GRIND MASTER Group · Robotics Crossing over into Machining Applications not addressed by CNC/PLC...
Transcript of GRIND MASTER Group · Robotics Crossing over into Machining Applications not addressed by CNC/PLC...
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GRIND MASTER GroupRobotic Machining – Flexible Solutions for
Fettling, Milling, Grinding and Finishing
Grind Master – Global Technology Leader
Turnkey Solutions for Metal finishing
NANOFINISH. ROBOFINISH. METALFINISH. DEBURR. SUPRAMATIC
• Mix of Home Grown and Acquired Technology & Know How
• Widest Range of Metal Finishing Machinery in the World
• More than 100 Pioneering Concepts – Breakthrough Solutions
• DSIR Recognized R&D Unit
• 8% of Revenues and 10% of Manpower in R&D
• IP Bank with over 20 Registered Designs, 20 Patents Pending, 5
Trademarks
Committed to Develop Technology to Transform Manufacturing
Passion and InnovationAbsolute Engineering
GM – Approach to Specialized Machine BuildingSystematic Approach of Handling Project
Turnkey Solutions
Partnership to Transform Manufacturing Processes
1970s 2000s Evolution of CNC Technology for
Machining Process – Milling, Turning, Grinding etc
Evolution of PLC Technology and Specialized
Machines for specific Grinding/Finishing/Machining
Functions
Limitations of CNC Technology
• Scalability
• Flexibility
• Complexity of Motion
• Cost
1970s 2000s Evolution of Industrial Robot
Technology for Handling, Welding Applications
2000 Onwards
Robotics Crossing over into Machining
Applications not addressed by CNC/PLC
Technology
Evolution of CNC Machining and Robotics
• Robotic Milling / Sculpting / Engraving
• Robotic Trimming / Cutting
• Robotic Grinding/Deflashing of Castings and
Forgings
• Robotic Finishing and Polishing
• Robotic Deburring
Robotic Machining – Where???
A Transformation in Manufacturing Practices with DEEP Impact on :
• Productivity
• Consistent Quality
• Health and Safety
• Flexibility / Multitasking
• LEAPFROG FROM Industrie 2.0 into Industrie 4.0 !!!!!
Robotic MachiningA Leap towards Next Generation Manufacturing
Technology
• Process/Application Development
• TOOLS and FIXTURES
• Control and Programming Softwares
• Merging Automation and Machining
Technology
Management
• Focus on Turnkey Solutions
• Long Term Vision and Committment
• Knowledge Building
• Partnership Approach
Key Technologies and Management Approaches
Robotic Machining Methodology
Robot Moving Tools
• One/Multiple Tools mounted on
Robot Wrist
• Workpiece is Clamped on Fixture
•Suitable for Large Parts with Many
Varieties
Robot Moving Parts
• One/Multiple Tools Fixed in Cell
• Workpiece is moved by Robot
with Gripper
•Suitable for Small Parts made in
Dedicated lines
Why ? • Complex Shapes
• Multiple Materials such as
• Soft – Foam/Wood
• Medium – Aluminum/Bronze
• Hard – Marble/Granite/Sandstone
• Large Sizes – from 1m to 10m
How ?• Heavy Duty Robots with Machining Spindles
• 7 Axis Machining - Configured with Rotary
Tables or Linear Axis
• Offline Programming Software
Limitations ? • Accuracy Limitation 1-2mm
Case Study : Robotic Sculpting
Specific Examples : Sculpting Ashoka Pillar Statue –1600X1600X2300 mm
Why ? • Productivity Jump – 5X
• Complex Shapes with High Quality
• Better Health and Safety
How ?• Heavy Duty Robots with Machining Spindles
• Tools Selection including Cutting Saws and
Milling Cutters
• Adaptive Software
Limitations ?
• Slower than Trimming Presses where
applicable
Case Study : Robotic Trimming
Specific Examples : Cylinder Block
Cylinder Block
Weight : ~ 15 kgs
Cycle time : 75 Sec
Why ? • Productivity Jump 8X
• Complex Shapes with High Quality
• Better Health and Safety
How ?• Heavy Duty Robots with Grinding Spindles
• Tool Selection including Grinding Wheels
• Adaptive Grinding Software
Limitations ? • Economical for Medium to Large Sized
Castings made in volume production
Case Study : Robotic Ferrous Casting Grinding
Specific Examples : Hydraulic Housing
Weight : ~ 60 kgs
Cycle time : 5 minutes
Uneven Fettling
Incomplete Fettling
Uneven Finish
Scratch Marks Digging Marks
Solve Quality Problems in Manual Grinding
Grinding Parting Lines, Core Prints Flush to base material to Within
accuracy of
1mm for Small/Medium castings
1.5mm for Large Castings
Robotic Grinding
Quality Parameters
After FettlingBefore Fettling
Robotic Auto Grinding - Economics
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Camshaft 5kg 55sec Hand Body Pump 12kg Hydraulic Housing 45kg240sec
Cylinder Block 180kg
ROI Calculation
India Mexico USA
Robotic Auto Grinding – Foundry Design
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Why ? • Productivity Jump 3X
• Complex Shapes with High Quality
• Better Health and Safety
How ?• Robots with WIDE Variety of
Machining/Grinding/Deburring
Heads/Spindles
• Adaptive Techniques for Casting-Casting
Variations
• Specialized Tooling/Application
Development
• Standalone Machines or Integrated
Manufacturing Systems ?
