This blog written by Mr. Yash Shah is about machine tools including workshop machinery, wood working machines, sheet metal machinery provided by Bhavya Machine Tools, a leading distributors of machine tools in India.
A laser marking machine is a highly efficient piece of machinery and it makes use of a laser beam to obtain permanent marks on the surface of different metals. The term “LASER” stands for Light Amplification by Stimulated Emission of Radiation and is a light wave consisting of a single unadulterated wavelength. The machine consists of an oscillator in which the laser light is amplified due to its reciprocating motion between the reflecting mirrors. This amplified laser energy causes a chemical & a physical reaction with the material, leaving behind a mark or trace on the surface.
A laser marking machine mainly consists of following components- Fiber laser source, Laser scanner, F-theta lens, Control board & marking software, computer, lifting pillar, 2D working table, and power supply.
Need for Laser Marking The laser technology has come a long way since its invention. Now, the laser cutting, marking, and engraving machines have become the need of the hour for the industries in order to have quick and high production rate resulting in higher efficiency. Forget the big industries, the laser cutting machine can also be seen in the smaller shops these days. It accommodates a large number of metals and carries the operation at a much faster rate. The materials that can be engraved or marked are plastics, metals, coated metals, stone, glass, and natural materials.
Laser Marking Machine Industrial Applications The laser marking machine finds numerous applications in industries due to its excellent workability. It is used for the marking of flexographic plates and cylinders. For this operation, carbon dioxide or co2 laser is used to evaporate the rubber plates and sleeve materials in order to produce a surface that is ready to print. This process makes sure that there is no integral ablation mask produced as a high power co2 laser burns away the unwanted material.
The fiber laser machine is one of the most widely used machines and has the most accepted technology for the operation of laser marking as it offers versatility and requires low maintenance. It also has a very low requirement of consumables and unlike the carbon dioxide laser machine, the fiber laser marking machine makes use of optical fiber doped with the rare element as the laser source. It is used to make barcodes, serial numbers, QR codes, personal details, graphics, etc. on the surfaces of materials like auto components, steel labels, etc. Additionally, this machine provides the best industrial solution for product identification and traceability. Fiber laser cutting machine is another machine that enjoys a lot of applications in a wide array of industries. The smaller beam diameter of the machine (than what is observed with Co2) makes it potent for intrinsic applications. It is mainly employed in the medical field, jewelry, automotive, electronics, textile industry, etc.
The Bottom-Line: Bhavya machine tools offer fibre laser marking machine for applications that require precise and detailed work. These laser marking machines are capable of producing accurate works and have high production rates. The fiber laser marking or cutting machine make use of laser beam to perform their respective operations. These machines serve a wide array of industries such as automotive, medical, textile, jewelry, etc.
A Bending machine is essentially a forming machine tool with the main purpose being to assemble a bend on a workpiece. It makes use of a linear and rotating move to manufacture a bend. This type of machine is durable, fast, cost-effective and is very useful for bending reinforcements bars. It is useful for many forms of bars like round bars, busbar bars. This is also known as a round bending machine. It has a high production capacity and is an essential piece of equipment for any steelyard.
These machines are easy to use and do not require any special skills to use either. This article goes on to describe the various applications of such a machine and the benefits of using it besides high production rate.
Benefits of a bending machine
There are many benefits of using this type of machine:
It is a computer-controlled equipment that is highly efficient.
This type of machine has high precision.
There are additional benefits for using this for busbar processing.
This machine is capable of executing several actions. For example, it is useful as a busbar bending machine,busbar cutting machine,busbar punching machine.
It is useful for punching round, oblong, and other types of holes.
This type of machine is also useful for embossing, shearing, slotting, round cornering.
It makes use of high precision ball screws and linear guides; This ensures that the machine is highly efficient and provides high precision.
One of the main advantages of these machines is the fact that even when used at maximum capacity they have high precision and allows for rapid production as well.
These machines are very accurate and easy to use.
There is a high level of automation hence it does not require very high skill level to operate it.
It has the capability of providing the perfect cut or bend and does not require any maintenance.
Applications of a Bending machine
There was a time when automotive companies and suppliers had to make use of a manual process for bending brake lines and fuel lines. There were many disadvantages of a manual machine and it also reburied a high skill operator level.
Agriculture industry: It is useful for Vineyard accessory, Agricultural Spring, Tractor part
Furniture industry: It is useful for decoration lamps, bottle holder, chair frame
Automotive industry: It has many applications in this industry for the production muffler hargers with end forming units, single head or head and collar, headrest frames, bonnet rods, tank floats, child seat hooks, etc.
Railway industry: Applications in the railway industry include railway clips, etc.
Construction Industry: There a large number of applications in the construction industry like scaffolding safety hooks, ceiling hook, frameworks concrete.
Appliances industry: It is useful for several appliances like barbecue accessories, refrigerator accessory, dishwasher accessory, oven grill, iron holder for axis, cooling coil.
Display material: It is useful to make material like postcard support and other display support material.
Fastening Industry: It is useful for many types of pins and hooks.
Gardening industry: Applications in the gardening industry include gas lever lawn mowers, mower lever, wire planter.
This machine also has several other applications as listed here:
LASER stands for ‘Light Amplification by the Stimulated Emission of Radiation’. It is implemented in several industries like spinal-implant, automotive, industrial & tooling, electronics, medical, military & defence, etc. It is also useful for welding, measuring, drilling and sensing.
There are many types of laser machines like a laser marking, laser engraving, laser etching, fiber laser cutting machine. There is a difference between each laser service which is mainly due to the marking surface and how deep a laser penetrates and the way it changes the overall appearance.
Laser has an ability to cut material as well and hence is useful in several manufacturing industries. To use it for the purpose of cutting, it is necessary to use a high power laser usually through optics and make use of technology like laser optics and CNC to focus it on the material.
Laser Marking Machine:
The purpose of laser marking is to allow the bean to interact with the surface of a material and alter its properties to some extent. A fiber laser marking machine implements a method of discolouration to create a high-contrast mark without disrupting the material. A laser works to heat the material that results in oxidation under the surface. This process does not affect the surface. This process is also referred to as laser colouration or laser dark marking. The Laser marking can be of many types like annealing, carbon migration, foaming and colouration. It is popular in several industries like stainless steel, titanium parts, etc. This process is mainly useful for bar codes, UID codes, QR codes, logos and several other identification requirements.
Fiber Laser Cutting Machine
The laser beam is generated by stimulating a lasing material using an electrical discharge or lamps within a closed container in the fiber laser cutting machine. Once the lasing material is stimulated a beam is reflected internally with the help of a partial mirror. This process continues until sufficient energy is allowed to escape a stream of monochromatic coherent light. In general mirrors or fiber optics are made use of to direct the coherent light to a lens and focus it on the work zone.
It is more advantageous to use laser cutting than mechanical cutting since it involves easier work holding and lesser contamination of the workpiece. Besides this laser is better for precision cutting as well since a laser beam does not wear during this process. Chances of warping the material being cut is also low since the laser systems have a very small heat affected zone. It also has many advantages over plasma cutting and is more precise and uses less energy as well.
This is the process of physically removing the surface of the material using a laser beam to expose the cavity and reveal an image at eye level. The intense heat created during the engraving process causes the material to vaporize. There are three types of laser engraving like etching, deep laser engraving and laser ablation. The main difference is how much is removed and the difference between the surfaces.
There are several applications for this including engraving serial numbers, logos and several other similar things. Many types of metal, plastic, glass surfaces and leather can be engraved in this method. This method is faster that other traditional methods as well.
This is a subset of laser engraving and occurs when the heat from a beam causes the surface of the material to melt. It melts the surface of the material using high heat. Once melted the material expands and causes a raised mark. A laser etcher changes the surface finish of metals and also alters the reflectivity and helps enhance contrast.
Thus, although all these processes make use of laser technology, each process is very different in nature.
A busbar is a metallic strip or bar that is used in electric power distribution. It is employed for local high current power distribution and is fitted inside the switchgear, panel boards, and busway enclosures. They are generally kept uninsulated and are employed to connect high voltage equipment at electrical switchyards, and low voltage equipment in battery banks. A busbar has sufficient stiffness to be supported in the air by insulated pillars.
Busbar Bending-Cutting-Punching Machine
A busbar bending-cutting-punching machine is technologically advanced machinery capable of performing the operation of bending, cutting, and punching simultaneously. It is used for producing a busbar and is capable of performing almost all the required operations. The machine has very high productivity and hence is synchronous with the growing demands of the numerous industries. The busbar machine has an independent station for performing the operation of bending, cutting, and punching. These stations perform the required task in parallel, thus ensuring higher rates of production.
Bending is a type of manufacturing process and it is used to produce a V-shape, U-shape, or channel shape along the straight axis in ductile materials, mostly sheet metals. The bending machine also has special tools for its bending station. The bending tool is unhardened & ungrounded and the speed at which the bending operation is carried out is 5mm/Sec. The machine also consists of a gauge stopper.
Another operation which the machine performs is that of cutting. The workpiece is being cut into the desired length with the help of the busbar cutting machine at the cutting station. The shearing station boasts of a hardened & grounded HCHCr Blade to carry out the cutting operation effectively. The cutting machine performs the cutting operation at the speed of 6 strokes/min. The oil tank capacity of cutting station is about 75 liters. The station is powered by a 5HP motor that is equivalent to 3.7KW. It also comprises of a gauge stopper.
The busbar punching machine has one suitable die & punch on its punching station. Punching is a forming process in which a tool is forced through the workpiece to create a hole by shearing. The machine has a separate foot switch for every station, i.e. punching, cutting, and bending. There is a provision made for special tools at the punching station of the machine. The punching operation is performed at its station with a speed of 13 strokes/min.
The busbar bending-cutting-punching machine is a highly compact and versatile machine. The machine is powered by the main drive motor. It comprises of a compact hydraulic power pack with a built-in control panel. The machine is highly durable and capable of giving out higher outputs. A high-speed version of the machine is also available. It boasts of hydraulic and electrical components of international standards that ensure the long life of the machine without any requirement of maintenance.
Summary: The machine has 3 different stations for bending, cutting, & punching. These 3 operations are carried out at their respective stations and thus it proves to be a versatile machine. Gauge stopper is provided at all three stations. The punching station consists of one suitable die & punch.
The Bottom Line: A busbar is being extensively used for electric power distribution. It is manufactured using a busbar bending-cutting-punching machine. The machine has separate stations for all the 3 process and thus the simultaneous operations help in greater productivity. The machine is also available in a higher speed version.
Laser marking is a procedure of leaving marks, symbols or any pictorial notations on the surface of an object. It also involves a colour change due to chemical/molecular alteration, charring, foaming, melting, ablation, and more. The fiber laser marking machine makes use of a fiber laser source. The laser generated is transmitted with the help of an optical fiber that cooperates with high-speed scanning galvanometer, used for workpiece marking.
The laser marking machine utilizes rare earth doped fibers as the gain medium. The presence of fine fiber core in the fiber laser eases the task of producing high power density in the fiber under the action of pump light. It eventually results in an inversion of the number of particles of the laser working substance. As a result, a phenomenon known as “Laser oscillation” occurs, when a positive feedback loop is formed to induce resonant cavity. The wavelength of the incident laser can be made adjustable in order to make it felicitous for numerous applications.
