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Compelling Changes

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Compelling Changes

High-speed machining has gained a firm footing in India, with policy support and market expansion inducing technological advances in this arena.

By Mitalee Kurdekar

When the first Industrial Revolution took place all those years ago, ‘economies of large scale’ was the obvious benefit that everyone was looking for. Years later, the same logic applies when one looks at the phenomenon of High-speed Machining (HSM) that has impacted modern-day machining requirements. These economies not only come directly from costs saved in large-size batch manufacturing, but also through productivity improvements and waste reduction, in addition to improved quality and longevity of machine tools used for such operations. In essence, HSM can well be termed the product of the 21st century industrial revolution. In simplest terms, high-speed machining allows machining of materials at 4-5 times of the conventional speed without compromising on quality or material removal rate.

Users are finding HSM centres useful, especially for large-scale batch processing.

As a keen user of such machines, M S Shankar, VP, manufacturing operations, centre of excellence for engine manufacturing, VE Commercial Vehicles, describes the benefits of HSM. He says, “HSM technology helps reduce the overall number of equipment needed to deliver the total volume while retaining the flexibility. On the HSM, one can quickly leverage innovations in cutting tool material and geometries. Improved rigidity and higher power available in contemporary high-speed machines enable faster metal removal.”
He adds, “The advantages of HSM include the requirement of a relatively lesser foot print, thereby enabling savings on overall shop floor size, provision of a consistent quality, savings through lower setup change costs and, most

The NF series by Grind Master.

importantly, allowing flexibility.”

Here To Stay
With its obvious economic advantages, HSM makes a compelling and convincing case for itself, and is therefore seen to be preferred when it comes to the machining requirements of the manufacturing sector. Given the focus on manufacturing put forth by Indian policymakers with programmes like Make in India and the efforts towards making India a regional hub for manufacturing, HSM spells magic for Indian manufacturers that wish to reach challenging targets. To make Indian businesses competitive, suppliers have to embrace HSM techniques and master these technologies. On its part, the Indian Government is working on requisite technology adaptations and then successfully embedding them in the Indian manufacturing sector. Creating world-class suppliers, therefore, is the most vital challenge. Further, the revival and sustaining of the Indian consumer’s demand also remains a key challenge. However, most industry players in the Indian machine tool industry, are positive about these changes.
As Terrence Miranda, MD, Phillips Machine Tools, states, “Manufacturing competencies are growing globally, driven by the latest CNC machining technology with machines, tooling, work holding and CAM all playing significant roles in this growth. HSM has already become pretty much a standard feature in most applications, including but not limited to moulds, aerospace, medical, etc. We see the machine tool market growing consistently in India and technologies such as 5-axis, high speed-machining, auto loading, additive manufacturing etc. will drive this growth.”
Putting things in perspective, Mohini Kelkar, MD, Grind Master Machines, confesses, “The manufacturing sector is undergoing very fast transformations due to several disruptive technologies. The 4th Industrial Revolution is one of them. Grind Master solutions are well equipped to thrive in an IOT-enabled world. Industry 4.0 concepts have been implemented in Grind Master products since 2015. Electric Vehicles (EV) is another disruptive technology set to change automotive manufacturing, especially with regard to the automotive powertrain. Grind Master is developing technologies for various applications including superfinishing of EV parts as well as finishing of EV castings. Grind Master is looking to broaden the market spectrum by establishing itself in European and American markets in the next five years.”

Technology Fit
Of course, the biggest improvement in HSM – over conventional methods of machining – has to be the speed in itself. In order to avoid clatter generation and excessive noise seen in conventional methods, HSM tec

n partnership with EOS Germany, Phillips has introduced additive manufacturing technology such as the EOS M 400 in India.

hniques use small-cut depths at very high-spindle speeds. In comparison, conventional methods meant machine feeds had to be at slow speeds, thus requiring more machining time. With HSM, it is possible to achieve this at 4-5 times greater speed, thus saving valuable resources. One cannot ignore the contributory research that has gone into the development of machining materials like composite materials, heat-resistant SS alloys, compact graphites and special aluminium alloys that require HSM techniques, but also make the use of HSM possible over conventional methods.
HSM techniques require the aid of computer programming to achieve the kind of precision and efficiency desired in the machining operation, together with the CNC machine that can run such programmes as well as special tools that enable multi-axis operations at a high-speed without damaging the work piece or the tool itself. HSM tooling is special because of the use of what is termed as ‘trocordial path’ generation. In this, the tool converts a straight line path into a series of circular paths, which is possible with the use of smaller tools and at smaller depths to achieve HSM specifications or set parameters. Cooling requirements in such cases are also reduced, thereby reducing costs and wastages.
As a result, HSM has become an accepted standard method for machining given the benefits of quality, productivity and user-friendly process. Kelkar suggests, “Modern foundries demand more flexible and faster grinding and fettling solutions using robotics & automation. Majority of foundries are upgrading their fettling setup from a traditional setup consisting of manual processes or semiautomatic processes, to robotic automation. Robotics in the foundry can simplify various processes like fettling, deflashing & grinding, which were traditionally done manually or using semi-automatic tools, are now successfully shifting towards robotic automation. Robotic automation in the foundry will enhance quality and transform human lives along with it.” She further explains, “Robotic machining is a 7-axis system, which consists of a 6-axis robot and an additional servo axis. This provides high-accuracy and reliability.”
Outlining their contribution with the NANOFINISH range, Kelkar proclaims, “Grind Master Machines is a homegrown technology in the field of metal surface finishing. Grind Master is a trusted partner for many reputed automotive and auto OEM suppliers in the world, providing a total and reliable solution for metal surface finishing.”

