Innovative Manufacturing Solutions

and
Technology Trends at IMTS 2004

1
Gautam Doshi
Productivity &
Quality
Improvement
Services
22nd Dec.
2004
 Topics
• General • Turning •Emerging
comments • Grinding Technology Center
• Significant • EDM •Smart Machines
trend • CAM •Trends in Metrology
• Software & Non contact
– Automation
products measurement
– Flexibility
• TPM •CNC programming
– Life Time
• Lasers & •Solutions in Volume
Costing
Water Jet
Production
• Sheet & plate
•Tool rooms & small
working
batch production
• Workholding
•Micro machining
• Tooling
•Nuggets
3
Exhibition statistics

• Five very large

pavilions
• 1250 exhibitors -
5 Indian
• 82,000 visitors

4
5
6
7
8
 Automation
• Prominent display of automation.
• Automation solutions at different levels
to suit each customer’s need.
• Solutions for industries rather than
product display.
• Justification for Automation - labour
saving and thereby cost reduction.

9


Conclusion
Automation - only solution to fight outsourcing
10
 Flexibility, not Speed
• Focus was on Flexibility, not
Speed
• Speed was required, but
flexibility was given more
importance in product display.
• Multi-tasking - buzz word

11
 Multi-tasking
• Solutions approached
from different routes
– Vertical Turning
Lathe ⇒ Turning +
5 side machining
– Horizontal
Machining Centre ⇒
5 side machining +
Turning

12
13
Multi-Task Machining
• Combining turning with
rotating tool applications
on single m/c
• Less set up – better
through put, fewer m/cs &
fixtures, improved quality
consistency
• High m/c cost & poor
productivity – multi
tasking tool eliminating
tool change and tool
positioning using five axis
control
14
ONE TOOL, FIVE
OPERATIONS
• Drilling, boring, facing,
turning and counter boring
performed with one
Pentatec Indexable Carbide
Turning Tool
• Variation of the
conventional trigon-shaped
carbide insert
• Drilling holes down to 8 mm
• Carbon and alloy steels,
aluminum, stainless steel
and cast iron
• Steel gear blanks and
bearing races
15
 Multitasking of aero
component
Conclusion


Productivity Improvement -

Cutting down idle times through

‘all in one tooling’

16
 Life Time Costing
• Machine tool buyers •Cost of lubricant
seriously looking at •Cost of spares
life time cost (LTC) •Cost of coolants & its
or Product Life Value disposal
(PLV) •Cost of maintenance
• Machine tool sellers •Cost of hydraulic oils
•Cost of quality
providing providing
•Cost of cutting tools
solutions to reduce
•Waste of idle times
LTC.
•Cost of energy

17
18
 Turning
• Inverted CNC vertical lathes seemed to be
displayed by most lathe manufacturers.
• Multitasking Lathes with tool spindles same as
VMC.
• Large oil field equipment - lathes with big bores
and multitasking capabilities.
Conclusion
• Focus on dry machining, precision turning, chip
evacuation & automation

19
Dry
machining,
Precision
turning,
Chip
evacuation
&
Automation

20
High production Self-loading NC Lathe

• Fixed turret and

traveling spindle loads
directly to the spindle ~
2.5 – 4 sec load/unload
• 6" chuck, A2-5 nose, 10
HP, max. 6000 rpm, 30
m/min rapid
• 12-station servo turret
with 0.5 sec - 180°
index time
www.tongtaiusa.com
21
 Grinding
• Grinding to hold out against outsourcing
• Grinding machines, extremely rigid, using
hydrostatic ways were displayed capable of
holding sub micron tolerances
• CNC controls of grinding machines with
substantial in-house developed software to assist
operator

22
 Thermal Modelling Program for
Cam Lobe Grinding
• Tetra4000 Cam Grinding Analysis Program with Thermal Modeling capability
- fastest possible cycle times while avoiding thermal damage to parts
• Mathematically combines cam lift specifications with practical machine
performance capabilities to automatically generate workspeed programs that
optimize cycle time and product quality
• “Thermal modeling tells us where we must slow down and where we can speed
up the grinding program while controlling grinder burn. After setting up a cycle
time for a cam lobe grinding application, the software enables the user to
immediately perform a thermal modeling to confirm that the part will remain
within the desired temperature range.”
• Color contour plot of the thermal distribution is provided for analysis by the
operator
• Avoid inducing excessive heat into the part to a depth that cannot be removed
in the finish feed increments
• Cam lobe grinding cycle time on one diesel camshaft was reduced to 5-1/2
minutes from 11 minutes per shaft using thermal modeling
23
www.landis-us.com

24
 Gear grinding
• LNS (low noise shifting),
directs the movement of
machine during grinding to
produce a random surface
texture in the micro-range,
which prevents discrete
excitations of the ground
gear when running with its
mate. The purpose of LNS is
to reduce gear noise at low
speeds and eliminate the
need for subsequent honing
for those noise sensitive
applications.
www.reishauer-us.com
25
Gear grinding

26
 Productive surface grinder
• Split splash guard
configuration, while the doors
are open and the operator is
exchanging parts, the machine
goes through the dress cycle.
Dressing and part exchange
happen simultaneously. By
combining part exchange and
dressing, overall cycle time
can be decreased by as much
as 40 percent in high-volume
production environments. www.grinding.com

27
Turn & Grind

28
 Taking Guess-work out of Job
Quoting & Production
• Programming system that allows shops to respond to RFQs with complete
confidence
• Jobs it should not quote and clearly lays out reasons why.
• Graphic representation of machine with necessary tooling
• Consists of wheel dressers, of which most important types are already
stored in database, and grinding wheels
• Grinding wheels is moved “virtually” to its working position to check for
collision
• Functioning grinding program using Studer tried-and-tested Pictogramming
technology
• X and Z positions of part can be taken directly from imported DXF file
• For parameters available database as well as grinding technology support
• Display shows total processing time required, including down time, feed time
and dressing time
• Table with set of parameters indicates cost break up based on standard 29
costing data
 On getting the order
• Operator downloads data and drawing directly to PC
workstation
• Based on virtual machining operator positions
dresser, loads grinding wheel, etc with certainty
• Simulates new program on the computer to identify
possible programming errors
• M/c is ready for operation
• In workpiece-linked data archiving, all programs, sub-
programs and additional documentation, such as
digital photographs of the set-up and chucking
arrangements, are automatically assigned to the
workpiece in question
www.grinding.com.
30
www.grinding.com. 31
 Grinding
Conclusions
• Extremely tight tolerances, extremely tough
materials, extremely fine surface finish, difficult to
transport ground components over long distances
& extremely small components
• Automate whenever possible
• Deskill through software - most complex metal
removal process. Good data base & intelligent
software can make process effective in absence of
skilled operator

32
 EDM fights back
• Substantial toolroom work is going off shore to
low wage competition.
• Only means of survival is through fully automated
robotic cells - integrating wire EDM, electrode
EDM, Hard milling, graphite milling, and
inspection
• Horizontal wire EDM is catching up fast

33
 Computer Aided Manufacturing
(CAM) & Software products
• CAM software generated tool path &
simulated it.
• Operator had to be careful about collision
of machine elements with workpiece,
fixture & tools.
• Difficult to do manually for multi-axis &
multi-tasking m/cs
• Simulation now not only includes
workpiece & cutting tools but m/c
elements.

