General Engineering_Mechanical

A TRAINING PRESENTATION

ON

GENERAL ENGINEERING

VERTICAL

Industrial & Process

Equipments

Paper & Wood

Machinery

Earth Moving

Equipments

Material Handling &

Heavy Machinery Marine Equipment

Design

Tool Design

Pipe Design

Civil Construction

ACTIVITIES

Material Handling

& Heavy

Machinery

Industrial &

Process

Equipments

Paper &

Wood

Machinery

Marine

Equipments

Civil

Construction

Piping

Design

Tool

Design

Component Design

Value Engineering / Design

Optimization

Manufacturing Feasibility

Study

Detailed Design

Design Automation

Reverse Engineering

Design Data Porting

Product Catalogue / Library

Capabilities CAD

General Engineering

(DESIGN)

Industrial & Process

Equipments

Paper & Wood Machinery

Marine Equipments

Civil Construction

Piping Design Tool DesignMaterial Handling

& Heavy Machinery

Conversion

A process whereby multiple layers of different elements are interlaced together to create the

illusion of three dimensions. This helps in visualizing a product and also preview the dimensions

During the conversion process text is separated and has its

own layer. Dimensions are integral and are shown by a

separate layer. Multiple layers can be created as per specification.

The final output is editable, which makes it more user friendly.

3D images provide more attraction and attention therefore boost

up sales.

Software Used: AutoCAD. Inventor, Solidworks, Pro-E

Clients: Electrolux Laundry Systems, Arboga-Darenth AB

2D drawing of a rear gable

3D Model of a rear gable

3D Modeling

3D modeling is the creation of 3D computer graphics based on wire frame modeling via specialized software. 3-D modeling shortens design cycles, streamlines manufacturing processes and accelerates product introductions by improving the sharing of product design information and communication throughout an organization, as well as among its suppliers and customers .

3D models are virtual prototypes where design analysis has supplanted physical testing to help optimize designs, reduce material usage , reduce costs and improve the quality of design

Software Used: Ideas, Unigraphics, Solidworks, Pro-E

Clients: Thule, Dellner Couplers, Johnson Pumps, Outotec, KMT Lidkoping

Input Skeleton of Heat Exchanger 3D model of heat exchanger3D model of a Coupler

Master Modeling

A model that can be modified as per requirements, by changing the dimensions. These changes in dimensions reflect directly on 2D drawings and 3D models.

Software Used: Pro-E Wildfire

Clients: Metso Panel, Raute, Andritz

Advantages:Reduction of design time upto 60%Reduction of lead time (faster delivery for manufacturing)Reduction in design costEasy modificationsInterferences can be easily detected

Arc Conveyor

Finished Product- Arc Conveyor

Belt Tablet ChargerFinished Product- Belt Tablet Charger

Re-engineering

Alteration of an existing design to suit the client requirements

Software Used: Solid Works, Solid Edge

Client: FTG Cranes, Kam Avida

Advantages:1. Output design was as per the market standards2. Competitive3. More popular and saleable

Existing design of FTG-Grapple Output design of Re-engineered Grapple

Assembling

Tooltechs capabilities:1. Material preparation and handling devices 2. Dryer section

3. Former section

Atlas Copco & Tooltech

Tooltech has a long standing partnership with Atlas Copco for the past six years. Today, a team of more than twenty Tooltech engineers work for Atlas Copco.

2002 2004 2005 2008 - 20092006

Pilot project for 3D modeling and creation of manufacturing Drawings

3 member team is invited to Sweden to work on other Projects

Tooltech is invited by Altas Copco to become a strategic off-shore partner for its mining division in Orebro

A resident engineer is sent to Sweden for relationship management and on-site support.

Inventor work from Atlas CopcoCralius(Marsta) starts.

Conversion from Inch Design to Metric Design

ProEngineer work from Atlas CopcoDrilling Solutions (Texas, USA) starts

Continuous work from 3 global offices

Support from Bangalore office starts

Projects for the creation of manufacturing drawings, assembly modification, design modification, concept design of bucket & dump boxes of earth moving equipment commence

Team includes: 2 onsite and 18 offshore engineers.

