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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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0

0.5

1

1.5

2

2.5

3

3.5

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

sameer.kelkar@grindmaster.co.in