Summary: Laser marking machine is used for the process of laser marking that is a process of leaving marks, symbols or any pictorial notations on the work surface. The machine makes use of a laser source. The wavelength of the incident laser emanating out of the source can be altered as per the application for which it is employed.
Features of Laser Marking Machine The laser marking machine is a highly integrated machine comprising of a superior laser beam possessing uniform power density. The machine is designed in a manner to ensure that its anti-reflection ability with optical isolator is increased. This makes the machine to perform the operations effectively on high reflective materials, such as- aluminum, copper, gold and silver without the shadow, etc. The laser marking machine has the ability to operate at high speeds without any deviation. The machine shows good stability for a small volume production batch. The machine is tweaked with the latest technology and has adopted an embedded operating system that imparts a good touch interface and powerful control system. The machine is capable of meeting most of the industrial demands and its compact structure makes it a very effective piece of machinery.
Fiber Laser Marking Machine Benefits The fiber laser marking machine has great working functionality and is capable of operating up to 100,000 hours. The small size of the machine enables it to consume less power for a required operation with the power consumption remaining below 500W. It has a very high efficiency for photoelectric conversion producing negligible faults in the operation. The laser marking machine has compact structure and high system integration. The fact that it is compatible with software like CorelDraw and AutoCAD makes it the machinery of utmost importance in industries. It also supports different extensions, such as- PLT, PCX, DXF, BMP, etc. and directly uses SHX and TTF fonts.
Summary: The fiber laser marking machine consists of a superior laser beam that has uniform power density. It is highly effective on reflective materials, like- aluminum, copper, etc. The laser marking machine is capable of working up to 100,000 hours ensuring high durability. The small size also enables it to consume a lesser amount of power.
Applications The laser marking machine has wide applications and is primarily employed for marking logo, words, brand, date, series number, batch number, sign, drawing, photo, QR code, etc. on the surface of metal & non-metal material. The range of metals include stainless steel, alloy, metal plate, aluminum, silver, gold, etc. and the non-metals include plastic: engineering plastic and hard plastic, etc. It is also used in electronic equipment, such as- integrated circuits, mobile communications, precision instruments, glass watches and clocks, computer keyboards.
The Bottom Line: The laser marking machine is used for a wide variety of marking applications, such as- logo, words, brand, date, series number, batch number, sign, drawing, photo, QR code, etc. on the surface of metal & non-metal materials. The materials include- stainless steel, alloy, engineering plastic and hard plastic, metal plate, etc.
A Radial drilling machine is a type of drill machine in which the boring head is mounted to slide along a spiral arm. It can be pivoted, raised, or brought on a vertical pole down to adjust the position of the drill over the workpiece. The machine has a vertical column mounted on a large base and is used for medium to large workpieces.
The column is supported by a radial arm which can be raised or lowered to accommodate workpieces of different height. This arm can swing horizontally to any position around the column over the work. There is also a drill head mechanism in the machine. It is provided for rotating the spindle and feeding the drill and is mounted on the radial arm. They can be moved horizontally to and fro from the column and clamped at any desired position. These three movements when combined together in a radial drilling machine permit the drill to be located at any desired position.
Parts of a Radial Drill machine
A Radial Drill machine consists of the following parts:
Base: The base of the drill machine is a rectangular casting. It supports column at one end and the other end is provided with T-slots to hold the workpiece.
Column: The column is a cylindrical casting mounted at one end of the base. It supports the radial arm which slides up and down. A motor is also mounted on top of the column which is used to impart vertical motion to the radial arm.
Radial Arm: It is mounted on the column extending horizontally over the base. It can be swung around the column.
Drill Head: The drill head is located on the radial arm and it drives the spindle. It houses a mechanism for providing different feed rate and speed. For the positioning of the drill, drill head can slide over the radial arm.
Spindle Drive and Feed Mechanism: The feed mechanism and the spindle drive controls the rate at which operation is carried out and the tool is fed to workpiece.
Radial Drilling Machine- Ex Stock Availability
Bhavya Machine tools offer supreme quality machines devoid of any issue. The Ex-stock availability of Radial Drilling machines at our facilities ensures quick delivery of the products ordered by you. The state of the art infrastructure facilities available at our industry ensures that every machinery is made with precision for performing accurate operations. These devices are manufactured using finest quality material and hence they are efficient, durable, and requires low maintenance. The machines are designed in a manner that it operates, producing lower decibels of noise with reduced vibrations.
We have variety of Radial Drill Machines to offer, namely- All Geared Radial Drilling Machine, Z Series – All Geared Radial Drill, Auto Feed Radial Drilling Machine (R40BA), All Geared Radial Drill Machine(BRDC-410), All Geared Auto Feed Radial Drill Machine (BR40AA), All Geared Heavy Duty Radial Drilling Machine (50 X 16 / 1300, 75 X 16 / 1600), and many more. These machines have Ex-Stock availability ensuring fast track delivery.
Lathe machine is one of the most useful machines that have acquired an important place in the manufacturing industry.
Lathe machine is employed for different operations like facing, turning, threading etc.
Lathe machine basically keeps the workpiece on a chuck & tool and then rotates it about an axis to execute operations like knurling, drilling, thread cutting, turning and facing to make an end product symmetric at the axis.
What is the main Function of Lathe Machine?
Mainly Lathe machine is operated to remove the excess metal from the product and provide it with the desired shape and size. The lathe machine can produce plane surfaces and cylindrical surfaces to the product placed at a right angle to the axis of rotation.
There are different types of lathe machines that have become part of different manufacturing industries.
1) Speed Lathe Machine: It consists of bed, tailstock, headstock & tool post installed on the adjustable side. It has no carriage or feed box lead screw. The speed of the lathe machine is 1200 to 3600 rpm. It even consists of two or three spindle speed. The depth of the same is less. This type of lathe machine is employed in spinning, woodworking, polishing and centring. The high speed of the headstock spindle has named it a Speed lathe machine.
2. Engine Lathe: It is operated by the pully mechanism or gear mechanism. It is one of the most used lathe machines. It consists of a bed, tailstock, head etc. The head tock even provides multiple spindles speed. Basically, the headstock is stiff in structure.
This type of lathe machine is utilised in workshops and many other industries. It is capable of feeding the cutting tool in the cross as well as a longitudinal direction while being connected with to the lathe axis with the help of leadscrew and carriage feed. It consists of three belts: Geared type, belt driven and motor driven
3. Bench lathe: These lathe machines are used for very detailed work and are normally small in size. These are mounted on bench and consist of similar parts like speed and engine lathe machines. It can perform all the operations of speed and engine lathe machine but the only visible difference is of size.
4) Toolroom Lathe machine: This lathe machine has similar features as of engine lathe machine but the only variation is of its wide range of speed. The spindle speed of the same accelerates from very low to a high speed that is up to 2500 rpm. This machine consists of taper turning attachment, chuck, draw in collect attachment, pump for coolant, steady and follower rest etc.
This machine is used for working on dies gauges, tool, grinding and for many other purposes. It is costlier than other lathe machines.
5) Capstan Lathe and Turret Lathe machines: The capstan lathe and turret lathe machines are employed in production work and are considered as an extension of engine machine. It consists of hexagonal turrent head and three tool post. Multiple tools can be fitted and fed into the work piece. This machine supports different operations and can produce different parts at a fast pace. It occupies more floor space and is used in large industries only.
. 6) Special purpose lathe: These lathe machines are meant for special purpose uses in the production industry. It can perform operations like grinding, drilling, boring, reaming etc.
Lathe machines are highly efficient machines that are employed in different industries for various purposes. Each type of lathe machine performs different operations and provides the desired end product. So, If you are manufacturing industry then lathe machine should become part of your manufacturing process for the precise outcome.
A Drilling Machine, also known as a Drill Press, is used to cut holes into or through metal, wood or any other materials which has the ability to withstand high magnitude drilling forces. The drilling machine uses a drilling tool, termed as Drill Bit, which has sharp cutting edges at its point. The drilling machines are categorized in 4 classes- vertical sensitive, upright, radial, and special function. Some of the drill machines which fall under these classes are Upright or Column drilling machine, Sensitive drilling machine, Gang drilling machine, Radial drilling machine, Multi-spindle drilling machine, Vertical drilling machine, Portable drilling machine & many more.
The components of a drilling machine are:
Base: The base acts as a supporting structure for the machine. It is usually made of heavy gray iron, and has slots to give support to the structures that are too large for the table.
Column: The Column is usually round structured and is made from gray cast iron or ductile iron for larger machines, or steel tubing for drill presses which are smaller in size. It gives support to the table and the top half of the drilling machine.
Table: The table is provided to move the work piece along the column. It can also be swiveled around the column in order to reach the intended working position. A large majority of worktables have slots, holes and other structures as accessories for holding the work. Some tables are also capable of being rotated around the horizontal axis.
Head: The spindle, quill, pulleys and the motor are all housed in the head of the drilling machine. The V-belt is attached to the motor driving the pulley located in the front part of the head. This in turn drives the spindle which causes the drill to operate. The speeds on a stepped V-shaped pulley drive can be altered by changing the position of belt.
Angle plates: To support the action by its edge, angle plates are provided. They consist of holes and slots to help clamp the work piece to the table and also holds it together. They also accurately align the work perpendicularly to the surface of table.
Drill jigs: Drill jigs are used when there is a need for multi-tasking. When several holes are required to be made in one particular place. It also helps in locating the work to the favorable drilling position. The drill jig is also used to guide the drill straight through with the help of drill bushings.
When the power supply is given, the spindle which is in conjunction with the motor starts to operate. The Radial arm is adjusted according to the type of operation and height of the work piece. The chuck is connected to the spindle and it holds the drill bit in its jaws. The Drill head is adjusted on to the point of application at work piece and a suitable feed is given. The drill bit then drives into the work piece very easily. When the hand wheel is rotated, the pinion which is attached to the rack also rotates which converts the rotary motion to the linear motion. This driving mechanism is called as Rack and Pinion mechanism.
The fundamental application of a drilling machine is to create holes of different shapes and size on any work piece. A number of drill machines are available in the market to perform various operations. Hand drills are used for screwing and fastening. Hammer drill is used by carpenters to drill and fix the wooden parts. Cordless drills are useful where electrical supply is not available. Milling cum drilling machine is broadly adopted in the industries where there is a requirement of mixing and grinding of solid and liquid substances. Pillar drill machine (also referred as drill press) is used in commercial applications where there is a requirement of bulk production of drilled materials in various size and shape like metal sheets, plastic, wood, glass, etc. The capacity of drill press depends on numerous factors namely- pillar diameter, spindle nose, spindle travel, spindle speed and electronic motor used in the machine.
To be a market leader in the industry, it becomes top most priority to understand which technology becomes a need fit to your business. You know your business needs well. You know precisely what is going to be the specific requirement at different point of time. You may know full details about the technology and arrival of new ones. Or otherwise the specialist of the same field may help you even better. But what can be done to cut the cost of the production is introducing the right machine. This also helps enhancing the benefits gained with learning from experience curve. ‘Milling Machine’ is one of the most popular and demanding machine which forms a shape to the product.
What is a Milling machine?
A milling machine is a tool consisting of cutters which have numerous functions in the metal industry. The milling machine is well known for its adjustable feature for doing a precise cut. Hence, it has become an important and advanced machine amongst the manufacturer. The idea of regulating cutters at the various range of speed to form a shape acknowledges as a deep subject which matters to those who serve as a manufacturer in the market.