Tooltech receives larger volume of high end work from Atlas Copco

Analysis of dye & punch, Gear box meshing, Reciprocating of cylinders and Dryer and Frame analysis

2007

Coal Project: Design

modifications in n

parts and

assemblies,

Create 3D

models/assemblies,

Creation / updating

2D drawings for

manufacturing.

Pro\Engineer

Wildfire-3

Team size was 8

2010

Alfa Laval & Tooltech

Tooltech has a long standing partnership with Alfa Laval, Sweden with over 15,000 hrs of work

executed over a period of 3+ years.

Alfa Laval wanted TT to reverse engineer design of

their heat exchanger plates

used in engines (ship,

automotive etc).

In addition, 3D models, assemblies and BOM (bills of materials) were to be created

for heat exchanger plates

A total of 8 members used UG (reverse engineering)

and Pro-E Wildfire 2 (3D

modeling) during the

project execution.

Design 3D models of Punch and Die for

forming tool

of a heat exchanger

plate

An on-going project with

Tool Design of 350

hours per

month and Reverse

Engineering of 750

hours per

month

Exhibited re-generation

and detailing skills for the first

time in TT

Next set of project involved tool design of

curves to model using

Pro-E skeleton files.

Critical issues ranged from model

creation of exchanger

plate to incorporating

the blends

Used Skeleton modeling for Punch &

Die while using Pro-E

wildfire

2005 2006-07 2007 - 08

Press Tool Design Modeling of Heat

Exchanger plates &

Press Tool.

Team size 5 members

2009 - 10

Metso Paper & Tooltech

Tooltech has a long standing partnership with Metso Paper, Finland, with over 20,000 hrs of work

executed over a period of 5+ years.

Generation of 3d data for FORMER (width 8250mm)

1 Project Manager, 1 Project Leader, 3 Team leaders, 15 design engineers & 4

engineers for Quality control & co-ordination worked on the

project.

First project lasted 4100 hrs and software used was Catia V5

Project involved Handling data for large assemblies with 4000+ parts.

Another project on the similar lines received for generation of 3D data

for FORMER (width 9650mm ) The output is similar to Project1

Project lasted 2900 hrs with a team of 22

members.

Project involved Handling data for large

assemblies with 3000+

parts

The next project involved Generation of

3d & 2d data for an

OPTIREEL

Project lasted 2000 hrs with a team of 17 members.

Project involved modeling with reference to CatiaV4 while using

Metso methodology

Further project involved Concept design, 3D modeling & Manf. drawings of a lifting arrangement for a 25 ton Roller

Project lasted over 900 hrs with a team of 7 members.

Additionally, Structural analysis was

carried out for the

designed tool

2005 2006 2006 - 07 2007 - 08

Design Automation for

Various

Dewatering

Mod5

Assemblies

(Wire Section) (Total

7 different

assemblies)

Project lasted 6000 hrs with a team of 5 members.

Project involved modeling with reference to CatiaV5 while using

Metso methodology

2009 - 10

First assignment was the creation of Master Model of a veneer feeding machine using Pro-Engineer

2 TT engineers visited the client onsite for a 2 week training program and later trained 4 others upon their return.

First project lasted 1050 hrs and software used was Pro-Engineer

Delivered Master Models of 16 machines in the plywood manufacturing layout (project size: 6750

hrs)

TT takes initiative in making a dummy project

for every project so that

the master model created

can be applied directly

All trainings conducted at Client side

Design and drafting of Master Models of

Plywood manufacturing

machines.

Delivered 13 Master Models and

project lasted 6000 hrs.

Additionally delivered 3 more copies of the project lasting 200 hrs.

Design and drafting of Master

Models of Plywood

manufacturing machines.

Delivered 5 Master models with project size of 1000 hrs. Additionally delivered 4 more copies of the project lasting 200 hrs.

36 master models created over 14,800 hrs. and 7 Project copies created of 400 hrs. Grew from 5 member to a 22 member team

Design and drafting of Master

Models of Plywood

manufacturing machines.

One onsite engineer for communication and design

10 master models created over 2,800 hrs. 4 offshore engineer with one onsite.

Core design projects were undertaken in this period.

2004 2005 2006 - 07 2007 - 08 2010

Raute & Tooltech

Tooltech has a long standing partnership with Raute, with over 19,000 hrs of work executed over a

period of 6+ years.