Overseas Influence
The Indian machine tools industry has experienced dependence on imports as its domestic supply has always fallen short of demand. Also, the research and development in homegrown technologies with and without the support of global players has been a recent phenomenon. While this picture could change in the coming years given the Governmental support for technology tie-ups, embedding such technologies and creating domestic & export demand for industry products, the reliance on overseas support for HSM technologies – at least for critical processes – would continue for some time.
In this regard, Miranda says, “Metal cutting technologies: milling, turning and grinding, and combining these together in one or more multi-tasking machines has been our focus with our product offerings from HAAS, HERMLE, HAAS MULTIGRIND, TSUGAMI, LK, PALMARY etc., focusing on 4- and 5-axis, turn mill, mill turn and mill turn grind technologies, with a focus on path-leading work holding, tool holding and job loading using pallet changers, auto parts loaders and robotic loading solutions. Global brands such as HAAS, HERMLE, TSUGAMI, PALMARY, KENT, LK etc. are all industry leaders in their respective segments globally, and this product strength backed by our sales and service network and nationwide technical centres provides us with a great competitive advantage.”
Explaining critical technological advances in such cases, Miranda points out, “Additive manufacturing is a new and exciting technology and its applications are growing in industries from aerospace to medical to injection moulds to pressure die casting to investment castings and so on. Our partnership with EOS Germany in the Indian market is designed to introduce our customers to this new technology, which will, over time, revolutionise the manufacturing environment.”

Vendor Support
Considering the extent of technological inputs and its criticality for processes, one cannot argue enough the importance of vendor support to HSM users in developing the right tools, machining parameters and, in many cases, CNC machine designs. Hence, the concept of HSM machining centres has quickly made its mark in the Indian industry. These centres have promoted HSM techniques as more and more users find them exciting for large-scale batch processing, particularly in automotive applications coming with suggestions for controls, tooling and supporting CAD and CAM systems.
As one of its key users, Shankar is convinced regarding the need for this support. He explains, “Flexible machines bring an opportunity to make investments in line with market demand. One can invest in modules catering to a fraction of the full intended capacity. A dedicated machining line often requires full capex upfront for the full capacity. Any major change in product would require high re-tooling costs on dedicated lines.”
He adds, “We are satisfied with the support received by our HSM equipment suppliers. We have partnered with Makino India and Mazak India for our requirements. In addition to providing technical and spare part support on time, Makino has helped us acquire the required competency to produce and maintain our equipment. We have received good support from these partners to implement our Industry 4.0 initiatives and Manufacturing Execution Systems.”

Programme Backing
Besides these factors, the Indian Government’s Make in India programme has been a great support for HSM as a concept and the promotion of its subsequent use by the Indian manufacturing sector. Industry OEMs agree. Apart from creating the right environment for manufacturing growth, supporting policies facilitate new technologies, financial backing and demand generation both in domestic and export markets. This is vital for any industry and the machine tools industry is no exception.
Miranda echoes this positive sentiment, when saying, “The Make in India programme has significantly changed the landscape of Indian manufacturing. As an Indian, I feel pride in the fact that our country is now looked upon as an attractive manufacturing destination. The marketing and policy changes needed to make this happen have been commendable. The machine tool industry is a key driver for the Make in India programme, which has driven manufacturing to India, which in turn has driven the CNC machine tool industry to a new high, and this looks set to continue.”
Providing statistics in this context, Kelkar states, “The machine tool industry has come a long way. The previous year’s import was 70% and only 30% were Indian machines. This year the figure has changed to 50% each. This indicates the growth among machine tool manufacturers. Make in India means manufacturing and manufacturing needs these machines. Machine tools are the mother tools, which are very vital. The Government is providing assistance for R&D of machine tools, but this needs to be stepped up. We have to step up the technology acquisition initiative of the Government of the India, wherein machine tool companies can acquire technology with assistance from the Government. Also, we need to handhold other companies, including all the machine builders and end product manufacturers, for developing new technologies. This will really make the machine tool industry grow in a positive way and ensure that Make in India is a grand success.”
In conclusion, while the necessity for HSM is now well-established in India, it is time to bring about faster technological development in this area in order to ensure more economic gains. And the Indian manufacturing ecosystem certainly seems to be on the right track.