“While the machines are getting more complex and are being equipped with improved capabilities, there is a significant effort to reduce the human skill required to operate these machines,” says Subbarayan, Sr. Consultant, Makino India Pvt. Ltd.
By Nishant Kashyap
Can you provide an overview of the current state of the CNC machining market in India, with a specific focus on the die and mould industry?
The Indian die and mould Industry has evolved over the years and currently caters to the complex, high-precision demands of end users. Earlier, these demands were met through imports from toolmakers in the far East and Europe.
Such demand for complex and high-precision parts is predominantly driven by the local manufacturing push by the global automotive OEMs. India is becoming their global manufacturing and development base, which is driving local mould makers to catch up with efficient machining technologies, processes, and equipment. We can see a similar trend in other sectors too, such as white goods, and electrical & electronics industries.
There is a growing demand for high-speed and high-precision spindles on machining centers, 4- and 5-axis machining capabilities to improve cutting efficiency and reduce processes. There is a clear shift from low-cost machines to high-speed/efficient machines, which can deliver the required precision levels within the shortest possible time. Large tool rooms are gradually shifting to automation to reduce expenses related to labour costs and challenges related to skilled labour availability. Additionally, independent manufacturing cells integrating milling and EDM processes with automated tools (electrode) and work handling are enabling unmanned lights-off machining.
What are the latest developments in CNC machining technology? How can these developments enhance the efficiency of die and toolmakers?
Today’s CNC machines are faster, more accurate, and very reliable. High-speed spindles enable the usage of very small tools, which machine fine and intricate shapes. Previously, this was done using the time-consuming EDM process. In combination with the 4th and 5th-axis capabilities, these spindles help us greatly minimise EDM work.
Besides, intelligent and user-friendly CAM software have been beneficial in simplifying the programming complexity associated with 4th and 5th-axis machining. Smart control systems have greatly simplified machine operation in terms of job setups, tool management, on-machine inspection, and unmanned operation. On CNC EDMs and WEDMs, the current generator technologies have vastly improved the machining speed and finishing capabilities, thereby reducing manufacturing lead times.
How have automation and digitisation influenced the CNC machining landscape?
The Indian die and mould industry is yet to incorporate full-scale automation. But larger tool rooms are actively considering automated cells for certain specific areas such as inserts and electrodes, mould base elements, etc. As the volume and scale of operations increase, we should witness more demand for automation solutions in the near future.
As far as digitalisation is concerned, I would say that it is still in the early stages. With most machine tool manufacturers offering IoT capabilities on their machines, customers are testing and evaluating the various solutions being offered.
However, with the ever-growing demand for efficient, and reliable manufacturing systems, most tool rooms will have to embrace automation and digitalisation in the near future.
Are there any notable trends or emerging technologies in CNC machining that you believe will have a significant impact on die and mould professionals in India?
CNC machines are getting smarter by the day. With the integration of digital libraries for tools, cutting strategies and materials, CAM programming has been highly simplified. Smart controllers on CNC machines are able to simplify job setups, manage tool data efficiently, and enable on-machine process verification. Besides these, various automation features help in implementing unmanned operations during the night and on weekends.
Today’s die and mould professionals in India need to get familiarised with the developments in CNC machining. While the machines are getting more complex and are being equipped with improved capabilities, there is a significant effort to reduce the human skill required to operate these machines.
In your opinion, what are the key factors contributing to the growth and adoption of CNC machines in the die and mould industry in India?
I would accredit the automobile industry here! Its sizable investments in local R&D are helping the die and mould industry in India grow qualitatively as well as quantitatively.
Most OEMs are upgrading their local R&D centres to meet the demands of the global market. They are actively developing local tool rooms to support them in their new product developments. Now, with the current focus on EVs, local tool rooms are heavily investing in upgrading their facilities with the latest CNC machines.
Besides the above mentioned factors, other sectors such as electronics, electrical, white goods, and FMCG are also fuelling the demand for a large number of CNC machines in the die and mould industry in India.
What would you say should be the main considerations for die and mould professionals when choosing CNC machines for specific applications?
Customers should look for key technology features, which will enable them to achieve accuracy and speed. Mere specifications could sometimes be misleading. So, one needs to first evaluate the technology behind these features and their long-term performance capabilities. The machines should also be future-ready in terms of implementing automation and digitalisation requirements.
Apart from the machines’ features and capabilities, one should also evaluate the machine tool providers’ capability to support technology transfer and training. Integrating the machine with the relevant supporting technologies such as cutting tools, holders, work holding and CAM is a key requirement that decides how well the machine is going to produce the expected results.
Looking ahead, how do you envision the future of CNC machining in the die and mould industry in India? Are there any upcoming developments or initiatives we should be excited about?
The die and mould industry faces tremendous pressure to reduce mould manufacturing lead times. As a result, there is an increasing trend towards unmanned operations, usage of 5-axis machines to reduce setup time and EDM operations, automation of work handling, smooth transition from milling to EDM, and other machining operations, and on-machine inspection to reduce re-machining and rejections at the assembly stage.
Going forward, we will be seeing more multi-process machines, and limited automation of work handling between milling (core/cavity and electrodes), EDM, and other processes. Metal 3D printing is also gaining relevance, particularly for rapid new product developments and for implementing conformal cooling requirements.
This interview was first published on TAGMA Times Newsletter
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