting coating is 100% dense with no voids or porosity. The basic system is made up of a laser to generate the beam, a set of optics to direct and focus the beam, a powder feeder, and a part manipulator. The laser and optics stay stationary and the part is moved in relationship to the laser. The laser cladding systems are fully automated providing precise control of the coating (cladding) process.

Advantages:

• One of the advantages of the laser cladding process is the concentrated beam of energy from the laser. It can be focused and concentrated to a very small

area and keeps the heat effected zone of the substrate very shallow. This minimizes the chance of cracking, distorting, or changing the metallurgy of the substrate. Additionally the lower total heat minimizes the dilution of the coating with material from the substrate.

•Coating thicknesses can reach .125” (3.1mm) with carbides in one pass and can go to any thickness with other materials and multiple passes.

• Because the feed stock is a powder, so there is a large variety of materials available including pure metals, alloys, or carbides. Further the development extensively with Inconel and Stellite alloys on a wide assortment of oil field applications.

Applications:

•Optimal Part Design by Dissimilar Metal Deposition

•Ideal for Repair & Restoration

•Material Research & Development

•Wear Resistance & Fatigue Life Improvements

In keeping with our policy of offering the best and cutting edge technology in all our product segments, for Laser too we are happy to announce that we have tied-up with leading manufacturer based in Germany, called OR Lasertechnologie GmbH.

OR Lasertechnologie is the leading manufacturer of innovative laser technology machines in Germany which are used widely in Plastic die-mould, Aerospace, Medical, Jewelry and Dental industry. Their Laser Welders, Laser Markers & Laser Cutters are considered one of the best and still most economical in the industry. We are happy to announce that we have been appointed as their Exclusive Dealer in India for the entire above mentioned segment.

OR Laser replaces the conventional methods of soldering, welding and fusing, but is far quicker, more precise and has repetitive accuracy: Set parameters can be easily called up again at any time. In contrast to normal soldering or Arc welding, the machine produces a homogeneous melt at the fusion point of the materials to be joined. Accurate point or area laser welding, therefore, delivers an optimum result without discoloration, spots or beads. This makes physical or optical quality defects and costly reprocessing a thing of the past, saving time and money. Laser instant adjustments can be carried out immediately.

Installation, commissioning, training and after sales service will be provided locally by the OR Laser team based in India. Critical spare parts like the laser lamp, filters, circuit boards etc. would also be available off the shelf most of the time.

For further details visit www.nickunj.com

Roshan Nair

[email protected]

LASER CLADDING

www.ibmart.in 25March 2013 www.ibmart.in 25


“Our mission is to make Haas machine tools the most reliable worldwide”

ON FACE

March 2013www.ibmart.in26


Haas Automation, Inc., is America’s leading manufacturer of CNC machine tools. All Haas products are manufactured in the company’s expansive facility in Southern California, and distributed through a worldwide network of Haas Factory Outlets (HFOs). Every HFO has complete showroom facilities, factory-trained service personnel, extensive spare-parts inventories, and fully stocked service vehicles to provide the industry’s best service and support.

Located at Mumbai the 8000 ft2, Haas India facility features a showroom stocked with the latest Haas machines running demonstrations and customer test applications. In an exclusive talk with MART, Terrence Miranda, Managing Director, Haas Automation India Pvt Ltd, shares with our readers Haas India journey towards success as well as their future plans.

HAAS Automation, today, is one of the leading companies in Machine Tools. Tell us about the start and the recent scenario.

In 1983, HAAS Automation was founded by Gene Haas in USA and since then, the company has been committed to produce top quality products at affordable prices. It relies on volume sales rather than per unit profit as its success mantra. HAAS delivers more standard features, high-tech innovations and rock –solid engineering in its products all at affordable pricing.

All Haas products are manufactured in the company’s expansive over 1 million squareftfacility in Southern California, and distributed through a worldwide network of Haas Factory Outlets (HFOs). Every HFO has complete showroom facilities, factory-trained service personnel, extensive spare-parts inventories, and fully stocked service vehicles to provide the industry’s best service and support.

Recently many global giants from Europe are entering rapidly into Machine Tools Industry. How HAAS Automation is making its prominence in the European market?

In Europe, HAAS has a 5787 m2 headquarters at Belgium to provide

support to the customers throughout Europe. The facility also incorporates an extensive showroom stocked with the latest Haas machines running demonstrations and customer test applications, and houses a fully equipped training area, where Haas personnel instruct HFO service engineers and

customers from all over Europe.

HAAS Automation is always acknowledged for its legendary service support. Please brief on this.

HAAS has made it a mission to make our machine tools the most reliable world

March 2013 www.ibmart.in 27


wide. In the event of a breakdown all HAAS machines are serviced worldwide through an extensive HFO network equipped with local HAAS-certified technicians trained, equipped and dedicated to service HAAS machine tools. All Haas distributors are provided with an extensive consignment inventory of service and maintenance parts for quick access. In addition, the California headquarters will ship a needed replacement part to the HFO the same day it’s ordered – 99% of the time. Haas owners receive state-of-the-art service through a worldwide network of distributors. New Haas machines are always installed by an authorized Haas distributor at no extra charge. Moreover, our Platinum One- Call Service and Parts Exchange Program are unique service initiatives designed to provide cutting edge industry leading service.

Tell us something about HAAS India?

HAAS Automation India is located in Mumbai in an 8000 ft2 facility. The Haas India facility features a showroom stocked with the latest Haas machines running demonstrations and customer test applications. The Haas India distribution system is designed around a network of local Haas Factory Outlets dedicated exclusively to the Haas product line. Every HFO fields a service department staffed with factory-trained personnel, and carries an extensive inventory of service spares. Technicians are locally dispatched in service vehicles fully stocked with the parts and tools needed to successfully repair the customer’s machine the first time out – more than 90% of the time.

All Haas facilities and personnel are focused exclusively on helping our customers succeed in their business with Haas as their CNC machine tool solution of choice.

Tell us about your dealership in India?

In India we have two dealers/distributors –CNCCSSIPL and MANAV MARKETING, who own nineHAAS FACTORY OUTLETSin the north, west and south of India. The 2 dealers sell around 600 machines annually. They have a large number of factory trained and certified sales and service engineers and have been our dealers since 1996. We believe in constant skill upgradation and therefore, customer surveys are carried out monthly in order to provide ratings to the dealers. They can find their score by logging on to our portal. This keeps them competitive.

What are the sectors that apply and enquire most for HAAS machines?

We see a range of manufacturing sector industries like Automotive, Mould&Die, Aerospace,Medical,Oil &Gas and precision engineering showing considerable interest in purchasing HAAS CNC machining centers, turning centers and rotary products. In India, Aerospace and Medical engineering are two sectors which are growing very fast and our products are ideally suited for both.

After having an order, how fast you can deliver a HAAS machine?

At HAAS we believe in Quality and Reliability. Orders are processed through our SAP portal and the entire manufacturing and assembly process is

automated and strictly controlled through our systems. Before leaving the factory, every HAAS machine goes through the Industry’s most thorough testing process.The typical Haas CNC machine is subjected to more than 300 quality control tests, including up to 168 (24 x 7) hours of actual running time while in Assembly. Quality control inspections follow each part from initial fabrication through subsequent installations.We have a number of machines in stock but for those not in stock typical lead times would be around 3 to 5 weeks.

Tell us about your HTEC initiative?

HAAS Automation has initiated the popular HTEC HAAS TECHNICAL EDUCATION CENTERprogram in USA as well as in Europe to create the best talent by giving


professional teaching on truly hi tech HAASCNC machines. It enhances the best international teacher-student exchange in latest CNC technologies.

When we can expect India to have this benefit?

We are working on a plan to bring the HTEC initiative to India though we already have a large number of HAAS machines working in leading educational institutions throughout India.

In USA, Engineering colleges have advanced hi tech facilities so that a student can get utmost benefit

from this program. HAAS also supports students in USA to understand the latest CNC technologies through skill building workshops, training and industry partnerships. Our goal is to do the same in India.

Tell us about your experience in IMTEX 2013?

IMTEX remains the leading machine tool show in India though of late we see more customer participation from the South of India as is to be expected given that the show is in Bangalore. The HAAS booth was very busy during the show and we have a large number of enquiries and customers visiting to see the latest HAAS machines on display such as the Dual Spindle Y axis turning center DS-30Y, our high speed drill tap center DT-1 and other popular models.


Christoph Hoene

[email protected] turning machines for the high-yield production environmentBoth, new and ongoing developments in the automotive industry tend to focus on increased component complexity. The best examples are lightweight construction, complex geometries and greater functional density. For the manufacturers of production systems in the machining sector this creates new challenges regarding precision, productivity and, last but by no means least, process integrity. With its vertical concept EMAG was able to score heavily, particularly in medium and large batch production. The VL 2 P and the VTC 100-4 are the machines with which EMAG has now rounded off their product range downwards.

The external dimensions alone indicate that with the VL 2 P and the VTC 100-4 for small flange and shaft components two very special products have hit the market. These machines are just 1,600 mm (VL 2 P) and 2,350 mm (VTC 100-4) wide – and with good reason: this way, it makes it easy to line up and connect a number of these vertical turning machines and not take up too much space.

The space-saving process chain has thus become an automatic design concept in the construction of these machines. Operator access to the individual machines is another factor that closely follows this basic requirement.

The user can operate all control units

from the front, from where he also has easy access to the machining area. At the same time, all important peripherals can be easily reached from the back of the machine – another important point where the intention is to interlink the machines.

Productivity writ large

The machine concept clearly favours productivity. The user is being given the opportunity to select the best solution, in the greatest detail, for his particular

requirements. For flange machining, for instance, there is the VL 2 P two-spindle vertical turning machine with pendular technology, on which the tool turret swings from workspindle to workspindle in a pendular movement (the „P“ stands for pendular). Whilst one workpiece is loaded, another one is being machined.

This considerably reduces idle times. With cycle times of 20s, even the productivity rates of multi-spindle machines can thus be equalled. And for shaft machining EMAG offers the VTC 100-4, a 4-axis vertical turning machine.

Even the smallest components can be machined

Both machines feature a 160mm chuck, which allows for the machining of even the smallest turned parts. The largest

METAL WORKING


workpiece diameter is 100 mm on the VL 2 P and 63 mm on the VTC100-4.

The maximum turning length of shafts is 400 mm, and the maximum length of chucked components 150 mm. Both machines also rely on the pick-up principle, where the machines quasi load themselves. On the VL 2 P chucker, this task is taken up by the main spindle, on the VTC 100-4 shaft machine by the two turrets.

Well equipped for any machining task

The 12-station tool turret used on both machines is well equipped for any machining task, whereby the VTC 100-4, as a 4-axis machine, features two turrets, of course. All turret stations can be equipped with driven tools with impressive speeds of 6,000 rpm and a torque rate of 22 Nm.

On both machines the interface is a BMT 55; but, on request, both machines can be equipped with a VDI 30 tooling system instead. This ensures that there are hardly any limits when the users choose the required tools.

