industry expectations-1

8/11/2019 Industry Expectations-1

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THEORY AND PRACTICE


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Theory and practice

Theory is when everybody knows how it suppose towork, but nothing works, on the contrarypractice is when everything functions, but nobody knows

why. In most cases, theory and practice go hand in hand:nothing works and nobody knows why. Anonymous

"In theory there is no difference between theory andpractice. In practice there is." Yogi Berra


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Abstraction vs Application

Credits:xkcd.com


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Theory vs Practice? There is always a tension between Theory and Practice. These two separate realms are connected through a

process of abstraction and application.

To explain this relationship by way of theory, Theoryde-territorializes Practice, and Practice reterritorializesTheory: a Theory which is a becoming-Practice and aPractice which is a becoming-Theory.

To explain this relationship by way of practice, Theoryis abstracted Practice, and Practice is applied Theory.

Ref: http://words.steveklabnik.com/theory-and-practice


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What can we do?

Theres an age -old problem with this particular relationship: Those who specialize in Practice often claim that those who specialize in

Theory are detached from the real world, ie, the world of Practice. Those who specialize in Theory often claim that those who specialize in

Practice have no fundamental understanding of what they do, and this

leads to contradictory, incongruous practices. Theres a third kind of person, though: one that embodies the becoming, the

abstraction/application process. These people are a conduit, fundamentally bridging the two worlds. Theres a certain art to explaining just the core of Theory in the words of

someone who Practices, and theres a certain art to combining theessences of Practices and presenting it to those who Theorize.

Building this bridge is an act of creation, of building, an opening of space.


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Examples Development of non-round

grinding solution Theory:

Kinematics of Non-roundgrinding

Machine kinematics anddynamics

Grinding process knowhow Practice:

Knowledge of building amachine tool

Project management

Management/Execution tomake it happen


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Examples Grinding Process

Solutions Theory:

Science behindthe grindingprocess

Problem Solving

Approach In-process

diagnostics Practice

Data drivenprocesses

Value proposition

to customer Lean project

execution Using Grind Trak

for diagnostics Grinding cycle time reduced by almost 50%!


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Examples

Solving chatter issuein grinding

Theory Origins of chatter

Grinding process Problem solving

approach Practice

Execution Management of

customer

production Data driven

approach

Chatter Marks on a crankshaft journalOD Chatter Impression (on sheet)

10chattermarks

Peak at 85 Hz observed on the work-headduring grinding.


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The Power of prototyping

http://www.ted.com/talks/tom_wujec_build_a_tower?language=en
http://www.ted.com/talks/tom_wujec_build_a_tower?language=enhttp://www.ted.com/talks/tom_wujec_build_a_tower?language=enhttp://www.ted.com/talks/tom_wujec_build_a_tower?language=enhttp://www.ted.com/talks/tom_wujec_build_a_tower?language=enhttp://www.ted.com/talks/tom_wujec_build_a_tower?language=enhttp://www.ted.com/talks/tom_wujec_build_a_tower?language=en


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How can we make adifference?


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Fulfilling Indias promise Indias product makers have a golden opportunity to join the global big

leagues. They should seize it. Indias manufacturers have a golden chance to emerge from the shadow

of the countrys services sector and seize more of the global market.McKinsey analysis finds that rising demand in India, together with themultinationals desire to diversify their production to include low -costplants in countries other than China could together help Indiasmanufacturing sector to grow six fold by 2025, to $1 trillion, while creatingup to 90 million domestic jobs.

https://www.mckinseyquarterly.com/Operations/Performance/Fulfilling_the_promise_of_Indias_manufacturing_sector_2943#top
https://www.mckinseyquarterly.com/Operations/Performance/Fulfilling_the_promise_of_Indias_manufacturing_sector_2943https://www.mckinseyquarterly.com/Operations/Performance/Fulfilling_the_promise_of_Indias_manufacturing_sector_2943https://www.mckinseyquarterly.com/Operations/Performance/Fulfilling_the_promise_of_Indias_manufacturing_sector_2943https://www.mckinseyquarterly.com/Operations/Performance/Fulfilling_the_promise_of_Indias_manufacturing_sector_2943


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StakeholdersEach of them will have different needs and theywill have to be met in differentcombinations.

Machine toolmanufacturers

Academia

Government CustomersVendors &Suppliers

Society

Nation

Customers ofCustomers

- Development of NextGeneration, High PrecisionGrinding Machine (DSTfunded) @ IIT Madras

- Bearing condition monitoring(Project Nidaan) - @ IIT Delhi

- Nano-finishing: Magnetorheological polishing (MRP)@ BARC

- Co-creation of value

- Identification of Synergisticopportunities

- Better integration into theproduct to improve customerexperience

- Key Accounts Program

- Alignment with customerobjectives

- Providing value addedservices

- Gram Niyojan Yojana

- Close interaction withorganizations like IMTMA,

DHI, DS, etc.


