IGTR visit Report

Indo-German Tool Room visit report at Ahmedabad, Gujarat.

1. A
Report on
Industrial Visit
At


“INDO GERMAN TOOL ROOM
AND
CIPET”




Submitted
To
Prof. Dr, Komal Dave




Mechanical Engineering Dept.
L.D. College of Engineering, Ahmedabad
Gujarat Technological University

2. Acknowledgement

The tree of knowledge grows best when it has sturdy roots and the strength of them is clearly
depend upon our intention. During the journey of knowledge we meet certain people who play a
pivotal role in our development and it’s a privilege to thank them for the same.
We are very grateful to IGTR and CIPET for letting us to do this visit. We express our gratitude
to Prof. Dr. Komal Dave and Prof. B.C Khatri who have guided us throughout this visit. We
are really thankful to employees of IGTR and CIPET who have been guided us in this path step
by step and have our path really simple to get through. It is due to their encouragement valuable
guidance and direction for this Industrial visit, which would not be finished without their help.

 Purpose of the visit
1. To gain the better knowledge about various machines used while processing the product.
2. Understanding the use of various CAD/CAM software used in industry
3. Learn about various specifications of different machines
4. Interact with the company personnel
 Duration
Duration of the industrial visit in both companies was from 10:15 am to 3:30 pm.
1. IGTR – 10:15 am to 1:30 pm
2. CIPET – 2:15 pm to 3:45 pm

3. Indo German Tool Room Ahmedabad (IGTR)

 History
Since liberalization of the economy established in 1994, India faces strong international
competition. Thus, growth and diversification of its industry are increasingly characterized by a
shift from simple to technically complex products. Many enterprises aim at high value-addition.
Modernization and automation of production processes increase productivity and reduce unit cost.
This is particularly true for the engineering industries (metal and plastics processing ventures) as
well as small and medium-scale enterprises (SME). They manufacture tools and molds or use them
for producing parts, components, systems, and final products, often as sub-contractors of large
enterprises. In recent years the quality of their products and the efficiency of their production
processes augmented considerably. Nevertheless, many SME still face constraints. They are
related to rapid changes of the market and accelerated technological progress.

 About the company
Indo German Tool Room, Ahmedabad is an institute for Tool & Die Making and training. IGTR
is strategically located in the city of Ahmedabad, the business center of Gujarat. IGTR ahmedabad
is equipped with the latest European machines and a motivated and trained professional team.

1. IGTR Ahmedabad is a nationally known source for designing and manufacturing of
international quality of plastic moulds, press Tools, Die Casting Dies and Jigs & Fixtures.
2. IGTR Ahmedabad undertakes precision machining job work using states of art machines
and software.
3. IGTR Ahmedabad offers Long Term, Medium Terms and Short Term training in the
areas of Tool & Die Making and CAD/CAM CAE.
4. IGTR Ahmedabad provides cultured, disciplined and day one productive manpower.
5. IGTR Ahmedabad offers specialised digital technology services in the area of product
development using CAD, CAE & RPT as well as tool analysis.
6. IGTR Ahmedabad offers quality control services including reverse engineering third
party inspection using latest equipments.
7. IGTR Ahmedabad offers plasma binding and metallurgy lab services.

4.  Various Machines and processes observed at IGTR
1. Wire Cut EDM
Machine Name: Charmilles Robofil Model
510 Wire EDM
Software used for Path generation of the profile
on the workpiece was PEPS software
Specifications:
 Max Workpiece Dimensions:
33.5” x 19.7” x 15.25”
 Max Workpiece Weight: 4400 lbs
 Max Taper Angle: 30 degrees
 Diameter of Wire for Threading:
0.004” to 0.012”
 Dielectric used is distilled water

2. Electric Discharge Machining (EDM)
Machine Name: Mitshibushi Electric EA 28
V
Specifications:
 Maximum workpiece Dimension
(WxDxH): 850 x 600 x 350 (mm)
 Maximum workpiece weight: 2000 kg
 4- Axis machine X, Y, Z & C (Circular)
 Electrode used was Copper, Copper &
Tungsten and Graphite
 Electrolyte used was kerosene/oil