Limitations ? • Selection of Components/Processes for
Economic Viability
Case Study : Robotic Aluminum Casting
Deflashing
Specific Examples :
Cylinder Block
Weight : ~ 15 kgs
Cycle time : 70 Sec
Transforming Foundry and Human Lives
Robotic Automation Solutions
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Standalone Machines
RCP and RMT Series
Robot Integrated Manufacturing
Systems RIMS Series
• RMT Series – Single Tool Systems
RMT Cutting Machine
RMT Deburring Machine
• RCP Series –
RCP Deflashing Machine Multi
Tool Systems
• Specialized Turnkey
Manufacturing Systems from
Casting to Finished Part
• Cutting/Trimming/Deflashing
Operations AND
• Additional Operations –
Quenching, Sensing, Knock Out,
Drilling
Robotic Cutting Machine
Model : RMT Series - With Tool in Robot
High Speed Cutting/Sawing System for Complex Castings
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Pvt. Ltd
Power Sawing Head with PCD/Conventional Saws
Total Machine Enclosure
Safe and Healthy Work Environment
• For Slicing Risers and Gates upto 100mm in
thickness
• Used as Universal Machine for Large Variety
of Components (maybe 6-7 variants)
• Complex parts where Trimming is not
possible
• Waste Material Disposal Systems
• Adaptive Cutting ROBOFINISH Software
• 20% Faster Than CNC Machining Methods !!!!
Deflashing Processes
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Pvt. Ltd
RCP Series Standalone Machines
Face Flash Removal with Axially
Compliant Milling Spindle Heavy Flash Trimming with
Solid Milling Spindle
Belt Grinding Processes
Parting Line
Removal with
Radial Compliant
Milling Spindle
Riser and Gate
Leftovers Removal.
Correct tooling
with Belt Grinder
for Access
Deburring Processes
Milling Process Trimming Process Cutting Process
Gate and Riser Cutting with
Power Sawing Heads
Integrated Manufacturing System
Turnkey Automated Casting Production
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Automation System from Casting to
Finished CastingAdvantages :
• Space Saving - Automation
along with Casting
Machinery
• Fully Automatic – no
human intervention
• Consistent High Quality
Production
Typical Automated
Operations :
• Sensing
• Overflow Breaking
• Drilling Holes
• Trimming / Cutting
• Deflashing
• Shot Blasting
Typical Cycle times : 60-120
sec – Aligned with Casting
Machine
PDC/GDC
Machine
One STOP
Turnkey
Solution
Dedicated High Volume
Automotive Casting Production
Robot Integrated Manufacturing System
Case Study : Step Holders
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Input – Loaded on Trimming Press
Output – Fully Finished on Conveyors
Cycle time : 60 sec for one pair of
castings – i.e. 30 sec/casting
Double Cavity Die Casting (2 pieces)
Need new video
Trimmed Casting (1 piece)
Deflashed and Polished Casting
Robot Integrated Manufacturing System
Case Study : Step Holders
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Robot#1
• Belt Grinding
• Gate Cutting
Robot#2
• Deburring
Robot#3
• Polishing
Why ? • Productivity Jump 2X
• Complex Shapes with High Quality
• Better Health and Safety
• Consumable Cost Reduction
How ?• Heavy Duty Robots with Finishing/Polishing
Tools such as Abrasive Belts and Buffing
Wheels
• Uniform Force Application Methodologies
• Process Development
• Complex Path Generation Technology
Limitations ? • Economic Viability only for Specific Products
Case Study : Robotic Finishing/Polishing
Specific Examples : Piston Rods, Bend Tubes
Component - Bend Tubes
Operation – Belt Grinding and BuffingCycle Time – 72 Sec
Why ? • Complete Deburring Mission critical Parts
• Productivity – 1.5-2X
• Deburring Inaccessible Areas
• Large Size Components
How ?• Robots with Deburring Tools
• Both Robot with Part and Robot with Tool
Configurations
• KEY Process Development – for Reliable
quality deburring
Limitations ?
• Economic Viability for non Critical
components
Case Study : Robotic Deburring
Specific Examples :Component - Crankshafts
Operation – Deburring Oil Holes, Keyway and Bolt HolesCycle Time – 72 Sec
Tool Selection
Tool Selection is Critical because
• Process Reliability
• Cycle Time
• Running Cost
Tool Selection Depends on
• Process/Operation
• Type of Material
• Material Removal
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Thank you
Sameer Kelkar
CEO