Success Story
Karan Motors was incorporated in 1989 and have been focused to manufacture of cylinder heads and engine blocks for over four decades. Providing the best range of Bedford Cylinder Head, BMC Cylinder Head, Caterpillar 3300 Cylinder Head, Caterpillar 3406 Cylinder Head and Caterpillar 3408-3412 Cylinder Head with effective & timely delivery in the Competitive market. Karan Motors also undertakes development of new components by reverse engineering with latest techniques of white light scanning and digitizing. Dimensional data in the form of point clouds and co-ordinates is subject to advanced high-end three-dimensional surfacing and solid modeling software. The result is a net perfect model of the component which forms basis for extraction of tooling for foundry and machine shop. Stocks for tooling are machined on CNC machines for optimum accuracy and then inspected for assembly and trials. Considering all scenarios from Design to Manufacturing, facing problems in editing the surfaces
Karan motors had three key goals in mind: •Seamless Interoperability between CAD Model and Autodesk CAM Software. •Editing the surface of the 3D Imported Models and reduce the cutting time for Cylinder Models. •To enhance the Manufacturing Productivity, Machine time, less wear and tear on the machines, and reduced machine maintenance costs.
In order to keep the data synchronized with the CAD Models, Karan Motors has chosen the “Autodesk Fusion 360 with PowerMill” software, implemented by Greenleaf IT consulting for the preparation of NC codes. The reason for transitioning to computer support was the lengthy process of manual NC code preparation in text editors, resulting in a higher scrap rate. The advantages of “Autodesk Fusion 360 with PowerMill” software has proven itself over the years of productive machining. Both production preparation and programming time have decreased significantly and the scrap rate has been almost eliminated. This is because “Autodesk Fusion 360 with PowerMill” software can be used for easy collision detection during virtual environment simulations (i.e. prior to the actual operation on the CNC machine). “We decided to acquire the “Autodesk Fusion 360 with PowerMill” software. The main benefit that convinced us of this CAM solution, was its unmatched toolpath quality for milling machines. Also,
Having fully integrated CAD CAM CAE solution, Karan Motors has found tremendous success in keeping pace with ever-growing demand for their expertise in 3D model Editing & Manufacturing using “Autodesk Fusion 360 with PowerMill” software without the need for added resources or overhead. In particular, Karan Motors team has noted the following: 1. Maximum depth of cut achieved on the machine in a single pass. 2. No bending or warpage found even after cutting too deep. 3. Average value of spindle load recorded during full depth cutting. 4. All the operations were done using full flute length of the cutter. 5. Observed Increased Tool life up to 3 times compared to regular machining The company has been using Autodesk PowerMill for milling and used for more effective distribution of cutting forces, as well as to program a continuous tool path with constant cutting resistance throughout the entire machining time, regardless of the shape complexity. Autodesk PowerMill can save 70% and more in
“Autodesk Fusion 360 with Autodesk PowerMill” software CAM software not only provides an effective tool path strategy, but also takes application-specific variables into account when applying that strategy. The preparation of CAM machining is now extremely simple because “Autodesk Fusion 360 with Autodesk PowerMill” software has the technology assistants which optimally control all machining parameters (e.g. the material to be machined, tool used, geometry of the model and the CNC machine data) In doing one roughing operation in the part, “Autodesk Fusion 360 with Autodesk PowerMill” software saved 70% in cycle time, which saved 7% of the overall machining time. “It is now the case that the CNC programs can be sent directly to the control system without us having to edit them. What is more, we can sleep easy at night while the machining runs unsupervised!” says Anil Dhiman, Tool Room Manager, Karan motors
Project summary
Duration & delivery
Increased CAM Programming Capability Contributes to 2X Productivity Gain
Founded in 2012 as a small company with a big vision, Raamtel Solutions was established in New Delhi, India to gain presence in the Indian Electronics market. A dedicated team of brilliant marketing and technical professionals came together with a strong business focus: wide range of RF, Advance Microwave Components, and RF Accessories. Raamtel Solutions follows a proactive, futuristic and process-driven approach to business generation that anticipates customer's needs. Raamtel Solutions understands the multiple levels of marketing required to promote any concept or product in India. They faced a challenge to meet production targets due to long machining time demands and a lack of seamless integration between CAD and CAM processes.
Implementation of Fusion 360 with Machining Extension
Toshi Enterprises is a die / mold manufacturers and injection molding focus company and is working for various OEM for plastic parts / component manufacturing. Having a small design studio, they were exploring a cost-effective solution for 3D Modelling and Doing FEA Stress Analysis before sending the 3D model to Manufacturing (CAM). Weekly client coordination also slowed down their design process and a seamless data exchange between 3D CAD Model with the CAM is also what they were looking for.
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