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Issue : XXXXIX March 2016
1
Dear Fellow Engineers ,
Thank you for the wholehearted support to us.
In this issue we are publishing article on “SERVO DRIVE TECHNOLOGY IN FORGING APPLICATIONS”- Ninad Sant, Manager (Sales),
Schuler India Pvt. Ltd., Mumbai. & also a special note on short meeting had with M. P. Jalan ,
With a view to increase dialogue, interaction amongst forging industry professionals, we have initiated activities such as
having suggestion from advisory board, dialogue with successful entrepreneurs and interview of worker.
We hope you take advantage of this initiative!
Please do share your thoughts and valuable feedback with us. Articles are welcome.
Chairman, Ramkrishna Forgings Ltd to
seek his guidance.
These are the encouraging words of Mr. M. P. Jalan, He advised to include “International Market Opportunities &
Chairman, RAMKRISHNA FORGINGS LIMITED when Business meets” also. He supported the idea of organising
group of Forging Technology Forum consisting of Mr. R.T. International Buyers' visit to reputed Forging Units of India.
Kulkarni, Mr. K. C. Gogate, Mr. Kiran Ambike and Mr. G. N. He also assured his all support to make this event a grand
Rao met him during his recent visit to Pune. Objective of success.
the meeting him was to seek his guidance for the proposed He also advised to organise some Training Programmes in
INTERNATIONAL CONFERENCE AND EXHIBITION ON Eastern side for the benefit of forging units in that region.
FORGING TECHNOLOGY FORUM DURING OCT. 2017.
YOU ARE ALL DOING VERY GOOD INNOVATIVE AND USEFUL ACTIVITIES FOR THE BENEFIT OF INDIAN FORGING FRATERNITY - M. P. Jalan
Chairman, Ramkrishna Forgings LimitedAdvisor, Forging Technology Forum
2
SERVO DRIVE TECHNOLOGY IN FORGING APPLICATIONSNinad Sant, Manager - Sales,
Schuler India Pvt. Ltd., Mumbai. E-mail: [email protected]
1 Introduction transfer from forming station to forming station also must be
considered. We can subdivide the motion into three basic When looking at the future potential of materials, the
sections. These are:subject can be approached from various perspectives.
There exists the possibility of achieving improved results Ÿ Forming process / die process
when using a certain material or of achieving some specific Ÿ Die opening
advantage using a different starting material. These
approaches are nothing new and have already been Ÿ Transfer window and auxiliary functions
successfully employed. This has led to the optimization of 2.1 Optimization of processing sections
traditionally available combinations within forming
systems. An expansion of the limits of such systems, The "forming process" section is determined by the
however, was only possible by means of small steps. It was material-specific parameters and the shape of the
only with the introduction of servo drive technology that it workpiece. Other factors include the permissible forming
has become possible to consider a major transformation in speed and tool-related characteristic features of the
system limits. In this process, particular attention is paid to forming. This is the critical section of the entire process, in
the material selected for use, since this factor accounts for which the workpiece quality is most significantly influenced.
the largest part of the cost. Using servo-drive technology this section can be expanded
to include "Keep die closed for auxiliary functions." These Since the introduction from press builders of servo-drive
auxiliary functions can be bi-directional forming or technology, the optimization potential of changing from
additional processing functions up to and including joining traditional drive forming presses to servo-drive presses is
functions.well known. In the meantime, new processing sequences
As a rule, the die opening" should take place as rapidly as have been achieved by intensive use of programmable
possible since no changes to the workpiece are being motion characteristics in combination with innovative tool
performed. For the subsequent transport of parts, technology.
accessibility between the die halves should also be created
What follows here is a re-examination of the basic as soon as possible. On the other hand, a slower opening is
information regarding the possibilities of influencing the required to allow for die-related functions such as spring or
forming process. Building on this, we will show what cylinder-actuated slide valves.
potential has been opened for existing processing methods For the section 'Transfer window / auxiliary functions" it is
—using examples of results already achieved also true that no workpiece changes are being performed
commercially. We will also show how the integration of and thereby should be traveled through as fast as possible.
secondary operations into the forming process can be On the other hand, there are also physical limits for the
achieved, specifically including mechanical and assembly transport of workpieces with an automated transfer system
steps as well as welding operations. In this way the or the required time for auxiliary functions, such as tool
processing steps for components can be consolidated, cooling and lubrication that are sometimes necessary in
thereby shortening the entire production sequence to the cold forming.
finished part.