Similarly open and simple in design is the control system for the machines. The user interface remains the same, whatever the chosen CNC. For the machines of the VLxx and VTxx series the user can choose between the 31i/32i from Fanuc (with integral PLC) and the Sinumerik 840D sl

from Siemens (with integral PLC S7-300). This very much simplifies both training and setting the machines.

For further details contact EMAG INDIA Pvt Ltd, NO17/G/46-3 & 17/G/46-3-1, Industrial Suburb, II Stage, Bangalore – 560022 Tel: +91 80 42544400


Sridhar Ramisetti

sridhar.Ramisetti@ dmgmoriseiki.com5-axis milling with additional capabilitiesCompact design, uniform stability and highly dynamic: DMG / MORI SEIKI‘s eVo centres meet the industry‘s high requirementsThe latest generation of eVo centres are impressively versatile when it comes to simultaneous 5-axis machining and sophisticated ergonomics. The innovative models available in this series range from the small DMU 40 / linear to the DMU 100 eVo / linear. The DMU 40 eVo / linear, DMU 60 eVo / linear and DMU 80 eVo / linear are also available as versions with integrated pallet changer. The innovative highlight of these centres is the fact that the DMU eVo centres’ range of applications can be further expanded with a milling-turning table for complete machining with integrated mill and turn technology.

The entire new DMU eVo generation is a symbiosis of the performance potential of a universal milling machine and a vertical machining centre. This makes it ideal for efficient milling and simultaneous 5-axis machining.

The design of the centre‘s X- and Y-axis, which is an optimised gantry, and which means that it has been possible to keep the distances between the guides extremely short, ensures an extremely high and constant level of stability

across the entire work area. This design also reduces the space requirements of the respective eVo machines and offers improved lateral access to the work area.

One of the outstanding features of the entire DMU eVo series are the machines‘ high dynamics. Even just the standard versions, with their 50 m/min in X, Y and Z, and accelerations of 6 m/s².

All of these models can furthermore be upgraded with linear drives, which will

increase the machines‘ maximum traverse speeds to 80 m/min and acceleration up to 1 g.

The above features apply to all of the series‘ models, as does the option of

METAL WORKING

•A perfect table design for 5-axis machining

•Fast rotary axes = 60 rpm •Optimised gantry machine design

•High rigidity, highly dynamic and high precision

•Footprint of the base module = 6.2 m², with pallet changer = 7.7 m²

•Alternative spindles available offering speeds from 10,000 rpm to 42,000 rpm

•Tool magazine (chain) for 30, 60 and 120 tools

• Chip-to-chip time < 5 seconds

•Can optionally be equipped with linear drives and milling/turning table


integrating a milling-turning table – which is yet again a stunning example of DMG / MORI SEIKI power of innovation.

The right machine for each application

The smallest model comes with traverse paths of 400 × 400 × 375 mm (in X, Y and Z). while the series‘ largest model has traverse paths of 1000 × 900 × 700 mm. This means that customers are guaranteed to find the right machine for their area of application and all sizes of workpieces.

The size of the NC swivel-mounted rotary table is 450 x 400 mm or 950 x 800 mm. The table of the DMU 40 eVo / linear can be loaded with workpieces weighing a maximum of 250 kg, and that of the DMU 100 eVo / linear with workpieces weighing up to 1000 kg.

The DMU 40 eVo, DMU 60 eVo and DMU 80 eVo are also available as versions with integrated pallet changer. This pallet changer distinguishes itself through its short changeover cycles and high level of integration, which means that it does not impact on the access to the work area.

The DMU 40 eVo, DMU 60 eVo and DMU 80 eVo also have an extremely compact footprint, with the DMU eVo requiring no more than 6.9 m², the DMU 60 eVo only 7.7 m², and the larger DMU 80 eVo only 9.6 m² of floor space.

These versions have been specifically designed for use in a number of different sectors, which range from the automotive to aerospace sector, from tool will enable customers to produce all of the component quantities they require, from individual parts to serial and mould making to medical and mechanical engineering - all of which are set to benefit to the maximum from these outstanding DMG / MORI SEIKI innovations. The possibilities inherent in this series of machines manufacture, and full performance up to simultaneous 5-axis machining.

Additional technologies available for integration with the eVo series

Individually designed to offer top performance, the modular structure of the DMU eVo series models also allows each machine to be expanded by a number of different additional technologies.

These include linear drives for high dynamic response and precision, a finely graded range of high-tech spindles that offer speeds of 10,000 rpm to 42,000 rpm (with torques of between 8 and 200 Nm) and customizable tool magazines for 30, 60 or 120 tools in SK40/HSK63.

The latest addition to these additional technologies means that it is now also possible to integrate a milling-turning table into these machines, allowing them to be used for both precision milling and turning using one and the same setup.

On the control side, the additional technologies available for the eVo series are rounded off with the DMG / MORI SEIKI ERGOline® control, which comes with a 19“ screen and 3D software. The eVo series machines are programmed with either a SIEMENS 840D solutionline with ShopMill or a Heidenhain iTNC530. Both of these controls deliver optimal performance in day-to-day production and noticeably increase the total productivity of the eVo machines.

For further details visit www.dmgmoriseiki.com

One of the outstanding features of the entire DMU eVo series are the machines‘ high dynamics

The latest addition means that it is now possible to integrate a mill-turn table, allowing the DMU eVo series to be used for both precision milling and turning in one setup.


MultiCon = Meter + Controller + Recorder + HMI in one package - Part IIIn the previous article we presented a concept and features of the MultiCon series devices and the outline of their possibilities obtained as a result of well developed software and a modular design. This part will describe other advantages, including simple operation and configuration using a TFT with a touch screen, a thing well knows from such devices as smartphones or tablets.

Easy change of data presentation and displayedchannels is a feature which might be useful in many cases.MultiCon offers numerous possibilities in this area ¡V the basicfunction is bringing up the contextual menu by touching thedisplay briefly. Then, a set of buttons appears on the bottom ofthe screen to switch between the display modes, channelgroups or to enter the menu (Fig. 1).

The “MODE” buttons allow a quick selection of datapresentation method on the screen. Depending on whether weneed detailed information on the signal value, quick insightinto the signal level, or parameter trend over time, the data canbe presented as:

• numerical values - Fig. 2a

• needle dials - Fig. 2b

• horizontal or vertical charts - Fig. 2c

• horizontal or vertical bars - Fig. 2d

• simultaneous presentation many groups - Fig. 4

In the first four modes, the panels present in a clearmanner the name and the unit of measure which are specifiedand entered by the user, its graphical or numericalrepresentation, and in addition a percent value in relation to aset level. The last mode allows presenting as numbers up to 30channels on one screen. This mode is particularly comfortable inMultiCon-141 equipped with a large 5.7¡¨ display.

The time graph data presentation mode is useful forrecording operation. Depending on the configuration, the graphbackground can be black (Fig. 3a) or white (Fig. 3b, 3c), and thegraph itself can be set as horizontal (horizontal time axis ¡V Fig.3c) or vertical to maintain conformity with traditional

paperrecorders (Fig. 3a, 3b). The user can also set the line thickness.

For the sake of clarity of results, the measurementchannels are assigned to groups. The “GROUP” buttons are usedto select the group which will be displayed. Figure 4 presents amimic board view with 30 channels from groups from 1 to 5.

Using the “GROUP” buttons will change the range of displayedchannels; this also applies to all other data display modes.

MultiCon CMC-99 has 10 groups, and MultiCon CMC-141 has 15. A single group can contain maximum 6 channels, but the channel assignment to groups is not restricted, and the same channel can be displayed in many groups, providing the user with full flexibility to group various

indications (e.g. one room, the same equipment, groups of measurements of the same type, etc.). For example, Fig. 5d shows a group related to one physical equipment. Selecting the number of channels assigned to a group, we can obtain different sizes of various indicators (Fig. 5).

At this point, it is worth emphasizing the mathematical capacity of MultiCon devices. In Fig. 5d, the channel “Power” is calculated from the “Voltage” and “Current” channels by setting the multiplication function - but this feature will be dealt with in more detail in part III.

The MultiCon series devices equipped with the ACM (Advanced Communication

MEASUREMENT

Arvind Gupta

[email protected]

Fig 1 Contextual Menu

Fig. 4: Simultaneous presentation, groups 1 to 5

Fig. 2: Basic data presentation modes on the screen


Module) allow also a very easy remote monitoring of measurement results using a web browser, as well as a very attractive graphical presentation in the form of built-in or user-created websites. Along with the device, the manufacturer supples a set of built-in Java applets which using the Modbus TCP protocol provide the programmers with easy mechanisms to retrieve data from the device, as well as ready-to-use formats of data presentation on the computer screen. An example of such a website is shown in Fig. 6. As you can see, its appearance and structure depend only on the programmer’s ingenuity.

In order to facilitate the use of their own websites by the users who do not know HTML, Simex has prepared a few examples which are distributed with the free DAQ Manager software used to manage the data recorded by MultiCon.

Press the “Menu” button to enter the main menu of the device (Fig. 1). If the menu is password-protected, a window will appear with a request to enter the password. Access to menu gives a

user extensive freedom to configure the MultiCon, and without knowing any programming language! Here are some potions available from the menu level: results presentation mode, panel appearance, measurement ranges and indication ranges, assignment of channels to groups, language (including Polish, English, German, Russian, French, Spanish,

Romanian, Czech), channel operation modes, disk operations, device data, configuration of communication interfaces. Let us focus on the presentation of results.

MultiCon allows a very precise configuration of the data display method, in particular it allows to specify the names and units shown in individual channels, rescale the measurement data and set ranges in the indicator and graph modes. A particular case – binary data can be presented not only as 0/1. Any text can

be assigned to the logical states. For example (Fig. 7a), the “ON” string on the green background is assigned to the “0” state, and in the “1” state the display will show “OFF” on the red background. Setting a string of spaces instead of the text, we get an imitation of a control light which lights up in any colour the programmer selects for a given state.

It is absolutely necessary to mention one more data display mode - “Setpoint” - although it is more related to the channel operation mode than presentation of results. Touching the screen in the field of such configured channel, the user can in no time at all change a fixed value assigned to the channel (e.g. a threshold in the

Fig. 5: Presentation of individual data groups

Fig. 6: Example of a website created using the Java applets

controller). In addition, this mode can be mixed with binary data presentation as described above (Fig. 7b, 7c) which allows an easy definition of function keys on the screen. The other interesting feature of the “Setpoint” mode is access to the settings. Depending on the needs, the admin can configure a channel so that the changes are made only by authorized users or any operator, also the one who does not know the password.

As a piece of interesting information, let us here present a “trick” - a quick access to group settings or settings of channels in a group. Instead of entering the menu and selecting the channel from the list, you can just touch and hold the screen in the area of the channel that interests you and you immediately enter the editing of this channel’s parameters (Fig. 8). Operation of the group is similar: press and hold the top bar on the group name and you enter a relevant submenu.

The next article will be dedicated to the

firmware potential in terms of controller

applications (including multiple PID controllers), mathematical capacity and operation in various communication networks.

