Training Programme on
Product Validation through FEA / FEM
Industries are faced with challenges on product design and development, including demands on lower cost of ownership by customers, superior performance and faster time to market and erosion in profit margins. Enhancing product value in terms of functionality has never been more important. The product development starts with conceptual design and goes through various stages viz. detailed design, prototype manufacturing, testing, modification, production and introduction in to market.
From the stage of detailed design to releasing the product in market consumes most of the time in product development. Ultimately the product is proven in the field when it is subjected to the operational conditions. Product testing can simulate many site conditions but this is highly time consuming and costly. The advances in the finite element analysis (FEA) plays a big role in this stage. The FEA can help validation of the product by simulating loading and site conditions. If done in proper manner, simulation can reduce the product development time and cost many fold. Thus FEA has become the mainstay of engineering design and development to accelerate new product development. Practical methods to implement FEA as a part of the design validation process needs emphasis with a proven approach addressing real-world situations. Indian Machine Tool Manufacturers’ Association (IMTMA) organized a 2 days programme on Product Validation through FEA/FEM on 16 and 17 June at IMTMA Technology Centre in Bangalore. The programme focused on :
- Domains of application for FEA
- Benefits of FEA in Product Design & Development
- Basic Concepts in FEA
- Design Validation Process for robust product design & development
- Step by Step method for performing Linear Static FEA
- Validation procedures & Convergence check for FEA - Errors in FEA
- Demonstration using Case Studies
- Life Prediction – Methods for assured performance
- Correlation to Field / Measured Data
- Real-World Case Studies on Design Validation
The programme was conducted by Mr. D B Kulkarni, former Chief of Technology, BFL, Bangalore. He is a Fellow of the Institution of Engineers, India and has over 32 years of industrial experience.
Delegates from ABI Showatech India, Advanced Machine Tool Testing Facility, Bharat Fritz Werner, Chennai Metco, Defence Research & Development Organization, Electrical Research and Development Association, Ferromatik Milacron India, Jyoti CNC Automation, Roots Multiclean, Siemens Technology and Services, and Toyota Kirloskar Auto Parts attended the training programme.
The programme was highly interactive and participants could raise questions and solicit feedback from the expert faculty.
Design of Gauges
When a part is manufactured, it must be measured to ascertain that it is of the right dimensions for fulfilling the purpose for which it is intended. Gauges are one of the commonly used inspection tools in production shops for quick checking and validation of the dimensions of manufactured parts. Thus, gauging has become an integral part of any machining process and gauges help in ensuring required degree of interchangeability among the millions of parts manufactured worldwide. The type and the design of gauges depend on the application, volume of production and precision levels required.
In addition to simple plug and ring gauges, functional gauges or receiver gauges are being used to check location of different features with respect to the datum reference frame, as required. Functional gauges are a very effective way to gauge products during or after manufacturing and they ensure smooth assembly and operation. In all the cases, design of gauges is of prime importance because, if the gauge is designed incorrectly, it will be built, but never get used. The prime considerations for gauge design include part tolerances, gauge material, simplicity of use, manufacturability, etc.
Indian Machine Tool Manufacturers' Association (IMTMA) organized a 2 day seminar on Design of Gauges on 9 and 10 June 2016 at IMTMA Technology Centre in Bangalore. The programme provided delegates an in depth understanding of the types of gauges, principles of gauge design, design of plug and ring gauges, design of functional gauges, selection of materials and manufacturing of gauges.
The seminar primarily focused on providing participants about an :
- Overview of attribute gauging system
- Types of gauges
- Gauge design Criteria - Taylor's principle; Gauge maker's tolerances
- Guidelines for fixing tolerances for design of gauges
- Selection of gauge materials
- Design of limit plug and gap gauges
- Design of functional gauges for checking the positional tolerances with M modifier
- Design of gauges to check angular features
- Introduction to design of thread gauges and gauge calibration
- Exercises in design of different types of gauges
The seminar was conducted by industry experts from Nettur Technical Training Foundation, Bangalore. Delegates from Abi Showatech India, Bonfiglioli Transmissions, Brakes India, Forbes Marshall, Honda Motorcycle & Scooter India, Kennametal India, Streparava India, Wabco India, Weg Industries India, and Wipro Infrastructure Engineering attended the seminar.
Finishing School in Production Engineering
6 June - 2 July, Pune
Indian Machine Tool Manufacturers' Association (IMTMA) organized the 2nd batch of the "Finishing School in Production Engineering" from 6 June to 2 July 2016 at IMTMA Technology Centre in Pune.
