Project with Ace Designers, Bengaluru
1. Thermal Compensation Strategy for CNC Lathes
Thermal errors are those that cause a relative displacement between the workpiece and the tool on account of deformation or expansion of the machine elements due to an increase in their temperature. Relative movement between the various elements of the machine such as motors, bearings, ball screws causes heat to be generated at the contact zones and it is this heat that leads to the deformation of the machine elements. This thermal error contributes to more than 70% of the dimensional variations (about 50µm) originating from the machine tool. Such a large variation is not acceptable since the final dimensions are expected to be held within 10 µm, typically. This project aims to reduce the thermal error to 5 µm through an in-depth study of the pattern of deformation and then compensating for errors during operation. This will substantially reduce rejection costs. The technology can be applied to any turning machine to improve the accuracy of components produced.
Schematic of thermal compensation strategy
Measurement setup used
Project with Interface Design Associates, Mumbai
1. Servo-Drives for Machine Tool Applications
The global market for machine tool drives is dominated by Siemens, Fanuc and Mitsubishi. CNC machine tools use electric servo drives to control the spindle rotation and movements of the linear axes. The objective of this project is to develop a 5kW axis drive and 25 kW spindle drive for machine tool application with better speed and position control. These are high precision servo drives with high torque/speed capabilities and fast response. Such machine drives with robust control algorithm ensure precision in machining regardless of mechanical and electrical disturbances and communication between the Drive controller and the Main Machine Controller, in addition to improving the efficiency and serviceability. These drives can be incorporated in machine tools widely used in aerospace, defense, power generation, oil and gas and healthcare industries. The price of the developed drive is expected to be 20-30% lower than imported drives.
Developed Prototype of Servo-Drive
Servo-Drive Controller Architecture
Projects with Chennai Metco Pvt Ltd, Chennai
1. Direct Drive Abrasive Cut-off Machine
The indigenous development of high-power large-scale direct drive abrasive cutting machine by AMTDC is a new addition to the existing small-scale direct drive cutters in India. A high power, high quality fully automatic cutting machine suitable for 300 mm to 500 mm cut-off wheels with the capacity to cut solid sections up to 150 mm in diameter is developed successfully with the newest technologies for fast cutting and deformation-free specimen surfaces. As the spindle is directly driven by the motor, the entire motor power is available for cutting thus enhancing the cutting efficiency of the system by 40% over that compared to belt-driven spindles. The developed technology using higher stiffness spindle and flexible pin-type coupling ensures minimized deflection of spindle during cutting and vibration free generation of surfaces thereby reducing chatter and burn marks. This heavy duty, precisely manufactured machine offering efficient, versatile and high-quality cutting, is useful for cutting of samples from large sized castings and forgings such as engine blocks, wheel hubs, brake drums, etc. This abrasive cutter's large workspace and simple design also enables rapid sectioning of samples. The machine has huge market potential in automotive, aerospace, defense sectors and is required by several entities like CVRDE, BHEL, BARC, and other metallurgical labs. The price of the developed machine is expected to be 40% lower than imported machines.
CAD Model of Direct Drive Cutter
Developed Direct Drive Abrasive Cut-off Machine
2. Orbital Motion Abrasive Cutting Machine
Orbital motion abrasive cutting machine is the next generation cutting machine which provide solution to the problems like long cutting time, high wheel wear, thermal damages in work-piece, etc. associated with the traditional chop or traverse cutters. The technology of orbital motion mechanism is developed indigenously and then incorporated in the abrasive cutting machine to facilitate a very high performance cutting of defect free surfaces at a much-reduced cutting time. Orbital cutting works by combining the best characteristics of chop, oscillation, and transverse and increment cutters and able to cut samples quickly without compromising cut quality by minimizing blade contact time with orbital cutting. The in-house development of orbital mechanism is done by a detailed understanding and simulation of the kinematics of various mechanisms and thereafter rigorous calculations of area of contact, MRR, cutting force and power for feasibility of the mechanism. The developed machine is a floor standing automatic orbital saw cutter that performs cutting at reduced ‘wheel-workpiece area of contact’ and therefore mitigates burn marks. The contact arc of the wheel can be controlled dynamically via the feed speed. Unlike the traverse and increment cutter, no special programming is required as part size varies. The orbital abrasive cutting machine is widely used for metallurgical sample preparation. This machine, indigenously developed by AMTDC is built to cater to the needs of various sectors such as, aerospace, defense and nuclear industries. The price of the developed machine is expected to be 40% lower than imported machines.
