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Pushing ahead with MIM

Breakthroughs in metal injection molding (MIM) have led to an optimized process, in turn incorporating parts with much tighter tolerances
Amidst a challenging global economy, the manufacturing sector is facing several major hurdles, and this has made leading manufacturing organizations look toward new innovative technologies and processes as a key differentiator in the marketplace. In this respect, metal injection molding (MIM) technology has a highly innovative capability that separates it from other conventional metal cutting and metal forming processes, especially as it has the capacity to inject complex contours, no matter how challenging the piece is in terms of design and structure. In a short space of time, MIM has become a value-addition technology that has helped automotive designers around the world to realize their design goals. However, it is important to note that there have been some bottlenecks with respect to the capability of MIM technology, such as with the many automotive components that have tolerances tighter than ISO 2768(M). It is here where Indo-MIM, a Bangalore, India-based supplier, has redened the scope of the MIM process, allowing for parts that have tolerances tighter than ISO 2768(M) to benet from the technology. In turn, this has helped to extend the boundaries of the application of MIM across the globe. As such, MIM technology has been used in areas of small parts and large volumes. Furthermore, the renewed capability of Indo-MIM has helped bring on board components that call for a higher amount of machining post-MIM. Most of the parts that are being constructed at Indo-MIM are made from materials that are not conventional steels. With extensive expertise in this arena, Indo-MIMs engineers have the capability to make components out of difcult to machine materials, including T400, Nimonic and Fe-50% Ni. In conventional machining processes, such parts were a challenge for customers and hence it was not possible to mass-produce them in a cost-effective manner. However, Indo-MIM has redened the rules in this area and has given customers the opportunity to use such materials in their product assemblies. This, in turn, has improved the life of the components, as well as meeting project goals set by the customer. As part of the process, Indo-MIM ensures that all components undergo washing, which is required to control reective and nonreective particles. Components that require a high level of cleanliness after machining are washed to remove the ner

The metal injection molding process ow combines the shape making complexity of plastic injection molding with the material exibility of powder metallurgy

Indo-MIM offers over 25,000m 2 of advanced MIM manufacturing and nishing capability to manage the MIM process from beginning to end

reective and non-reective particles. This high-end washing process is undertaken in a dedicated washing machine under high pressure to remove contamination. A Leica micro analyzer is used to inspect the quality and quantity of contamination. The washing, cleaning and inspection of the parts is carried out in a pressurized clean room-like environment with a controlled atmosphere. In addition, electrochemical machines complement the accurate machining ethos of the process, serving to remove the burrs off-line. Online gauging is implemented to reduce the cycle time and for better dimensional capabilities. A process data system (PDS), which includes online data management software, has been initiated by senior management at Indo-MIM to administer all aspects of the data effectively. One of the main advantages of the PDS is its exible nature and its capacity to make changes rapidly. Furthermore,

the data is made available to all processes. Built by Indo-MIM engineers who worked on the manufacturing system, PDS enables software engineers to think like a process owner, taking into account build system issues and goals. Regarding post-MIM machining, the process capability of specic operations such as turning, milling, grinding and lapping has been well established at Indo-MIM. Indo-MIM is a Lean Six Sigma company, with a Kaizen ethos, meaning its engineers are constantly improving process capabilities for all the processes of individual parts that the company manufactures at both its plants in Bangalore.

han, Indo-MIM Meenakshi Prad 22 89 4 20 2 T. +91 80 m p@indo-mim.co E. meenakshi. m .co im m W. ww w.indo-

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78 // March 2014 // Engine Technology International.com