34
 E2E Machining Solutions
• End-to-End Manufacturing solutions from Process Planning to NC programming to NC
Verification and Inspection.
• DELMIA’s Process Engineer, project is initialized in conceptual product design phase,
capturing logistical information such as location, labor, production shifts, production volume
& budgets
• DELMIA’s Manufacturing Hub to facilitate all ongoing communication and collaboration
• In-process models form the basis for numerous other activities in the E2E machining flow
such as tolerance charting, 2D drawings, fixture design and NC programming. Details on tool
paths, tool orientations, approach/retracts and tool change positions are eventually added to
these models, resulting in the NC code that drives the machines.
• Tool paths can also be verified upfront from a process perspective by simulating machine
movements to check reachability and detect potential collisions on tool paths even before the
NC code is generated
• DELMIA’s INSPECT allows users to design inspection paths with desired probe approaches,
retracts, part alignments -- and verify them for collisions. Any conflicts can be resolved in
the virtual environment, increasing productivity and reducing time-to-market.
• Execute process planning activities simultaneously during the design phase 35
36
 CMM
VIRTUAL

http://www.delmia.com

37
 Software Developments
• GE Fanuc iCELL OEE TM
• Minitab
• PEMS
– Fix-Des
• Intelligent Grinding Advisory System
Software

38
 GE Fanuc iCELL TM
OEE

• Detailed reporting on OEE - drill down on

machine level as well as cell level. Windows
based supervisory software that manages and
monitors multiple CNC machines and supports
operations such as part machining, data
collection, remote diagnostics and state -
change monitoring. E.g a faulty proximity
switch which momentarily goes on and off.
• Fanuc booth had sections titled Availability,
Productivity & Quality
• www.gefanuc.com
39
 Minitab

• Statistical software tool including basic

statistics, SPC, Design of experiments,
project files to store analysis history of
projects, Quality Companion, which
includes Process Mapping, FMEA,
Meetings, CTQ Matrix, Brainstorming/
Affinity Diagram, Multi-voting, Cause
and Effect diagram. All supported by
strong training courses.
• www.minitab.com
40
Parametric Engineering for
Manufacturing Systems -
PEMS
• Software product to help users design,
evaluate & optimise production line design.
PEMS involves graphic information
processing directly in CAD environment
with process simulation and cycle time
estimation. Includes functions of tolerance
analysis and fixture design. Objective to
reduce manufacturing planning time from
weeks to hours with validated solutions
• www.me.wpi.edu/Research/CAMLab
41
 Fix-Des (part of PEMS)
• Computer-Aided Fixture Design involves
automated generation of fixture design based
on product and process information & fixture
design verification functions such as fixturing
accuracy analysis, stability analysis,
accessibility analysis, & interference
checking. Ensures timely fixture design
quality, avoids overdesign and integrates into
current CAD/CAM software.
42
 Intelligent Grinding
Advisory System Software
• Systematic way of optimising &
controlling various grinding
processes
• Can be used with various grinding
machines to make them more
“intelligent”
• http://widget.ecn.purdue.edu/~si
mlink/
43
44
 Software Developments
• Watchdog Agent TM
• Analysis and Optimization
Software for Fixturing of
Machined Parts
• i-Beans
• MEPT

45
 Watchdog Agent TM

• Near-Zero Downtime
• Intelligent Maintenance System to track
parts & structures which wear naturally
& slowly. Internet based condition
monitoring, some fancy mathematical
signal processing and feature
extraction, and some fancier
performance evaluation and prediction
algorithms
• www.imscenter.net

46
Analysis and Optimization
Software for Fixturing of
Machined Parts

•Fixturing design software

for reduced set up time
•http://precision.me.gatec
h.edu

47
 i-Beans
• Ultra low-powered, self organising wireless
sensor(+software) networking system
• Smart m/cs will have sensors embedded
everywhere; difficult to wire because sometimes
they are on moving parts or inaccessible.
• Long battery life 10 years.
• Already used in wireless gauge reading to
pressure/flow/temp monitoring as well as
condition monitoring - strain gauge
• www.millennial.net
48
Metrology Interoperability
Project Team - MEPT
• Metrology products software standards
- to seamlessly integrate measurement
products into measurement systems
through standard interfaces
• Reduce product development cycle time
& manufacturing costs through
standardises software & hardware in
CMMs
• www.aiag.org/committees/mept.asp

49
Conclusions
• CAM suppliers are differentiating
themselves by partnering m/c
manufacturer or user
• From stand alone software to integrated
software
• Software development for Smart Machines

50
 Total Productive
Maintenance
• Easy to clean
• Easy to Counter
lubricate
• Easy to inspect
⇒ measures to
reduce waste
& forced
• Easy to deterioration
maintain

Tracking & monitoring OEE

51
TPM software from GE Fanuc Proficy™ MTE

52
Easy to maintain

53
 Lasers & Water Jet
• Considered as 2D m/cs - suitable for blanking; edges
to be finished
• Multi axis m/cs allow profiling of parts to fit - fixture
parts cut & ready to assemble without welding
• Pipes cut to assemble without welding - bridge
• Water Jet machining with compensation for taper to
get exact right angle edges
• Water Jet m/cs can be assembled by user as all parts
are available individually
• Water Jet is the fastest growing area today in m/c
tools in the world
54
ELC LaserCell

55
 ELC LaserCell
• Multifunctional Production Centers
• Consolidation of process streams
• All machining technologies and processes
that can be applied to round and "not so
round" workpieces, including ready-to-
install components and component
assemblies
• Loading number of different components -
metal-cutting operations - matching +
press-fitting - repeated laser welding -
brushing - measuring and removal of the
completed assembly
• Throughput time reduction for main shaft
of an automatic transmission for premium
cars – by a factor of 1:16!
56
 ELC LaserCell

Advantages of laser welding are:

• High power density
• High processing speeds
• Low heat load, maintaining
minimum component distortion
• Exceptional integrity of the
process capability
57
 ELC LaserCell

• Components, such as the gearwheels and clutch bodies for passenger

car transmissions, are frequently machined individually, then assembled
and welded. This makes transmissions more compact and meets the
highest demands for noise level reduction and power density
58
 • Image processing system checks type and
position of every workpiece
• The two constituent parts are matched and
press-fitted in the assembly station. Press
force and speed are NC programmable,
which drastically reduces set-up times.
• EMAG clamping technique ensures that
the workpieces are clamped very precisely
• Teeth on both workpieces are also well
protected against weld spatter.