Here are some of the commonly used Milling Machines:
The column is the simplest machine to understand.It merely functions with 5 basic components. They are as follows:
It is vertically suspended tool which allows drilling of metals. The column is used to form small shapes and handy parts fitted in the car.
Bridgeport Type or Turret:
Turret or Bridgeport Type is a functional milling machine which can produce a variety of products to be used in addition to Car parts. One of the beneficial features is that it can be repositioned in accordance with the requirements.
C Frame is popularly known for industrial settings. With the use of Hydraulic Motor, it becomes a powerful machine.
Horizontal Machine works parallel to the ground. The object is placed on the table here. Then the object moves sideways. Thereon cutter goes ups and down.
As the name suggests, on the bed itself the work table is located usually.You can see the movement in a longitudinal position, a bit free movement is there.
This model is also considered similar to the bed mill. For a wider range of milling actions, the planer style is used. It includes cutters and heads.
Based on the master machine, Tracer Controlled has the ability to reproduce the parts.It’s usually seen in the automotive industry. The specialisation of machine parts and its products becomes easier. Hence, with the major classification of Milling Machines, one can easily realise which one can be functional to their purpose.
Benefits of Milling Machines:
• The size and durable construction of the milling machine give tremendous support to handle large and heavier machine without damaging itself.
• It provides flexible computer control options for cutting purpose.
• It reduces the chances of human errors.
• It assures accurate cuts.
• Availability of customization.
• Use of multiple cutters.
• It can do multiple cuts simultaneously.
With the renewal of product ideas, the updation of production machine becomes essential. This demands in-depth knowledge of the production technique, product life-cycle, and total production cost per piece or unit wise
Conclusively, the benefits direct the proper attention to recognise what actually is needed. Moreover, the specialist enhanced with same knowledge can help you well to access the hidden benefits as well by selecting the right one.
Any CNC milling or drilling machine is referred to as a CNC machine center. There machines tend to include an automatic tool changer along with a table to clamp the workpiece. The way it works is that a tool rotates while the workpiece stays in place. Most important characteristic of this machine is the orientation.
This machine makes use of Computer Numerical Control and allows precise control over a majority of the parameters like speed, location, coordination as well as the feed rate. It is possible for a single programmer to control the machine work using a computer console on a CNC machine. This is the equivalent of multiple operators working on other machines like lathes, grinders, routers and mills.
These computerized automated machines are usually more efficient as well. This article goes on to explain benefits of using this machine, how the horizontal CNC machining one is different from the vertical CNC and their applications.
Why CNC Machining Center?
The main reason for using CNC machine is because of all the automation features. Besides that, it is faster, has a higher production rate and is highly accurate as well. These machines have good cutting quality. These machines make the process of working on complex surfaces easier. There are many other reasons of using these machines as per this list:
Lowers chances of going wrong
Ability to monitor process
Less need for test runs
Higher cutting parameters
Past, Present and Future of CNC Machining Center
A lathe machine has been around since the 3rd century BC in ancient Egypt. Mycanean Greek implemented it during the 13th and 14th century BC as per various discoveries made. There is also a painting from the 3rd century of a lathe device and several artefacts from the 6th century. It was an important device during the industrial revolution and is the mother of all machine tools.
Prior to the late 19th century, this machine was mechanically driven however, it has been replaced with electric motors since then. Further advancements lead to the introduction of the computerized control panel. Precision level of these machines is expected to become better in the future.
Some of the next generation technology includes a next generation computer numerical controls (CNC), advanced CNC programming, implementing CNC intelligence along with automation & 3D printing as well as virtually reality.
How Horizontal & Vertical CNC Machining are Different?
The main difference between a vertical CNC machine and horizontal machine center is spindle structure; one has a vertical spindle and the other a horizontal. There is a difference movement pattern as well. The vertical machining center column usually does not move. Moveable ones will do so only in X and Y direction. On the other hand, the horizontal machining center is a moving column of type T. It moves along X direction, and the column of an inverted T type moves along Z direction. A vertical machine is also easier to install and operate. The debugging process is also easier. Structural complexity of the horizontal one is higher, and production capacity is lower.
Industrial Application of CNC Horizontal Machining Centre
A Horizontal Machining Centre is best suited for heavy duty and high-speed machining as well as when machining is necessary on multiple sides. It is useful for big and small parts and applicable in a high or low production environment. It is useful for both low as well as high volume production requirements.
Industrial Application of CNC Vertical Machining Centre
Vertical machining centres are useful for die sinking. VMCs are known for milling and have several applications in many industries include the oil industry. There are many advancements in CNC machine tools and thus are useful in a greater number of applications.
A surface grinder as the name suggests is meant for grinding operations. This is one of the most common machines for grinding operations. The main purpose is to ensure a smooth finish on a flat surface. There are a several types of surface grinders like those of different orientation (vertical / horizontal). These are precision devices and are able to produce perfect ground surfaces. However, the degree of precision depends the type and usage.
Main features of a hydraulic surface grinder
A hydraulic surface grinder is important equipment which meant for grinding of engine blocks, facing engine heads, etc. There are many advantages of using this is equipment since it has many good features as per this listed:
This has segmental grinding wheel which offers high accuracy for grinding.
All the settings and adjustments are easy to manage.
It is also easy on the pocket.
There is an option of a micro feed (with the wheel head) that is hand operated.
It is heavy duty and has a robust base structure.
It has a slide with excellent rigidity and is also capable of handling heavy jobs.
Offers high rigidity and z axis accuracy.
A magnet slide is immersed in oil bath. The other parts are lubricated with oil using a centralised lubrication pump.
Spindle is mounted on a spindle housing, which runs on bearings. These bearings are packed with grease to improve overall life. They make use of high precision and antifriction bearings for this purpose.
It provides a direct drive feature; hence this eliminates any vibration.
The hydraulic surface grinder has several accessories as well; some of which are optional, and others are standard ones. The accessories extend the features of the equipment and make the tasks simpler and more flexible.
Here is a list of few accessories:
Grinding Wheel, Leaving Screws
Flange Puller, Spindle Locking Spanner
Wheel Flange, Diamond Dresser Block
Table Guards, Magnetic Clamp Boll
Diamond Dresser with Holder
Spanner for Wheel Change
Micro feed for Elevator, Electric Panel
Micro feed for Cross Slide, Electric Motor, Magnetic Chuck
Work Light, Coolant Pump with Tank & Flash Guard
Wheel Adopter Puller
Angle & Radius Dressing Attachment
Wheel Balancing Stand with Mandrel
Centralised Lubrication Pump
Tips on buying a hydraulic-surface-grinder
The hydraulic surface grinders are for use on metallic and non-metallic materials. They provide such material with a more refined appearance. This is mainly due to the removal of an oxide layer and other impurities on the surface due to previous work done on it.
This equipment is the best to ensure a desired surface structure is achieved and that it is functional. This equipment consists an abrasive wheel, along with a work holding device (chuck) and a rotary table. The role of the chuck is to keep the material in place while it is being worked on.
There are several factors to consider when searching for a hydraulic-surface-grinder:
The material of the grinding wheel itself.
Material of the piece being worked on.
Be informed that the workpiece materials include steel and cast iron.
Keep an eye out for corrosion when grinding at high temperatures since this tends to weaken the material. There is also a chance of magnetism if applicable.
There are several types of surface grinders. The horizontal spindle surface grinder is the one where the periphery of the wheel is in contact with the workpiece. This ensures a flat surface. This type of grinding (peripheral grinding) is usually associated with high-precision work and is usually performed on a flat surface.
The other types include the vertical spindle surface grinder, disk grinders and double disc grinders. For the vertical one, the face of the wheel is for use on a flat surface. Such wheel face grinding is usually for fast material removal. The disc grinder has a larger contact area between disk and workpiece similar to the surface grinding and can be either vertical or horizontal.
A shearing machine has several functions like cutting through hard metal sheets, cloth, plates of metal and several other types of material. This machine can be powered in many different methods like it can be pneumatic, hydraulic or electric. This shearing machine has sturdy blades that are made from sturdy high carbon steel. This is one of the most popular machines used in the metal manufacturing industry.
What is a Shearing machine?
A shearing machine specializes in steel sheet metal cutting. It is essentially as per the structure of a sub-gantry shears, discs shears, punching, etc. There are several types of shears, for example, the gantry shears can cut the straight edge of the sheet of wool bud. The aim of the shearing process is to make sure that sheared surfaces are straight and parallel with minimum plate distortion.
Types of Shearing machines?
There are several types of Shearing machines as per the list here:
This has a hinged jaw to cut metal and hence it is named as alligator shear. It is powered with the help of hydraulic cylinder and mainly comes in use for cutting long metal stock. This includes angle, iron, pipes, l-beams, etc.
The bench mounted shear is ideal for cutting rough shapes from a medium sized sheet metal to offer an additional mechanical advantage via a compound mechanism. Hence larger the machine, greater is the stress withstanding power to produce a better burrs free cuts.
A guillotine is a machine that consists of a shear table, a work holding device as well as a gauging device along with upper and lower shears. This can be either mechanical or hydraulic and even powered by foot. The moving blade is kept straight or can even be set on an angle. The aim of getting the setting right is to reduce the amount of force required to cut a large metal piece.
The power shear is the optimal selection of machine for blanking large piece of sheet metal. It can be operated both electrically and pneumatically. It can cut in straight lines or large radius curves and are more flexible, efficient, accurate, and durable with better finish quality.
This type of sheer is the best one to use to make a straight, intricate curved or irregular cuts as well as throat less sheer. The main difference being that its design allows it to move round freely.
This is a type of hand too that can cut sheet metal and is of few different types like snips, tinner snips, compound action snips. The tin snips have a circular pattern, the hawks bill pattern can cut radii on the inside and outside of circles but require sharp turns when cutting.
The nibbler also works like tin snips that work of a punch and die formation. The main benefit being it is robust and durable and has an ability to produce distortion free cuts, it is fast and has a low force feed.
Future of Shearing Machines
Although the principle of shearing is the same there are several improvements coming into the section of NC and CNC. The machines are shifting in the digital era and tend to have lesser controls to operate. They only have the bare minimum control and a digital readout or a push button for essential purposes.
There are also some advancements and future scope for improvements in the control technology, accuracy, back gauge speeds. Additionally, usages of ball-screw and servo drives are making the shear more valuable and cost effective.
Milling Machines are used for machining of solid particles. They are been used in the industries for cutting metal, wood, and other solid materials. The machine can be positioned in the direction to cut and shape out the workpiece. There are different types of milling machine used in different industries. One of the most commonly used milling machines is the vertical turret milling machine that has its own characteristics
Milling machines are been classified by the orientations of their spindles that are either positioned horizontally or vertically.
Following are the features of the vertical turret milling machine used in industries –
The table is been moved around the cutting blade in all directions and has the ability to cut various types of objects.
In order to cut the workpiece, the table is been moved perpendicular as well as parallel direction and the stationary spindle plays it role
Vertical Turret Milling Machine consists of the quill that helps to raise as well as lower down the milling cutter in the vertical direction for cutting the required material
The machine can be repositioned anytime in order to improve the functionality
It comprises of several options for aligning the spindle in number of positions
The machine is known for its low maintenance and high performance
It is comprised of computer numerical control technology also known as CNC. With this latest technology, the user has to input simple as well as complex instructions in order to operate different parts of the machine.
