Training Programme on
Gear Manufacturing Processes
Gear manufacturing is a fairly complex metal cutting process and forms an integral part of many industrial products. Gears and Gear drives are one of the key components of all kinds of vehicles, machine tools, aircrafts, household appliances as well as a broad variety of industrial equipments. Proper understanding about the various Gear manufacturing processes and controlling parameters is essential in order to meet the growing demands for better productivity and quality of gears.
Keeping this in view Indian Machine Tool Manufacturers' Association (IMTMA) organized a 3 day programme on Gear Manufacturing Processes from 18 to 20 April 2016 at IMTMA Technology Centre in Bangalore.
The programme dealt with the following:
- Introduction and overview of Gear terminology
- Process flow of Gear manufacturing
- Gear blank preparation
- Gear hobbing - process parameters; work set up and Hob set up methods; process optimization and productivity improvement
- High speed gear Hobbing with case studies
- Gear shaping - Working principle; process parameters; work set up and cutter set up methods
- Shaping of internal and external gears; Industry application examples
- Gear shaving – Working principle; advantages and limitation; industry application examples; process capability in terms of gear quality and surface finish
- Cutting tools for hobbing, shaping and shaving
- Gear heat treatment
- Gear grinding - Need for Gear grinding; advantages and limitation; industry application examples
- Types of grinding machines
- Gear Grinding - process parameters; work set up and wheel set up methods; process optimization
- Gear Finishing - bore, face grinding, coatings
The programme was conducted by Mr. Ved Parkash, former Head - Quality & TQM at Ashok Leyland and Head - Quality at Hero Honda Motors and industry experts from Liebherr Machine Tools & LMT India. Delegates from HMT Machine Tools, Sphoorti Machine Tools, S & T Engineers, Shakthi Tech Manufacturing, RACL Geartech, Sanjeev Auto Parts Manufacturers, Amalgamations Repco, MSC Software Corporation India, Bharat Forge, Renault Nissan Technology and Business Centre India, and Hillman Gear attended the training programme.
Training Programme on
Inspection, Testing & Calibration of CNC Machine Tools
CNC Machines are deployed in diverse range of manufacturing industries. Users need to test Machine tools at the time of purchase and also periodically during its use and operation. Evaluation needs to be done in accordance with international standards & procedures which can be broadly categorized into three areas, mainly geometrical alignment test, functional and machine accuracy capabilities. Conventional testing methods of machine tools are limited essentially to static measurement of geometrical machine structures under 'no load' conditions. However, the performance of a machine tool is evaluated in terms of compliance to tolerances, surface finish of components and so on. These are essentially determined by static and working accuracy of machine movements. A proper knowledge of static and working test, positioning and repeatability test, cutting trials on standard work piece will help users in assessing the capability of the machine.
Machine tool calibration is rapidly becoming an essential part of the manufacturing process with customers demanding higher accuracy from machine tools for handling precision parts with tighter tolerances. Machine tools are subject to positioning errors which might increase over a period of time due to natural wear and tear or failing parts or worn out moving parts. Periodic calibration helps identify potential problems with machine tools, such as bad bearings, faulty servos, slip-stick conditions, and so on. Hence an early detection enables to schedule preventive maintenance and avoid unexpected downtime, especially during critical production runs. In other words, it is a 'health-check' or 'condition-monitoring' of any machine tool. Thus calibration of machine tools becomes an essential part of predictive maintenance programme in companies to achieve "Doing it right the first time".
Indian Machine Tool Manufacturers' Association (IMTMA) organised a 2 day programme on Inspection, Testing & Calibration of CNC Machine Tools on 27 - 28 April 2016 at IMTMA Technology Centre in Bangalore. The program had focused on machine tool testing standards-dynamic measurements, static measurements, thermal, analysis, accuracy, etc. Machine tool calibrations like errors in machine tools, Linear and rotary calibration methods, ball bar measurements, analysis of calibration results, preventive maintenance trends, volumetric compensation, etc., were also covered.
Delegates went through a Live Demo of Vibration Analysis (Frequency Response Function), Static Analysis / Power Efficiency, demonstration of Laser Calibration & Ball Bar measurement. The training programme saw participation of delegates from Advanced Machine Tool Testing Facility, Brakes India, DRDL, DVB Design + Engineering, International Aerospace Manufacturing, KEMS Auto Components, Kirloskar Oil Engines, Larsen & Toubro Limited, S&T Engineers, Tata Motors, and WEG Industries (India).
The programme was conducted by industry experts from Renishaw India. The faculty shared their rich experience in testing and calibration of different types of CNC machine tools used in the manufacturing industry.
Towards Zero Defects in Welding Applications
23 – 24 June 2016
Today, welding has acquired the status of a top class manufacturing process and is required by almost every sector of industrial activity, everywhere in the world. Means of transport whether it is road, rail, air or water - all of them necessarily depend on welding technology for their manufacturing. The same holds true for consumer durables and white goods industry. The quality needs of various welded sheet metal and other components are vital for the producers to reach the A-class level of competence and consistency of the integrated final product.
The modern fast and automated manufacturing technology required in these mass-manufacturing industries, involves welding processes such as resistance spot, seam, projection and butt welding, MIG/MAG welding, FCAW, laser cutting and welding, friction welding and friction stir welding. In spite of the high end technology the quality and inconsistency arising due to distortion and welding defects are still the major issues every welding engineer faces.