ELC
LaserCell
59
ELC LaserCell
• Welding station features two
spindles. Whilst one spindle
accommodates the assembly
during the welding process the
second spindle is used to
unload the previously welded
component and to load the
constituent parts for the next
assembly. The welding optic
"shuttles" between the two
spindles, making optimal use of
the laser and thus increasing
the output rate of the machine

• www.EMAG.com

60
 Sheet & Plate working
• Emphasis on solutions with automation
from sheet & plate store to m/c & back not
just m/c handling
• Lights out production of sheet metal parts
• Combined cell with Hydroforming & 3D
Laser cutting to trim with integrated
handling
• Simple low-cost plasma m/c sharing same
control as CNC milling

61
 Trends in Workholding
• Automation of clamping, eliminating manual
intervention
• Miniaturised pneumatic & hydraulic elements
• Tombstones on pallets with hydraulic clamping
with removable actuators & accumulator - no
hoses or pipes to tangle with pallet changers
• Electromagnetc clamping elements - electrical
source is withdrawn after actuating electro
magnet; holds till current reversal
62
 Kitagawa’s DL Series Dual
Lock Power Chuck
• Radial guideway power chuck
with no jaw lifting, and z-axis
repeatability near zero.
• Clamps the workpiece using
traditional radial actuation
• Performs a final axial, z-axis
pull-back movement to a fixed
stop
• Sealed to keep dust particles
out and lubrication in
• Allows for seating confirmation;
www.ntwhi.com
suitable for automation 63
 EXTRA LONG JAW STROKE
SPECIALTY CHUCKS FOR ODD
SHAPED WORKPIECES
• Long jaw stroke power
chuck with up to 1”
stroke per jaw, in three,
two and single jaw
configurations
• Jaws open far enough
to clear the larger
diameter flange and
grip on the smaller
diameter datums
• For square, rectangular
or unusually shaped
64
workpieces
 Special chucks

Thin walled component For mounting on pallets,

stackable

www.smwautoblok.com
65
 Workholding software
• Workholding elements in e-catalogues on
CDs & on internet. Library of elements
available as per user’s CAD software;
possible to design complete fixture using
these elements and then integration with
CAM for simulation checking
• Software available for selecting clamping
elements as well; suitable for new generation
of shop floor engineers who are computer
literate, thus promoting their products
66
 Workholding
Conclusion
• Speciality solutions for niche markets
• Software for fixture design
• Solid model element library for integration
with design software
• Analysis of fixture design through software

67
 Trends in tooling
• Industry wise stall layouts
• More grades, more coatings, more cutting
edges
• Speciality cutting tools to tackle problems
in machining
• Effective solutions for deburring

68
 Tooling
BlueSwarf hands on demo of
• Effect of tooling imbalance in HSM
• Run-out
• Toolholder taper inaccuracy,
• Machine/tool dynamics
• Improper assembly of tool holding components
• Lean tooling

http://www.BlueSwarf.com; http://www.HaasToolingCenter.com
69
 Innovative tooling

• www.cogsdi
ll.com
• www.heule.
com
70
 Tool vibration & Chatter
Dynamic or vibration behavior of cutting not yet well
understood
• Pre-process prediction of tool point vibration response
– Natural frequency of the system using a hammer.
– Stability charts, which identify chatter free regions.
– Helps increase cutting parameters without chatter.
– Four times increased productivity.
• In-process vibration monitoring
– Ultrasonic fluid probe as a non-contact sensor for tool
vibration during machining
71
 Tool vibration
• Hardware & software solutions for practical
measurement & analysis of machining vibrations
in milling, drilling, reaming, turning & boring
• Drilling simulation software, hand held machining
vibrometers & web & PC based dynamic machine
monitoring & analysis software
• Developing a cutting geometry based on process
requirement - software
www.mfg-labs.com; http://highspeedmachining.mae.ufl.edu;
www.lasson.com; www.opsourconline.com
72
 Tap machining at full speed
with i-tec® SLOTT
• Taps held in adapters; DIN
specifies shank tol. of h9, not
acceptable to shrink fit
• Shrink fit needs h6
• “Shrinking flexible” -shrink fit
chuck is slotted
• Provides a considerable increase in
torque and stiffness
• Much better concentricity values
are achieved – measured at 3 x D,
these are 5 µ - which again
increases the cutting edge service
life and reduces costs 73
 Shrink fit tooling
has come of age
• Kelch i-tec®L shrink fits
carbide, HSS & tool steels
upto 32 mm without
problems
• Enter shank dia. & material
& rest taken care off - no
overheating; no tool holder
damage
• No heating of tool taper or
tool shank
• Water cooling jacket to
reduce cycle times to
www.kelch.de seconds 74
To Bore or not to!!!!!!!!

Finish boring from Komet

75
 PcBN insert for high wear-resistance
for machining cast iron & powdered
metal
• BN700’s tool life was 1.5
times longer than that of
contemporary for
induction-hardened gear
• BN700 geometries are
multi-cornered with
numbered edges for ease
in indexing
• Precision-ground
tolerances
• Wiper, honed and no edge
prep www.sumicarbide.com
76
Replaceable carbide tip drill - one
drill body accepts multiple size
heads
• Carbide replaceable
drill head can be
reground
• 3X and 5X diameter
coolant-thru drill bodies.
• Ground serrations on
the back of drill head
allow for precise, two-
screw assembly and
exceptional hole
accuracy
www.sumicarbide.com
77
 Drill & chamfer in single
operation
• Unique collar that fits securely
around solid carbide drills
• Two standard inserts per unit
are 180º apart & with two cutting
edges
• With or without chipbreaker; one
insert grade for all materials
• Chamfer head sizes (ER20,
ER25 and ER32) capable of
drilling diameters from 4.00mm
to 20.0mm
• Collet chuck assemblies feature
a ball bearing nose piece for
www.sumicarbide.com
greater accuracy
78
 Grooving Insert
• Grade EH510V with new
“V” coating, designed for
superior wear & notch
resistance
• Heat-resistant steels,
titanium alloys, N, Fe &
Co-based alloys.
• Can be accommodated by
industry-standard
competitive toolholders &
boring bars
www.sumicarbide.com
79
 High feed milling
• Face & cavity milling
• M/cs with limited spindle
speeds, low depths of cut,
high feed rates, high
material removal rates
• Plunge milling is
emerging as an important
roughing method
• Cutters are specially
designed for high feed &
plunge milling operations
• Feed rates as high as 3 – 4
mm per tooth
80
SQUARE SHOULDER MILLS PROVIDE
TRUE 90°° CORNER MILLING

• High positive geometry and

unequal pitch; accurate 90°
corner milling
• Thru-the-tool coolant
supply on all versions
• Ultra-durable nickel-plated
bodies
• Precision indexable inserts
are available in both 11mm
and 17mm insert lengths
with a variety of corner radii
81
 COOLANT-THROUGH TURNING
HOLDERS FOR LONGER TOOL LIFE.