Kopar & Tooltech

Tooltech helped this Finnish client in re-engineering (Modification / Reconsideration / Modernisation) of their existing design of Drum Basket Filter.

Converting cast steel structures to steel plate

structures & wght. reduction

supported by 3D CAD-data & 2D manufacturing drawings using Solidworks while re-engineering existing design of a Drum Basket Filter.

Developed a competitive

product by change of material & weight reduction for competitiveness.

2006 - 2007

Re-engineered design is converted

to various sizes of

equipment for

different filter

diameters &

respective length

Variants.

Additionally analyzed the load

bearing capacity of

the newly designed

Drum & Basin

using different CAE

tools.

The new design made

the product

- more competitive

- Easily

manufacturability

- 30% reduced

weight

- Improved drive

mechanism

- Different variants of

the same design for

various sizes

Re-engineering of

Raw-water filtration

Equipment

1. Team size : 4

engineers+ 1

project leader

2009

General Engineering (ANALYSIS)

Structural Strength / Durability

Analysis

NVH / Acoustic Analysis

CFD AnalysisMold Flow Analysis

Structural

Strength Types

of Analysis

Pre- Processing Processing /Solving Post-Processing

Hypermesh ANSAAbaqus-

ImplicitNastran Ansys Optistruct

FE Safe/

FEMFATAnsys

Hyper-

works

Abaqus-

viewer

Linear Static

Non-Linear

Static

Thermal

Analysis

Couple field

Analysis

Thermal -

Electrical

Analysis

Parametric

Modeling

Durability

Analysis

Capabilities : CAE

Overview of CAE Activities

Type of Analysis done by Tooltech:

Meshing:

Surface Meshing

Solid Meshing

Structural Analysis :

Linear Static

Non-Linear Static

Vibration

Dynamic

Seismic (Earthquake/Power Spectral Density)

Thermal

Coupled Field

Type of Analysis outsourced by Tooltech:

Structural Analysis :

Impact Analysis (Using LS Dyna)

Fatigue Analysis (Using FE Safe)

CFD Analysis :

Steady State Flow

Transient Flow

Cavitations Study

Particle Tracking

Thermal Flow Analysis

Two Phase Flow

Study of Pump Performance

Sump Flow Study

Type of Industries to target for Structural Analysis :

Gear box manufacturers

Power jacks using hydraulic/pneumatic drives

Pump industries

Heavy equipment manufacturers (cranes/hooks/carriers/forklifts)

Silos (stone crushing, mineral handlings equipments, cement

mixtures)

Paper & wood manufacturers

Construction companies

Forging, die and casting manufacturers

Plastic injection molders

Ship builders

Railway coaches manufacturers

Forest & agricultural machineries

Valve manufacturers

Type of Industries to target for CFD Analysis :

Pump manufacturers

Water supply boards (government bodies)

Thermal power plants

Boilers

Heat exchangers

Gear Box Manufacturers:

Casing strength of Gear Box: A casing is the external covering of gear box. The casing has to be analyzed

for its sustainability for which linear or non-linear static analysis is performed.

Bolt Adequacy Check:Is the analysis of adequate number of bolts and bolt size required.

Vibrational Analysis of Gear Box.

Ex:

Hydraulic & Pneumatic Power Jack Manufacturers:

Static Analysis Non-Linear Analysis of Hydraulic and Pneumatic Equipments

CAE Analysis Capabilities - Industry Wise

Stones Crushing Equipment Manufacturers:

Static Analysis of Shell

Vibrational & Dynamic Analysis of Handling Equipments

Pump Manufacturers:

Vibrational Analysis Dynamic Analysis Seismic Analysis Torsional Analysis

CAE Analysis Capabilities

Heavy Equipment Manufacturers:

Strength Analysis of Lifting Equipment (i.e crane, hooks, fork lifts etc.)

Torsion Analysis of the ShaftAnalysis of the torsional dynamic behavior of a rotating shaft system as a

result of transmission of power and speed.

P.S.: A shaft is the rotating part in the center that transfers power.