For further details write to Arvind Gupta, Director, SIMEX ControlsIndia, Mobile :+919879540503 or visit http://www.simexcontrols.com


EPLAN speeds up the completion of coiling and winding equipment projects by 30%

Advanced Machine & Tool, AMT, of Fort Wayne, Indiana, saw considerable productivity improvements by using EPLAN solutions and has switched from AutoCAD Electrical to EPLAN. Time-consuming product development steps, like device tagging, wire numbering, and machine design standardization, including archiving and re-using recurrent content, have been simplified and accelerated.

The process that led Advanced Machine & Tool Corporation (AMT) of Fort Wayne, Indiana, to adopt EPLAN three years ago had an unusual genesis. Most companies switching to EPLAN do so after recognizing their existing CAD software isn’t sufficient for their current or future requirements.

AMT engineers, working in AutoCAD Electrical, didn’t sense they were lacking anything until a major auto industry customer made a point of stipulating it wanted EPLAN electrical drawings for the machines it orders to expedite the

production of documentation and improve their accuracy.

This set AMT researching whether EPLAN was indeed a better option. Deciding it was, AMT began a gradual process of switching all electrical and fluid power assignments to the EPLAN Platform. Today, the engineers are happy the company switched. “I thought we were comfortable with our old CAD system, but I sure wouldn’t go back to it now,” says electrical engineer Mark Lohrman.

Builds machines that manufacture motors

AMT specializes in the building of coiling and winding equipment and other machines used in the production of electric motors, generators, alternators and other devices for the automotive and other industries, much of it for OEMs.

The engineering phase of fulfilling an order can take as little as three days, or as much as 60 weeks for the most elaborate projects, but a typical order involves a customer wanting a single

MANUFACTURING IT

TEAM EPLAN

[email protected]

Accelerated Design for many Specialized Machine Projects


machine to produce a new motor or for augmenting or streamlining current production.

“It might be as simple as adding a machine similar to one they have now, or showing us a product they want to produce and asking, ‘How do we manufacture it?’,” says Lohrman.

All projects now done in EPLAN

Besides the one automotive customer that required EPLAN documentation, AMT took a conservative approach to implementing EPLAN. Projects were benchmarked to verify productivity gains and over time, more and more projects were done in EPLAN.

“Now we are at a point where regardless of what is being released, we do it in EPLAN,” says Lohrman. Switching to EPLAN has made it possible to generate accurate and well-structured documentation faster than previously possible.

Automated most time-consuming tasks

For an assignment that might have taken two weeks working in AutoCAD, the biggest savings using EPLAN – about 23-28 work hours – were achieved in four areas.

- Device tagging and wire numbering used to be a manual task. Now it has been automated along with the generation of the actual device tags, wire numbers and terminal tags. AMT engineers use the internal functionality of EPLAN to set up the printers by transmitting an Excel spreadsheet with all the data… 4-5 hours saved.

- Error-free terminal diagrams and BOMs are automatically generated… five hours saved.

- Standard circuitry is archived and re-used from project to project… 8-12 hours saved.

- Fluid schematics have been integrated into the overall project, eliminating errors with devicenaming and missed components… six hours saved.

For larger projects, the savings are proportionately greater.

Archive of macros continues to expand

“Automatic numbering is a big thing for us,” says Lohrman. “I can go to the parts

list and pick out a part. If there is a macro associated with it, I am set.”

The benefits of archiving and re-using standard content are growing with the amount of content items stored as EPLAN macros: now over 300 processes and over 500 components. “Drawing are archived and can be easily found. I can bring up a complete set of drawing in just a few minutes – I don’t have to go back into paper files. While the vast majority of our machines are custom, there are a few we repeat with minor adjustments. With EPLAN, we can pull up the drawings, make minor adjustments quickly and easily, and spit out a set of plans for it.”

AMT engineers also use another source of parts data: EPLAN Data Portal. They use it to download component data sets including Allen Bradley, WAGO and other information.

“Data Portal is easy to use,” says Lohrman. “It’s a major time saver not having to go through all the pages of documentation to find out measurements. If I want a new part, I always go to Data Portal first.”

Engineering becoming more integrated

For AMT, EPLAN’s support has made for a smooth transition. “We get a quick turnaround when we make a request – usually within the day. (An EPLAN support technician) can go online and see my screen, he can see the problem, which makes trouble-shooting so much easier.”

AMT’s way forward with EPLAN is likely to

include closer integration of electrical and fluid design as more engineers are trained in EPLAN Fluid. That way, two disciplines could work side by side to accelerate projects and optimize outcomes.

Other future steps might include adopting EEC One – the new EPLAN Engineering Center One, to begin designing machines mechatronically in functional units.

EPLAN Software & Service develops engineering solutions that accelerate the product engineering process. Interdisciplinary expert systems ensure a maximum of productivity and data integration.

The solution provider develops tailor-made PDM and PLM concepts customer-specifically and provides comprehensive services such as customizing, consulting and training. Innovative development competence, a consistently practical approach, and international presence are the success factors.

EPLAN is part of Rittal International and thus of the FriedhelmLoh Group with 11,500 employees worldwide and generated revenues of about € 2.2 billion in 2011. EPLAN is therefore synonymous with continuity and investment security.

The company’s presence in 50 countries support 30,000 customers with more than 90,000 installations worldwide. ‘Efficient Engineering’ - the corporate motto underlines the consequence of optimized, efficient processes which keep companies competitive in the long term.

For further details visit www.eplan.in

“Data Portal is easy to use.” Access over ¼ million components from over 46 manufacturers with the click of a mouse.


P J Yogesh

[email protected] Planning and Scheduling Software Advanced planning and scheduling software (APS) has brought many benefits to companies involved in the chemicals and pharmaceutical businesses in different types of application. This is best illustrated by looking at some examples.

DAPSA (Destilería Argentina de Petróleo S.A.) is a manufacturer of petroleum products including lubricants, greases and asphalts and is based in Argentina. The company’s oil lubricants and greases are mainly produced for the big petroleum companies in Argentina such as Repsol, Total, Fiat Lubricants, Castrol, Agip, Esso, etc. with the remainder being used for their own brands.

The installed capacity of the oil plant allows the production of 6,000 CM/month of lubricants (6,000,000 litres/month) and due to the variety of finished products the company has considerably in excess of storage 100 tanks ranging in capacity from 15,000 to 600,000 litres.

The process of mixing the base oils plus the addition of any special ingredients

takes place in three blending resources that make use of different technologies: In Line Blending (ILB), Automatic Batch Blending (ABB) and Sequential Automatic Batch Blending (SABB). All tanks, blending resources and packing lines are connected by an intricate array of tubes and valves.

The planning and scheduling system used by DAPSA is Preactor 400 APS. Preactor has to manage the overlapping of operations when filling and emptying tanks as well as make use of different routes depending on which blending resource is selected and in addition take into account the Quality Control (QC) operations done before and after the packing process.

Quality control prior to the packing process is of utmost importance due to very stringent customer requirements. Because of this, the Bill of Operations (BOO) of products has additional

operations that can be activated in case an adjustment is required for a work order that has to be re-processed in order to obtain the correctly specified final product. Preactor also has to treat the myriad of connecting pipes as secondary resources (real restrictions at the time of the scheduling process) and enable valid scheduling routes only when there is an actual available connection between the relevant tanks.

The success of the implementation is the result of the DAPSA planning team working closely together with SIMLog, a Preactor Accredited Partner. Together they analysed DAPSA’s processes, defined the company’s standards and identified the best possible routes to manufacture each product using the correct selection of available tanks.

Optimised set-up matrices were also developed for tanks and packing line resources that will receive final products and commercial products. For example if

MANUFACTURING IT



a light coloured oil is followed by a darker coloured one, set up times are minimised and there is no risk of contamination whereas the opposite is true if a dark coloured product is followed by a lighter one.

Oscar Ridecos was the former project leader of the Preactor implementation and comments that, “with Preactor, scheduling of production in DAPSA has become a whole different ballgame.” Two very powerful examples of this are the reduced risk of contamination and the improvements made in scrapped products.

To avoid contamination pipes must be cleaned and each time this is done, the ‘end of line’ pipe is scrapped. According to Oscar Ridecos, the ability to reduce the risk of contamination has been one of the key justifying factors of the Preactor implementation.

Not only did Preactor do this, it also delivered a conservative estimate of a 50% reduction in scrapped products which ensured that DAMSA’s achieved a Return on Investment (ROI) in less than six months of using Preactor.

Another example is Universal Products (Lytham) Manufacturing Ltd (UPL). They are a leading contract manufacturer serving the pharmaceutical and personal care industries including liquids, creams, lotions, ointments and gels.

Operating on a Make to Order basis, UPL produces in the region of 40-45 million

units per year with order sizes ranging from 1000 to 1,000,000. Each of the company’s 500+ products comprises two essential components – raw materials and packaging. However while the lead times for raw materials are normally between 1 to 4 weeks, packaging lead times, which may include design and printing can extend out to 18 weeks depending on what is specified. To complicate matters further, some customers choose to supply their own packaging which needs to be available before the product can begun to be made.

Alison Walmsley, the company’s planner explains why the relationship between packaging and filling is so important. “Clearly we can’t fill a product if we don’t have anything to fill into but it’s more complicated than this.

Many of our products have to be mixed in very exact ways, in dedicated tanks at specific temperatures. Some have to be stored at a certain temperatures and also kept at the specific temperatures required by the filling machine that is needed to fill the tubes, jars or bottles in question. Each of our mixing, storage and filling resources are therefore a potential bottleneck and we cannot begin a job and keep it on hold while we wait for the packaging to arrive.”

As Alison notes, resource utilisation extends beyond the use of machines to ensuring that sufficient staffing levels are in place. “We run a variety of shift patterns and when demand is high we may need to run weekend shifts and take on extra people.”

The non availability of people as well as unplanned maintenance also needs to be carefully managed with the company ideally needing to evaluate a number of alternative scenarios to select the most effective plan. Seeing the impact of a decision on all the existing live orders

as well as those further upstream then becomes increasingly important.

The ability to update the plan as and when required and push it to everyone in the company means that they now only work to the same, up-to-date plan. UPL can now react much quicker to unexpected changes in customer orders, supplier problems and unplanned maintenance situations and in the case of larger disruptions, perform numerous ‘what if’ scenarios.

The Preactor Group of companies represents world leadership in production planning and scheduling software used by a wide range of businesses. Preactor has an extensive installed based around the world including India and other parts of Asia. Its subsidiary in India is based in Bangalore where planning and scheduling experts, support and implement Preactor.

The current trends in manufacturing are towards lowering inventory levels to reduce costs yet still being able to respond to shorter lead times to satisfy customer demand. Preactor offers a family of applications ranging from mid- and long-term capacity planning to detail scheduling and is translated into over 30 languages.

Frequently integrated with ERP, MES and Supply Chain Management solutions, Preactor’s breakthrough technology is used by more than 4,000 small, medium and large multinational companies located in 75 countries.

For further details write to P J Yogesh, COO, Preactor Software India Pvt. Ltd, “VARMA CHAMBERS”, No.18/3, WOOD STREET, Ashok Nagar, Bangalore-560 025 Tel: +91 80 25513259-62 Mobile: +91 9845427078 Web: www.preactor.com



P S Satish

[email protected] a SME in India - Part 3Journey towards excellenceAs a continuation of last article, we will discuss on few more points to manage SME’s better in India

8.0 Defi ne roles and responsibilities

How do we defi ne Public Park?