CAD Model of Orbital Motion Mechanism
Developed Orbital Motion Abrasive Cut-off Machine
3. Automated Multi-Station Grinding and Polishing Machine
Designed and developed by AMTDC, the indigenous production of a fully automated multi-station grinder and polisher is set to replace the traditionally employed manual machines that are widely used in Indian academia and industrial metallurgical laboratories. This automatic machine, for its features like uniform application of load, correct positioning and holding of the samples, fixed time of polishing etc., is capable of completely automating the grinding and polishing aspects and thereby improves the quality, consistency and productivity of the metallographic inspection process. Four grinding/ polishing stations are installed in the machine’s sturdy aluminium housing. Touch-screen-controls facilitate up to 10 different operations to be sequenced for a particular application. The various options include pre-grinding, grinding and polishing as well as ultrasonic cleaning and drying using warm-air dryer with timer. Fully covered, automated grinding and polishing machine automatically proceeds from one step to the next, eliminating the manual, time-consuming task of cleaning, re-fixing of sample, etc. between steps. 5-level foil-stacker and automated foil changing mechanism are in-built in the system. This fully automated machine has huge potential to cater to the needs of various sectors like, Nuclear, Aerospace, Automotive etc. The cost of this indigenous developed machine is expected to be 20-30% lower than the imported machines.
CAD Model of Automated Grinder & Polisher
Projects with Jyoti CNC Automation Ltd, Rajkot
1. 5-Axes CNC Multi-Tasking Machine
The development of a next-generation sophisticated 5-Axis Multi-Tasking Machine indigenously in India in itself is a stepping stone in the path of re-forming Indian manufacturing scenario in terms of making next generation machine tools. The machine, MTX 300, at par with its international counterparts, is capable of producing air craft landing gears, turbine impeller blades, gun barrels, complex shaped components used in oil and gas industry. Uniqueness of this machine lies in its capability of performing multiple machining operations such as turning, milling, grooving, gear cutting/ hobbing, boring, drilling, reaming, fly cutting, grinding and threading etc., in a single set up maintaining a high precision finish. The machine also ensures a reduction in set up time and thereby enhances productivity. This technology is a niche machine tool and so far, is being imported at a huge cost of around Rs.8 to 10 crores. With a domestic demand of about 20 machines per year, the MTX 300 machine will not only save huge foreign exchange but also benefit many sectors like aerospace, defence, power generation, oil and gas as well as healthcare sectors by reducing their cost of production, as the cost of MTX 300 can be availed at around 30% lower price than that of its imported variants.
Developed 5 Axes Multi-tasking Machine
Inner view of Multi-tasking Machine
Inner view of Multi-tasking Machine
2. Development of 5 axis CNC Universal Machining Centre
The 5 axis CNC Universal Machining Centre is a Mother Machine having 5-axis simultaneous machining capability and facility to machine large prismatic components in a single setup. These machines are used to produce components with complicated profiles and design features along different orientations, which otherwise would require multiple machines. The machine is being developed with key enabling technologies such as high stiffness rotary hydrostatic table, high precision gear drive technology and error compensation strategies. These key indigenous developments will ensure 5-axis machining capability with high precision and vastly improves productivity and precision by reducing machining cycle times and setup errors.
The major user sectors are aerospace, defense, power generation, oil and gas, healthcare, etc. The machine is enquired by several agencies like CVRDE, BHEL, BARC, etc.
The cost of the machine is expected to be 15% lower than a similar imported machine.