(e.g. In case of a vehicle there is a rotating shaft between the front wheels and rear wheels)

Paper & Wood Machine Manufacturers:

Linear & Non-Linear Analysis Vibrational Analysis Dynamic Analysis Seismic Analysis

CAE Analysis Capabilities

Heavy Engineering Companies:

Linear & Non-Linear Analysis Vibrational Analysis Dynamic Analysis Seismic Analysis Thermal Analysis

Forging, Die & Casting Manufacturer:

Impact Analysis for Forging Static Analysis for Die & Casting Manufacturer

CAE Analysis Capabilities

Plastic Injection Mould Manufacturers:

Coupled Field Analysis : A combination of Thermal

analysis & Structural Analysis. i.e. Linear/ Non-Linear,

Vibration, Dynamic Analysis

Railway Coaches Manufacturers:

Structural Analysis of axle, brakes, drum brakes, brake shoes &

couplings.

Thermal Analysis of Motor Casing Torsion Analysis of Shaft & Spindles

Forest & Agricultural Machineries:

Structural Analysis for Cutting Tools & Machineries

CAE Analysis Capabilities

CAE CFD Capabilities

Analysis Of

1. Steady State Flow: The fluid properties (i.e velocity & pressure) at any single point in the system do not

change over time. (eg. Water flowing in a canal)

2. Transient Flow: The speed of fluid varies with time. (eg. engine of vehicle)

3. Cavitation Study: The conversion of fluid to gaseous state. (e.g. water in a boiler converts to steam)

4. Particle Tracking: The study of effect of particles passing through a fluid.

5. Thermal Flow: The behavior of fluid when temperature changes.

6. Two Phase Flow: Combination of two fluids (i.e air, water & gas) (eg. Water storage tank with water and air)

7. Study of Pump Performance

8. Sump Flow Study: The study of flow of fluid through a sump. (eg. Water pumped from a tank)

9. Silt Deposition in the Sump: The study of suspended sediment in a water column of any surface water

body .(eg. Water storage tank)

Business Development

Activities In

General Engineering

Vertical

Industrial & Process

Equipments

Paper & Wood

Machinery

Earth Moving

Equipments

Material Handling &

Heavy Machinery Marine Equipment

Design

Tool Design

Pipe Design

Civil Construction

What do we market?

Engineering Services in the areas of Design and Analysis using different CAD and CAE

softwares

Who are our Targets?

Manufacturers, OEMs, Tier-I, Tier II and Tier III suppliers, Consultants, Service Providers

What are our USPs?

Engineering services with European competencies and at an Indian cost.

Expertise in all major industry verticals including Automotive, General Engineering, Ship

Design, Aerospace and Oil & Gas

Neutral engineering software platform company with expertise in over 30 different softwares

Marquee management leadership team

Mixed model that combines west European engineering maturity with skilled competence

and cost efficiencies of offshore work teams in India and East Europe

Services, Targets & Sales Pitch

Business Plan

Type of Companies to be researched (Key words for search):Machinery, Machine Tools, Paper and Wood, Earth Moving, Waste Management System

Target countries:Sweden, Finland, Denmark, Norway, United Kingdom, Belgium, Germany, Netherlands and

INDIA

Listing of all OEM's and Tier I suppliers present in India

Listing of relevant Magazines

Listing of relevant industry trade events

Listing of Trade associations, embassies and consulates.

Identification and interaction with key technical team members

Preparation of a comprehensive document which includes overview, competitors etc.

Objectives

50 new researched companies in the database at any point of time.

Minimum 25 contact per day

Minimum 4 leads (handovers with proper requirement) per month

Reports:

Weekly Reports:- Call status

Monthly Reports:- Conversion ratio

Random Update Reports:- Lead Status

- Lead NOT taken further

Google, Kompass,

Thomasnet, Association

Websites etc.

TelemarketingContact establishment,

Requirement probing,

Information sharing,

follow-up scheduling

Requirement

Y/N?

Get details of the requirement.

Visit the client. Take inputs from

vertical head. Draft proposal and

follow-up for acceptance and

subsequent inputs for execution

Check for suitable time

frame for you to follow-up

for future requirements

Update database

statusClose

Update database

status

N Y

Market Research

Stages of Telemarketing @ TOOLTECH

P.S.: In case of proposal being rejected or not acceptable by the client. Maintain a separate database for Enquiry Not taken Further cases. This will be reviewed by the management at a later stage.