One of its meanings is that it belongs to everybody. Another meaning that goes together is that it belongs to nobody. Many of areas in SMEs look like Public Park with meaning of former.

Tasks or responsibilities are very loosely defi ned leading to a situation where everybody is trying to do everything. When I mentored a company recently, fi rst step I tried was to prepare an organization chart defi ning roles and responsibilities. Is role and responsibility same?

Many times it is used diff erently giving a meaning as though both are same. Actually both are diff erent. Role defi nes the role he is going to play in an area. For example, works manager of a company may also be

playing the role of project manager. His responsibilities in these two diff erent roles are diff erent. All of us play diff erent roles in diff erent situations,with diff erent people. I play the role of father to my children,role of husband to my wife, role of mentor to companies.

In the organization, having defi ned the roles of individual next step is to defi ne the responsibilities under each role. This is little bit complex in SMEs as typically one person plays many roles. Though there is a variation of complexity, roles and responsibilities are same between large and SME companies.

Before fi xing the responsibility to a person, it is important to debate to defi ne responsibilities and also to fi t to capability of the person. E.g. For a person playing the role of quality engineer,instead of saying responsibility as taking care of quality,

SME EXCELLENCE

www.ibmart.in40

works manager of a company may also be responsibility as taking care of quality,

better to defi ne clearly as ‘ensure quality of process and products from receipt to despatch including customer complaints’.

More clearly the responsibilities are defi ned, better will the accountability. Transfer the defi ned roles and responsibilities to the organization chart may be as annexure. Review this periodically to see if any enrichment is required for a person or adjustments when a person leaves or promoted.

Major advantage of clarity of roles and responsibilities is that it will identify any redundancy and gap, make employees more accountable, builds sense of ownership and helps to defi ne targets in each area.

Along with roles and responsibilities it is important also to defi ne the authorities at least for managers and supervisors. Responsibility without authority is like lion without teeth. When I joined a company to restructure supply chain area, I asked Managing Directorthat I should be given authority to change any person including sacking if required. Situation improved with this authority.

Guidelines have to be fi xed in defi ning authority. If a marketing manager with responsibility of expanding in new territory is not given authority to make own decision on travel things will not work.My observation is that in SMEs where responsibilities are loosely defi ned, authority is missing. There is a good potential to improve in this area.

9.0 Delegate to develop people

Having defi ned roles and responsibilities for all in the organization, next step the CEO or proprietor to think is about delegation. Genius with 10000 workers will not work. It would be a catastrophe if the genius leaves. To avoid this, delegation must be encouraged in the organization.

The delegation is nothing but distribution of responsibility and author-ity to others while holding them accountable for their performance.

www.ibmart.in40


Typical in SME is that owner tries to do everything. In a company I visited many important things related to business was pending because the owner had gone 2 weeks away on personal holiday. When I asked him upon his arrival, his answer was that nobody can do the job he can do and people are not capable. It went into a blaming game without thinking on how to make it better. The customer do not like if all decisions are centred on a person because of fear that business will come to stop should something happens to this person.

The psychological reason for not delegating is because of fear of losing authority. This is one of the bottlenecks for the growth of SMEs. The owners wants to everything by themselves and all the time is lost in running around the current business and day to day operations. Where is the time available to think strategically or on improvements? Delegation creates extra time to focus on new ideas,changes and opportunities.

The delegation is nothing but distribution

of responsibility and authority to others while holding them accountable for their performance. The people have to be made capable through training and coaching so that they are suited for delegation.

By delegating, the organization creates new leaders, make employees more committed, dependence on few reduces.Question would be whom to delegate and what to delegate?Find person who is fit, has the skill, capacity and finds work stimulating in that area. If you donot have on the company, search for suitable person to recruit. Do not delegate those jobs that you should be doing and in last minute. Typically unpleasant things are delegated. It is not good. I will give a simple example of delegation.

In one of SME with 60 persons working they have an attendance card at the entrance maintained by security. They enter in and out timing. The HR administrator at the end of the month enters all this data in a register to calculate number of hours employee has put in, overtime and absenteeism. An idea came

up on why security should not be given a PC with training so that each day he enters timing for each person. Security had abundant time. With this, HR administrator has more time do something else better.

Once delegated do not do micro management and allow them to find their own way to execute the job. Do not do policing job. But you may have a control by periodic review. Support them to do their job well and appreciate their contributions periodically and reward suitably. Do not have fear of losing. Delegation saves lot of time. The growth of company comes not just by using well resources and people but also by usage of available time. Use effectively delegation techniques to manage SME better.

I will continue the article in the next issue. Please send your inputs,remarks,suggestions to P.S.Satish,Mentor and Trainer, M/s Saraswati Industrial Services, Q-103,Mantri Paradise Apartments,Bannerghatta Road, Bangalore-560076. Email :[email protected]; Visit www.satishps.com Wishing good day to you all.


Venkatesh B Kabra

[email protected] Policies of Employees in the OrganisationEmployee should be loyal to the organisation. Organisation gives chance to newcomers to start career, but after gaining 2-3 years of experience why one thinks of getting into another job? For money, change, transition…? Why?

MANAGEMENT

Hello friends, the year 2013 has just started and by March everyone will be curious on their appraisals, promotions, transfers, switch on, etc. Thus employer will also be in a tough task in retaining and managing employees who are hard or smart working.

It has been said, “Nothing in the world is interesting if you are not interested” and it applies to each sector of the society. It becomes priority of the employer to keep the environment as well as interest of the employee in the organisation.

It becomes a mandatory move for the employer to check upon following things for the benefit of the employee ultimately resulting in progress of the organisation:

Timely increments, incentives and perks as per progress of the organisation which really keeps the interest of the employee in organisation. Taking proper care of employee insurance, which really adds to their comfortable zone as well as security to the family. Good food to be provided to ensure good health to the employee resulting in major attendance by the employee. Certificates of attendance, performance, good behaviour presented

regularly to motivate the employee towards their work. Quarterly medical checkup of the employee be done to avoid major incidence during or in working hours.

Aptitude, gatherings, sports activities be encouraged to create social environment and team bonding within departments concluding in competitive spirit within organisation. Regular outings should be provided to executives with family to ensure satisfaction for the family of the employee to encourage loyalty to the organisation. Regular motivating lectures of an hour or two with brainstorming sessions should be conducted to enhance productivity within organisation.

Nowadays, in middle management jobs incentives like washing allowance (for clothes), shoe polishing, transportation facility or petrol allowance, medical allowance, certain mobile allowance etc. can also be given to the employees. These things annually cost very less, but in reality can make psychological difference to the employee, giving the feel of luxury with job satisfaction. Additionally, these incentives will also help to make a healthy atmosphere in the organisation and make

the employee feel confident.

Another method of retaining good employees is making their appraisal in the second half of the next year so that one does not have the freedom of shifting to another job. The thought of getting the arrears in the second half is itself competent to make the employee stay in organisation. Moreover appraisal can be given to performing candidates only, so that rest of the employees will get the understanding of improving themselves.

It is most difficult to retain higher management employees. With their experience and performance they can be easily absorbed by other organisations. These employees need to be taken proper care of with share allotment, incentives, perks, etc. At times, organisation should take care such that no expenses are borne by the employee. The respect shown by organisation towards employee can reflect in the performance of the employee.

Employee should be loyal to the organisation. Organisation gives chance to newcomers to start career, but after gaining 2-3 years of experience why one thinks of getting into another job? For money, change, transition…? Why?

If there are any issues in the mind of employee, it should be sorted out instantaneously. Many employees in

the organisation lack proper skills in communicating with seniors. They cannot

express their feelings to their boss and in vain finally makes the decision of leaving organisation. This can be avoided

by making suggestion/complaint box in the organisation and encouraging them to express freely - weekly or monthly - these issues can be taken care of by the human resource department. For this, every organisation should have excellent human resource department. This


department mediates between employee and employer. The department in-charge should be well competent in handling and managing employees.

Organisation can also provide quarters to the higher and middle management employees within organisation premises. This helps in creating a social atmosphere and a feeling of security within organisation. With family interactions, bonding is created between families. Social and cultural programmes are conducted in the organisation. When families get settled within the organisation socially, employees would hardly have any thought of shifting to any other organisation.

Organisation should promote higher education of the employees. Many employees are interested in further education but because of their responsibilities or financial position are not able to do so. Nowadays distance education is prominent in India. Many universities are affiliated to UGC & AICTE. Organisation should take initiative to introduce them to employees.

Managers of the organisation should motivate the employees to go for further education. This will also benefit the

Haas Automation, Inc., of Oxnard,

California, reports that 2012 was the best

year in the company’s 30-year history,

with revenues exceeding $967 million – an

increase of 11.5 percent over 2011 – and

CNC machine tool production exceeding

13,300 units, an increase of 5 percent. The

2012 numbers reinforce Haas Automation’s

position as the world’s leading CNC

machine tool builder.

Sales of Haas CNC machine tools remained

strong throughout 2012, with December

yielding a near-record 1512 units sold.

Total sales for the year exceeded 13,000

machines – an increase of 6 percent over

2011 – and the company shipped a total of

13,324 units worldwide, with more than half

going to international markets.

All Haas products are built in the company’s

1-million-square-foot manufacturing facility

organisation to develop well-trained staff. If the financial position of the employee is not sound, organisation should make finance facility legally in agreement which can be reimbursed in installments to the organisation from monthly salary. By this policy both organisation and employee will feel secured. Employee will be highly educated and organisation will also get the benefit of their education. Organisation should cooperate with the employee to get the education completed.

It is the demand of present time to retain experienced and smart working employees. If the employment is interesting and they are in the comfortable zone, they would not think of going anywhere else. Judge the employee on their strength and weaknesses so that they can be kept according to their interest and enhance productivity of the organisation. Replacing the regular employee with a new one can also affect the productivity and channel work of the organisation. Mandatory notice period of one or two months should be the norm for an employee to leave the organisation.

If the atmosphere of the organisation is kept healthy and energetic, employees would not search for another job.

Medication, insurance, education, and appraisal are the areas of concern for the employees. If organisation takes proper care of these things, their word-of-mouth publicity will attract employees from other organisations.

Employee retention management is the prime factor of any organisation to sustain position in the market. Organisation without trained and experienced staff is like a car with a new driver. Ranking of the organisation is the result of employee performance. Administration of organisation should be efficient of not only retaining the employees but also managing them well. So at last ‘success never depends on the size of brain; it always depends on size of thoughts, speed of execution, depth of determination, length of vision and strength of attitude.’

The author Venkatesh Bhagwandas Kabra is working as an Architect & Interior Designer for Institutional, Commercial & Residential projects. He also provides Legal Services as an Arbitrator for Disputed Lands, works as an Registered Approved Valuer for Immovable Property and also the visiting Faculty Member for M.B.A. in I.T.S. Engg. & Management College. He can be contacted through his mobile +91-9422380971 and +91-9401091051.