3. Vertical Machining Center (VMC)
Machine Name: HAAS Milling machine VF3
Specifications:
 Travel- X Axis-1016 mm, Y Axis-508 mm, Z Axis-635mm
 Maximum Weight on table: 794 kg
 Haas Controller was used
Figure 1: Wire EDM Machine
Figure 2: EDM Die Sinking machine

5. 4. Injection Molding Machine
Machine name: Aswa 650T
Specifications:
650 ton Clamping force
Maximum product weight 4.1 kg
Process

Other Injection molding machines were:
a. Aswa 100T /210 gm
b. Aswa 350T / 1.2 kg


5. Heat Treatment Machine
Machine Name: Plasma Nitriding System
Specification:
Maximum Loading: 500 kg
Vacuum Chamber size: 1 meter diameter and 1 meter height
Power Supply : Pulsed DC 1000 V





Plastic
beads
Barrel Heating (Zone wise)Pumping through nozzleSprue
Cavity &
Filling
Cooling
Figure 3: Vertical Milling Machine

6. 6. Profile Projector
Machine Name: BATY International SM 20
Specification:
 X, Y and one Rotational measurement
can be done
 X Axis – 50 mm, Y Axis – 150 mm
and Rotaional – 360
o

 Maximum 2 kg workpiece can be
placed on the profile projector table
 Used for only measurement of 2-D
dimensions
 Accuracy 2 microns
7. Coordinate Measuring Machine
It is used to measure 2D or 3D dimension’s using ruby
probe of minimum diameter as per requirement.The path of ruby probe is generated by Elipso
software

8. 3 D printer
i. Machine Name: Fortus 360 mc
Method: Fused Deposition Method
Machine Price: 4.5 crore
Material of cartridge: ABS (Acrylonitrile Butadiene Styrene)/PC (Poly Carbonate)
Table Dimensions: 250 x 350 x 250 (mm)
ii. Machine Name: Concept Laser Hofmann Innovation
Method: Selective Laser Sintering (Metal prototyping)
Powder Material Used: CL-50 WS (Hot worked steel), CL 20 ES (Stainless Steel), Inconel,
Invar 36, CL 91 RW (Stainless Hot Worked Steel), CL 100 NB (Nickle Based Alloy), Tool
steel. 30 to 80 micron layer of powder. Software used for modelling: Megics software

Figure 4 Profile Projector
Figure 5: (i) Fortus 360 mc (ii) Concept Layer Hofmann Innovation

7. CENTRAL INSTITUTE OF PLASTICS ENGINEERING &
TECHNOLOGY (CIPET)
 OVERVIEW
Central Institute of Plastics Engineering & Technology (CIPET) was established in 1968 by
Government of India with the assistance of United Nations Development Programme (UNDP) at
Chennai. The main objective of setting up of the institute was to develop manpower in different
disciplines of Plastics Engineering & Technology as no similar institute was in existence in the
country. International Labour Organization (ILO) served as the executing agency. During the
initial project period between 1968 and 1973, the institute achieved the targets envisaged and was
rated as one of the most successful UNDP projects implemented worldwide. Today CIPET is a
premier national institution under the aegis of the Ministry of Chemicals & Fertilizers, Govt. of
India fully devoted to Skill Development, Technology Support Services, Academic and Research
(STAR). CIPET operates on hub & spokes model with 28 locations - 5 High Learning Centres, 12
Other Learning Centres, 3 Specialized Centres, 2 R & D Wings, 5 Vocational Training Centre, 1
Petrochemical Data Services spread across the country catering to the needs of Polymer and allied
industries. 11 more centres are in the process of establishment.
CIPET stands tall not only as a premier institute in the country but also emerged as a global
institution renowned for its research & development in the niche areas of Polymer Science &
Technology and high quality Education & Skill development in the field of plastics. CIPET has
been accredited with ISO 9001:2008 QMS, ISO/IEC - 17025, ISO/IEC - 17020 certification on
Design, Development and Conduct of specialized training courses in Plastics Engineering &
Technology and rendering technical /consultancy services in design, tooling, plastics processing
& testing for the benefit of plastics & allied industry. Besides, STAR activities, CIPET also plays
pivotal role in generating employment opportunities especially for unemployed and
underemployed youth, promoting entrepreneurs though various skill development training
programs.
Headquartered in Chennai, CIPET has centres at Ahmedabad, Amritsar, Aurangabad, Baddi,
Balasore, Bhopal, Bhubaneswar, Chennai, Gurgaon, Guwahati, Gwalior, Hyderabad, Hajipur,
Haldia, Imphal, Jaipur, Kochi, Lucknow, Madurai, Murthal, Mysore, Raipur, Valsad and
Vijayawada. All the state-of-the-art centers are equipped with excellent infrastructure facilities in
the areas of Design, CAD/CAM/CAE, Tooling & Mould Manufacturing, Plastics processing,
Testing and Quality Assurance with plan fund support from Government of India. The
infrastructure facilities in terms machinery, Equipments and technology are continuously upgraded
and modernized in tune with needs of plastics & allied industries.
CIPET renders Technology Support Service in the areas of design, tooling, plastics processing and
testing and quality assurance in India and abroad. CIPET has been in the forefront of strengthening
the technological capabilities and has been constantly building capacities and leveraging its
expertise, caliber and skill sets to meet the emerging and evolving needs of the industries.