• Point Blank’s patented holder

design with top plate, or coolant
nozzle design, directs coolant
on the cutting edge. Orifice size
on Point Blank top plate
maximizes coolant velocity;
leads to unsurpassed chip
evacuation, increased tool life
and improved surface finishes,
even at higher cutting speeds.
• Tool holders for CNMG,
WNMG, VNMG and DNMG
styles
www.lmtfette.com
82
 Increase precision of deep-
hole drilling
• First advantage - precision of
the hole - Guided by pilot hole,
drill does not drift when drilling
holes deeper than 4x diameter.
http://www.mikron-tg.com
• Centering function combined
with a pilot hole
• Pilot hole whenever drilling depth
is > 4x diameter with 90° cmf
• PilotDrill in diameter range from
0.4 to 3 mm; pilot hole should be
0.01 – 0.015 mm larger than
succeeding bore size
• Second advantage – life
expectancy of tool - The smoothly
guided drill does not chip the
cutting edges, as it sometimes
happens when using standard
center drills.
83
 Small diameter drills
•4 to 5 times longer tool life than commercially available twist drills
•Up to 20 times higher drilling speeds than best available small drills

Steel Aluminum

http://www.mikron-tg.com
84
 Small hole deep drilling up
to 15 x Diameter
• Combination of a
centering drill, and
through tool cooling
• Diameter ranges
between 1 and 4 mm
• Additional hole in the
shank for diameter
ranges smaller than 2.5
mm
• Alternative to the more
www.CrazyDrill.com
complex and expensive
deep-hole drilling 85
Minimum quantity lubrication

86
Minimum quantity lubrication

87
Emerging Technology Center

Three areas identified

• Nano Technology
• Non contact measurement
• Smart Machines (Smart Technology)
88
 Definition of Nanotechnology

Nanotechnology is a fundamental, enabling technology,

allowing to do us new things in almost every conceivable
technological discipline.

Nano means “dwarf”(one billionth of a meter) but of high

potency, and emerging with large applications piercing
through all the disciplines of knowledge, leading to
industrial and technological growth.

Nanotechnology concerns with minimum one dimension

of 1-100nm
Source: CMTI
89
 Introduction to Nanotechnology

To-day’s Nano technology is concerned with the

design and manufacture of molecular scale
devices by manipulation and placement of
individual atoms and molecules with precision on
the atomic scale as a “Bottom Up” along with the
other“Top Down” fabrication techniques.

Source: CMTI
90
 NANO MANUFACTURING

NANOSCIENCE
NANOSCIENCE
**Physics
Physics **Chemistry
Chemistry
**Materials * Biology
Materials * Biology
**Information
InformationSciences...
Sciences...
NANO NANO-
NANO-
NANOTECHNOLOGY
TECHNOLOGY
**Design
Design **Fabrication
Fabrication MANUFACTURING
MANUFACTURING
**Integration * Characterization
Integration * Characterization **Materials
NANOSCALE
NANOSCALE **Production/system,
Materials
Production/system,…. …. **Processes
Processes
Structures
Structuresand
and
Functionality APPLICATIONS **Instruments
Instruments
Functionality APPLICATIONS
**Biological,
Biological,medical,
medical,health
health **Modeling
Modeling
**Electronics, optics, devices
Electronics, optics, devices **Structures
**Energy,
Structures
Energy,chemical,
chemical,environment
environment **Products
Products
**Structural,
Structural, coatings,….
coatings, ….

IMPACTS
IMPACTS
**Society,
Society,economy
economy
**Ethics,
Ethics,legislation
legislation Source: CMTI
**Education
Education, ,training
training...
...
91
 NANO MANUFACTURING PROCESSES

Nano Manufacturing processes are grouped

according to the following three main areas:

Conventional Machining

Nano Fabrication

Nano Manipulation

Source: CMTI
92
 Conventional Machining Processes

 Processes relevant to manufacture of

Ultra-precise microstructures are,

 Diamond Turning,
 Diamond Milling,
 Contour Boring,
 Micro Grinding and
 ultrasonic assisted processes
( like Ultrasonic honing, lapping, etc.)

Source: CMTI
93
 Nano Fabrication

With regard to nano fabrication, it implies that,

1. Every atom and molecule is positioned in

the correct place

1. Structures follow the laws of physics and

chemistry that are specified in atomic detail

Source: CMTI
94
 Nano Fabrication

 Nano fabrication covers a range of manufacturing

processes that produce patterns and/or layers of
material to form nano-structures.

 The semiconductor/ microelectronics industry has

led the development and application of the photo
and electron beam lithography techniques, which
are the main basis for continuing miniaturization in
large-scale production in the near future.

Source: CMTI
95
 Typical Nano Fabrication Processes

 The industrial applications of Energy beam

processing is rapidly increasing. Electron Beam
Machining (EBM), Focused Ion Beam (FIB), Reactive Ion
Etching (RIE) and Pulsed Laser Ablation are effectively
swarf-free, virtually zero force processes.

 Nano fabrication includes, chemical surface

modification methods with low surface energy Plasma
Polymerized Fluorocarbon film deposited in the field free
zone of plasma reactors.

Source: CMTI
96
 Nano Manipulation

The latest trend in Nano Technology is the Molecular

nano manufacturing or nano-manipulation.

The concept is the ‘self assembly’ in which atoms,

molecules, molecular aggregates organize and arrange
themselves into ordered functioning entities without
human intervention.

Self assembly is a nano fabrication technique that

involves aggregation of colloidal nano-particles into the
final desired structure.

Source: CMTI
97
 Nano Metrology

 In nano manufacturing, to have a adequate control

over the motion of the systems a knowledge of
dimensions and displacements is necessary.

 Some of the nano metrological activities are,

1. Atomic Level Displacement and Position

Measurement
2. Multi-Dimensional Measurement for Surface Texture
and Atomic Imaging
3. Form Measurements

Source: CMTI
98
 To-days Scenario of Nanotechnology

• World market in 2004 for nano materials, nano tools,

nano devices and nano biotechnology which put
together is expected to be over 100 billion dollars. It has
been noticed that the fastest growing area among these
is nano biotechnology.

• Molecular switches and circuits along with nano cells

will pave the way for next generation computers. Ultra
dense computer memory coupled with excellent
electrical performance will give society low power, low
cost nano size and yet faster assemblies.

Source: CMTI
99
 To-days Scenario of Nanotechnology

• Today a few countries such as USA, Germany , Japan,

UK have already taken the lead and invested more
coherently and cohesively in thrust areas of
nanotechnology. The global funding for nanoscience
and technology has now risen to approximately 18
billion dollars in the year 2004

Source: CMTI
100
 To-days Scenario of Nanotechnology

• Rapid advances both in terms of materials and devices

are taking place globally.
• Almost 300 novel materials and 50 devices with unique
characteristic have been successfully developed
around the world.
• Many of these inventions In materials and devices
created today by nanotechnology were beyond human
imagination.
• This technology will have a large domestic market
potential and hence would be very robust and immune
to the changes.