The technology helps to increase the productivity of the user as well as enables to produce a large number of accurate products
Bhavya Machine Tools deals with different types of machines used in industries that include food processing machines, woodworking machines, welding machines, and other special purpose machines. Our other products include different types of drilling machines, all geared lathe machine, bandsaw machine, different types of milling machines and many more products. For more information about the machines contact us today and know more about the different special purpose machines used in industries.
Drilling machine is widely been used in different industries for drilling holes of different sizes as well as a wide range of operations that includes tapping, countersinking, counterboring etc. On the contrary, there are different types of drilling machines been available that are been used in the industries according to the requirement.
How does the drilling machine work?
Basically, a drilling machine consists of the components that include arm, column, drill head, and base. The function of this equipment is the ability of the head to rotate about the column at a radius similar to the arm. The height can be adjusted accordingly depending upon the size of the workpiece.
There are various drilling machines available having its unique features and its capacity. The radial drilling machines help to make work easier and faster for large as well as for small-scale industries. Following shows information about the all geared drilling machine
All Geared Drilling Machine –
The various industrial segments for all geared drilling machines include woodworking, metal working, construction, quarries etc. It is been considered as an important tool in several manufacturing processes. The all geared drilling machine consists of a large geared drilling head that is been mounted to slide along a radial arm. In order to adjust the position of the workpiece it can be rotated, lowered or raised.
This type of radial drilling machine helps to save a lot of time, as it allows relatively large workpiece as the arm can swing out and can place a heavy workpiece on the base. In order to assure better durability, a typical radial drilling machine has an oil bath, , and hardened gears. All geared radial drilling machine is known for its heavy-duty and high productive nature. Likewise, it is also been generally utilized in diverse industries that include construction, metal & woodworking etc. All geared radial drilling machine is also been used in the petroleum industry for repairing and handling of many large workpieces that are related to oil research
Offers good speed and consistent quality
Large as well as small components are properly balanced
Effective drilling, tapping and reaming
High reliable components including arm, work head, and gears, columns
High durability with excellent performance
Precision Designing and Easy Maintenance
Bhavya machine offers you with high-quality different types of radial drilling machines. Different radial drilling machine includes a radial drill machine, auto feed radial drilling machine, all geared auto feed radial drill machine, all geared heavy duty radial drilling machine. These radial drilling machines are been chosen according to need in the industry. We offer you these machines with advanced components for smooth operations and rigidity. Along with radial drilling machines, we also export bandsaw machine, milling machine, woodworking, shearing press, hydraulic machine, different lathe machines and many more. For more information about types of radial drilling machines and other machine contact us today and get acquainted about different machines been used in the industries
With the growing manufacturing industry, milling machines have replaced the role of other types of equipment. It is one of the most important machine tools in the manufacturing industry. Initially, milling machines were been experienced for a simple processing equipment, but today it performs multi-functional high- intelligent processing. The development of the milling machine shows high performance, intelligence, environmental protection integrated machines. Not only simple processing but has also shown a tremendous change in electrical appliances, transmission structure etc.
Milling Machines in different industries are designed for machine shops and different industries to manufacture high precision products and parts of different size and shape. Apart from this milling machine can also perform tasks such as drilling, cutting gears, producing slots and many more.
There are different types of milling machines been used that is described as follows –
All Geared Universal Milling Machine
All Geared Universal Milling Machine is been designed to shape metal and other solid materials. It can be operated manually, automated and digitally automated CNC milling tools. This machine is highly efficient due to its high cutting capacity that is generally been used in large-scale industry. Depending on the type of industry as small scale or large scale, the machine is available in different specifications. Different models are been available for all geared universal milling machine considering the working surface, the range of spindle speeds and many more factors
All Geared Vertical Milling Machine
All Geared Vertical Milling Machine is been specifically designed to meet the requirements of engineering, process and construction industries. There are various features of this type of machines that includes low maintenance, safety, high productivity & quality. This machine is known for its high efficiency and cost-effective performance. Its properties like high tensile strength, perfect milling offers flawless shaping for solid materials.
Universal Milling Machine
Universal Milling Machine is used for processing of different surfaces that includes parts for serial production. With the help of this machine milling of helical, horizontal, grooves, fissures, angles can be performed. It can also be split as a vertical & horizontal milling machine.
Vertical Turret Milling Machine
Vertical Turret Milling Machine is assorted for milling jobs for shaping metal and many solid materials. This machine is economical and stable due to its various features that include durability, reliability, efficiency and higher productivity. It can perform multi-axis machining with different operational modes that includes manually operated, mechanically operated and digitally operated automated CNC mills. It provides high stability with rectangular table guideway, automatic motorized lifting and lowering of the product.
Considering the demand of the milling machines in different industries Bhavya Machine offers different types of a milling machine. The above-mentioned milling machine has a different application in industries. With the milling machine, we also offer different types of machines used in industries that include welding machine, different types of lathe machine, shaping machine, CNC machines and many more. We are also dealers in specialized machines that include welding machine, food processing machine, sheet metal machine, and other special purpose machines.
Today, Sheet Metal Machines are being widely used to perform cut, drill, press and shear on various hardened materials including aluminium, brass, copper, steel, tin, nickel, etc. These operations help reform the shape and size of the materials. Uses of sheet metal machinery range from making panels for packaging to making parts for machines. These machine tools have also helped make various medical equipment and various mechanical tools. But the sheet metal machine we know today has gone through huge changes since its invention. In this article, we will see how the sheet metal machines evolved and became what we know it as today.
Introduction of the punching machine
Humans have been engaged in sheet metal works from centuries now. In the prehistoric times, need for making sophisticated tools, vessels and pieces of jewellery was one of the reasons which triggered the invention of sheet metal machines. Punching Machine is considered as one of the very first sheets metal machine. It is still used as a manual tool in small-scale industries to punch holes in metal sheets. Punch machine was used to drill holes in metal sheets using manual force.
Folding/Bending of metal sheets
When just punching hole was not enough for making a complex tool, bending of metal sheet was introduced. In the beginning, sheets were placed between a set of rolling cylinders. These cylinders clamp on sheets and form the bend. If the desired bend is not obtained, the sheets are passed through the cylinders again. This process continues until the desired bend is obtained. Modern technologies have made this machine to evolve into Magnetic Bending Machine in which electromagnets are used to form the bending.
Since the tool to be made from metal sheets varied, it was not possible to work with just folding and punching. As the use of metal products increased, there was a need for the introduction of a process that would allow cutting of large metal sheets. This was made possible only after the introduction of pivoted scissors. This enhanced the production process. Shearing Machines are still being used widely in today’s industry. These modern machines tools are made from high carbon and chrome steel blades which provide higher stability while performing the operations.
Modern machines tools
Sheet metal machines have evolved far from its predecessors. Introduction of steam power was the first turning point for these machines. Use of steam power replaced manual handling of tools and provided far better performance with a high rate of production. Next leap was the introduction of electric control machinery such as Electric Operated Slip Roll. The electric control not only eased the usage but also helps increase the productivity of the system. At small scale production plants, hand and foot operated machinery are still used but demand for a higher rate of production is forcing the replacement of traditional machines with modern machines.
Radial Drilling Machines – Their Advancements & Benefits
Radial Drilling machine mechanism has fully changed the appearance of the industry. It is been designed for medium to large and heavy work pieces. They are been characterized by their straightforward handling, with its powerful drilling performance. It has extreme stability and large traversing range. Radial Drilling Machines provide precision, efficiency, and dependability in batch production environments. They provide portability for installation and assembly work. With the growing technology, industries have been benefited with the advancements in the Radial Drilling Machine.
It has changed the phase of the drilling operations. This machine includes the parts like-
Head: Place where the penetrating piece is been found that consists of extraordinary apparatuses for holding the bit
Gearbox: Changing with the speed of operation that can be expanded or decreased relying on the operation.
Handle: Controlling with the boring apparatus
Supportive Section: Shows where the head and arm pivot is about.
The main principle that puts the radial drilling machine front as compared to other machines in the drilling industry is the adapting framework for substantial output by empowering it to pivot over a wide circuit which that performs overwhelming mechanical works. There are also some key commitments of the radial drilling machine to the drilling industry. The key commitment to the industry is its adaptability and simplicity of operation.
Working Principle of Radial Drilling Machine:
A hole is been generated with the help of this machine as the rotating edge of the drill exerts a large force on the work piece. In the drilling operation, the removal of metal is been done by shearing and extrusion
Benefits of the Radial Drilling Machine to the Industry
Radial Drill Machine consists of the drill head that can be moved, adjusted in height and rotated. It is capable of positioning its head through its radial arm mechanism. This is one of the reason, industries are benefited and prefer using this type of drilling machine
Works efficiently on different metals and wood materials
Quicker use and operation due to the compact size
The device is rugged and durable as well as resistant to adverse conditions.
Movement can be either manual or power driven
The table is rotated through 360 degrees
High Precision and Accuracy
Bhavya Machine Tools is one of the leading suppliers and exporters of this type of types of machinery. There are also types of drilling machines that includes portable drilling machine, sensitive drilling machine, upright drilling machine, automatic drilling machine, deep hole drilling machine and many more. We offer with the wide variety and series of the drilling machine that includes All Geared Radial Drilling Machine, Auto Feed Radial Drilling Machine and many more. Different types of models are been available for drilling machines. Rather than drilling machines, we are also leading in other industrial machinery as well. Our other types of machinery include workshop machinery, sheet metal machines, plastic and printing machines as well as other special purpose machines.
Human cravenness for perfection with less effort has made wonders in economy. Everyday everything is going smart just like a mobile phone, machineries in manufacturing house are also adopting advanced technologies to serve the requirements of mass production.
Nowadays, most of machines come with CNC system, CNC stands for Computer Numerical Control. Some of the examples of CNC machines are CNC Lathe Machine, CNC Milling Machine, CNC Turning Machine, and many more. This article mainly focuses on CNC Turning machine and its specification and application.
What is CNC Turning Machine?
The CNC Turning machine is used for milling and shaping purposes of a non-rotary material in the factories. It provides shape to material by cutting away unwanted material. It is controlled by CNC system.
The equipment is very useful if one has to manufacture similar items in a symmetrical fashion for large scale basis.
The turning machines are usually used to machine and produce specific and important components, especially intricate designs such as automobile parts and components, aeronautical parts, railings, table and chair legs, as well as other similar parts.
Overview of CNC Turning Machine and its Components
The CNC system helps the operator to easily operate turning machine. The system has various alphabetical and numerical keys on it. The alphabetical keys are for G code which is used for Tool functioning and the numerical keys are for M code which is used for Machine functioning.
The CNC system consists of control panel through which the operator can control the functioning of the machine. It also contains a screen by which the machinist can check parameters of the machine and also any edit or input value in the system can be witnessed on screen.
There is also a mechanism called Feed Controller which can regulate the cutting speed of machine. The RPM can control the speed of spindle which can be done automatically by pressing its button as well as manually.
The CNC machine has an amazing feature of alarm, which starts ringing whenever any issue occurs with machine.