2012 Best Year ever for Haas Automationin Southern California. They are distributed

worldwide through a global network of

Haas Factory Outlets (HFOs) that provide

the industry’s best sales, service and

support.

Currently, there are more than 170 HFOs

in more than 50 countries worldwide, with

more planned for the future.

“Our growing HFO network allows us to

provide Haas customers around the world

with local access to Haas products, sales

assistance, replacement parts, and factory-

trained service personnel,” continued

Mr. Murray. “This commitment to serving

our customers is one of the driving forces

behind Haas Automation’s global success.”

For more information about Haas

Automation and Haas products

visit www.HaasCNC.com.

“It was an incredible year, our best year ever. And we owe a lot to our international customers. We will continue investing in our growing international markets to ensure that all Haas customers receive the high-quality products and world-class service they deserve.”

Bob MurrayGeneral Manager, Haas Automation



L Jyothish Kumar

[email protected] used Additive Manufacturing TechnologiesIn continuation with the regular article on Additive Manufacturing, we further discuss about commercially available Addi-tive Manufacturing Technologies in this issue.

1. Stereolithography Apparatus (SLA):

This technology is the commercially most popular and widely used method of Rapid Prototyping. 3D systems of Valencia, California, USA, launched this technique in 1987.

In this technique three-dimensional models are built from liquid a photosensitive polymer that solidifies when exposed to ultraviolet light. As shown in the following fig, the model is built upon a platform which is situated just below the surface in a vat of liquid epoxy resin. A low-power highly focused ultraviolet laser traces out the first layer, solidifying the object’s cross section while leaving excess areas liquid.

After, an elevator incrementally lowers the platform in to the liquid polymer. A sweeper re-coats the solidified layer with liquid, and the laser traces the second layer atop the first. This process repeats until the prototype is complete. Afterwards, the solid part is removed from the vat and rinsed clean of excess liquid. Supports are removed and the model is then placed in an oven for complete curing.

Stereolithography process is used to for producing accurate prototypes and it has applications in rapid prototyping.

Advantages: • Can build Complex geometry parts. • Can achieve high quality surface finish. • Can produce clear model with good resolution.

Applications: • Models used to flow visualisation & stress analysis • Fit, form and functional prototypes for testing in Aerospace,Automotive, Electrical and Electronics and consumer goods industries.

• Parts used as a master pattern for rapid tooling & investment casting (lost-wax casting) applications.

2. Selective Laser Sintering (SLS) Process

This process was first developed by Carl Deckard, (University of Austin, Texas) for DTM Corporation (3D systems) in 1986.

Selective Laser Sintering involves fabrication of a physical model by the selective melting of powdered material layer by layer. This process uses a fine powder which is heated with CO2 laser so that the surface tension of the particles

is overcome and they fuse together. Before the powder is sintered, the entire bed is heated to just below the melting point of the material in order to reduce the thermal distortion and facilitate fusion to the previous layer.

The geometry of the object is created as CAD data and CAD files are transferred in to an STL

file system. The STL file is then sliced and drawn as one cross-section at a time. The laser selectively fuses powdered material by scanning cross-sections of the object on

the surface of a powder bed.

After each cross-section is scanned, the powder bed is lowered by one layer thickness, a new layer of material is applied on top and the process is repeated until the part is completed. Compared to other processes a relatively wide range of powder materials can be used in this process. Polymer powders like nylon, glass- filled nylon and polystyrene and metal powders like steel, titanium, alloy mixtures and composites can be processed.

Advantages • Post curing is not necessary • Unfused powder acts as the support •Support material can be easily removed

Applications • Fit and functional prototypes-mechanical &thermal tests • Aerospace, Automotive, Electrical and Electronics and consumer goods industries. • Parts used as master pattern for rapid tooling applications .

3. Fused Deposition Modelling (FDM) Process:

Fused Deposition Modelling is the second most widely used rapid prototyping technology, after stereo lithography.

ADDITIVE MANUFACTURING


In this technique, filaments of heated thermoplastic are extruded from a tip that moves in the x-y plane. FDM builds plastic models by extruding a semi-molten filament through a heated nozzle in a prescribed pattern onto a platform. The nozzle is moved over the platform in the required geometry of the part which is driven by the CAD data.

The platform is maintained at a lower temperature, so that the thermoplastic quickly hardens. After the platform is lowered, the extrusion head deposits a second layer upon the first layer. The process is repeated until the required object is built. The supports are built along the way which is fastened to the part with a weaker material. Support structures are fabricated for overhanging geometries and are later removed by breaking them away from the object. A Water –soluble support material which can simply be washed away is also available.

Stratasys Inc. makes variety of FDM machines which are ranging from fast concept modelers to slower, high-precision machines. The most commonly used materials in this process are ABS which offers good strength, elastomer (96 durometer), polycarbonate, polyenolsulfone and investment casting wax which extend the capabilities of the method further in terms of strength and temperature range.

Advantages • High strength and cost-effective process • Process offers multiple material with greater strength (ABS, PC, PC -ISO, ABS Plus etc.)

Applications • Fit, form and functional prototypes for testing in Aerospace, Automotive, Electrical and Electronics and consumer

goods industries. • Parts can be used as a master pattern for rapid tooling & Investment casting applications

4. Objet-PolyJet™ Technology

Objet Geometries, Israel - Introduced and patented PolyJet™ technology in early 2000. PolyJet inkjet technology works by jetting photopolymer materials layer by layer in ultra-thin layers (16µ) onto a build tray until the part is completed. Each photopolymer layer is cured by UV light immediately after it is jetted, producing fully cured models.

Advantages • Parts and models are of high quality, smooth and accurate • Fine details and thin walls (600 µ or less depending on geometry) • Fast and clean process with multiple material options.

Applications • Automotive, Electronics, Architecture, Defence, Medical and Dental, Jewellery etc.,

5.Direct Metal Laser Sintering (DMLS) & E-Manufacturing using Laser Sintering.

Direct Production of Metal parts by Laser Sintering. - Is an additive metal fabrication technology developed by EOS Germany.The technology fuses metal powder in

to a solid part by melting it locallyusing the focused laser beam (High-powered 200 watt Yb-fiber optic laser).Highly complex geometries to be built directly from 3D CAD data in hours without any tooling. Materials used in this technology are MaragingSteel (MS1), StainlessSteel(GP1&PH1), Aluminum, NickelAlloy IN718 (Inconel), CobaltChrome MP1

(CoCrMo super alloy), Titanium Ti64 (Ti6Al4V-light alloy)

Applications • Automotive, Aerospace, Medical and Dental, Jewellery etc.,

The author L Jyothish Kumar is the Founder and CEO of Rapitech Solutions Inc, Bangalore. He is also the President of Additive Manufacturing Society of India. For further details do write to him at [email protected]

Case Study1: Aerospace Applications of DMLS Technology.

Company: EADS (European Aeronautic Defence and Space),-AIRBUS Process: Direct Metal Laser Sintering (DMLS) Project Aim: To reduce material and energy use.EADS-AIRBUS used DMLS technology to produce ‘Combustion Chamber’which is a thin walled, large part with complex design.Built as ‘one piece’ with integrated perforations and holes.

• Material- Nickel Alloy-(Inconel -IN718) • Time to build in DMLS: 108 hours • Time to build in Conventional Machining/Casting: 5 weeks (IN718 Tough to machine,secondaryMachining operations like heat treatment, hand polishing, casting)

Case Study2: Medical Applications of DMLS Technology.

Company: OrthoSensor Inc., USA Process: Direct Metal Laser Sintering (DMLS) Project Aim: To produce bio-compatible Knee Implant. Material: Bio-compatible Cobalt Chrome Alloy-(CoCrMo)- OrthoSensor Inc., produced Knee Implant using DMLS and supplied to surgeons for a patient’s orthopaedic surgery using bio compatible CobaltChrome.

(Source: EOS, gmbH)

(Source: EOS, gmbH)

www.ibmart.in 45


V Viswanath

[email protected]

Corridors of Development

The need of the hour being generating greater investor confidence and providing business incentives to hasten investment revival, the Union Budget 2013 overall includes strong features to promote investment and direct the economy on the high growth path leading to inclusive and sustainable development. The 82nd national budget presented by Finance minister P Chidambaram promises much for MSME sector.

The Finance Minister has made a proposal to enhance refinancing capability of SIDBI from Rs 5,000 crore to Rs 10,000 crore per year. This doubling would enable SIDBI to provide credit facilities to micro, and small enterprises at affordable rate through banks and SFCs. The beneficiaries would be over three and a half lakh MSEs.

However, the current bureaucratic procedures of large banks for loan approvals are a cause of concern for SMEs. MSMEs to avail the credit facilities in an effortless manner, there should be more

High priority is given to infrastructure development in this year’s Union budget. Industrial corridors and special zones are to see huge investment from the Government.

Finance Minister P. Chidambaram said that Delhi-Mumbai Industrial Corridor (DMIC) project has made rapid progress and plans for seven new cities on the corridor have been finalized. The work on the first two smart industrial cities in the country at Dholera, Gujarat and Shendra Bidkin, Maharashtra will start during 2013-14.

The corridor with an overall length of 1483 km runs across the states of Delhi, Haryana, Rajasthan, MP, Gujarat, and Maharashtra. Dholera Special Investment Region is expected to come up as the biggest industrial hub with smart community living facilities and high environment efficiency. 62 per cent of the DMIC project runs through Gujarat.

Two more industrial corridors between Bangalore-Chennai and Bangalore-

small local banks.

Small units being exempted from discontinuation of benefits or preferences until three years after they have grown to a higher category is a significant proposal. Currently, the rate of growth is low due to the fear of loosing

EZONE

Mumbai have started. The Chennai-Bangalore Industrial Corridor project is to come up along the stretch of Chennai, Sriperumbudur , Ranipet, Bargur, Hosur and Bangalore. The completion of this corridor would enable quicker movement of goods from these places to the Chennai and Ennore ports, thereby enhancing commerce between South India and East Asia.

It is proposed to reduce the distance between Chennai and Bangalore to 100km with new roads. The manufacturing units in this belt would be able to move goods faster. The consumer electronics manufacturers in Sriperumbudur, leather industry in Ranipet, granite in Bargur, IT companies and commercial vehicle makers in Hosur are the other potential beneficiaries of this corridor.

According to Shinya Fujii, director general, JETRO (Japan External Trade Organisation), Chennai, this industrial corridor is being modeled along the $100 billion DMIC

project. The states of Tamil Nadu, Andhra Pradesh and Karnataka would collaborate in the development of this corridor. A comprehensive plan for the Chennai-Bangalore Industrial Corridor is being prepared by the Department of Industrial Policy and Promotion (DIPP) and the Japan International Cooperation Agency (JICA).

Another Industrial Corridor starting up is the Bangalore-Mumbai. This corridor would be along the industrial areas including Vasanth Narasapura of Tumkur, Bharamasagara of Chitradurga, Shimoga, Savanur of Hubli, Haveri, Kushtagi-Gadag, Yelburga of Gadag, Belur of Dharwad, Hukeri of Belgaum and Navanagara of Bagalkot.