Source: CMTI
101
 Nanotechnology Products/Areas

• Carbon Nano structures

• Carbon Nano Tubes
• Nano Photonics
• Nano Machines
• Nano Machining Processes
• Bio Micro Systems
• Bio Molecular Motors
• Advanced Semiconductors Circuits
• MEMS/NEMS Modeling
• Chemical Synthesis
Source: CMTI
• Nano Surface and Films
www.nanomat.com
102
 Emerging Technology Centre
Nano manufacturing processes
• Precision Manufacturing
• Multifab - Rapid manufacturing & Repair
• Laser assisted machining, laser hardening, laser
cladding & laser peening
• Mirco miniature machine tools
• ELID Technologies
– finishing surfaces at nano levels, e.g. special dressing
technique for metal bonded wheels
(www.eng.utoledo.edu; www.interams.com)

103
 Sensors for precision
manufacturing
• Grinding & machining sensor systems that provide
real time force feedback for ultra-precision
grinding, milling & turning.
• Applications include diesel fuel injector grinding,
optics grinding & turning, fine grinding, micro
milling & micromachining
• Components for medical, micro machines, &
electro-optical devices
www.me.psu.edu/mdrl

104
 Rapid Manufacturing & Repair
Multi-Fabrication System
(MultiFab)
• Uses direct energy such as photons, electrons, electric arc,
plasma arc to ‘grow’ or ‘print’ metallic components via direct
metal deposition, near-net-shape, solid free form additive
and subtractive manufacturing.(milling, drilling, turning)
• Prototype m/c developed to include all processes in one m/c
- 5-axis M/c center, 6-axis robot,Nd:Yag laser, welding
power sources with wire feeders, computer controlled
multiple powder feeding system, cutting tool changer &
store, laser deposition head with store, welding torches,
laser scanning probe, & PC based CNC
• MultiFab also includes scanning & post process inspection
www.engr.smu.edu/rcam
105
 MultiFab control
• Online monitoring size of molten pool in laser-
based deposition
• Closed-loop control of laser power
• Computer-controlled multiple powder feeding
system (up to four powder feeders)
• Computer-controlled heat & mass flow rate in
welding-based deposition processes
• Software for automatic path planning for 2D & 3D
deposition
106
 Laser based
manufacturing
• Laser-assisted machining of ceramics &
high temperature alloys
• Laser hardening
• Computational tools for designing &
implementing these proceses
• http://tools.ecn.purdue.edu/~clm

107
 Micro miniature machine
tools
• To produce complex components in the range of
few to a few hundred microns.
• Prototype machines for micro endmilling, micro
drilling, micro turning.
• Integration of micro m/cs with handling &
assembly to form micro factories.
• Optics, electronics, medicine, bio-technology,
communications, avionics
• www.mie.uiuc.edu/mmt http://precision.me.gatech.edu

108
 Conclusion

• Nano manufacturing is an important activity of

nanotechnology which covers both conventional and
non-conventional processes.

• Machining of nano surfaces of required configuration is

the prime factor to be considered in nano
manufacturing, which covers both conventional and
non-conventional processes.

• Measurement of dimension, of nano size particles and

form of finish of nano surfaces is made possible with
the latest instruments like STM’s and AFM’s.
Source: CMTI
109
 President Dr. APJ Kalam’s
Views about Future of Nano Technology in India

“As the country was acquiring the technologies of steel,

agriculture, Space, Missiles and IT, we grew to be any
where between the third to fifth nation in merit. We
believe that Nanotechnology would give us an
opportunity, if we take appropriate and timely action to
become one of the important technological nations in
the world.”

Source: CMTI
110
 Smart Machines
“ • Generating and executing their own process plan
• Making the first part (and every subsequent part)
right
• Knowing their capabilities/condition and being
interviewed
• Monitoring, diagnosing, and optimizing themselves
• Knowing the quality of their work
• Learning and improving over time ”
Richard A. Curless, Director, Global Research and Development for Cincinnati Lamb

www.CincinnatiLamb.com
111
 Dynamic evaluation of machine
tool process capability
• Novel techniques & strategies for dynamically measuring process capability of m/c
tools
• Process capability information to accurately estimate machining cost
• Real-time sensor data with unique cutting force feedback model
• Open-architecture machine tool controller used to collect & store measurement data,
run model simulation & dynamically update process capability
• Focus on effect of tool run out, tool deflection & tool wear
• Testing on variety of cutting conditions, cutter types, ferrous & non-ferrous materials
• Completion of this research project will give machine self knowledge of process
• Designers can optimise their designs because of accurate estimate of machining
costs
• Design tolerances can be matched with process capability of specific m/c to achieve
zero defect
• Part quality can be maintained over time by adjusting cutting strategies & conditions
in response to changing process capability http://www.unh.edu/dml 112
 FIRST STANDARDIZED SYSTEM FOR
MONITORING SPINDLES DURING
OPERATION
• Spindle Condition
Monitoring SpiCoM
• Non-contact (eddy
current sensors)
measurement of
relative displacement
between shaft and
housing during
operation.
• www.ina.com  113
 SpiCoM
• Increased machine accuracy owing to displacement
compensation in the machine control system
• Monitoring of bearing stress through measurement of
non-repeatable runout
• Reduction of consequential damage in the event of
crashes
• Chatter identification from path signals
• Higher machine availability through monitoring of
bearing wear as well as crash identification and
reduction of crash consequences

114
 Productivity improvement using
SpiCoM
Cutting parameters can be better optimized due to
objective information about bearing stressing and
incipient chatter.
Monitoring of bearing wear and identification of crashes
lead to increased machine availability. Planned
maintenance can be carried out at a convenient
time. Crash identification permits minimization of
consequential damage
Measurement and compensation of misalignment
enable improved machine accuracy. Often individual
parts (fitting surfaces etc.) need to be manufactured
to higher accuracy.
115
 Machine control gauges
Tokyo Seimitsu
• ATC run out detection system using eddy
current sensor
• Gap-jet 
– Ultra precision non-contact measurement of
inner diameter
– Repeatability ± 0.08µ
– Diameters between 1 – 5 mm can be measured

116
Adaptive feed rate control
GE Fanuc i Adapt

117
 Indramat Intelligent servo
drives
• CNC machine diagnostics detects failure, not
prevention. Preventive maintenance replaces
irrespective of actual wear & tear
• Condition monitoring certainly helps but is generally
external
• Possible to sense & monitor position (angle), speed,
current, temperature, DC-bus voltage, winding
temperature, rotor position, rotor speed & motor current
• Measured values can be continuously recorded &
mathematically manipulated  118
 Smart Machine Platform
Initiative
Techsolve, AMT+SME, National Labs joint initiative
to develop technology plan to impact manufacturing
sector through development, understanding &
deployment of Smart Technology
• Test bed for demonstrating & validating various
Smart technologies, devices & methodologies
• Development & deployment of Smart technology for
commercial use & its implementation in
manufacturing
• Funding & propagation to investment, venture
capitalists and manufacturing communities
119
 ArtiFACT

• ArtiFACT : Hardware and software that
allows a machine tool to self-check its
calibration, determine its calibration trend,
and certify that the machine is functioning as
intended. If the machine reaches a limit
boundary, ArtiFACT will notify designated
maintenance personnel of the pending issue,
identify what actions need to be taken, and
assist in restoring the machine to normal
operation.www.CincinnatiLamb.com
120
INTERACTIVE TECHSUPPORT

• INTERACTIVE TECHSUPPORT: An
intelligent communication tool linking a
machine tool and its support center with
voice, data, and video over normal telephone
lines or a cellular phone. It includes the
ability to command the machine remotely,
and an artificial intelligence module to assist
in quick diagnostic and corrective action for
any specified fault or alert.
www.CincinnatiLamb.com
121
Automatic Test System
• Automatic Test System (ATS): A system
that uses Precision Engineering
Measurement Software (PEMS) Intelligence
and Instruments to verify, correct, and report
the geometry of a machining center against a
known specification. ATS is available only
through Cincinnati Plus services.