The very useful component of the machine is chuck which is used to clamp, unclamp and hold any material. It is bolted on spindle which rotates the chuck. It is two, three and four jaw according to the requirement of machine. Basically, two jaw is for rectangle work piece, three jaw for round and four jaw for square work piece.
The spindle rotates and shapes the material is due to hydraulic pressure which is managed by Hydraulic System.
The system also contains conveyor which carries the raw material to the chuck and brings back the finished products.
To facilitate the user in the best manner, the machine contains a feature of Emergency Release, which is used to skip any operation of the machine simply by pressing it.
The CNC turning machine also considers the operator’s safety. Hence, it comes with Chip Guard Door so that the product does not pop out of the machine and hurt anyone during operation.
There is lubrication system which promotes smooth functioning of the turning machine. It reduces the friction between the components of machine caused due to its continuous working. There is alarm which is attached to it that rings whenever there is insufficient quality of lubricant.
Another important feature of this machine is its coolant function which outpours the liquid, generally water to cool down the finished products.
Safety Measures for Using CNC Turning Machine
The safety always comes first while dealing with manufacturing of any product.
The operator must have PPE, that is, Personal Protection Equipment. It consists of Helmet, Goggles, Mouth mask, Ear plugs, Dungaree and Apron, Hand gloves and Safety shoes.
The PPE is essential for operator’s safety as it will lessen the effects of uncertainties during the operation or manufacturing process.
Conclusion: One must ensure the maintenance of CNC turning machine to maintain its high performance levels.
Why Bhavya Machine Tools?
Bhavya Machine Tools is a leading supplier and exporter of CNC Turning Machine in India. The company offers a wide array of high quality products such as Press Brake, Slotting Machine, Wood working Machine, Radial Drill Machine, Lathe Machine, Hydraulic Lathe Machine, Machines Tools, Shaping Machine, Sheet Metal Machinery, Universal All Geared Lathe Machine, Lathe Machine Accessories and many more equipment.
The company is equipped with an advanced infrastructure and skilled and experienced staff. We deliver supreme grade products and unmatched customer services at cost-effective rates to our esteemed customers throughout the world.
Are you fascinated by the world of machine? Can imagine a world without machine? It might be tougher question to answer than you think, as many people don’t actually know to which extent we are dependent on it.
One can’t even lead a day without machine as people are habituated with cozy lifestyle. One requires alarm clock to wake them up, computers or any machinery to make their work easier. The life would be difficult to manage in its absence as the human efforts will increase substantially. The human nature often suffers from boredom due to physical work and repetition of work process, and it may result in error or discontinuation of work. Thus, invention of machine became necessary to undertake various production activities smoothly.
Plato rightly quoted, ‘Necessity is the mother of invention’.
Though the invention and evolution of machines was not a cakewalk journey as it require persistence. It also required a deep study and proper execution of science and technology respectively, to invent anything which can reduce human efforts.
Now, the question is how it began?
The agricultural revolution began by 18th century; it was a period of technological improvement and increased crop productivity. Soon, the food production started increasing, so as the population and their ever-increasing demands. The manufacturing companies have observed a significant evolution; it started its journey with manually operated machine, grew to semi-automatic and reached to make it fully-automatic.
It became high time for producers to produce machines in bulk and speedily to cater the needs of millions of people in the world for varied purposes like for construction, steel rolling, automobile, and the list is never-ending virtually.
Dependency on industries
One can witness that every manufacturing industry depends on another for tools or equipment.
For instance, a constructing company requires tools which are made by manufacturing industry. It depends on one who produces the steel and other alloys and that factory depends on mining, and the process continues in this manner.
Machinery in Modern Age
One requires well-designed machines which can work without interruption and accurately to make mass production so that it can cater the needs of various manufacturing companies.
For example, lathe is very important in any industry as it used for cutting, deforming, cutting, knurling and drilling of tools to create objects which have symmetry about the axis of rotation. It is known as mother of machine tools because it maneuvered to the invention of other machine tools.
Today, the lathe machine is available in varied series and types for diverse utilities. It is used in ship building, steel rolling, mining, power plant, etc.
Another major transformation is Bandsaw machine. It promotes uniform cutting and smooth finishing in woodworking, metalworking and lumbering. It has made cutting easier and faster with the help of its blades.
Prior the origination of drilling machine, the holes were usually made by hammering a drill quickly and repeatedly on a material. The radial drilling machine was introduced for drilling medium to large and heavy work pieces such as various metals. Thus, machines have become an integral part of any industry; the constant transformation in it has made the production activity, a speedy and hassle-free operation.
Why Bhavya Machine Tool?
Bhavya Machine Tools is one of the major suppliers and exporters of machine tools in India for more than four decades. We are an ISO 9001:2008 certified company. We offer a wide range of machines such as Workshop Machineries, Sheet Metal Machines, Wood Working Machines, Welding Machines, Milling Machine, Food Processing Machines, Press Brake and many more. Our every machine is well-built, reliable and durable which can be used for distant future. We provide supreme grade machinery and unmatched customer services at competitive rates across the world.
Recently, the machine tools industry is enjoying unprecedented surge in demand worldwide. To the surprise of many manufacturers, the output is still unable to satisfy this demand. There have been certain areas of the machine development and innovation that have been the focus of most users, and prompting machine tools manufacturer to put in more research and effort into them. These include;
High Speed and Efficiency in Operation
There is mounting demand for greater maximum main spindle speeds as well as feed speeds that are aimed at avoiding the chatter vibration during operation. In the years of the 1960’s to the 70’s there was much research on reducing the vibration, mainly described as the regenerative and the forced chatter vibration. There has been much progress in this area, with the incoming of the CNC machines, but still the vibration problem resurfaces when harder materials and being machined.
Multifunctional Machine Tools
In addition to enhancing of efficiency, there has been a great focus on increasing the multifunctional ability of the machine tools. This includes the development of 5 axis machining centers and the combined multifunctional turning centers. According to engineers and machinists, the advantages of combined multifunctional machines include;
Improved machining accuracy with reduced production time (one chuck process)
Machining of complicated shapes.
Combination of processes such as hobbing, polishing, slope machining/drilling, milling, external circumference machining, boring and many other processes can be combined.
There have been many types machining centers developed to match up with the current needs of the tool room equipments. With the addition of the orthogonal 3-axis vertical machining centers, there has been rapid improvement in efficiency of the tool room machines. Some of the available machines from the Yash machine tools company have become widely renown due to their production efficiency are;
The available models of the lathe include; Light duty lathe machine
This equipment is designed to make industrial tasks easier, faster and error free. The bed is made from hardened cast iron, with the boring done with induction hardened boring head and ground spindle made from alloy steel. Many other innovations have been added to make the equipment best for light duty lathe machining operations.
Medium Duty Lathe Machine Medium duty lathe equipment comes with latest engineering design, with sturdy materials of construction which are also durable and firm. Important components like the machining bed, head stock, and saddle are carefully machined to guarantee operational accuracy.
Heavy duty lathe machine
The heavy duty lathe is developed with important innovations in parts design such as the bed design is stress relieved, gear box and feed box are new and improved to guarantee high speed performance.
CNC Lathe Machine
The company has also developed the CNC lathe machines, including the Flat Bed CNC Lathe and the Slant Bed CNC Lathe machines. The equipments have been made with advanced technology that eliminates the chatter vibration to minimum levels and thus increasing the machining accuracy of the equipment.
Vertical Turning Lathe
This equipment has been designed with the high output user in mind. The turret style machine has a high torque drive to achieve some of the toughest cuts in process. The massive castings and the extra wide way system will ensure very accurate and stable machining and high quality products are achieved.
The lathe machine has been well described as the mother of all metal shaping processes. The computer Numeric controlled lathe has taken metal shaping a notch higher by making it possible to machine metal parts in an automated process, thus reducing the human supervision required and increasing the total output of the machine.
The design and development of the CNC lathe has therefore been able to maximize productivity and efficiency to guarantee increased profitability than before. The use of this special computerized control technology reduces the need for human supervision and has eliminated downtimes associated with fatigue and other human factors such as concentration and human errors.
Types of CNC Lathe Machines
The latest machining trends indicate that CNC lathe machines have replaced the traditional lathe due to their accuracy of machining, precision, repeatability and ease of operation. The equipment has been developed to utilize modern tooling techniques including carbide tools, for maximum production efficiency. Different types of CNC lathes vary with different manufacturers. There is however some common features in all these machines.
The basic operation involves the turret which houses the tool holder and directs them as required. The spindle is designed to hold the work piece and the inbuilt slides allow the turret to move in multiple axis. CNC machines are completely enclosed during operation to guarantee safety to the operator.
Special Features of CNC Lathe Machines
With the rapid technological development, different lathe machine manufacturers employ different technologies in the user interfaces that may make operators experience difficulties learning the system.
The development of affordable and advanced computers with operating systems such as the Linux and other open source CNC software has made these machines more affordable and available in machining industry.
A wide range of innovations have been made depending on the needs of the target markets of these lathe machines. The dual spindle lathe machine combines the y axis with the c axis as well as live tooling to enable multiple operations to happen. The tool room lathe is made in such a way to allow easy tool machining and variable parts making.
Special Purpose CNC Lathes
Horizontal milling is carried out using horizontally configured CNC lathe machines. The equipment is designed using rotating and cylindrical cutters with ability to move in up to five axis and therefore able to produce a variety of shapes, holes, slots, and other details in a three dimensional work piece.
With increasing production and need for quality and long lasting parts , special purpose CNC lathe machines have been developed . The 3 Axis CNC lathe machine has several important features that keep it ahead of the other models.
It is able to accommodate a large number to tools during machining.
The equipment is designed to handle both long and thin work pieces without any machining challenges
Equipped with strong servo motors for both the X and the Z axis motion.
The collet clamping system is pneumatically controlled hence smooth in operation.
The CNC lathe machine is the epitome of excellence. The computerized turning center remains a symbol of perfection in machine tooling. The high precision and high performance turning processes achieved by this equipment has taken parts manufacturing processes to new heights of automation. More advanced equipments are being developed including smaller versions of the machine such as those used in manufacture of medical equipments and other sensitive operations.
The various types of bending machines include the bus bar bending machine, profile bender, pipe bending machines, metal sheet bender, motorized and manual pipe benders. These are innovative forming machines generating bends on a metal work piece. This is achieved using linear rotating motion. They are developed with high flexibility that allows easier exchange of work pieces and ability to generate smooth even bends without deformation of the work piece. The profile bending machine is equipped with special hydraulic motor and gearing system with special hardened steel for durability. The bending machines are sturdy in construction and workmanship, and all safety concerns have been addressed. Operation is through advanced control systems that also enhance efficiency of the process.
Iron Worker Machine
Iron worker machine is a combination of productivity and effectiveness in metal working. The iron worker machine is very user friendly designed for durability and low maintenance costs. It has been developed by very competent engineers with vast experience on the metalworking processes and the needs of the industry. Has a strong and rigid structure for noise less operation and reduced vibration. Some application include cutting and shearing operations on angle lines, I section cutting,punching, notching and other customized operations. This is equipment that has a guaranteed return on investment. The control system is advanced with easier tool handling as well as completely safe operation.