A variable time-travel principle is required for independent The logical continuation of these developments will be a
optimization of the three motion sections. This can be consideration of the range of application for servo-drive
achieved by changing the nominal stroke rate throughout presses in terms of component design and the
the entire cycle. In other words, the press drive changes its configuration of the manufacturing sequences.
nominal stroke rate during its 360° cycle in order to achieve
2. Process optimization by changeable motion the optimal speeds within the various sections of the motion
characteristics curve.
The selection of the drive concept has always been based 2.2 Influencing the motion curve by servo technology
upon the consideration of the required forming process and The ideal motion curve for the overall forming process can
related tool technology. In multi-station processes, part be achieved by adapting the motion in specific sections of
3
the curve. 3.3 Integration of joining processes
2.3 Pendular stroke and programmable stop An optimized process with an integrated spot welding
operation. The production rate was doubled.The freedom of curve definition permits completely
different motion characteristics while using the same
press. Thus, a sinusoidal eccentric motion can be
changed to a motion curve of a link drive press or, by use
of the pendular stroke function, the stroke length can be
reduced by the required amount. In addition, the drive,
pendulates " around bottom dead center (BDC)
depending on the required stroke length as per a
programmed crank angle. In this way the curve shape can
be further influenced.
For the integration of auxiliary processes, dwell times can
be inserted, in which the continuous motion can be
interrupted. This can also take place within defined limits
under programmable load in BDC.
If a process requires a slow forming speed due to
material-specific properties at ambient temperature, the 3.4 Process integration and combination of cold and overall cycle can be optimized by opening the die and warm formingtransferring the part at maximum speed.
Complex manufacturing processes can be shortened in 3 Application examples the forming process. In this way, it is also possible to
combine semi-finished products into one single part.3.1 Example of optimal forming speed
In this example a combination of cold forming and warm Here optimization was applied to the die process, die
forming creates an integrated billet out of two billets and, opening and transfer window sections of the curve. In
in addition, the material forming limits are expanded. addition to the improved part quality, the cycle time was
Within the press pass a change to warm forming is made. reduced from 2.5 seconds to 1.5 seconds.
In this way all of the potential of the material can be
utilized.
3.5 Summary
The use of servo-drive technology allows utilization of the
full potential of our materials.
The use of servo-drive technology permits the optimal
adaptation of the press movement to the total process.
Complex components with a high number of forming
stations can thus be reliably formed on servo presses.
Interruption of motion in the range of BDC offers the
possibility to integrate additional mechanical processing
steps, forming operations, heat treatments, and joining/
assembly operations. In this way, processing sequences 3.2 Process integration with curve dwell involved in manufacturing components can be drastically
reduced. Or, heating the component in the press pass If the time defined by the forming process does not allow
permits switching from cold forming to warm forming, for the integration of processes at the stroke return point
thereby making greater degrees of material deformation (BDC), then the motion curve can be adapted by
possible.programming a dwell time. This leads to a longer cycle
time but permits a shorter overall processing time by These new possibilities in forming systems open new integrating subsequent downstream processes into the potential for improving material applications and material forming process. utilization.
Mr. K. C. Lathesh – CEO of ForgePro India Pvt. Ltd. had meeting with Mr. R D Mehta (Co-Editor Metal Forming Magazine) on 27.01.2016 at the plant. Mr. Lathesh has replied pleasantly for his company, goal and for his role.
RDM : Good Morning Sir, Please tell me about your
childhood & education.
RDM : Why you have selected engineering?
RDM : What you did after Diploma?
RDM : How you have balanced your career & family?
RDM : Please share your career path till date?
RDM : Can you please tell more information about your
current company?
RDM : Please share operational areas in which you
have expertise.
