Case study : Simplifying Machines

DQC Bureau
New Update

Eagle Seals and Systems India Ltd (ESSIL) manufactures mechanical seals and

sealing support systems for core sector industries like chemical, petrochemical,

fertilizer and pharmaceutical industries.


The company's engineered seals are designed to meet the ever-growing need for

longer-lasting seals in applications where speeds exceed 10,000 rpm, pressures

are greater than 100 kg cm2, and temperatures are less then 200 degrees C or

greater than 600 degrees C. ESSIL has a large range of pusher seals with more

than 20 varieties of multi-spring and eight varieties of single coil spring

seals including bi-directional options.

CAM needed

ESSIL has a variety of 3, 4 and 5-axis mill-turn CNC machines. These machines
were programmed manually for 15 years. But the need to speed the programming

process, combined with the desire for better machining quality and surface

finish, convinced the company that it was time to upgrade to a CAM solution. In

its search for CAM software, ESSIL originally evaluated six programs but none

had a post-processor that could successfully generate code for the company's

Mazak Integrex machine, a combination turning center and full-function machining


CAM Express and Solid Edge Machinery and industrial products At this point,

ESSIL got in touch with Gnosis InfoTech, a value-added reseller (VAD) for

Siemens PLM Software products. A Gnosis representative demonstrated the

functionality of the CAM Express solution from Siemens and its interoperability

with ESSIL's CAD software, Solid Edge, also from Siemens. The demonstration

clearly showed the strength of CAM Express compared to other CAM software.

“Between that and the support that Gnosis could provide in terms of training and

post-processor development, we decided to implement CAM Express,” said PN Mehta,

GM-Manufacturing, ESSIL.


Speaking about the deployment, Kailash Ghandat, Proprietor, Gnosis said,

“Eagle had machines that were complicated. Most manufacturing machines are 3 or

5-axis. However, in this case two machines that were 7-axis machines. We took on

the responsibility to work on those 15-16 machines.” Ghandat added that the

challenge was to develop a post-processor and that took a while.

Overcoming hurdles

Gnosis provided training that started out with the basics and progressed to

an advanced level. The VAR developed a post-processor with the help of Tata

Consul­tancy Services, which allows ESSIL to take full advantage of the Mazak

Integrex machine. With this support, successful cutting was achieved on every

machine and ESSIL has since been reaping the benefits of the Solid Edge/CAM

Express solution. For example, the company is expecting to reduce machine

programming time in the range of 15 to 25 percent due to the increased

productivity of the programmers. The company has also achieved its goal of

improving machining quality and surface finish.


Ruth Samson