Imported Sheet Metal Machine
Imported sheet metal machines include tube benders, profile end grinders, swaging (bead bending machines, profile bending, shearing machine and slip rolling machines. The shearing machines are designed with high grade steel and a robust construction to give strength and rigidity to the equipment. The sheet metal machines are able to achieve better cutting accuracy on thin sheets with a lower rake angle and also designed with automatic rake angle adjustments. They are also pre-calibrated for easy adjustment of the blade gap. They are also able to achieve smooth and low noise operations as well as high power usage efficiency. Operator safety is also well considered.
Wood Working Machine
Wood working machines include the Combination planners, surface planner models, thickness planners, spindle molders, spiral lathes, wood saws and circular saws, radial saws, grinders and chisels. The equipment is built with compact design and of rust resistant material making them highly durable. They have been built to provide high power and precision which translates to reduced material wastage and good return on investment. The planner equipmentshave been highly automated to produce very good finishes in the shortest time possible.The J 601 heavy duty planners are especially great for extremely busy environment and works efficiently with no downtimes or machine failures.
This welding equipment is versatile with advanced control system and achieves efficient welding over a long period of time. The models available include the MIG and the MAG welders. The equipment comes with the wire feeder and pressure regulator devices including the flow meter and measuring gauge. The Arc welding machine models are very affordable and require less maintenance. They can offer power saving of between 30 – 60% and offer very good arc formation as well as a power factor of up to 0.9. The equipment is suitable for all kinds of electrodes and light in weight for easy movement. The welding machines have also been fitted with protection against under voltage, over voltage and surges in power levels.
The available models for CNC Machining Center include DL – MH series and the TD Series for drilling and tapping centers. The CNC machines are able to guarantee long term reliability and efficiency through sturdy construction, high quality manufacturing material and automatic lubrication systems. The CNC machines are also equipped with automatic tool length setters that ensure allmeasurements during production are highly accurate and there is no material wastage. The machining centers are also equipped with programmable logic control systems as well as automatic memory system that avoid repeated calibrations when similar work pieces are being operated. The equipment can also accommodate a wide variety of spindles required during the different operations.
CNC Vertical Machining Center
The vertical machine center can be referred to as an industrial work horse, able to deliver parts with high accuracy and has reduced production time. The spindle design is robust and well designed to deliver exceptional horse powers, superior torque and variable machining speed as may be required by the work pieces. With this level of automation, the CNC vertical machining center can cut a wide variety of materials, lower production cycle times, reduce the cost of machining and increase the profitability of the process. The machine has been developed with great hind sight from the engineers to reduce the downtimes associated with frequent quality checks
Slant Bed CNC Turning Centre
Slant bed CNC Turning Centre is a high speed production lathe that has a high precision and a bi-directional indexing turret. The eight station tool turret increases the production efficiency and decreases waste. The guide ways are also developed in a way to ensure accuracy and high level of feed as well as cutting speeds. The 45 degree slant bed CNC turning centre feature of the bed enhances the accuracy of operation and machine stability. The spindle structure is also designed and mounted in such a way as to prevent deformation of the work piece.
Excellent gantry design for greater functionality and performance
May come in gantry or table design
Singular or multistage carriage design
Good pass between the columns for maximum usability
The milling cum drilling machine offers flexible machining which can integrate up to 5 axis milling head
Long term accuracy is guaranteed through sturdy and rigid framework that eliminates unwanted vibration.
Some of the units come with enhanced tool management system for easier tool changing, automated lubrication and very user friendly control system for smooth operation.
Re-sharpening machine is a very innovative equipment made to withstand rigorous and hard metal sharpening operations. It delivers very precise grinding results with an accuracy of up to 0.02mm. The equipment is easy to learn and operate and will sharpen a drill bit in 20 seconds. The power consumption is good and the grinder usage of approximately 0.2 mm. The quality of the grinding wheel has been ensured by using diamond dust wheel grinding material. The tool box is also well secured. Some of the units are portable hence can be used at the work site. Various models of drill bit re-sharpener and universal drill grinders are available depending on the customer’s needs in machining.
Some models of the hydraulic press include the c-type hand operated press, c-type power operated, H-type power operated press. The pressing equipment is built with great versatility and designed to run at variable strokes and die sizes. They are developed to handle various production needs and different tool sizes as the production demands. The ability to have variable stroke length allows for various applications including punching, straightening, pressing, transfer molding and other applications. Due to the variable stroke length, a wide range of die heights can be used and still be able to maintain the required tonnage during operation.
After settling on the model of the lathe machine suitable for your needs, people tend to forget that planning for installation is equally critical for efficient operation of the equipment. It is wise toscrutinize all details of the installation area before the actual day of delivery and machine setup. Where possible it is recommended to obtain a two dimensional drawing of the equipment before arrival for better space and position planning. Illustrated here are some very important ideas when setting up your new Lathe machine.
Confirm Electrical Requirements
It is wise to be clear on the electrical requirements that your CNC lathe machine needs, the power rating, current requirements in order to determine the contacts switch system to use and even the correct cabling for this type of load.
It is recommended to check the placement of the electrical source and ensure that it is accessible near the new machine station. A qualified electrician, who ensures that the connection and integration requirements are met, must do all electrical fittings.
Planning For Oils and Lubricants
Always settle on a particular type of lubricating, hydraulic and coolant that your equipment will use. They must be purchased before running the machine to ensure that the equipment can be run and tested during the day of installation. Manufacturers recommend having a specific grade of coolant determined by themselves, for efficient operation and long life of the equipment.
Pre – Planning Space Lay Out
Here you will need the machine drawing to determine the placement of the machine. Following the installation guidance from the manufacturer helps avoid major running problems in the future.A good example for consideration is the door clearance. Different sizes of equipments will require different clearances. Pre planning these clearances before installation prevent the nightmares that emerge when running and servicing the machine.
For good running and durability of the lathe machine, the air source needs to be free of humidity as much as possible. This prevents rusting on the inside parts of the machine which are never dried or cleaned. This condition has been observed in compressor systems that have no dehumidifiers. Moisture management must be done since rust can quickly destroy an otherwise good machine tool.
Machine tools and especially the Lathe machine are heavy objects. The equipment must be held on a good solid slab that would not easily crack or bend due to vibration. Uneven surface will also lead to poor and incorrect operation of the machine. You may also get help from the manufacturer over the best foundation for the machine.
Entry Way and Machine Orientation
It is always good to avoid surprises such as the equipment not being able to fit through the entry to the workshop, where part of the wall has to be damaged then repaired again.
When all these steps have been followed accurately, the installation process is smooth and successful. It is then important to have a proper plan for general maintenance of the equipment. Bhavya machine tools supply these innovative lathe and CNC machine tools. The company also provides great guidance on the installation and maintenance requirements.
Bhavya Machine Tools is a company that deals with manufacturing and sales of machine tools in India and the rest of the world. The company has firmly established itself as a market leader in manufacturing of high quality and efficient machine tools including machining centers, drills, tool room equipments, hydraulic equipments , Sheet rolling machines, woodworking machines, welding equipments, construction machines and general workshop accessories.
With more than four decades in existence, the company has made major advances in technological innovation and has been a leader in manufacturing of highly efficient and advanced equipments.
We have a vision to become a global leader in innovation and development of efficient and effective machine tools, workshop machines and accessories, which will positively impact humanity and manufacturing sector.
The company has a mission to develop long-term relationships with our clientele as a way of sustaining growth and reaching out to other global markets through high quality products and great customer service.
To achieve the quality objectives, the company has complied to the requirements of the ISO 9001: 2008 quality management system and been certified against this standard. We are continuously improving our operations by engaging highly qualified staff and adopting strategies that will lead to business growth and success.
The company upholds high business ethics and integrity, ensuring our clients and business competitors are held in high respect and ensure customer satisfaction is achieved. Our products have made it to the global markets due to the advanced technology and great workmanship, making them easy to use, maintain as well as achieve the throughput that your industry requires. Some innovative categories of products are detailed below.
Power Tools and General Accessories
Some of the innovative power tools include the bench grinder, polisher, pedestal grinders, electric motors, burners, blowers and many other related accessories. General accessories include bench vices, tilting tables, self adjusting vices, precision grinding vices, Magnetic chucks, and various types of pipe vices, anvils and many other general accessories. The construction of these machine tools is such as to maximize durability and strength to handle the mechanical stresses during operation.
New Construction Machines Design
Some important considerations in procuring the construction machines include affordability, reliability, durability, ease of maintenance and installation. The company has invested in modern manufacturing technology, which ensures that we produce equipment that meets the current manufacturing demands.
Vertical Machining Center in Foundry
Most metal forming processes involve more than one-step machining. The old model machining centers were largely unable to cope with rapid feed rates and the quality of finish required. In foundry, accuracy is a very critical element. The design of the spindle, thermal and construction stabilityare the primary considerations in choosing an excellent vertical machining center.
A good spindle is able to maintain the Z axis accuracy, which is essential during manufacture of parts that are required to mate during operation.
Current machines have internalas well as external cooling, enabling heat removal at the source and thermal as well as machining stability is guaranteed.
Butt-welding is a technique of joining parallel metal plates without any overlap. This is done using the butt-welding machine. The process involves heating the two adjacent plates and joining them under certain amount of pressure. This machine is very economical and reliable since it runs continuously without stop over’s during the production process. The butt-welding machine also does the joining without adding any supply of metals. A hammer is then used to remove the waste material produced.
ARC Welding Machine
The Arc welding machine uses electricity generated by the welding power supply. The machine then creates an electric arch. The heat created by this machine is usually enough to melt the metals. When the metals cool, they then bind together. The arc welding machine first came about around the 19th century and today it is commonly used within the steel and vehicle industries.
SPOT Welding Machine
The spot welding machine works in such a way that the metal surfaces being worked on are usually put together using the heat that is generated from the resistance to the electric currents. The energy generated will be directly proportional to how large the current is and how long it will take. The spot welding machine is mostly used in the manufacturing industry, in the orthodontics’ clinics as well as making of batteries.
The swaging machine uses dies that are placed onto the machine then rotated by a motor. Usually, this machine is very common with the blacksmiths. The swaging machine forms metals into many different shapes that would be hard to form if a hammer alone had been use. The machine also comes in handy when putting together fittings to pipes and cables.
This electrical device usually turns alternating current to direct current so that it can flow in one particular direction. DC Rectifier can be in the form of vacuum tube notches or other silicon based semi conductor switches. The rectifier has broad range of uses , mostly on devices that will never run on the alternating current. They provide equally high power output and ha lesser power losses during transmission.
This machine is almost like a shaper but it is larger in size. The Planer Machinemakes use of linear movement between the piece being worked on and the cutting tool to cut the piece. In most scenarios, the machine provides flat surfaces that are in a way more precise as grinding. It is also used to generate slots for keys. Currently, this machine has undergone various technological advancements to avoid being replaced by the drill bit grinder, folding machine and mini-milling machines.
HOSE Crimping Machine
This machine is mostly suitable for operation in the rubber industry. Hose Crimping Machine is suitable for pressing tubes such as pipes that have substances flowing in high pressure. This machine is mostly used in the mechanical engineering industries to pass on hydraulic pressure.
Mortising machine usually makes the waste get out in one simple operation. It operates in a better way than the chisel or router. It has better speed, has better quality and is more efficient.