KCL: I am a farmer's son from a village called Thirthahalli in
Shimoga district, Karnataka. I did my schooling upto
S.S.L.C in Government. School which was situated 4Km
away from my home. I used to walk both ways, as there was
no public transport available at that time. The journey was
so furious, as lot of wild animals were crossing the road. We
used to get heavy rain fall during rainy season close to 6
months & electricity was abrupt.
I did Diploma engineering in Metallurgy from Bhadravati.
I have 35 years of work experience at various levels in KCL: I was interested in Engineering field specifically engineering industries. As a Top Management employee, inclined towards Material Science & pursued in Metallurgy.Handled green field projects, design of dies/tools,
processes, selection of equipment & vendors, product
realization, estimation & costing, marketing including KCL : After completing Diploma, I realized that the Diploma quality management & finance.qualification is not enough to pursue my childhood ambition
to become a technocrat. Then I joined National Institute of Attended many management trainings around the world, Foundry & Forging Technology, Ranchi. Getting selected to visited forging industries in Japan, Russia, Germany, this prestigious Institute was not easy. Their selection France, Switzerland, Taiwan, China, Ukraine and USA. I process was so tough, that only 2 students (7th Batch) were had implemented many world class manufacturing system selected from Karnataka, I was one among them. Only 12 in the plant with the knowledge gained thru visiting forging students were passed out of 45 at the end of second year. industries. I was the pioneer in technology transfer from
Daifuku Webb Company, USA.I did specialization in Forging Technology in 1980. I was
fortunate to get selected by Bharat Forge, Pune in Campus
Interview.KCL : I have been very particular with my responsibilities
towards my career & family life. I am giving equal priorities
to my family & career. The moment I get free from my work, I KCL : I started my career as shift engineer & promoted to Sr. directly go to home, discuss with family members about Engineer in 1984. Later Joined Trinity Engineers, Pune as their routine activities, problems along with future plans.Forge shop Superintendent till December 1988.
I have two daughters, elder daughter studying M.S in Joined as Works Manager in Apten Forging, Bangalore in Virginia Common Wealth University, USA and younger the year 1989 till 2002.daughter is studying Architect Engineering in Bangalore.
Joined Bill Forge, Bangalore as Assistant General Manager
in the year 2002, promoted to Dy. General Manager in 2005
and I left the organization in 2006.
KCL: ForgePro India Pvt. Ltd., Bangalore is owned by Since 2006 I am working as CEO/President at ForgePro Daifuku-Webb, USA, worldwide leader in providing India Pvt. Ltd., Bangalore which is a subsidary of Daifuku solutions to all material handling systems.Webb Company, USA.
The company is engaged in manufacturing high precision & In the year 2011 I have been promoted as Director & durable closed die steel forgings in the range of 25 grams responsible for conducting Board of Directors meeting.to 10 kgs.
ForgePro established in the year 2006 in Bangalore and
started its operations in Jan 2009 to meet the growing KCL : I am working for an multinational USA based forging
needs of the market; we produce high quality products & company as CEO/President/Director.
deliver the products in time. We are committed to exceed
4
customer satisfaction through continually improved Bench marking with best forge shop
processes & employee involvement.World Class material handling system & Facility
Piece rate contract
KCL : Yes of course ! by nature I like to accept challenges & KCL : I suggest young generation to followwin them. Challenging phase came into my life, when I
joined ForgePro India Pvt Ltd. Since I was working under P Positive attitude towards workmanagement of the company based in USA (as I said
Think for big always & aim highearlier). I have came across number of challenges in order
to meet the strict norms, specifications from day one; as we Implement morning dreams
are manufacturing critical components. It is vital to maintain Complete the work on the same day
same norms, specifications because the components are Be leader in the teambeing made in USA.
Sincere, hardworking & to be on timeI am successful to make plastic free company with the
strong effort of my company. Enjoy working on any department
Be with good people & move with them
Respect others, be a good listenerKCL:
Plan your life cash flow & spend with in the cash flowZero accident, Safety First
Respect time managementPlanting Trees to maintain 'Greenery'
Innovative mind
RDM : Is there any challenging phase through which
you have gone in your career?RDM : What are the suggestions for young generation?
RDM: Which are the policies & quality norms of your
plant?