www.CincinnatiLamb.com
122
 FREedom Software

• FREedom Software: Web-based machine monitoring

software system with integral artificial intelligence
intended to assist factory floor management of
performance of the machine and related processes.
FREedom provides predictive failure and restoration data
analysis and generates advanced response solutions. It
complies with the Association for Manufacturing
Technology’s “Production Equipment Availability” time
monitoring and data capture standard as specified by
QS9000. www.CincinnatiLamb.com
123
 Oil Sentinel & Precisecomp

• Oil Sentinel: A sensor module developed in conjunction

with Los Alamos laboratories to provide intelligent
monitoring of hydraulic fluids. Oil Sentinel can detect
fluid oxidation, water contamination, fluid temperature,
and reservoir fill level.
• Precisecomp: An intelligent software tool to monitor
environmental thermal factors and compensate a
machine’s positioning accuracy for the particular material
being machined e.g. for aluminum, steel, titanium, etc.
www.CincinnatiLamb.com
124
 PC-DMIS NC

• PC-DMIS NC : In-process metrology
software that enables on-machine part
inspection and verification using spindle-
mounted probes. Retains data from sequential
inspections to enable trend analysis of machine
performance. Used in conjunction with
FREedom to generate flexible, user-specified
reports and alarms. (PC-DMIS NC is a
trademark of Wilcox Associates, Inc.)
www.CincinnatiLamb.com
125
 Conclusions
• Smart Technology is development of Sensors
& related software; probably investments are
manageable
• In India we can do a lot if we make a team
with machine tool manufacturers, software
companies & National Labs (ISRO, IIT, etc).
• May face technology denial or technology
costs may become prohibitive
• We must be quick and patent 126
 Trends in Metrology
• “Anywhere CMM”
• Laser metrology
• Portable measurement system
• Vision systems
• Hybrid systems
• Robust measuring instruments

127
 Brown & Sharpe
• Shop floor measurement
• Linear bearings - no requirement of air
supply
– Recirculating bearing packs are sealed
to resist airborne contaminants,
– volumetric accuracy and repeatability
equal to those of air bearings
• High-density polymer composite base
– 10 times more vibration dampening
– absorbs high frequency noise
• Aluminum/silicon carbide matrix material
– reduce weight
– minimize the influence of thermal
effects on measurement results. www.brownandsharpe.com

128
Laser Tool length, Wear & Breakage measurement

http://www.Blum
-Novotest.com

129
 IR bore gauge
• Fast measuring cycle
• Micron resolution
• Bidirectional data programming
• Infrared data transmission
• Up to 8 measuring positions
– Diameter
– Position
– Cylindricity
– Roundness
130
Thermal Compensation

131
Z - Nano

132
 Enhancing tool presetters with
vision system & software

• Cutting edge contour of form tools consists

of lines and arcs
• Vision system on the presetter records the
contour & compares with CAD
• Form testing/ OP & CMM eliminated
• Software takes care of straight & fluted tools
• Microsoft compatible; measurement program
can be stored, records generated
www.kelch.de 133
134
135
 Leica Geosystems armless and wireless
T-Probe portable measurement system
• Just walk around with a hand held CMM Probe and take 3D -
measurements wherever needed
• There are no wires, no cables, no mechanical restrictions and no targets –
this really is the world’s first-ever complete Walk-Around CMM solution,
and it will bring another dimension to the shop floor
• It offers measurements accurate up to 0.1 mm in a measurement volume
equivalent to that of a full-size car
• T-Scan, with which users can easily digitise objects both large and small
with virtually no set-up time, can be combined with the T-Probe to create
what amounts to a new ‘all-in-one’ solution for industrial measurement
purposes.
• The new technology is based on a camera embedded at the top of the
tracker (the T-Cam), which allows the user to measure precisely the
orientation of an object in space, while the tracker simultaneously
determines it’s position.
136
T-Probe

137
 Ball Endmill Vision
Measuring System
• Vision measuring system dedicated to
measurement of ball endmill
• Chuck holds endmill, allowing it to rotate
• Digital angle counter indicates positions of
endmill cutting edge as it is rotated
• Mitutoyo QSPAK® software compares
actual and nominal values to determine
edge wear
• Checking for abrasion wear of ball endmill
R-contour helps user to forecast when to
re-grind or replace, thus helping to
maintain tolerances and improve process
stability
• CCD camera to accurately detect position
which reduces focus time and avoids
focusing error
www.mitutoyo.com 138
 Quick Vision STREAM™ CNC vision
systems measure “on-the-fly” for 5x faster

• Progressive camera
with stroboscopic
illumination bundled
with powerful QVPak®
software to enable the
machine to register
measurements while
the camera-head is in
motion
Molded plastic or metal parts & PCB assembly
139
 Surftest® SV-3000 supports easy
integration of CNC surface roughness
testing, and automation

• Integrate CNC surface

roughness measurement
into automated material
handling and downstream
machining and assembly
processes.
• Surface roughness
measurement of
transmission gears and
connecting rods or for two-
sided surface roughness
testing of leadframe hoop
irons
140
Combination vision/ultrasonic
probe system measures micro
holes and features

• Hair-like ultrasonic probe

• Vision system is used to position the tiny
probe (20µm diameter) for insertion into
holes or other miniature features
• Probe is then activated ultrasonically and
the measurement data is taken according
to the wave-form changes when contact
is made.
• Probe tip, made of carbide/glass, is 2mm
in length, and thin enough to measure
the diameters of fuel injection nozzles,
optical ferrules, ink jet printer nozzles
and other tiny holes and features

141
 Coolant Proof Digimatic™ Caliper
protected to IP67 and immersible

• IP (Ingress Protection) 67 certification means digital caliper is dust

proof, chip proof, coolant-proof and virtually immune to toughest
conditions found on production floor
• 0.01mm resolution with ±0.02mm accuracy for a 6” and 8” models
• Absolute® linear encoded measuring scale
• Expected battery life of three years
• Accessories for digital SPC-enabled models - IP67 rated connector
and cable; Digimatic™ gage/PC input device (USB, keyboard, and
RS-232C types) 142
 Electronic Height Gage
• Easy-to-read LCD display, and
intuitive control panel www.star
rett.com.
• Clear bar graduations,
resolution of 0.01mm, RS232
output, superior stability, &
full range of user functions
• Overall accuracy is ± 0.04mm
• Set ZERO at any position
• PRESET button to install any
reading at any position 143
PC based CNC controls

144
 Shop floor CNC Programming
• Manual Guide i Simulation Software
from GE Fanuc for offline use &
Windows based
• Turning, milling and compound
machining
• Easy-to-use icons; single CNC screen
• Component to be machined can be
created graphically and interactively on
the screen
• 3D machining simulation for both
turning and milling, including milling on
an inclined surface, helps reduce the
time for part program checking and
virtually eliminates errors
145
 CROSS HÜLLER
• Speed and acceleration of linear
motor drives with the improved
stiffness and rigidity of a parallel
kinematic construction for X and
Y axis
• 500mm x 500mm pallet;
16,000 RPM spindle; 25 HP /
37.5KW; accelerations of 2.5g
and velocities up to 180m/min
• Z-axis is powered by a
conventional ball screw and
servo motor combination to
provide higher feed forces than
possible with linear motor drives
• www.crosshueller.com
146
Parallel kinematic construction
for X and Y axis