SPM or Special Purpose Machines are those that are used in various industrial applications. African and the Gulf Countries have recently seen a huge change in their economy. Both these countries have seen several political and social ups and downs in last few years. Now, their economy is facing towards a new beginning and that has a deep impact on their industries. More and more industries and factories are built up and the demand for SPM heavy machines like Hydraulic Thread & Form Rolling or Bolt Threading Machine is augmenting day by day. These machines are highly useful in various industrial applications as per the need of the modern time.
Easy To Operate
These new age machines are always easy to operate. That means the factory owners do not need to have trained or experienced workers to run these machines. Most of them are automatic or need a slight manual contribution to perform the daily task. These machines save huge time in the production processes. Thus, in African or Gulf countries the demand of such machines is very high because they do not need to hire experienced or skilled workers for the same. It can be easily operated by workers with nominal knowledge about machines.
When you go to the market to buy products like Hex Nipple Threading Machine or Gear Hobbing Machine, then you can find that they are highly cost-effective. In countries where economy is not very strong, buying and using such kind of machine is always the best thing can be done to augment the production in factories. That is another big reason for the augmentation of the demand of these heavy machines in such regions. There are lots of companies all over the world including India and Pakistan from where you can buy these machines at reasonable rates.
Little Maintenance Is Required
The demand of SPM heavy machines is high in African and Gulf countries for another reason. Since these regions are witnessing a massive growth in industries thus they need machines that are robust and come with nominal maintenance factors so that better and faster production can be enjoyed. Whether it is a Hose Crimping Machine or a Bed Type Milling machine, you can use it for long hours and days without spending much time for maintenance process. They have auto clean techniques that can let the machine to clear themselves when necessary. You can order them online and get the shipment within a few days.
Versatile In Use
There are lots of new and interesting industries are growing in the Gulf or African countries. Thus, they demand for the heavy machines that are versatile in use. These SPM machines can be used in several industries for different applications. You can have them for nipple threading or tread rolling, or meet the treading demands of nipples that are made of metal. That means all these machines can help you to perform several types of tasks that are highly useful for your business and production. The versatility of these heavy machines makes them more and more popular in these countries.
It is said that few organizations can prosper without innovation. This has been very profound in the field of machine tools which has gone in leaps and bounds through innovation leading to tremendous improvements in the production capacity and overall efficiency in production and manufacturing. Some great innovations include;
Computer Numeric Controls
Impact of computer-controlled machines such as on the lathe and machining centers has been the biggest of all in manufacturing. Today, CNC technology has allowed development of machines that are highly productive, flexible, and with the ability to integrate different production processes onto one machine.
The current challenges in use of this technology have shifted from the machine capacity to the ability of technical staff to set up, program and effectively operate these machines to maximize their capacity.
Innovations for Extending the Cutting Tool Life
All manufacturers are looking for a competitive edge in their manufacturing operations. Machining operations are brutal and heavy energy consumers. One of the factors that contribute to tool damage is temperature generated during operation. A key innovation that has led to extended tool life is the coolant fed tool where the coolant is pumped through the tool to very near the tools primary cutting point. This has led to longer tool life from enhanced lubrication and reduced friction, higher speeds and feeds as well as the flushing action to remove developing chips.
Through elimination of manual feeding systems to automated feeding and calibration, there has been improved accuracy in machining and cutting performance, therefore reducing the need for secondary operations after achieving good surface integrity. These secondary operations include reaming, boring and grinding which are also costly.
Easier Installation Procedures and User Friendliness
Installation and operation of equipment as well as the ease of programming has also been an area of innovation. The development of machine tool from manual operated equipments to use of programmable logic controls to advanced computerized systems has influenced heavily on the global production and supply of these equipments as well as the production industry.
Noise Dampening Elements
With the current efforts to reduce noise levels in the engineering field, manufacturers are placing efforts of noise control from the source, which is very important in machine tools. Damping is a technique where equipments such as chutes, hoppers and machine guards have a bitumastic material stuck to the surface, which can reduce noise levels from 5 – 25 decibels during machine operation. Machines feet, gearboxes, pumps are mounted on rubber bonded cork to reduce transmission of vibrations of the machine.
Some ergonomic factors in machine tools design include operator interface height, operator access, safety mats, emergency stops, visibility and ease of maintenance. Innovative designs have been developed which factors all these attributes while still achieving the required output of the machine.
Innovations in machine tools design has been broad and directed towards maximum efficiency of the equipment. Development of computer controlled equipment, measures for extending the cutting tool life, enabling greater output efficiently, user friendliness and safety concerns have been the key areas of innovation. These have led to great positive change in production and manufacturing and the trend is set to continue.
In the history of machines, the range of evolution is something beyond our imagination. Whenever something new technologies come to the market, users can get something better and smarter than the previous versions of the machine. Change is the only constant thing in this universe, and that can be proved strongly when you look at the world of machine tools. Typically, machine tools are machines that are used to give proper shape and design to the metals by cutting, grinding, shearing, and boring them. The machine tool also uses some other techniques for the deformation of the metals as per the needs of the industry. With the advent of modern technologies, the journey of machine tools becomes more interesting. It goes from mechanical to electronics and then beyond that.
Getting Something Easier
In the history of machine tools you can find instruments like bow drills, potter’s wheel and others. These were used in the period known as BC. With the passing course of time, people understand that the more complex a machine can be the better production it can offer. With this realization, a separate industry of machine tools builders is formed who are specialized in making and selling advanced kind of machine tools only. Then they tried to build separate machine tools for different industries like textile, medical, engineering, automobile, and many more others. All these industries now can get parts and components as per their individual needs.
Proof of Technical Advancement
When you follow the journey of machine tools to understand the pattern of its evolution, then you have to understand the factors that work behind this progress. The transformation of machine tools from simple to the complex ones is the proof of technical advancement. Earlier there were mechanical tools, and most of them need human help to be run. With the development of the technologies, now you can have electronics machine tools that do not need any human assistance to perform. There are semi-automatic/fully automatic machine tools that can work in a better way than their ancestors.
Save Time save Money
The main motto of this transformation is to save the time and money of the users. The factories that have advanced machine tools do not need to employ too much manpower to operate those machines. These electronic machines can get their power from other sources than human muscles. There are electrically or hydraulically run machine tools that can perform 20 times faster than the older versions. Thus, these machines can save the time and money of the owners to a great extent.
More Précised Production
Since the human effort becomes almost nil in these machines, the production becomes more and more seamless. Machines hardly make mistakes. Therefore, you can expect perfect and accurate shaping or designing of various components of other machines and manufacturing equipment. To obtain a more précised production in the factories owners must need the specific machine tools. That is why the evolution of these machine tools becomes highly significant in the modern era where perfection is mandatory.
Workshop is the core of learning about different Materials, equipment, tools and manufacturing practices that are observed in different manufacturing functions and operations. Workshop is also of prime importance when you want to gather about the practical knowledge.
There are different types of workshop power tools dealing with several sectors of industry like carpentry, bench work and fitting shop, casting and foundry, sheet metal, machine shop electric welding and many others.
Understanding the Significance of Power Tools
Here is a lot of power equipment that are intensively in use for engineering workshop. Understanding its significance will give the user a broader perspective on its usages.
Bench Grinder: one such appliance that is used for welders and fitters. The significance of bench grinder machine is that, it makes the job of fitting a lot easier and faster than usual.
Grinder cum polisher: It is the device that is particularly helpful in engineering workshops and can also be used for occasional and buffing and grinding jobs.
Pedestal Grinder: The pedestal grinder is used in various crushing, grinding and mining jobs. This is one of the advanced solutions where size reduction is required.
Drill cum HSS Tool Bit Grinder: Bit crusher is necessary so that the holes that are made can be bored with ease and quickly. It also provides with high drilling speed for various industry operations.
Electric Motor: Now largely used for industry for various reasons, initial cost being low and long life of equipment being two of the reasons. Also this machine requires low maintenance allowing lower cost of production.
Bench Mounting Belt Grinder: An electrical device that sued to smooth the surface of materials like wood, plastic and metal. It is designed to remove unwanted residue that gets accumulated in the surface with an ease of using it.
Flexible Shaft Grinder: Widely used for fabrication workshops, heavy industries and foundries. Used mainly where the job is quite lengthy or heavy and is not possible to move it up to the grinding instrument.
Magnetic Drill Stand: As drills are crucial in building of works in metal, wood and concrete, the magnetic ones are portable in structure and specialize on steel for structural drilling.
Cutt off Machine: These cut off gears are used in the place of manual crushers for accurate cutting with free mobility in both outdoor and indoor. It also ensures that the work carried is accurate.
Hydraulic Test Pump: It is usually compact and portable in structure, which is driven by air.
Hand Operated Spur Gear Chain Pulley Lock: It is mainly used for long lasting lubrication with minimal maintenance. It makes lifting heavy weights an easy process.
Electric Operated Spur Gear Chain Pulley Lock: In the electrically operated locks there is no need for manual labor and most work is done faster.
Monorail Gear Trolley: this is mainly designed for heavy duty application with upper and lower switch that manages the limit, preventing over travelling and safety.
Wire Rope Hoist: The industries that are involved in mass production uses this mechanism for modular construction and to save space.
These machines are of uniform quality and unmatched value so that it can provide with the accurate solutions to different industrial operations.
Manufacturing industries dedicated to produce equipments, pharmaceuticals, vehicles, machines, food and beverage and many other components greatly relies on moving raw materials, semi finished products and final products. This is effectively done through materials handling equipments.
Essential features of hydraulic hand pallet truck
This is the most versatile and ubiquitous material handling equipment. The manual forklift uses hydraulic principles to lift materials, transport them and off load them by disengaging the hydraulic mechanism.
Hydraulic Hand Pallet Truck equipment comprises of steering wheel mounted on handle that can turn through 50- 180 degrees to turn the fork lift clockwise or anticlockwise. By cranking the handle up and down, the hydraulic fluid is pumped into the jack they by lifting the materials. It is capable of transporting materials weighing up to 5000kg.
The front and rear wheels are made from reliable materials such as special rubber, nylon of polystyrene. The forks penetrate the pallet boards to hold and secure the merchandise when lifting and transporting. Their width and length can be adjusted to handle different pallet sizes.
Hydraulic & Semi Electric stacker series
These equipments are improvement of the manual pallet fork lift equipments. They are used for lifting, loading, moving and unloading materials. Unlike forklifts, stackers lift materials, transport, packaging and stack them. Hydraulic and Semi Electric stacker series are easy to handle, use less space, are more sturdy and have increased functionality. The manual model uses the hydraulic action where the operator pumps hydraulic fluid using the reciprocating movement of the handle. The electrical type uses a motor to pump hydraulic fluid for lifting materials. They lift materials to different heights ranging from 1600 mm, 2000mm, 4000mm depending on the model.
Features and uses of high lift trucks
These are specially designed to High Lift Pallet Truck heavy merchandise to high height. Instead of having flat forks to hold the pallets, they have a set of scissor bars for extra load support. They make heavy loads easy to lift to high heights.
Advantages of drum handling equipments
These are specially designed equipment to move round shaped materials. They move drums, buckets and circular objects which cannot be clamped, held easily or loaded onto the pallet. Their main advantages are; they reduce the work associated with camping; they eliminate the need to load and clamp a drum onto the pallet board, prevent spillages and accidental falling of drums when moving, as well as make lifting and moving circular objects easy.