Keeping this in view, Indian Machine Tool Manufacturers' Association (IMTMA) organized a 2 day programme on "Towards Zero Defects in Welding Applications" on 23 - 24 June 2016 at IMTMA Technology Centre in Pune. The objective of the seminar was to help the practicing engineers in developing full technical understanding of the subject and solve manufacturing issues related to welding processes.
The seminar primarily focused on giving delegates:
- A perspective on what is Zero Defects in Welding – Man, Machine, and Method.
- Taking into account the needs of the materials for generic process of welding - the Science of Welding.
- Important material properties which directly interact with these processes - they dictate the process.
- Overview of welding technology to logically comprehend given processes.
- Welding arc as a heating source – know the physics for correct application.
- Evolution of various arc welding processes.
- Snap shot of various Arc Processes – SMAW, SAW, ESW, GTA, and PLASMA.
- MIG/MAG_CO2 Process : Equipment, Power Sources, Controls, and Productivity.
- Fitment issues in MIG / MAG, Defects, and Distortion in Arc Welding.
- The six Resistance Welding Processes: Commonalities & Basics.
- Resistance Spot, Seam and Sheet Projection Welding Process.
- Solid Projection, Upset Butt and Flash Butt Welding Processes.
- Friction and Friction Stir Welding.
- Laser Processing : Cutting, Heat Treating and Welding.
- Electron Beam, Ultrasonic, CD Stud and Arc Stud processes.
- Other solid state welding processes.
- Safety, Maintenance, Productivity in Welding.
The seminar was conducted by industry consultant Mr. Vijay Agwan. Delegates from AAM India, BBM Acoustic, Daimler India, Rabwin, Reliable Autotech, Siemens & Weldcon Services.
"Machine Tool Design - MECHANICAL"
An 8-week training programme on “Machine Tool Design –Mechanical” was conducted at the IMTMA Training Centre, BIEC Bangalore from April 8-May 28, 2016. As many as 17 delegates, including 3 from Kenya participated in the training programme.
Training sessions were conducted by more than 20 industry experts that included various case studies for the benefit of the delegates, which they can imply in future. It also included industrial visits to companies like Ace Designers and Ace Foundry, which helped the delegates to get a live demonstrations.
The course included introduction to design fundamentals, with focus on machine tool design and a complete design of CNC Turning center carried out from concept to finish. Pre-process activities like design input, conceptualization, machine specification, 3D modeling of parts, sub-assemblies and final assembly using popular design CAD tools and preparing the final manufacturing drawings in par with industry standards, Design for Accuracy, Design for Manufacturing and Design for Assembly was addressed during the course. The entire training session and covered all aspects of machine tool design aspects.
Presentations included various topics like Introduction to CNC machine tools, Training on Design Softwares, Design of Hydraulic Power Pack for Machine Tools, Limits Fits & Tolerances, Design Spindle, Axes, Slides, Machine Structure & Analysis, Subsystem Lubrication and Coolant Systems that were accompanied by case studies. The training programme was interactive and participants designed a complete CNC machine from the scratch.
Within the training programme, a sub-module, "Design of Hydraulic Power pack for Machine Tool," was scheduled on April 30, which was open for Industry participation. The event saw participation of 8 nominations across Industries and as individual.
The program was well accepted by all the participants and their feedbacks indicated at a lot of value addition to their future.
"Design of Fixture – Specialization"
(Machining / Welding / Assembly and Inspection Fixtures)
A six-day course on 'Design of Fixture - Specialization' was conducted as an introduction to Fixture Design basics to final design was from May 16-21 at Pune. Design of fixture is a key effective utilization of machine tools. Basics of fixture design if not implemented correctly results in poor productivity and quality problems. Set-up time and cycle time reduction, increased accuracy on components, deskilling the job setting operation are the obvious advantages of a good fixture. Competence in right fixture differentiates excellent organizations.
Fixture Design for Crank Case of Two Wheeler
This event incorporated not just Machining Fixture but also Welding / Assembly and Inspection Fixture.
The program included an introduction to fixture by Mr. S.K. Gupta, Retd. Tata Motors design expert, on the first day followed by training on SOLIDWORKS, and real time fixture of auto components.
On 3rd and 4th day, Mr. Deepak Kumar Ravilla, Manager, Head of Fixture division, Kennametal, discussed complete process of designing a fixture from concept to finish. The 5th day witnessed Mr. Raghupati Karanth and Mr. Abhay P Kulkarni from TATA Motors talking on various case studies applied in various industries and a key point of applying at the BIW stations.
On the final day, Mr. Avinash (Head Pune Tech Centre - IMTMA), with 33 years of experience at TATA Motors, touched upon topics like, Fixture for Machining of Very Large Part, Handling and Transportation of parts, Manual drilling, piercing, nibbling, cutting, de-burring, grinding, painting of parts, Inspection of parts on CMM, Laser Welding /Roll forming / Roll Hemming of parts, etc.
The program concluded with half-a-day visit to TATA Motors, Pune for live demonstration of the implementations process of Fixturing learnt during the training.
A total of 18 candidates including one candidate from Dubai, who was nominated by industries and Individual, participated in the training program. Other delegates were from companies like Dover, John Deere, Jyoti CNC Automation, Martiaen Engineering, Setco Automotive, Spicer, Steel-Smit and Lucy Switchgear FZE (Dubai).
"This training was good and I will implement learnings in the shop floor of my company"
- Bhaumik J, Lava Cast
"We were delighted to have an expert faculty speaking on welding fixture designing and a visit to the Tata motors. The plant visit gave more insights into the day-to-day operations of the industry."
- Perumal Loganathan, Lucy Electric, Dubai (Nominator - Manager - Manufacturing Engineering)