147
 CROSS HÜLLER
• Twice the Production of Two
Single Spindles in nearly the
Same Space as One Single
Spindle Module
• Volumes in the 500,000 part range
• Each spindle has individual Z-axis
drives
• Patented guidance assembly with
more space between axis guide
ways
• Y-guide is equipped with an
additional guide rail between the Z-
slides
• One of the two Z-slides can be
equipped with an adjustable spindle
mounting in X and Y direction 148
 GIDDINGS & LEWIS & HÜLLER HILLE
BLUESTAR 5 HORIZONTAL
MACHINING CENTER
Tech Specs BLUESTAR 5
• pallet 500mm Security Package
• rapid rates 50mm/min • 2 year warranty
• acceleration 7m/sec • 96% guaranteed
• 180 deg pallet changer, uptime
load 500 Kg, 7 sec • life-time training
• 10,000/ 15,000 RPM • installation in 20 hrs
spindle; 18Kw
or else G&L pays
• Sk 40, chip-to-chip 3sec
149
Twin-spindle Machining
Center
• FEM optimized, thermo-
symmetrically constructed rigid
gantry column
• Machine bed designed as rigid
weldment, with steep slopes and
wide chip conveyor in transverse
direction to the Z-axis, to ensure
optimal chip removal
• Simultaneous machining of like or
different parts, such as left- and
right-hand parts
• Two separate, highly dynamic
quill units in Z-direction and two
separate chain magazines and • Speed and Z-axis feed can
tool changers be adjusted separately
150
• MQL is demanding on
machining accuracy
and control of thero
growth during
machining
process;funnel-shaped
stainless steel work
area enclosure shields
effectively against heat
transfer during
machining. •Chip-to-chip time of 2.6
• Exhaust system with seconds; HSK 63
air circulation •Rapid traverse of 60
minimizes heat m/min in all three axes
emission and extracts •14 m/s² in Z-direction
dust from air •10,000/16,000 rpm; 34 Kw
www.heller-machinetools.com
151
Flexible manufacturing system strategy for Tier
One Supplier when product life is unknown

Op1

Op2

Op3

Op4
1st yr

2nd yr
2nd yr

3rd yr Transfer
Prod
4th yr
vol Machine
4th yr
6th yr Transfer
Machine
0 500000 5th yr
152
 Agile system
• Permits debugging of design in first year (part design
change upto 4 months before m/c delivery as it only
affects fixtures & tools)
• Permits ramp up & ramp down
• M/c Centres ⇒ Dual Sp m/c centres ⇒ Transfer m/cs
⇒ Dual Sp m/c centres ⇒ M/c Centres
• All fixtures between CNC, Dual Sp CNC & Transfer
System are common; pallets are also common
• All tool shanks common; also m/c centres & transfer
m/c with head changers
www.heller-machinetools.com
153
 Reconfigurable
manufacturing systems
• To cater to frequent changes of product
demand, both in features & volumes
• Reconfigurable machine tools
• Reconfigurable inspection machines
• Methodologies & software tools for
system- level design & quick ramp-up
• New breed of engineering graduate
accustomed to interdisciplinary
teamwork
• http://erc.engin/umich.edu 154
 Production CNC
Machining Module
• Linear Tool Changer (LTC), 4 or
6 CNC machining module for
production of Al parts to reduce
toolchange time to <1 sec.
• Production machining app. use
< 20 tools, incl 24 or < op. &
require cutting cycle times of 3
sec. or less
• Cluster of 4 or 6 spindles,
eliminating toolchangers
• “Toolchange” time is 0.8 sec it
takes to position another
spindle on workpiece
• M/c centers able to achieve
15% productivity on Al part
with remainder used to position
and change tools - idle time
• Driven by single 15 kW motor
• CD is just 160mm
• Acc. spindle by 1000 rpm requires
only 0.1 sec
• Conventional machining centers
would use average of an add. 1.5 sec
in acc/dec time from and to 0 rpm.
• Rapid traverse for LTC is 60m/min
• Axis travels of 400mm X 400mm X
630mm
• Pos. accuracy of 0.01mm and
repeatability of 0.005mm.
• Stroke of 160mm
• HSK 63 tool holder
• Maximum tool diameter is 125mm
with a 5 kg weight capacity 155
 Examples of using LTC
• Aluminum steering knuckle, 13
tools required
• Total cycle time with m/c
centers was 143 seconds
• Tool change time was 5 sec
per tool
• Productivity increase of up to
75%
• End machining a crankshaft
would be a typical application
where total cycle time could
be reduced by 8-10 seconds
per part.
• Very useful module in transfer
or rotary transfer m/c www.licon.com
156
 SMARTTOOLS™
Multi-Functional Tools Reduce Cycle Times, Set-ups &
Cost
• Closed-loop boring systems that automatically compensate for tool wear without
operator intervention
• Diameter falls below a lower specification limit, the finish boring bar is then
brought back into the work zone and automatically adjusted
• Tool changeable plug air gauge measures the bore diameter and software
monitors the diameter and computes required coolant pressures
• Ability to program a taper and to remove a predictable tapered bore problem
• Superabrasive plated wheels for both face and ID grinding applications on m/c
centre
• Superabrasive honing process uses programmable through-spindle coolant
pressure to control the expansion of the superabrasive plated deformable
sleeve; tolerances due to additional fixturing and the need for flexible hone
connections are eliminated
• Special cutting fluids are not required for honing or grinding on m/c centre

157
 SMARTTOOLS™
• Long boring bar, with hydrostatic bearing support brings advantage of line
boring to m/c centres; through-spindle coolant to hydrostatically support
finish boring bar
• Back boring feed-out head that also utilizes coolant controlled feed-out
technology to finish machine final diameter of the bore
• Rough bore the cylinder on the “in” stroke, under minimal coolant pressure.
• At the end of the stroke (bottom of the cylinder), the coolant pressure is
increased, extending the finishing insert out past the roughing inserts to a
desired diameter from a programmed pressure value. Tool is then fed out
of the cylinder, thus finishing boring while retracting.

Attempting to get productivity of SPM on m/c centre

158
For SSI (Mom & Pop shops
in USA)
• Why go in for CNC Toolroom Milling
M/c

• Why go in for CNC Lathe in a toolroom

• Why probing as an effective SMED sol.