P
P
P
P
P
P
P
P
P
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The Best Article onCost Reduction thro Low Cost Automation
Cost Reduction thro Process Control
or
By Shop Floor Engineers
Last Date to Submit Article is 31.3.2016
ARKEY TECHNICAL TRAINING AND RESEARCH INSTITUTEAnnounces
Win
` 5001
to
An Award` 5001
5
3 Months Course - Jointly with VITFor details contact :
Mr. D.G. Chivate,
M : 9422010972
E-mail :[email protected]
SHOWCASE OF FORGING DEFECTS
We appeal to forging units to
Send defective Forgings to
FOUNDRY & FORGING TRAINING CENTRE
“WILL BE USED FOR TRAINING”
SHOWCASE OF FORGING DEFECTS
We appeal to forging units to
Send defective Forgings to
FOUNDRY & FORGING TRAINING CENTRE
“WILL BE USED FOR TRAINING”
CASE NO.
PROBLEM COMPONENT ANALYSIS
1DIE
BREAKAGE FREQUENTLY
DIE BREAKAGE FREQUENTLY
TOP DIE COUNERLOCK BREAKAGE CAUSING INTERRUPTION IN PRODUCTION AND WAS UNABLE TO COMPLETE THE SCHEDULE.
2 POOR YIELD
( 67% )HORIZANTAL STUB
AXLE FRG.
1) EXCESS FLASH THROWN IN GUTTER AT STEM SIDE .
2) UNEVEN FLASH PATTERN.
3) LOWER PROFIT MARGIN AS COMPARED TO OTHER ITEMS.
3WEB
DISTORTION4- CYLINDER CRANKSHAFT
1) TOP AND BOT. COUNTER WTS. GETTING DISTORTED.
2) DEFECTIVE PRODUCT QUALITY.
3) UNBALANCED CRANKS.
4POOR YIELD
( 69% )4 CYLINDER
CRANKSHAFT .
1) EXCESS FLASH THROWN IN GUTTER ALLOVER .
2) FLANGE FLASH MORE.
3) LOWER PROFIT MARGIN AS COMPARED TO OTHER ITEMS.
FOR LEARNING/TRAININGFOR LEARNING/TRAINING
Suggest SOLUTIONS
FORGING TECH FORUM’SACTIVITIES
FORGING TECH FORUM’SACTIVITIES
FORGING TECH FORUM’SACTIVITIES
FORGING SOLUTIONS CENTRE - SPECIALLY FOR MSME
: Contact for :
Technical Assistance Metallurgical Problem Solving
Worker's Training Programme Rejection Reduction
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PROPOSED QUESTIONS FOR WORKER INTERVIEW- Mr. Prafulla Kumar Sethi, ForgePro India Pvt. Ltd.
Mktd by : New Tractor Parts. [email protected].+919923400594
ITALIAN TESTING EQUIPMENT
Conference on
Theme : PROGRESS THROUGH PARTNERSHIPFORGING TECHNOLOGY
22nd – 23rd September 2016 | Hotel Sun-n-Sand, Pune. Call f
or
Paper
TOPICS SUGGESTED
, R.D.Mehta
Ÿ Simulation Applications
Ÿ Cost Reduction Through Low cast Automation / Process
Control
Ÿ Developments in Steels / Raw Material / Die Steel
Ÿ Quenching Oils
Ÿ Development in Induction Heating
Ÿ Heat Treatments - Furnaces, processes
Ÿ Energy Saving Techniques / areas – case studies
Ÿ Maintenance of Hammer and Presses
Ÿ Die life enhancement
Ÿ Yield Improvement
Ÿ Use of Optimization Die Lubricants
Ÿ Gas as Alternate Fuel
Ÿ Vendor Capability Development Strategy
Ÿ How value added activities will help each other.
Ÿ Self Certification.
Ÿ Parts Development through partnership
Ÿ Challenges / constrains of MSME
Ÿ A Panel Discussion with theme “Joint initiatives for cost
reductions” Ÿ SMED Techniques
Confirmation of Tittle of the paper and name of the Author by 15th April, 2016
The Abstract of the paper shall reach us by 15th May, 2016
Full text of the paper by 30th June, 2016