Knowing the rapid progress in DMIC, we can expect the stretches of Chennai-Bangalore and Bangalore-Mumbai to witness large-scale infrastructural developments in the coming years. Finance Minister’s budget for the year 2013 gives a heads-up on the growth in industries and commerce in these areas.

Budget 2013 and the MSME sector



Fast reacting collision protection device from Schunk

benefits enjoyed as a small or medium unit. This proposal would encourage them to mature and continue to grow as they would continue to get the benefits for a further three years.

The budget also proposed non-tax benefits to the sector. Market Development Assistance scheme and Design Clinics Scheme are among them. These schemes are significant for MSMEs supplying goods and equipment to the retail sector.

Funds to participate in international fairs and trade delegations to help MSMEs develop overseas markets would be made available under the Market Development Assistance scheme. The purpose of the Design Clinics Scheme is to advance the application of design and innovation to promote design as a value-adding activity.

Investment allowance of 15 percent for investment in machinery of more than Rs.100 crore was announced at the budget. This is a fillip to all the MSMEs considering further automation.

With a response time of 1 ms, the OPR-063-M collision and protection device from SCHUNK, the competence leader for clamping technology and gripping systems, is setting new standards for robot applications. The rapid lightweight consists of a housing which is made of hard-anodized aluminum alloy, weighs 290 g, and has been particularly designed for

applications on small robots.

Here the monitoring is not carried out with internal proximity switches, but is carried out by an exchangeable magnetic switch from the outside. After a collision, the unit only has to be returned into its original position, disassembly is no longer necessary.

This makes operation simpler, minimizes malfunctions, and reduces the need for spare parts. The triggering force and moment can be adjusted via the operating pressure. With the help of a standardized adapter plate, the module can be quickly and simply integrated into the system.

For further details call +91 80 40538999, Email: [email protected] or visit www.schunk.com

The increase in allocation for HRD and other sectors would lead to development of skilled manpower required for the existing and upcoming units.

Easing of norms for SME exchange listing was also proposed in the budget. Innovative and young start-ups can list their units on the exchange with simplified processes. Angel investments are being exempted from tax.

The Finance Minister has said that the Security and Exchange Board of India (SEBI) will prescribe requirements for angel investor by which they can be recognised as Category I AIF venture capital funds and thereby, get tax benefit. However, it has not been made clear whether the tax benefit is for ‘Angel funds’ or ‘Angel networks’ or both. This tax exemption would bring in more investors, lead to new ventures, and in turn employment growth.

It was also announced in the budget that funds provided by corporates to academic incubators will come under Corporate Social Responsibility. This would enable the

incubators to get 2 percent CSR initiative. This gives a boost in the direction of investment in innovation.

A slew of announcements in the budget are beneficial to the MSME sector. These include assistance of Rs.2,200 crore during 12th Plan period for setting up 15 Tool Rooms and Technology Development Centres by the Ministry of Micro, Small and Medium Enterprises; Rs.2400 crore under ‘Technology Upgradation Fund Scheme’ for the textile sector; setting up of Apparel Parks under the ‘Scheme for Integrated Textile Parks’; implementation of a new scheme ‘Integrated Processing Development Scheme’ with an outlay of Rs.500 crore to address the environmental concerns of the textile industry, and availability of working capital and term loans at a concessional interest to handloom weavers.

The Budget is quite progressive for the growth of MSME sector where over 60 million people are employed and which is contributing to around 40 percent of the country’s total exports.

STATEMENT ABOUT OWNERSHIP AND OTHER PARTICULARS ABOUT THE NEWSPAPER

INDUSTRIAL BUSINESS MART (FORM IV, SEE RULE 8)

1. Place of Publication : Bangalore 2. Periodicity of its Publication : Monthly 3. Printer’s Name : Hari Shanker A G Whether citizen of India? : Yes

Address : No:217, 3B Main, OMBR Layout, Bangalore – 560 047 4. Publisher’s Name : Hari Shanker A G Whether citizen of India? : Yes Address : No:217, 3B Main, OMBR Layout, Bangalore – 560 047 5. Editor’s Name : Hari Shanker A G Whether citizen of India? : Yes

Address : No:217, 3B Main, OMBR Layout, Bangalore – 560 047 6. Names and addresses of individuals who own the newspaper & partners or sharholders holding more than one percent of the total capital : Hari Shanker A G, No:217, 3B Main, OMBR Layout, Bangalore – 560 047

I, Hari Shanker A G, hereby declare that the particulars given above are true to the best of my knowledge and belief.

Dated 1st March 2013 sd/- (Publisher)



EVENT SCAN

Seminar on Sheet Metal Rollforming TechnologyIMTMA organized a seminar on “Innovations in Sheet Metal Rollforming” in Bangalore and Mumbai recently. About 70 participants from various types of industries had the opportunity to learn about the technology and the areas of application. The renowned speaker Dipl.-Ing. Albert Sedlmaier joined by Dr. Ing. Krzysztof Szarowicz from data M Sheet Metal Solutions GmbH informed the basics of sheet metal rollforming, technology being used worldwide and the future technology.

Sheet Metal Rollforming in India

The Sheet Metal Roll forming process is being used India since Independence to make varieties of products. High productivity, consistent quality, minimum material handling being the few of the many more advantages, the usage of roll formed products in India is extensiveand the process is unheard to most of the manufacturing industry.

The coaching about Sheet Metal Rollforming at various institutes / colleges is still basic and minimum as compared to other Sheet Metal forming process beingeducated. Manufacturing Industry has not yet taken pro-active measures to adopt and benefit with Sheet Metal Rollforming technology.

Limited expertise and demand

The availability of reliable-affordable-local resources such as Rollforming machines, Skill roll tools designers, in-time supply of roll tools and skilled machine operators are still the road block to many industries wanting to start with Sheet Metal Rollforming.

The demanding end-users of roll formed products are forced to choose between the extreme situations of high priced quality product or low priced poor quality product. This has kept the demand for new product development by roll forming process as a last remedy.

The Seminar

The contents of the seminar were

perfectly tailored to touch upon varieties

of industries and the skill level of the

participants. The seminar started with the introduction of the speakers and a

live simulation of the rollforming process using COPRA® FEA RF which is being used by most of the renowned roll forming

companies around the world to verify the roll tool design even before they are manufactured. In between the several topics discussed during the seminar, Dr. Ing. Krzysztof Szarowicz gave a regular update to the participants on the progress and the observed effects from the live simulation.

Roll forming process and application

A short introductory video on the roll forming process was an eye catcher for those participants being not familiar with the process. The following presentation on the application of the roll formed products in aviation, automotive, railways, oil & gas, construction, furniture, agriculture & farming,

electrical, storage industries etc gave a quick understanding on the opportunities and possibilities that still left unexplored in

the Indian market.

COPRA® Product and services portfolio

Dipl.-Ing. Albert Sedlmaier informed the participants on software modules available for varieties of products being roll formed such as open profiles, roofing and cladding sheets, tube & pipes and hollow special shapes etc. Dr. Ing.

Krzysztof Szarowicz demonstrated those software modules by taking few simple examples.

Design Software Technology – COPRA® RF

COPRA® RF software for designing having all the features a beginner and experienced designer would need to develop a roll tool design was demonstrated. The forming


sequence design being made easy with the spread sheet type user interface showed how easy it could get to design using such a software tool.

The next step of optimizing the forming sequence based on the parameters such as number of stands, distance between the stand, material yield strength and the stiffness factor was shown to make the participants understand the simplicity and the need of optimization even the designer start designing the roll tools.

The features offered in COPRA® RF for roll

tool designing, roll tool detailing, roll tool assembly plan and roll tool cost estimation was convincing to the participants about the completeness of the design using COPRA® RF software.

Simulation software Technology – COPRA® FEA RF

The obvious dilemma of the designer around the world on the performance of the roll tool while at production was addressed through the state-of-the-art rollforming simulation technology COPRA® FEA RF software. With its usage in industry for nearly a decade, COPRA® FEA RF has earned the recognition as the one and one

software solution to meet the R & D standards followed worldwide.

The participants were able to learn how accurately the software is able to show the effects and defects that are familiar with the conventional practice of product development by practical tryouts that demands time, effort and money in terms of machine time, roll tool cost,

material for tool tryout etc. COPRA® FEA RF allows the designer to input all the details as during the practical tryout and perform the simulation to check the roll tool performance.

Localization of data M

data M Sheet Metal Solutions recognizes the demand of the India market and has founded a subsidiary data M Software India Pvt. Ltd. (dSI) to server the customers locally. dSI incorporated in 2005, now has team of 5 members with technically qualified engineers to understand

and realize the customer demands.

In India, dSI has been offering software solutions, training, consultation, roll designing and product development handholding services related to sheet metal roll forming and the related pre and post operations such as stretch bending, tube drawing etc. The participants were also introduced to Mr. Santosh VenkataSubbaiah and Mr.

Suprith Kashyap. dSI being familiar with most of the roll forming companies .

Future Technology – Flexible roll forming

Load adapted profile shapes are commonly manufactured by press operation. The first of its kind in the roll forming industry – Flexible roll forming is being widely discussed in automotive industry due its potential to produce consistent and larger

volume of products. The need to use high strength steel to light-weight the vehicles has increased the complexity to achieve the required quality and numbers with the widely used process such as press forming.

Roll forming being already the first choice to produce uniform long members made out of high strength steel, flexible roll forming is increasing the chances to handle complex shape and material with the continuous R & D done at data M Sheet Metal Solutions GmbH. The partcipants were able to learn about the practical advancements and the research in-progress to put this technology to industrial use.

New product launch – COPRA® Profile scanner

The participants were also introduced to a new product COPRA® ProfileScanDesktop. The device could measure profile sections or short samples contactless by means of a sensor and a turntable, thus the whole visible cross section. The system measured with both the highest accuracy as well as highest flexibility. Whereby measuring rings with a number of sensors around the profile section used to be required, COPRA® ProfileScan now uses a single laser sensor principle. The device designed to work as a plug & play allows direct connection to notebook computer or desktop PC with no separate power and controller. The quick assembly/disassembly of measuring device and transport case makes it use easy and portable.

For further details write to SuprithKashyap, Email: [email protected], Mobile: +91 99002 40193


CORPORATE MART

Lapp Group shows Moderate Growth Investment programme expanded further. 150 new posts created worldwide.

Characterised by the varying developments in global markets and the uncertainties in the Eurozone, the Stuttgart-based Lapp Group recorded moderate growth in the financial year 2011/ 2012 (1 October to 30 September). The leading provider of integrated solutions and branded products for cable and connection technology increased revenue by 1.5% to around 860 million euros (previous year: 847 million euros).

Growth would have been higher without the drop in copper prices (by 8% annual average), as the price calculation per cable is based on the daily market price of copper. In the previous year, revenue rose by 7% due in part to a rise in the average price of copper. The situation was aggravated by the double-digit fall in France, Italy and Spain, which have been heavily affected by the Eurozone crisis. Without these factors, revenue would have increased by 3%. The number of employees increased from approx. 3,000 to approx 3,150 worldwide. Pre-tax profits were at 54.3 million euros (previous year: 68.2 million euros), this too reflected an impact of around 7 million euros from the trend in the copper price.

