01 OVERViEW

02 MY CONTRiBUTION

My work in Machining to Grinding (M2G) projects catered all these three domains:

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1. Feed Optimization Algorithms:
   In a team of three, I devised a process algorithm where the surface velocity of work-piece varies as per the radius of curvature of the profile to reduce the cycle time by almost 20% while maintaining surface integrity as compared to regular method of constant angular velocity. Another algorithm was programmed by me to eliminate burn on the high contact area through constant temperature process, where temperature of grinding surface is maintained constant irrespective of radius of part. 
    

2. Path Planning Software: (First of its kind in India)
   Complex, non-round and asymmetric profiles of work-piece meant requirement of a software to generate the tool path in the machine controller for synchronizing relative rotational movement between tool and work-piece. My teammate and I have programmed both front-end and back-end of a desktop software application, called GrindZen, that includes profile analysis, process planning and visualization interface. This CAD/CAM software was developed in Qt on C++ platform with an interactive and user-friendly GUI that can take in various formats of profile coordinates and gives out final learning control codes (P codes) directly transferred to the machine. This desktop application assimilates the feed optimization algorithms developed earlier and uses FOCAS to establish direct communication to the Fanuc CNC controller.
    

3. Process or Application Engineering: 
   As a team of three, we developed a digital knowledge database of more than 40 conventional wheels and 10 super-abrasive wheels tested for the application, including the process signature using GrindTrak and the output quality report. I have also successfully implemented the software and validated the process using a super-abrasive cBN wheel, that led to a purchase order worth nearly 2 Crore INR to MGT.

This assignment required close involvement with Customers, Partnering companies and as well as the entire MGT team. I have expanded my NRG application skills to this M2G process development which posed a large set of challenging constraints and demanded deep analytical skills along with bias for action. Although my core contribution has been on producing many programs and processes for achieving the target, I have actively interacted with almost all the departments, including the purchase and vendor logistics, to ensure timely delivery of the results for internal deadlines. These cross-functional skills enabled me to be more result-oriented and even helped me step up to take complete responsibility of the project in its critical phases as well.

A complete package of Computer-Integrated Manufacturing (CIM) software for automated part program generation with features 
 

• Path-planning for any given custom profile, including profile definition and analysis

• Choice of grinding modes and feed optimization for efficient grinding methodology

• Direct in-process communication with the controller of the machine

I have also successfully implemented the software and validated the process using a super-abrasive cBN wheel, that led to a purchase order worth nearly 2 Crore INR to MGT.

As a team of three, we developed a digital knowledge database of more than 50 wheels tested for the application, including the process signature using GrindTrak and the output quality report.
 

With my experience in profile analysis, path planning and optimization, I've developed and trained two other teammates to develop a desktop application for the Computer-Integrated Manufacturing (CIM) solution for this grinding application - GrindZen. This software gives a complete solution of geometric and kinematic analysis of the profile; allows the user to choose the grinding mode; and also provides the set of codes as an output for instructions to controller to grind the select profile of the workpiece, directly communicated to and fro the machine.