8. CIPET works in close liaison with industries to implement its initiatives in the areas of Polymer
and allied industries in accordance with the environmental policies of the country. CIPET's
sustained efforts in creating awareness on environmental issues towards plastics and plastics waste
management has been very well received by the industry.
 ABOUT CIPET - AHMEDABAD
CIPET Centre in the state of Gujarat was established at Ahmedabad in the year 1984 to cater the
need of Plastics industries of the Western part of the country.
CIPET campus is spread in an area of 9 acres of serene environment conducive for academics and
is located at "Vatva GIDC Industrial Area" at Ahmedabad with all the necessary infrastructural
facilities.
CIPET is divided into Four department that are
1. Tool Room
2. Design (CAD, CAM & CAE)
3. Processing
4. Inspection & Testing

1. TOOL ROOM
The Tool Room of all CIPET centres makes it an ideal tool room for any tool maker. All CIPET
centers are well equipped with ultramodern, state-of-the-art Tool Room machines and CNC
machinery that enable the centres to handle commercial job assignments for mould fabrication,
high precision machining and manufacturing of standard mould bases for plastics products of any
profile, shape or complexities. Besides, the tool rooms also undertake job orders of varying
magnitude such as repair of moulds and dies, CNC machining, CNC spark erosion, grinding,
drilling, designing, development of jigs and fixtures, tool parts etc.
FACILITIES AVAILABLE
CNC MACHINES
 Universal milling and boring Machine
 Die sinking - EDM
 Universal lathe with hydrobar feeder
 High precision surface and profile grinder
 Wire cut EDM
 HAAS USA High Speed 5 Axis machining centre
 HAA USA High Speed 3 Axis Machining Centre
 CNC EDM Spark erosion Machine

9. i. Chakra BMV-60
Specifications:
a) X/Y/Z – 1050/610/610mm
b) Table – 1250 x 600mm
c) Rapid rate – 32 m/min
d) Spindle – BT40,8.000 rpm,11kW
e) Siemens 828D CNC
f) 24 Tools
g) Coolant Gun
Machine Unique features
a) Three strategically positioned support points with co-axial anchoring Bolt & levelling
screws for quick levelling.
b) Precision LM Guideways and Ground Ball Screws in all 3 axes
c) Higher Z- stroke for Bigger size components
d) Higher rapids on all 3 axis
e) High accuracy rigid spindle for precision machining including boring (Spindle bearing
dia 80mm).
f) Easy & close access to table / spindl e
Centralised lubrication for all three axes.