“Our company is fundamentally healthy - despite the Eurozone crisis - and we have positioned ourselves well. We will continue to lead the Lapp Group from a position of

strength towards a good and successful future”, said Andreas Lapp, Chairman of the Board of Lapp Holding AG.

Uneven development in the regions

The Lapp Group is organised into the three regions Europe, Asia and America. The way countries are allocated into the regions does not always follow geographical lines. South America, Africa and the United Arab Emirates are served by Lapp Europe, for example. North America includes the USA, Canada and Mexico while Asia also covers Australia and New Zealand.

1.Europe: The continuing uncertainty around the future of the Eurozone led to a fall in domestic demand. Revenue came in at 594 million euros (previous year: 620 million euros), a drop of 4%. Within Europe, the individual countries have developed very differently. Countries such as Great Britain, Russia, Ukraine and Turkey experienced strong growth. Countries that have been sucked into the European sovereign debt crisis (France, Italy, Spain) only recorded negative growth. As the strongest single market, Germany maintained its revenue share of 36% of the total group revenue. Revenue was 306 million euros, 1.5% higher than the previous year (302 million euros). Over 1,200 people were employed in Germany alone, around 50 more than last year. With a 69% share of total turnover (previous year: 73%), Europe remains the core market for the Lapp Group.

2. Asia: The powerful economic growth in Asia has been particularly positive for the Lapp Group’s companies in the region. Growth was at 20%, leading to revenue of 183 million euros (previous year: 153 million euros). Targeted investments in this region supported the above-average growth. This

helped the Asia region to increase its share of total company turnover to 21% (previous year: 18%).

3. America: Revenue developed very dynamically in America. Revenue rose by 12% to 83 million euros (previous year: 73 million euros). Revenue development in the USA was particularly positive, with growth of 22%.

Stable earnings and financial situation

Driven by the further consistent expansion of production and staff capacities, staff and material costs rose from 262 to 280 million euros. The price of copper, which was subject to volatile fluctuations throughout the financial year, had a big influence on the moderate growth. In the annual average the DEL quotation (German electrolyte copper quotation for conductors/exchange-traded price of copper) was 614 euros per 100 kilograms, around 8% lower than in the previous financial year (previous year: 667 euros/100kg).

Pre-tax profits came in at 54.3 million euros, a drop of 13.9 million euros compared to the previous year. This drop includes, however, a “copper effect” of around 7 million euros. Despite this, net liabilities to banks were repaid in full. As in previous years, the company showed a strong cash position. At the same time, the equity ratio of the family company rose to 54% (previous year: 50%). “Despite record investments and a very strong cash position, we were able to expand the equity ratio. This means we have all strategic options open and can invest react quickly to market requirements where necessary”, says Dr. Uwe Schwellbach, responsible for Finance and Controlling.

Andreas Lapp, Chairman of Lapp Holding AG



Significant increase in investments

The Stuttgart-based Lapp Group increased its investments in the 2011/2012 financial year, laying the foundations for further growth. Investments therefore rose to 33 million euros (previous year: 21 million euro). The largest investments came in Germany. For example, the interior construction of the new fully automated service and logistics centre in Ludwigsburg cost 16 million euros. The state-of-the-art goods warehouse (total investment: 48 million euros) entered service last autumn and will be officially opened in mid-2013. Another major investment was the opening of a second Indian production plant in Bhopal and the expansion of production capacities at existing sites such as Contact GmbH in Stuttgart, Camuna Cavi in Italy or Lapp Cable Works in the USA. Further expenses resulted from the 100% acquisition of the long-time sales partner Coelco Trade S.R.L in Romania as well as licence payments to SAP for ECC 6.0 of around 1.3 million euros.

Asia will be the focus of investment for the current financial year. For example, a new plant in Shanghai, China (5.5 million euros) and the further expansion of the plant in South Korea (2.7 million euros) for the production of electron beam cross-linked cables, for example for photovoltaics. In Europe, the construction of a new administration and logistics centre in Poland (approx. 4.1 million euros) is in the pipeline. The continuing implementation of SAP alone will cost 1 million euros in the current financial year. This new information and communication technology will enable the Lapp Group to optimise its processes even further, improve service and fulfil customer wishes even quicker. Total investments for the current financial year are 35 million euros.

Numerous innovations

Innovations are also being driven forward full steam ahead. In order to bring new high-quality and cost-effective products quicker to market and set new global standards, the product development process is being reorganised using a stage-gate process. The first pilot projects have begun.

In the last financial year, the company was able to prove its pioneer status in cable and connection technology with numerous new innovations. For example, two new

innovative versions of power and control cables, proven for over 50 years, were launched on the market: the new ÖLFLEX® Classic 110 and ÖLFLEX® Smart 108 are even more versatile, efficient and with even better performance. The company is particularly proud of the ÖLFLEX® SMART 108, which thanks to the standardisation and recycling of their own PVC reclaimed material can be offered to the market at a much lower cost whilst simultaneously protecting the environment. For the wind energy sector, 20 ÖLFLEX® cables are already on offer that meet the new guidelines for construction and erection of wind power installations in North America (UL 6141).

Extraordinary application examples

•Europe’s biggest display system and the third largest in the world was installed at the 13,500 capacity Fenerbahçe Ülker Sports Arena (capacity 13,500) in Istanbul. To enable the “flying cube” to safely move up and down, Lapp planned a 28.5 metre long and 415 kilo SILVYN CHAIN® energy supply chain, which uses ÖLFLEX® connection and control cables to ensure reliable operation.

• On the roof of the stadium of German soccer champion Borussia Dortmund, a total of 8,800 thin-film solar modules (total power of 924 kwp) were connected with 4 Y array harnesses. Up to 60% fewer solar cables are required between the modules and the inverters for these solutions.

•For the Norwegian company Aker Solutions, Lapp developed durable special cables that are particularly suited to the harsh weather conditions on oil rigs. That is why Lapp was recently officially named as Aker Solutions’ preferred supplier for connection technology.

•Students from the University of Applied Sciences in Constance took part in the “Solar Decathlon Europe 2012” international competition in Madrid, for which they designed under the project name ECOLAR a building that uses an intelligent energy concept to meet the standard of a zero-energy house. All the required cables were provided by Lapp. The team from Constance came 4th in the competition.

•The charging systems developed by Lapp for e-mobility are also prevailing on the market. Their use in mass production

is growing continuously. For example, a French manufacturer’s e-vehicles are being equipped with Lapp charging cables. The start of series production for complete Lapp charging systems at several German premium manufacturers is just around the corner. Demand is high, especially for the innovative LAPP HELIX charging system. This is a “snail-design” charging cable. It offers significant savings in terms of space, weight, materials and costs.

Outlook for the current financial year 2012/2013

The Lapp Group assumes that growth conditions will no change much in the current 2012/2013 financial year. The growth in revenues is single-digit and are roughly similar to the levels from the previous year, slightly lower in some subsidiaries. “We foresee a continuing stable development for the coming years”, explains Dr. Schwellbach. Due to the high investments, amortisations and cost increases, profit for 2012/13 is seen lower than in the previous year.

In order to compensate for the increasing expenditure in investments and higher material and staff costs, a programme has been initiated for increasing efficiency and reducing material costs. No job cuts are planned. On the contrary: the total number of staff worldwide is set to increase slightly in the current financial year.

A particular focal point in the current financial year is the further development of our staff’s social skills. This means improving teamwork skills and encouraging an integrated work method in order to train staff for cross-department projects. Andreas Lapp: “Our staffs are highly motivated and performance-oriented. Thanks to their commitment, our company will continue to grow in the future.”

Dr. Uwe Schwellbach, Finance and Controlling



Kennametal Extrude HoneTM announce HYDROMTM, the ADD-ON Electrolyte Cleaning Unit

Compact, durable, robust: New worm gear unit series SMI from NORD

well as management skills.

Hikari manufactures special purpose grinding machines achieving a high level of efficiency, operation and maintenance per-formance. Some of their products targeted for India are CNC Double Disc Grinding Machine – Planetary Type (with complete unmanned operation) and Oscillation type. Their CNC Single Disc Grinding Machine is good for complex shaped works in cutting tools. CNC Brush Honing Machine is de-signed to perform radius honing on the top edge of tungsten carbide inserts.

Operator friendly CNC Chip Breaker Grinding Machine, Diamond Tool Grinding Machine, 4 stationed CNC Rotary Grinding Machine are some of the other offerings from Hikari Kikai. All Hikari machines come with one year guarantee system, after sales service available as long as machines are used and their spare parts and consumable parts are made available.

For further details and dealership enquiries contact Mr. Akito Yasui, Director, Hikari Kikai Seisakusho Co., Ltd, Japan Tel: +81-59-227-5511, Email: [email protected], Web: www.hikarikikai.co.jp

For manufacturers facing complex or stringent machining or finishing issues, electrochemical machining (ECM) is a notable process by which material can be removed in micron increments, reaching areas unreachable by other methods. To support the ECM process, Kennametal Extrude Hone (Latrobe, PA), has designed an electrolyte cleaning unit called HYDROM as an add-on to electrochemical machines. It delivers constant electrolyte quality to ensure constant gap for better quality and

NORD DRIVESYSTEMS now offers a new range of worm gear units in a robust, one-piece UNICASE housing in five sizes with a maximum torque of 427 Nm. New, larger output bearings allow users to choose increased shaft diameters than the previously available series. In addition, the large bearings ensure a much extended service life.

The aluminum permanent mould casting process was optimized for the SMI series, resulting in an especially smooth surface that prevents dirt build-up. Closed SMI worm gear versions are washdown-capable, and can therefore be easily cleaned along with other systems during plant cleaning processes.

If required, these gear units are available with NORD´s NSD tupH surface conversion treatment which transforms their durability with up to seven times the hardness of

the base aluminum material, providing excellent protection against acids and alkaline solutions. A synthetic long-life lubricant makes the worm gears maintenance-free during their entire service life. Equipped with oil gauge screws, the gear units are now also suitable for use in hazardous areas.

Illustration: Worm gear units from the new SMI series - pictured: a model with an input stage - have larger output bearings and a

very smooth aluminum housing

The worm gear units provide transmission ratios between i=5:1 and i=3000:1. Thanks to the modular design, they are easily configured according to application requirements. Users can optionally select the field-proven and extensive SI series modular worm gear unit program which is flange-compatible to the SMI series, allowing for very versatile configuration. On the drive side, several standard IEC interfaces (B5/B14) are available for every gear unit size. The worm gear units can be foot- or flange-mounted and equipped with solid or hollow shafts, and as closed or open frame versions.

For further details contact Jyoti Mishra, NORD DrivesystemsPvt Ltd, 282/2, 283/2, Village Mann,Tal. Mulshi, Adj. Hinjewadi MIDC II, Pune 411057 Cell: 09765490890, Email: [email protected]

MART UPDATE


superior process stability.

Electrochemical machining accomplishes metal removal by the dissolution of surface atoms without direct contact between the tool and workpiece material. The amount of material removed is proportional to the time and intensity of an electrical current flowing between tool and workpiece. The process is highly controllable and can machine or polish areas previously unreachable by other methods, including hand polishing and deburring.