IMTMA's "Finishing School in Production Engineering" focused on all the practical aspects of modern machining - from reading an engineering drawing through measurements and quality control
- including machining processes, CNC programming and operation, process planning, tool materials, selection of cutting tools and optimizing machining parameters, limits, fits and tolerances, GD & T and selection of measuring instruments. In addition to the technical inputs, emphasis was given to develop soft skills as necessary for manufacturing industries.
The course was conducted by industry experts from IMTMA Technology Centre, Sandvik Asia, Esprit, and Master Fluids. Industry visit to PMT Machines Ltd. in Pune was organized for the participants to get ‘live’ experience of the actual production environment.
The workshop was attended by 11 delegates. Six delegates were fresh engineers. Rest of the delegates were final year Mechanical engineering students.
|Hands on Measuring Practice||Hands-on session|
|Session on Esprit – CAM software||Hands-on session|
Group photo at Sandvik Asia, Pune
The programme concluded on 2 July with live interaction from all the candidates. Most of them expressed as below :
- "The course gave me a very good experience on the industrial scenario. The hands-on training on CNC machines, metal cutting, tool selection, and industrial practices, etc. have prepared me for the industry. Students will not get this type of learning experience anywhere else. I would like to thank IMTMA for conducting this course and training us.
– Ms. Jidsy Stephenson
- "The greatest thing I learnt was hands-on experience of working with CNC machines. IMTMA exceeded my expectations greatly in this. The training I underwent has given me immense confidence to operate machines."
- Mr. Anand Dhariya
- "IMTMA is an indispensable platform for a beforehand glimpse into manufacturing industries and hands-on training."
– Mr. Rishabh Maiti
- "It was a wonderful learning experience, something designed in a very practical and different way."
– Mr. Mustafa Mulla
Design of Spindle - Specialization
A six - day course on 'Design of Spindle - Specialization' was conducted in Gurgaon from June 20 - 25. It was structured considering Machine tool spindle as the most sophisticated member in machine tool and which plays a vital role for better performance, higher efficiency and accuracy. Design of spindle being a very important and a critical activity of machine tool design process.
The program started with an introduction to the spindle by Mr. H V Rajashekara, Sr. Director - Design Institute, with over 27 years of experience at HMT and Johnson Electric. Topics delivered by him were Introduction to CNC Machine Tool Spindles, Spindle Specification & Design Calculation, 2D Conceptual Spindle Layout, and Sketching of Assembly & Parts.
On the third day participants were trained in SOLIDWORKS by Mr. Rahul Vylen, on modules like part modelling and assembly and the on the fourth day, delegates developed a real time spindle for a particular application. Topics on Spindle stiffness calculation and bearing life calculation were also discussed on first principle basis.
On the fifth day, Mr. G Baskhar, carried the project further in terms of pulley and key design along with calculations. On the final day Mr. M A Khallaq, Managing partner M/s XL CNC and an ex-HMT as a Dy general Manager, severed the R & D dept, discussed Design of Boring and Grinding Spindles.
Turning centre Spindle – A25
A total of 8 candidates attended the from various industries viz. Bansal Brothers, Bestek Engineering Pvt Ltd, Jyoti CNC Automation, Macht Technologies Pvt Ltd, Micromatic Grinding Technologies Ltd., Raj Hans Pressing Pvt Ltd, Rimaco Machines, and Turntro Mechanical Works
- I enjoyed all my six days here and learnt a lot. Special thanks to Mr. M.A Khallaq for clearing all doubts regarding our queries, all the faculty members were outstanding specially Mr. Rahul Vylen
- Mr. Karun Kumar
- The course was very good and effective. I request IMTMA to include and start elaborate courses on Gear and CAM Manufacturing
- Mr. Harpreet Singh
Training Programme on
Basics of Programming & Operation of CNC Machining Centres
CNC machines have become the order of the day in every manufacturing industry. These applications are widespread in mass production units, batch production as well as in tool room industries. Thorough understanding of programming and operation of CNC machines is a must in order to realize maximum output.
Keeping this in view, Indian Machine Tool Manufacturers' Association (IMTMA) organized a 5 day programme on Basics of Programming and Operation of CNC Machining Centres from 23 - 27 May 2016 at IMTMA Technology Centre in Pune.
The programme primarily focussed on:
- Elements and different modes of CNC machining centre.
- G and M codes applicable to CNC machining centre.
- Structure of a CNC programme for CNC machining centre.
- Work and Tool set up; cutter radius compensation.
- Dimensional control; correction of wear offset for achieving tolerances.
- Selection of tools and machining parameters.
- CAM programming – Usage and advantages.
- Autonomous maintenance principles - Procedure and check points.
- Hands-on practice in CNC vertical machining centre.
The training programme was conducted by industry experts from IMTMA Technology Centre. Delegates from John Deere and Kennametal India attended the programme.