159
CNC Lathe for small batch prodn

• Directly convert CAD drawings into

programs and download CAM
generated programs
• Chuck sizes 6”, 8” or 10”
• 6,000 RPM
sorgm@hurco.com
• 12 station turret 160
 Micromachining Technology
• Focus on micromachining has captured the imagination of nearly every
industry segment, from the medical appliance industry to the automotive
world, and the potential in new and exciting products is emerging daily.
• Challenges revolve around economically controlling the micro
manufacturing process
• Thermal considerations, low vibration tooling, hybrid tool length
measurement, high-precision tooling & ultra precision feed back systems
• As one single degree of temperature change can affect precision when
machining at the submicron level, Makino Thermal Guard™ technology
encloses the entire machine in order to create a controlled working
environment.
• Capable of a tool change and machining with cutting tool with a step
variation of approximately 0.2 µm, and to program a part effectively using
0.1µm command increments
• Automatically wire thread a 20-µm diameter wire through a 70-µm start
hole; machine radii in the 17-µm range 161
EDGE2 Sinker EDM with
Fine-Hole option
• Fine-Hole machining option
capable of automatically
changing 0.0039-inch diameter x
12-inch long pipe electrodes
from the ATC unit.
• Fine-Hole machining option
capable of utilizing 0.0012”
diameter electrodes.
• Special electrode dressing
operations permit automatic
dressing routines to produce
electrode to as small as 0.00024”
diameter.

162
 Hyper2J Delivers Hyper Precision
For Micromachining
• Research institutes and
prototyping shops involved in the
manufacturing of precise and
detailed part; outstanding
submicron accuracy.
• Medical instruments,
biotechnology products, semi-
conductor devices, fiber optical
communications and optical
products like liquid crystal
displays and aspherical lenses
• Machine can be enclosed in a
“thermal chamber”
• Granite base for outstanding
vibration isolation and superb
thermal conductivity control; m/c
weight 5,000 Kgs
• Each axis is capable of
submicrometer movement
• 12 m/min. rapid and feedrate
• 0.5 nanometer scale feedback
• Positioning accuracy of +/- 0.3
microns, with a repeatability
accuracy of +/- 0.2 microns
• Work table size of 11.8 x 7.87
inches (300 x 200 mm)
• Direct-chucking 40,000 RPM
spindle, with an optional 170,000
rpm spindle
• Non-contacting spindle position
measuring device to minimize
microscopic level differences in
machined surfaces 163
Micromachining Technology

164
 UPJ-2 Horizontal Wire EDM
Machine
• Horizontal wire EDM machine
for automatically threading and
machining with wire as small as
0.02 mm through 0.07 mm
diameter start hole with 0.15
mm pitch
• Gears for micro-miniature
molds, fiber optics, inkjet
nozzles and medical
instruments
• Unique core and slug removal
unit improves particulate
flushing and enhances uptime
• Temperature inside the covers
to within 1 degree F (0.5
degree C)
• X-, Y-, and Z-axis travel are
200 x 200 x 60 mm, with the
U- and V-axis traveling +/-10
mm
• 50-nanometer (0.00005mm)
scale feedback
• Core removal unit, facilitated
by the horizontal wire travel
system adopted on the UPJ-
2, substantially improves
machine uptime by
automatically cutting out
cores following machining.
165
 V22 Compact Vertical Machining
Center
• Small and intricate molds for
plastic injection-molding
operations
• Ultimate hard-milling solution for
complex materials, including
ceramics
• 40,000-RPM spindle; Makino’s
patented core cooling and under-
race lubrication system
• Work zone and table size of 450
mm x 350 mm
• Rapid traverse and cutting
feedrates 20,000 mm/min
• Hybrid, automatic tool length
measuring device
• Tiny level differences can occur
at the seams of machined
surfaces due to tool changes
• Polishing these features to
correct such small levels is very
time consuming
• Tool tip position is measured
with low-contact pressure
probe, while the spindle nose
position is measured with a
non-contact sensor
• Straightness and
perpendicularity of 3 micron full
stroke.
166
UPJ-2 Horizontal V22 Compact Vertical
Wire EDM Machine Machining Center

167
 Align Adjustable
Height
Workbench
• Can be easily adjusted to
accommodate the worker with the
appropriate worksurface height
• Aligns with the worker's optimal
reach zone to reduce fatigue, stress
• Height of the worksurface can be
easily adjusted from 25 ½” to 41
½”
• Repair, testing and assembly of
mechanical and electronic products
and components, packaging,
calibration and R&D development
168
 Wet Blasting m/c boasts
superior finishing capability

• Abrasive blasting machine, but

with the added benefit of water
• Prevents heat generation,
decreases non-productive time
and provides a significantly
smoother finish
• Deburring, matte finishing, scale
removal, peening, surface
treatment, edge-breaking and
cleaning
• Engine parts, transmission parts,
turbo fans, clutch parts, fuel
injection nozzles, ABS parts and
even intricate workpieces
www.toshiba-machine.com.
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 CERBEC® Ceramic Balls
• Hybrid bearings (steel races and CERBEC balls)
• Machine tool spindles, aerospace instrumentation,
automobile wheels and gear boxes, electric motors, turbo
molecular pumps, centrifugal pumps, vacuum pumps,
robotics, and power tools
• Lower thermal expansion, higher hardness, higher stiffness,
lighter weight, increased corrosion resistance, and higher
electrical resistance that increases performance
• Decreased lube degradation and less wear, yielding longer
bearing life; higher operating speeds, such as in the case
for spindles, result in increased productivity; and reduced
product downtime with less maintenance provides higher
product reliability
• Larger ceramic balls spaced by smaller steel balls
• Using both ceramic and steel balls, which resist adhesion,
provides higher load capacity, greater reliability, and an www.cerbec.com
enormous increase in the number of cycles. 170
 Advancement in Inertia
Friction Welding
• Radial “orientation” – • Better accuracy and repeatability due to
possible using Inertia more spindle position adjustments for the
Friction Welding cycle. same weld.
• Spindle position • Better accuracy and repeatability
adjustments required to because the adjustments to spindle
achieve orientation occur position are smaller.
during the time that the • Small adjustments don’t require over-
spindle decelerates from specified drives and motors.
Weld Speed to Zero
• Orientation is achievable with very fast
• Any weld that can be welds without sacrificing accuracy or
made with the Inertia weld quality.
Welding process can be
– Aluminum and Aluminum tubing
oriented with the Inertia
Welding process – Thin wall tubing.
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Orientation in Inertia
Friction Welding

www.mtiw
elding.com

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Stores & Inventory Control

173
Stores &
Inventor
y Control

174
 Bi-Metal UNIQUE™ Saw technology
with revolutionary solid-state
diffusion bonding
• Resistant to breakage, cut fast, and last longer
• Joins two strips of high-speed steel wires to a backing steel in solid phase
• 170% more weld contact area compared to existing bi-metal high-speed steels
• Teeth develop a groove in the very thin center of backing material at cutting
edge to create Multi-Edge Performance™
• Produces dual chips that are more easily removed from the cut & allows
access to coolant
• 20% faster cuts and 22% longer blade life

www.starrett.com

175
 LOW VIBRATION
DAMPING BALL SCREW
• Vibration damper inside
hollow ball screw shaft
greatly improves
positioning accuracy
• Low noise through
reduced vibration &
higher speed
capabilities
• Operation beyond
resonance point &
improved surface www.thk.com
finishes
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• Ball thread shaft
177
 E-exhibition
• On IMTS website there is an e-exhibition, which
continues after the actual exhibition
• Also contact details of all dealers of machine tools
are readily available in case some Indian
manufacturer is searching for a dealer.
• All visitors had e-cards, which were swiped for
additional info.
www.IMTSNET.org

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