As an electrolytic solution (water and specialized salts) flows over the workpiece surface, a DC current is applied between the tool and the workpiece. The amount of material removed is determined by the amount of electrical current flowing between the negatively charged tool and the positively charged workpiece. The tool is normally designed to have a mirror image of the final surface of the workpiece. Since the tooling, known as a cathode, never touches the workpiece, there is virtually no

tool wear in the process. Typical deburring and polishing times are extremely fast - between 10 and 30 seconds for most applications. Depending on production requirements and the workpiece size, multiple part fixturing can be used to obtain high production rates.

Now making the process even more effective is the HYDROM add-on cleaning unit. Combine HYDROM with a CFP - chamber filter press -- and reduce disposal costs on filter cake by up to 10%. CFP cleaning time can be reduced by up to 6x, and cathode tool life is extended. Accordingly, machine availability increases.

HYDROM can be delivered with new ECM equipment but also as an add-on to existing machines of all brands. For complex machining and finishing, HYDROM will help companies increase competitiveness and improve quality and productivity in cost-pressured manufacturing markets.For more information, visit http://www.kennametal.com/extrudehone


Ashok Makhija to lead VARGUS IndiaCutting tools professional brings extensive experience in international business development & marketing to Vargus India

VARGUS Ltd., a world-leading manufac-turer of premium quality cutting tools for threading, grooving and hand-deburring for the metal and plastics industries, has named Ashok Makhija as its new General Manager at Vargus India.

Makhija will head the Indian operations of Vargus India based in Pune in the Indian state of Maharashtra. Prior to joining Var-gus India, Mr. Ashok Makhija oversaw the International Business of Electro Minerals Division of Carborundum Universal Limited (CUMI). Prior to CUMI, Mr. Makhija worked with two major European cutting tools manufacturers as well as the local Bajaj Auto Limited. Mr. Makhija has performed a wide variety functions throughout his career, such as Manufacturing Engineering, Vendor Development, Domestic and Inter-national Sales and Marketing and Logistics.

David Wolfe, Vice President Sales & Marketing, VARGUS Ltd. announced “We wish Mr. Makhija great suc-cess in his new role at Vargus India in the ever growing

Indian metal cutting tools market. Given Mr. Makhija’s extensive experience in international business development as well as domestic marketing and logistics, we feel confi dent that he will be a tremendous asset to the company and particularly well suited to addressing the future needs and development of the Indian market.”

The opportunities Vargus have in India?

As India is becoming manufacturing hub for Automotive and Engineering Industries, we believe it off ers immense opportunities to be in India. Vargus is universally recognised as the market leader in Thread Turning and Thread Milling applications. Vargus has recently launched GROOVEX, an innovative line of Groving tools for groove turning, groove milling and micro machining ap-plications. Vargus has introduced new line of products for Gear Milling as well. It is a very innovative solution for gear milling in-dustry, off ering a competitive alternate to traditional Hob system. Gear manufactur-ers can now mill external splines, external cylinderical gears, sprockets and racks as well as many additional gear applications with VARDEX gear millling tools.

What are your marketing strategies in a competitive and growing market like India?

While Vargus has been active in the Indian market for over 16 years, we decided to upgrade our presence in India by estab-lishing our own subsidiary so that we can off er greater support and service to our end-users and channel partners. Vargus will actively work with Indian customers to provide “solutions” to their complex needs in threading, grooving and gear milling ap-plications. Further, Vargus will collaborate with Indian customers and educate their engineers for productivity improvements to make them even more competitive.

Your future plans for Vargus India?

Vargus-India’s warehouse at Pune will stock its products to meet ever demanding delvery levels of indian customers. Also, we will increase our sales and application team alongwith new channel partners in unrepresented areas to service customers effi ciently.

Vargus India was established as a wholly owned subsidiary in November 2011 in Pune in order to provide greater support and

service to Vargus end-users and channel partners throughout the country. Harry Ehrenberg, Presi-dent, VARGUS Ltd. elaborated, “While the Indian

market has experienced dramatic growth in recent years, we have also noticed that Indian customers have become increasingly demanding and quality conscious, demon-strating an ever greater focus on service and solutions as opposed to product. Therefore our future eff orts in India will be concentrated on adding more technical support and service than ever before in order to be customer ready 24/7.”

At the forefront of the tooling industry for over 50 years, VARGUS Ltd. is a member of the NEUMO Ehrenberg Group headquar-tered in Knittlingen, Germany, comprising 26 companies operating in more than 30 countries. Today VARGUS’ fl agship VARDEX line is universally recognized as the market leader in thread turning and thread milling applications. Vargus also recently launched GROOVEX, an innovative line of grooving tools for groove turning, groove milling and micro machining applications for indus-trial use. The SHAVIV line of leading hand-deburring tools rounds out the company’s off erings with professional solutions for fi nishing metal and plastic components.

For further details www.vargus.com

MART UPDATE

Ashok Makhija

development & marketing to Vargus India

VARGUS Ltd., a world-leading manufac-turer of premium quality cutting tools for

Vargus India was established as a wholly

March 2013

www.ibmart.in 55March 2013 55


HMS Industrial Networks acquires IXXAT Automation

Newest CADlink software from Antech for CNC wire EDM

HMS Industrial Networks has acquired IXXAT Automation – a leading supplier of communication technology for indus-trial automation, machine manufacturing and the automotive industry. IXXAT was founded in 1987 and is headquartered in Weingarten, Germany.

“IXXAT’s hi-tech products and services are great supplements to HMS’s business,” says StaffanDahlström, CEO at HMS Indus-trial Networks. “Their strong product offer-ing and market position will strengthen our presence especially in Central Europe.”

While IXXAT is known as a leading supplier of CAN-based as well as EtherCAT-, Power-link and FlexRay- communication technol-ogy, HMS has a leading position in the Pro-fibus/ Profinet and DeviceNet/ EtherNet/IP markets. Together, the two companies will have the most complete and competitive offer of communication technology for the automation markets.

IXXAT

IXXAT Automation has a turnover of 14 mil-lion Euro and employs 85 people of whom 50 are product development engineers. IXXAT offers software and hardware solu-tions for CAN, a number of industrial Ether-net standards and IEEE 1588, FlexRay, and LIN. They also offer customized hardware components within embedded subsystems as well as complete embedded system

CADlink-9 from Antech is CAD based soft-ware for NC programming of CNC WIRE EDM machines. It allows user to take full

solutions for a broad range of world-wide markets like industrial, medical, power generation and automotive.

HMS Industrial Networks

HMS Industrial Networks is the leading independent supplier of products for industrial communication including remote management. HMS develops and manufac-tures solutions for connecting automation devices and systems to industrial networks under the Anybus® and Netbiter brands®.

Acquisition logics

IXXAT’s strong position on the important German market will widen the customer base of the HMS group and will allow cross-selling of the existing product lines. IXXAT holds a leading position in emerging functional Safety technology for automa-tion including solutions for OpenSafety, CIP-Safety and Functional Safety over EtherCAT. In combination with HMS´s new Anybus Safety concept which is focused on PROFIsafe, the HMS group will have the most complete technology offer for functional Safety solutions.

With 50 new development engineers, HMS’s overall development resources will be strengthened both when it comes to headcount and experience. The acquisition also gives HMS the opportunity to market their products towards new segments such

as medical equipment and the automotive industry.

HMS’s world-wide sales channels will give IXXAT access to a wider market. In ad-dition, HMS’s experience within manu-facturing and logistics will also provide opportunities for improved efficiency and profitability.

benefit of geometry mak-ing of any CAD software. And with least question-naire it converts dwg files into NC code compatible with CNC WIRE EDM of various makes. It also has various modules like GEAR/CAM and complex shape programming.

Newest CADlink software takes data from various 3D CAD packages like Medusa, Solid edge, solid works, ProE, UG and Catia as well.

Generated NC programs can be transferred

MART UPDATE

www.ibmart.in56 February 2013

“Together IXXAT and HMS will become an industrial communication group with

350 employees and sales of more than 50 million Euro – a world market leader

in our industry,” says Staffan Dahlström, CEO of HMS Industrial Networks AB.

to CNC machines directly via RS232 port. Once DNC is active at PC end, NC programs can be called from CNC. This module can be used only if RS232/422 port is available with CNC. If RS232 port is not available, other DNC peripherals like RE93, 20 MA, TTY can be used for PC-CNC communication. Multiple CNC machines can be connected to DNC PC with additional hardware. Some old models of Japax machines can run from PC based controller software.

For further information contact Antech Micro Systems Pvt Ltd, 4 Chandramohini Apts. Subhash Nagar, 1227 Shukrawar Peth, Pune 411002 Tel : 020-32921973, 9823041317 Email: [email protected] Web : www.antechmicro.com


Dear Readers,

Perseverance is one of the important ‘P’ amongst the 4P’s for the success in life, - the other three being Passion, Patience, and Persistence.It means steadfastness in doing something despite diffi culty or delay in achieving success. It is a function of tenacity and dedication. I have made an attempt to look at some of the instances across the globe that speaks volumes about Perseverance.

February is the annual Budget time in our country, and so was the Budget presented by our Finance Minister – a truly strong and subtle pitch to the monetary authorities in the country. He indicated that he had presented reforms that are good for people in a way that India continues to grow at a pace of 8 % and above. Growth will pick up and so will revenue.

Japan, the world’s third largest economy, has seen its currency change signifi cantly in the global economy. The cheaper yen is lifting the profi ts up for exporters, who account for 15 % of overall economic output of this country. The Nikkei 225 has soared by a third to its highest level since 2008. Mr.Shinzo Abe, the Japanese Prime Minister, has ordered one of the largest fi scal stimulus packages in the country.

Meanwhile, I got an opportunity to read about a company called Huy Fong in ET – a company known for its fl agship product Sriracha (name coming from a port town in Thailand) Hot Chilli Sauce (hot sauce production is the eighth fastest growing industry), that is the fastest growing food company in US, in spite of the fact that it has never advertised in US, and does not have either a FB Page or Twitter account. Even their website was last updated in 2004. This seems unbelievable in today’s internet age, but this is the truth about David Tran, who is founder and owner of this company who moved from Vietnam to Los Angeles. He – a very humble person – is mastermind behind turning an unknown product, popularly called Rooster sauce, into a household name.

DilipShanghvi, owner of Sun Pharmaceuticals, was recently in news for hiring his own boss - Israel Makov as Chairman. He refers this as his ability to identify a higher purpose, &pursue it in a selfl ess manner. He says that with the business becoming bigger & more complex, he needed someone to handle it, because he couldn’t - all this for the benefi t of the stakeholders. The stock has outperformed Sensex 5.3 times in the last decade - Rs.10000 invested in 2003 is worth Rs.2.4 lakh today.

With such examples of Perseverance around us, we in the Indian industry could always look out for more success. We need to bench mark areas and companies for our individual fi elds and pursue eff orts to excel in our fi eld.

As always, we need your input on the industry news, views and any observation about the industry around you. Your feedback will be useful to us to better inform our reader’s about tomorrow’s manufacturing solutions.

Till then, Happy Technology!

Manoj KabreMember - MART Editorial Advisory Board

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