GRIND MASTER Group Robotic Machining Flexible Solutions for Fettling, Milling, Grinding and Finishing
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1 GRIND MASTER Group Robotic Machining Flexible Solutions for Fettling, Milling, Grinding and Finishing Grind Master Pvt. Ltd
2 Grind Master Global Technology Leader Turnkey Solutions for Metal finishing NANOFINISH. ROBOFINISH. METALFINISH. DEBURR. SUPRAMATIC
3 Passion and Innovation Absolute Engineering 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
4 GM Approach to Specialized Machine Building Systematic Approach of Handling Project Turnkey Solutions Partnership to Transform Manufacturing Processes
5 Evolution of CNC Machining and Robotics 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 2000 Onwards Robotics Crossing over into Machining Applications not addressed by CNC/PLC Technology 1970s 2000s Evolution of Industrial Robot Technology for Handling, Welding Applications Limitations of CNC Technology Scalability Flexibility Complexity of Motion Cost
6 Robotic Machining Where??? Robotic Milling / Sculpting / Engraving Robotic Trimming / Cutting Robotic Grinding/Deflashing of Castings and Forgings Robotic Finishing and Polishing Robotic Deburring
7 Robotic Machining A Leap towards Next Generation Manufacturing 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!!!!!
8 Key Technologies and Management Approaches 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
9 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
10 Case Study : Robotic Sculpting Why? Complex Shapes Specific Examples : Sculpting Ashoka Pillar Statue 1600X1600X2300 mm 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
11 Case Study : Robotic Trimming 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 Specific Examples : Cylinder Block Limitations? Slower than Trimming Presses where applicable Cylinder Block Weight : ~ 15 kgs Cycle time : 75 Sec
12 Case Study : Robotic Ferrous Casting Grinding 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 Specific Examples : Hydraulic Housing Weight : ~ 60 kgs Cycle time : 5 minutes Limitations? Economical for Medium to Large Sized Castings made in volume production
13 Solve Quality Problems in Manual Grinding Scratch Marks Digging Marks Uneven Finish Uneven Fettling Incomplete Fettling
14 Robotic Grinding Quality Parameters Grinding Parting Lines, Core Prints Flush to base material to Within accuracy of 1mm for Small/Medium castings 1.5mm for Large Castings Before Fettling After Fettling
15 Robotic Auto Grinding - Economics 3.5 ROI Calculation Camshaft 5kg 55sec Hand Body Pump 12kg Hydraulic Housing 45kg 240sec India Mexico USA Cylinder Block 180kg Grindmaster Pvt. Ltd
16 Robotic Auto Grinding Foundry Design Grindmaster Pvt. Ltd
17 Case Study : Robotic Aluminum Casting Deflashing 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? Specific Examples : Cylinder Block Weight : ~ 15 kgs Cycle time : 70 Sec Limitations? Selection of Components/Processes for Economic Viability
18 Transforming Foundry and Human Lives Robotic Automation Solutions 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 Grindmaster Pvt. Ltd
19 Robotic Cutting Machine Model : RMT Series - With Tool in Robot High Speed Cutting/Sawing System for Complex Castings 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!!!! Power Sawing Head with PCD/Conventional Saws Total Machine Enclosure Safe and Healthy Work Environment Grind Master Machines Pvt. Ltd
20 RCP Series Standalone Machines Deflashing Processes Deburring Processes Parting Line Removal with Radial Compliant Milling Spindle Belt Grinding Processes Riser and Gate Leftovers Removal. Correct tooling with Belt Grinder for Access Milling Process Trimming Process Cutting Process Face Flash Removal with Axially Compliant Milling Spindle Heavy Flash Trimming with Solid Milling Spindle Gate and Riser Cutting with Power Sawing Heads Grind Master Machines Pvt. Ltd
21 Integrated Manufacturing System Turnkey Automated Casting Production PDC/GDC Machine Automation System from Casting to Finished Casting One STOP Turnkey Solution Advantages : 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 Dedicated High Volume Automotive Casting Production Typical Cycle times : sec Aligned with Casting Machine Grindmaster Pvt. Ltd
22 Robot Integrated Manufacturing System Case Study : Step Holders 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) Trimmed Casting (1 piece) Need new video Deflashed and Polished Casting Grindmaster Pvt. Ltd
23 Robot Integrated Manufacturing System Case Study : Step Holders Robot#3 Polishing Robot#2 Deburring Robot#1 Belt Grinding Gate Cutting Grindmaster Pvt. Ltd
24 Case Study : Robotic Finishing/Polishing Specific Examples : Piston Rods, Bend Tubes 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 Component - Bend Tubes Operation Belt Grinding and Buffing Cycle Time 72 Sec Complex Path Generation Technology Limitations? Economic Viability only for Specific Products
25 Case Study : Robotic Deburring 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 Specific Examples : Component - Crankshafts Operation Deburring Oil Holes, Keyway and Bolt Holes Cycle Time 72 Sec Limitations? Economic Viability for non Critical components
26 Tool Selection Tool Selection is Critical because Process Reliability Cycle Time Running Cost Tool Selection Depends on Process/Operation Type of Material Material Removal
27 Thank you Sameer Kelkar CEO Grind Master Pvt. Ltd
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Wagner Magnete GmbH & Co. KG Obere Straße 15 D-87751 Heimertingen Phone: +49 (0) 8335 980-0 Fax: +49 (0) 8335 980-270 www.wagner-magnete.de e-mail: info@wagner-magnete.de Technology Full of Attraction
CONTENTS TABLE OF. Introduction. Company Details. Organization Chart. Certificates & Insurances. Our Products. List of machineries and Equipment
TABLE OF CONTENTS Introduction... 01 Company Details... 02 Organization Chart... 04 Certificates & Insurances... 05 Our Products... 10 List of machineries and Equipment... 31 Other Companies of Group...