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Major Gaps In the Industry

Microstructure and MetallurgicProperties

Conservative ProcessParameters

Controlling wheel topography

CBN Applications


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Microstruct

ure andMetallurgicProperties

Grinding is used to produce smooth surfaces and precisetolerances without causing any metallurgical changes

Great cost savings can be achieved if both the

geometrical requirements as well as correct mechanicaland metallurgic requirements can be obtained viagrinding

To achieve this the grinding process must input and alsodissipate the correct amount of thermal and mechanicalenergy into the workpiece

Conservative Process

Parameters

To guarantee required surface integrity , productiongrinding processes are developed and certified usingexperimental trial and error, and extensive surfaceevaluations

The industry still lacks a clear understanding about thethermal and mechanical interactions on the workpieceduring grinding thereby making the process veryconservative in process parameters having low removalrates

Furthermore post operations like shot peening arerequired to remove further surface defects which addsto the cost

Ref. J.F.G. Oliveira, et. al. , Industrial challenges in grinding,


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Controlling

wheeltopogra

phy

The efficiency of the grinding operation is highly dependent on thegrinding wheel surface topography

Parameters like grain distributions, wear flat area etc. can highly changethe result of the grinding process

There is till no system available in the industry to control the topographicproperties of the grinding wheel during the process

Technologies have been developed to characterize wheel topographyusing LASER and AE (acoustic emissions). The AE tool has been developedbut needs further development in terms of robustness, signal detectionand image recognition for process diagnosis

CBN

Applications

Requirement of harder and lighter materials is making grinding using CBNmore attractive as it bears the advantages of having lower wheel wear,stability at high grinding temperatures and also high speed capabilities

Despite all the advantages, CBN is not used to its full potential because of

the lack of proper understanding of the process and the increasedmachine complexity in terms of system stiffness, higher thermal loads,lower friction components etc.

CBN will be leading the future of grinding but the industry still lacks thetools and the understanding to use this technology to its maximum extent



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Research opportunities

Improving Process Energy Efficiency

Grinding Process Modeling and KnowledgeDatabase

Grinding Technology Ultra LargeComponents

Specific Grinding Solutions


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ImprovingProcess

Efficiency

Grinding is one of the most energy intensive among allmachining processes

The energy required to grind a unit material (30J/mm3) of

steel or nickel is almost three times the energy requiredrequired to melt the same amount of material 10 J/mm3

Considering the large amount of grinding operationsperformed worldwide improvements in energy efficiency canhave a significant impact

Research in new grinding wheel technology, advanced coolant

and coolant delivery can bring down the friction in thegrinding zone and greatly reduce the energy requirements

GrindingProcess

Modelingand

KnowledgeDatabase

The Grinding and processes currently developed areconservative in terms of process parameters

The industry needs predictive models for better process

control and to develop new and optimize existing grindingstrategies

A few grinding softwares have been developed, tested andused in the industry but thses softwares are confined tosimplae geometries furthermore the demand of highlyoptimized parameters bears concerns of process instability



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GrindingTechnology

for UltraLarge

Components

The windmills for power generation require ultra largecomponents with diameters greater than 1 m weighing morethan 5 tons

The grinding technology for critical components of thesewindmills is vital for improving the efficiency of powergeneration

The industry needs solutions for reducing the cycle time anddeveloping new grinding technologies for high stock removalrates, in process gauging (due to heavy weight ofcomponents) multi surface grinding processes

Specific

GrindingSolutions

Critical part geometries and difficult to grind materials lead tovery challenging problems that require newer process concepts

Some classic examples are the development of the Centre-lessprocess to grind long and slender

Developing newer grinding processes are related to new tool ormachine concepts, the solutions are complex and provide a goodopportunity for research

One of the ongoing research is in process combination of hardturning and grinding to tackle low stiffness in ID grindingmachines


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One of the limitations in the industry to day is the gap between developing new technologyand applying/replicating it

In order to bridge this gap the industry needs to move beyond isolated efforts in science,engineering and management, towards a more integrated approach for all the three disciplines

The industry needs individualswith a strong academicbackground who cancomprehend the fundamentalsand apply them in practice

Why?

How

?When?

Theory

Business

Acumen

Practical

Skills

Knowledge Practical skills

Learning concepts, principles and informationregarding a particular subjects throughacademic sources, media etc

The ability to use an information and apply itin a context


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Manufacturing

Knowledge

DesignEngg.

MaterialEngg.

Robotics

Electronics

Material Selection Predicting interaction on the

Workpiece for processoptimization

System layout and Plan Machine Design Equipment Selection Software based analysis Optimization

Process plan and layout Process prediction Process Optimization

On Board Diagnostics Data Acquisition Signal Processing

Automation Designing and Implementing Machine Kinematics


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