Senior Profiles in the Department

J.B. Naik

CTO

[email protected]

Ph: 020-30511345

V. Ravindra:

Head General [email protected]

Ph: 020-30511226

Srikrishna Kadle

Sr. Manager - Projects

[email protected]

Santosh Kulkarni

Asst. Manager Projects

[email protected]

Ph: 020-30511292

Mr. Javed Shaikh

Asst. Manager Projects

[email protected]

Ph: 020-30511274

BalaMurali KaliyaMoorthy

Head - CAE

balamurali.kaliyamoorthy@tooltech.

Ph: 020-30511332

Nitin Chore:

Sr. Project Manager

[email protected]

Ph: 020-30511250

Shivaji

Asst Manager Projects

Ph: 020-30511250

Software Capabilities

CATIA V4

CATIA V5

SolidWorks

Vertex G4 Pro-Engineer Unigraphics SolidEdge I-DEAS

AUTOCAD MDT Inventor

CAD

CAE

Pre / Post-Processor

Hypermesh

Ansa

I-DEAS

Patran

FEMOD

ANSYS

Animator

Solvers

Abaqus

LS-Dyna

Ansys

Nastran

Pamcrash

CFD

Pre- Processor:

Gambit

Solver & Post-Processing

Fluent

T-Grid

Tribon

Clients All stated with permission

Project & Quality Management

Tooltech is certified by Bureau Veritas for;

QMS ISO 9001:2008 ISMS ISO 27001:2005Quality is achieved through

SMART targets, which are set, achieved and improvised

Following documented Procedures & Guidelines

Documenting best practices & knowledge management

Extensive use of check lists, work instructions etc.

INITIATION

EXECUTION MONITOR & CONTROL

Project scope | Contract Review

Project Feasibility

Detailed execution procedure | Train and develop team

Supervise execution | Perform quality assurance auditSchedule control | Cost control | Perform Quality control

Manage Project Team | Report Performance

Monitor & Control Risk

Project Closing

Capture lessons learned

Update Knowledge base

Create WBS | Assign task Schedule

Project Budgeting | Quality plan | Resource plan

Communication plan | Risk mitigation plan

PLANNING CLOSING

We Deliver

Strategic Partner for Clients

We Add Value

We Build Trust

- by choosing the right business/operational model, in coordination with the client and

taking entire responsibility for qualification, total delivery and new costs

- through our Project Management experience in collaborative engineering by flexibly

combining work with the clients processes

- by catering to strategic needs of our customers through experienced execution

- by securing clients intellectual property through their preferred methods

- by acting as advisors and developing board level relationships

- European Engineering competence at Indian cost, without any compromise on quality

We Act - As a seamless extension to our clients design office and R&D process

- As an Internal advisor to our clients to ramp up resources at all levels of operations

Contact Us

Tooltech Sweden

Plejadgatan 3,

41757 Gteborg, Sweden

Ph: +46 (0)706 94 13 56

Tooltech Deutschland GmbH

Frankfurter Ring 117,

80807 Mnchen

Tel: +49 -89 3220 92 250

Fax: +49 -89 3220 92-25

Head Office

Tooltech Global Engineering Pvt. Ltd.

401 Beta 1, Gigaspace,

Viman Nagar, Pune 411 014, India

Tel: +91 -20 -30511200

Fax: +91 -20 -30511201

Email: [email protected]

www.tooltech.net

Tooltech Europe Oy

Mikonkatu 8,

00100 Helsinki, Finland

Tel: +358 -40 -5631205

Fax:+358 -89 -678783

Tooltech Romania

Sos. Borsului nr. 20,

410605 Oradea,

Romania

Tel: +40 -72 -8837788

Tooltech Global Engineering Pvt. Ltd.

Prestige Technology Park,

2nd Floor, Jupiter (2A) Block,

Sarjapur-Marathahalli Ring Road,

Kadabeesanahalli Village, Varthur Hobli,

Bangalore 560 037

Tel: +91-80 -41256556

Tooltech Denmark

Forskerparken 10,

5230 Odense M,

Denmark

Tooltech Deutschland GmbH

Registrierte Zweigniederlassung

Austria

Dr.-Auner-Str. 22,

A-8074 Raaba/Graz, Austria

Tel: +49 -89 -357191-51