Welcome to IMTMA Technology Blog. Here you can browse through the training reports, press releases and articles of interest for machine tool industry and IMTMA Technology Centre.

Towards Zero Defects in Welding Applications

Seminar on

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

Training on

"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)

Training on

"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).

Feedback

"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)

Geometric Dimensioning and Tolerancing (GD&T) Certification by ASME

Geometric Dimensioning and Tolerancing (GD&T) Certification by ASME


Geometric Dimensioning and Tolerancing (GD&T) defines a set of symbols and rules to mention the dimensions and tolerances in a engineering drawing.


Why GD&T ?

No doubt, ultimate aim of any design is that, it should be manufactured in minimum cost and of course with optimum quality standards. GD&T enables Design team to critically review the design based on functional requirements and assembly considerations. Thus the design intent is brought forward with utmost clarity and conveyed all across the organisation. Team members from other functions including Engineering, Production, Quality, Assembly, etc.,interpret the drawing in the same manner with out any difference of opinion.

Advantages of GD&T ?

Reduction of manufacturing cost and lead time can be realised by proper application of GD&T. In the Globalised Manufacturing environment prevailing today, GD&T ensures seamless communication across industries, customers vs suppliers, etc.., enabling universal interchangeability.

ASME-GDTP Certification

The American Society of Mechanical Engineers (ASME) in recognition of the needs and benefits associated with standard qualifications for professionals using geometrical dimensioning and tolerancing and the ASME Y 14.5M standard established the Geometric Dimensioning and Tolerancing Professional (GDTP) certification programme. The programme provides the means to recognize proficiency in the understanding and application of the geometric dimensioning and tolerancing principles expressed in Y14.5.

There are two levels of certification. The first level, Technologist GDTP provides a measure of an individual's ability to understand drawings that have been prepared using the language of geometric dimensioning and tolerancing as defined in the Y14.5 Standard. The second level, Senior GDTP provides the additional objective measure of an individual's ability to select and apply geometric controls to drawings.

Indian Machine Tool Manufacturers' Association (IMTMA), as an authorized training provider of ASME has trained around 125 industry professionals since 2013 in GD&T preparatory courses for ASME GDTP certification. The training programme focuses on understanding the system of GD&T and the methods of applying it in real time design by using case studies, examples and exercises. The programme covers the philosophies of how, when and where to apply geometrics for producing quality parts. Unique hands-on sessions in measurement lab to practice with the application of GD&T rules using the functional gauges, conventional as well as state-of-the-art measuring systems such as CMM on various engineering parts and components are a part of the programme. On behalf of IMTMA, Mr. M. Krishnamoorthy, Director of IMTMA Technology Centre and an authorized training instructor with ASME imparts training for industry professionals. Mr. Krishnamoorthy had recently undergone training on Advanced Concepts in GD&T from ASME at Seattle, USA.

Course details at bit.ly/1O8H3Hw

Cost reduction and Quality enhancement through VA / VE

Training Programme on

Cost reduction and Quality enhancement through VA / VE

The value analysis/ value engineering is the foundation for success for any new product/ process being developed. It is also a useful tool to deal with post product release problems and process improvement innovations. The value engineering is used to create functional breakthroughs by targeting value mismatches during product, process and project design. In today's competitive world the organization need to become faster, better and cheaper to survive. The VA/VE helps the organization to place their product in the market with an edge against the competition. The value analysis approaches and techniques will help the persons involved to obtain a better answer to their problems that determine costs and quality, in competitive business. This difference can change the organization from being "Good" to being the "Winner".



Keeping this in view, Indian Machine Tool Manufacturers' Association (IMTMA) had organized a 2 day programme on Cost reduction and Quality enhancement through VA / VE on 3 and 4 May 2016 at IMTMA Technology Centre in Pune.



The training programme focused on :

  • Understanding concepts and approaches of value engineering and analysis
  • Use of Kano's model to determine customer perceptions
  • Types of value analysis and case studies
  • Value map and value creation
  • How to use value analysis
  • Orientation phase
  • Function analysis
  • Creative phase
  • Evaluation phase
  • Implementation
  • Cost reduction and quality enhancement
  • VE/ VA Exercises



The programme was conducted by Mr. Krishna Raghavendra Bhat, former Vice President - Manufacturing at L. G. Balakrishnan & Bros., Coimbatore. Mr. Bhat has over 35 years of experience in manufacturing engineering and plant operations. Delegates from NRB Bearings Ltd, Tata Steel Processing and Distribution, Tata Motors, Steer Engineering, Shalaka Shafts, Rotex Automation, Schrader Duncan, and Valeo India attended the training programme.