CAD Schematic of MX machine
CAD Schematic of Hydrostatic Rotary Table
Projects with MTAB, Chennai
1. Low-Cost Machine Tending Robot
The AMTDC-Centre of Excellence has timely conceptualized the in-house development of low-cost machine tending robots suitable for the Indian manufacturing industries. The design of 6-axes articulated robots of two variants of 6 kg and 10 Kg payloads are made successfully, with the help of detailed analysis of the static and dynamic behavior of the structure. The influence of link length on the work volume of the manipulator has been studied in detail and optimized. Based on this optimized link length, the torque requirements are estimated. The robot-design is finalized by the iterative fine tuning of controlling parameters to achieve the desired accuracies. As developed, the 6 Kg payload robot is a compact, small robot with high speed and performance and comes with the advanced 6-axis controller. The robot can be mounted on the floor, or at an angle, and can perform a variety of applications ranging from machine tending, material handling, assembly to picking and packaging. The six articulated axes are driven by electric servo drives that allow optimized programming of the operation. Flexibility is maximized through a wider work area and larger reach. The robotic arm having a modular construction and standard-rich feature is capable of bringing high speed to the production line. The robot being developed indigenously will be available at around 20-30% lower cost than similar imported products.
Low-cost Machine Tending Robot
2. Ultra-Precision Micro-Machining Centre
Ultra-Precision Micro-machining Centre is a CNC-controlled 5-axes machining centre that is specially developed for the demands of micro-machining in numerous industries. While most Machine shops offer 3 or 4-axis milling services, AMTDC-CoE is confident about advanced 5-axes micro-machining capabilities. In combination with the rotary and swiveling unit, the efficient computer numerical control (CNC) enables the machining of 2.5D, 3D and freeform surfaces by the use of up to 5 simultaneous axes of motion. According to the selection of ‘tools’ and the process parameters, a wide variety of materials can be machined to the highest precision of 0-1 micron. The spindle speed can reach up to 50,000 rpm, which allows tools in the range of 250 micron to 8 mm to be used. The base of the unit is made of cast-iron structure filled with epoxy concrete, which guarantees the highest long-term thermal and mechanical stability and effectively eliminates vibration. Together with high precision of the individual axes, a high precision is ensured for the entire unit. The machine finds huge application in manufacture of dental and bone implants; instrumentation, electronics, jewelry manufacturing industry and precision Aerospace industry components. This vertical ultra-precision machining centre, being developed under this project is designed to match the performance of similar imported machines at a cost about one-third of the imported variants.
CAD Model of Micro-Machining Centre
Developed Ultra-precision Micro-machining Centre
Projects with Micromatic Grinding Technologies, Bengaluru
1. Hydrostatic Guideways and Spindles for Machine Tools
AMTDC-Centre of Excellence has successfully developed technologies related to Hydrostatic Systems (Guideways and Spindles) that are essential to build high precision machines in the machine tool industry. Hydrostatic systems contain a layer of pressurized oil between the moving surfaces which provide a higher stiffness and damping compared to physical bearing systems. This is essential for applications like high speed CBN grinding, ceramic grinding, super finishing applications, high speed internal grinding of small precision parts, etc. The developed hydrostatic components can be used in manufacturing industry covering a variety of sectors ranging from defense, aerospace, automotive, textile and energy sectors. The technology of hydrostatic guideways, spindle and flow controller were so far closely held by a few companies in the world namely Hyprostatik GmbH, Zollern GmbH, JTEKT and Schaeffler INA. With this in-house development, it is now possible to design and manufacture these critical elements in India, thus reducing import dependence and bringing down the cost of these elements.
Developed Flow Controller
CAD Model of Test Rig
2. Automation of Grinding process Intelligence
We report an indigenous development of a process monitoring system for achieving a fully automated grinding operation. Unlike other machining processes, even a small variation in the grinding input has a large impact on the performance of the grinding. Therefore, developing a process monitoring system which is self-learning from the input variations and from their effects on output has been a challenging task. A detailed study of the system over several cycles led to the understanding of the relationships between the parameters. The grinding machine is equipped with sensors which feed the information about the process parameters continuously back to the control system which automatically learns the pattern using Machine Learning Techniques. This learning or ‘Acquired Intelligence’ by the system is then used to control the grinding process to get the desired output in terms of surface finish, cycle time, dimensional tolerance etc. This technology is an important step towards ‘Smart Manufacturing’ and Industry 4.0. The monitoring system and intelligence are in-built into the grinding machines and can be used in any manufacturing industry covering a variety of sectors ranging from defense, aerospace, automotive, textile and energy sectors. The implementation of this system will bring productivity gains and greater precision to grinding operations in industries.
What is AGI?