Figure 6: Chakra BMV-60

10. ii. EDM Drilling Sparkonix
Specifications
 Electrode pipe Diameter - 0.3 to 3.0 mm
 Max Drilling Depth - 300 mm
 Work table size ( L X W ) - 600 x 450 mm
 Travel -X axis - 450 mm
 Travel – Y axis - 350mm
 Travel – Z axis - 300mm
 Travel – W axis - 230mm
 Measuring system - Absolute Encoder
 X ,Y & Z axis feed rate(max) - 1000 mm/min
 Maximum work piece weight - 350 Kg on machine table
 Maximum work piece height - 300 mm
 Net weight of the Machine - 2300 kg
 Machine Floor Area - 1750 (2500 Arm Extended) x 1950 mm

Figure 7: EDM Drilling
CNC Controller
 Siemens 828 D Dedicated control unit
 Controlled/Programmable Axes : Standard X,Y,Z,W

11.  Simultaneous controlled axes : X,Y,W
 Monitor: High quality 10.4” TFT color display
 I/O of programs & data transfer: Ethernet,USB port & CF card
 Minimum programming increment: 1 µm
 Program/Data store capacity: 3 MB
 Electronic hand wheel : For manual axes movement
iii. BFW F30
Specification
X-Axis – 1280 mm
Y-Axis – 700 mm
Z-Axis – 650 mm
Table Size – 1500x650 mm
Max Load on table – 1200 kg
Spindle Speed – 8000 rpm
Tool Storage Capacity – 10


Figure 8: BFW F30

12. 2. DESIGN / CAD / CAM / CAE
Facilitated with the latest systems and software, the Design and CAD/ CAM/ CAE departments of
CIPET provide world class technology and engineering services. With an excellent combination
of engineering knowledge and software skills and industrial experience, CIPET offers spectrum of
engineering services in CAD, CAM and CAE that results in fulfilling the design and engineering
requirements of the customers across the globe. The departments provide services to the plastic
and allied industries in the following areas.
 3D solid Modeling
 Plastics Product Design and Mould
Design
 Plastics Flow analysis
 Failure analysis
 Finite Element Analysis (FEA)
 Reverse Engineering
 Rapid tooling
 Product/ mould design validation
 Optimization of process parameters
 Manufacturing Automation
 Rapid prototyping and Rapid tooling
 CAD/ CAM/ CAE software training
MAJOR SOFTWARE RESOURCES
 MASTERCAM x2
 Solid Edge
 IDEAS
 CIMATRON
 UG MOLD WIZARD
 LS DYNA
 Pro - Engineer
 Unigraphics
 CATIA
 AutoCAD
 ANSYS
 Hypermesh
 Moldflow

3. PROCESSING
CIPET is equipped with the state-of-the-art processing machinery like double colour Injection
moulding machines, micro processor control machines, all electric machines, multilayer blown
film machines, stretch blow molding machines (at selected centres), roto molding machines, etc.
As a measure of providing hands on training to the students on commercial moulding and
processing of different plastic materials using various process parameters, CIPET is undertaking
precision job orders in the areas of:
 Inspection, proving and evaluation of moulds and dies and moulding of components.
 Testing of mouldability and optimization of processing conditions/parameters.

13. Further CIPET also conducts dedicated moulding/processing seminars for the benefit of the plastic
processing and recycling industries.
4. TESTING
Equipped with the modern equipments, the Plastics Testing Centres (PTC) of all CIPET centers
are accredited with ISO / IEC - 17025 Standards by National Accreditation Board for Testing &
Calibration Laboratories (NABL). CIPET provides complete range of analysis for polymers,
plastics and composites and provide best services to the Plastic and allied industries by undertaking
assignments of plastics materials/ products/ composites testing as per various National and
International standards.

CIPET's Plastics Testing Centre (PTC) is one of the best plastics testing facilities in Asia. CIPET's
testing laboratories are accredited with ISO/IEC-17025 standards by National Accreditation Board
for Testing & Calibration Laboratories (NABL) and also recognized by Bureau of Indian Standards
(BIS) for third party certification of plastic products as per various Indian standards.

 CONCLUSION
A one day Industries visit at IGTR and CIPET has fulfilled all its objectives namely to get an
exposure to what is being done at the level of the industry and also to learn more about various
CNC machine and there machining processes such as CNC Turning, CNC Milling, CNC Wire
EDM Cutting, Extruder, Dimensioning Measuring At precise level, 3D Modelling etc. The Visit
has helped us to understand these all Machines ant there Process.
This has been a unique learning experience as a student as this Visit made the theory and practical
aspects of machines applicable at same time and experience it.