Advance features of scissor lift tables
Scissor lift tables are designed to handle heavy load securely and move it to the required position. They are also used as portable workstations and can safely lift a number of worker and their equipment to high heights.
Their design allows them to handle very heavy loads and move them to the required distance. The table is made to high strength steel capable of withstanding high loading. Their scissor legs are arranged to withstand high loading as well as allow raising and lowering of table. Opening the scissor legs lowers the table while closing the legs raises the table. The equipment is installed with special hydraulic check valves to ensure that once the table is raised, it cannot be lowered unless the operator releases the hydraulic fluid. This prevents accidents of unintended lowering during power failure. . .
Using materials handling equipment to improve throughput
Movement of materials must be done effectively to increase safety, reduce transportation time and increase worker ergonomics. When using the right handling equipments, materials can be moved at ease and this process wastes no time and increases production throughput.
It is said that a machine can perform the work of a hundred men. This is true with the lathe machine that is regarded as the mother of all machines. It is versatile and very useful in manufacturing, production and maintenance workshops.
Bearings on the other hand are widely used in automobile, motors, pneumatic and hydraulic machines, engines, wheel hubs, gear boxes, industrial transmission lines, aircraft and ship. They are virtually applied in nearly all equipments that have rotating parts and therefore represent a large local and international market.
The main types of bearings are ball, roller and the journal bearings. All these require the lathe machines during their manufacture.
Manufacture ball bearing
These have an outer and inner race, the ball and cage to mount and hold the balls. Specially designed lathes are used to turn cylindrical work pieces in large quantities to form the inner and outer race. The turning operation ensures that the inner and outer rings of bearing have very accurate and precise diameters that meet the tolerance limits.
The device is also used to lap or smooth the inner and outer race to minimize friction. The lapping operation gives the bearing a very smooth surface where shaft and balls can roll on. The outside faces are also cut to the required flatness.
It is also used to face and lap the inner surfaces where the ball rolls. The type used depends on the size of the bearing with heavy duty all geared type being suitable for large diameter sizes.
For very precise applications such as those in aviation, medical equipments and sensitive instruments; the CNC type achieves the required precision and dimensional accuracy.
Application in manufacture of roller type
These have rollers instead of balls. They are used in heavy loading applications such as gears, transmission shafts and areas with high axial thrust. Again turning and facing operations are performed using this machine tools. The precision, size, accuracy and tolerances determine the type of equipment to use with CNC be favored for high precision work.
Use of lathe to manufacture journal bearing
They are applied in all internal combustion engines and forms the rotating parts of crank shaft. They are also used in large turbines, motors and heavy machinery where roller and ball types cannot be used. Essentially, this device is made of two rotating parts that slide along each other.
Specially designed turret and capstan lathes are used in mass manufacture of these journals. These reduce the diameter (turning) to suitable inner and outer diameter. This is followed by parting-off or cutting the concentric cylinder to accurate length.
For journal to function effectively, they must be smoothened. This is achieved using lapping operation. The cylindrical work piece is rotated against smooth abrasive material to remove a very small layer of materials and achieve high quality and extra smooth surface.
The use of Engine-Turning Lathe began sometime before the 1770s. During that time, this particular machine found application in the production of designs and decoration in stoneware and earthenware. Primarily, the widespread use of this equipment originated from England, where highly skilled potters used it for cutting exclusive patterns and creating unique designs on pots and stoneware. Well, the machine used to work on the principle mechanism of rotation. To put it in a comprehendible manner, pots used to rotate on it, eventually allowing the equipment to carve out specific embellishments.
Tracing the adaptations
What potters achieved as the end-result was beautiful pots with stunning graphic designs. Moreover, these amazing designs were perfectly visible through the interplay of lights as well as contrasting colored slips. Since then, the engine-turning lathe has been the go-to tool for every ingenious potter. However, there have been substantial changes in its appearance and functioning over these years. From its inception to the present times, this particular equipment has readily adapted to the changing trends in the pottery industry.
Perhaps, it is impossible to trace its significance, adaptations and contributions to the pottery sector without delving deep into its past. If you really wish to know a lot about this tool, then you will surely find this article quite engaging.
It will be judicious to begin with a brief history of the equipment. The idea of applying this machine in pottery began as early as 1763 in Birmingham. Josiah Wedgwood was the person who conceived this concept after an intriguing encounter with the machine, at a metal-working facility run by one of his friends. Later, this man differentiated the functioning of this tool in the woodworking and metalworking industries from its operations in the ceramic industry.
At first, it was the simple-turning lathe machines, finding use in the creation of exquisite designs. The engine-turning ones were nowhere in the picture then. Slowly and steadily, the machine adapted to the emerging trends, rising demands, and advanced technology. And these factors came together to produce what is known today as the engine turned Lathe. Potters felt two significant benefits while operating with this device.
Firstly, the machine had the capacity to lathe-turn hollow wares. As the outcome, the process of carving designs on the mugs, cups, jugs and bowls became quite easier than before.
Secondly, the equipment was apt for cutting unique designs and regular patterns on even the clay items, thus creating decorative elements.
The simple and advanced versions
It won’t be quite possible to understand the adaptations of this equipment, without a bit of information on the earlier models. Breeze through the following points for a pristine clear idea on the uses of the old engine-turning lathe.
The classic model: Wedgwood developed the “rose and crown lathe”, where the rose and crown refers to the edge and end cam respectively. Simple versions of engine lathe were primarily manufactured with the edge cam. And that is the reason that bigger pottery projects demanded the rose and crown ones.
Major components: Presently, every pottery project demands the newly constructed Lathe machine. The major components of the machine are the steel frame and the central axle, on which the end-cam, edge cam and mandrel are supposed to be mounted.
Customized pattern generator: Mandrels, also popular as chums are customizable into various designs and forms. And that proves to be highly beneficial in generating diverse patterns.
Allows lucid operation
Another important aspect is the flexibility in operating the machine. Especially, the pulley placement enhances the flexibility of operations with the machine. The engine-turned lathe has come a long way from just being simple pattern-carving equipment to a highly advanced design-making tool. Today, every ingenious Potter makes perfect use of the machine for belting out some great pot designs.
The packaging equipment making such as plastics and paper processing are heavily mechanized process in industry and there are various equipments used in this process. These include corrugation machines, rotary cutting and greasing machines, slotting machines, sheet-pasting machines, board cutting machines, sheet-pressing machines, stitching equipments and mill roll stands.
Carton erecting equipments include stamping machines, paper folding, and board creasing machines.
Plastic Manufacturing Equipments Parts
Plastic packages manufacturing is also highly automated and carried out in various processes. The Injection molding process is commonly used in batch manufacturing where high output is required. Production of the injection mould relies heavily on the use of the milling machine. Mold machining requires making of complex 3 dimensional forms. Some of the important pieces made using CNC milling include stamping dies, forming dies, forging dies, injection moulds and blow moulds. These parts are made to mirror the intended final shape of these mass produced items.
Milling Machine in Batch Manufacturing Of Components
Having the right equipment combined with the correct process produces high quality products. High precision milling process is used to make lighter milling passes progressively, to achieve the required geometry and the best surface characteristics. Milling of manufacturing components also heavily relies on hard milling processes because moulds and dies are machined in their hardened state. This is done to avoid heat-treating work pieces, which could interfere with their geometry.
CNC Milling Versus Traditional Milling in Industry
The practice of machining has been transformed by new generation milling machines, which are currently being preferred. Since the inception of the CNC technology, it has been found to reduce costs , reduce lead times in manufacturing, achieve higher quality ,reduce excessive tooling and increase the productivity of the equipment.
Important features of CNC machines include perfect accuracy in cutting, faster production of identical parts, continuous production, and easier upgrading. Changes of design are easily incorporated through software and programming design updates. To check the accuracy of a new design, visual simulation is done on the computer before production has begun of the work piece.
Types of Milling Machines
Various types of milling machines are available in industry. In production of packaging machinery equipments high speed and precision is of utmost importance. The vertical machining center (VMC) has the spindle in vertical orientation and is primarily used for high tolerance milling such as making of fine die’s and moulds.
Other important types of milling machines include the horizontal milling machine, the bed type milling machine, planer machines, rotary table machines, tracer controlled and the CNC machines.
The milling machine is referred to as the father of all machining operations. In manufacturing of packaging equipments, it is vital equipment, which can never be substituted. They utilize rotary cutters to remove material from metallic work pieces to achieve a desired design. In manufacture of plastic making equipments, milling is done in making of injection moulds, stamping dies, forming dies and forging dies. Automated milling processes have enhanced the efficiency in the packaging equipment manufacturing due to accuracy and high-speed batch production.
SPM machines are equipments designed to perform tasks that ordinary machining tools cannot handle due to the size, weight and unique features of the work piece. The ship building industry is characterized by larger and heavier size engines requiring heavy duty machine tools. Production of flanged shafts and stepped shafts for engines is common in the ship making processes. Various heavy metal forming processes such as large sheet metal cutting, planning and finishing, gears making and production of customized designs are processes involved in manufacturing vessels. Special equipments useful in this process include;
The Planning Machine: Operation and Utilization
Planning Machine is used in machining of large sized flat surfaces as well as “V” shaped guide ways. It is also built to machine T –slots, vertical, horizontal and inclined surfaces. In construction, the bed is made of cast iron with high strength properties. It also has sufficient box section with adequate double walled ribs to the floor line. Special features include the rigid construction, ample bearing surface, automatic lubrication systems, table of box Cross section and scrapped V ways for maximum load bearing, quick return mechanisms and high precision cut gears for maximum efficiency.
Bolt Threading Machine
This machine is designed to produce very accurate threads in pipes and rod applications. Bolt Threading Machine used in making threads in pipes on materials such as stainless steel High tensile steel and mild steels. Sturdy construction of the machine ensures efficiency and accuracy in the machining process, and durability of the equipment.
Hex Nipple Threading Machine
The hexagonal nipple is a pipe connector with both ends being threaded with the male threads. The nipples are used to allow connections to other systems such as straight end pipes, water heaters and other plumbing’s. They are manufactured using special nipple threading equipment. The equipment is able to deliver precision and fine threading that ensure leak free and reliable connections and can thread various materials such as stainless steel, brass and carbon steel.
Gear Hobbing Machine
This equipment is designed for manufacturing of gears. In the hobbing process, gear teeth are cut in the work piece through a series of cuts with the cutting tool called a hob. Using this special equipment, the process becomes efficient and affordable while still maintaining the required accuracy. This has made the gear hobbing machine the most widely used in making of spur and helical gears with reduced time to completion.
Hydraulic thread and Form rolling machine
Hydraulic Thread & Form Rolling is used in production of various types of threads through an efficient cold forming system. The equipment is user friendly with very high efficiency in operation. To enhance efficiency, the machine is equipped with low pressure hydraulic system thus reduced power consumption.
Other Industrial Applications of the Special Purpose Machines;
Other industrial applications of special machine tools include petroleum exploration, gear making, aerospace engineering and turbines in hydropower generation. The equipments have high demand in the ship manufacturing process, as they are able to machine unique and customized parts. These machines are available through certified manufacturers capable of delivering high quality and long lasting equipments.
The ability of machine tools to perform repetitive actions is a key factor that has made them best for the automobile industry. Additionally, the machines have higher production rates because there is very little down times and changeovers are eliminated. With the invention of the computer numerical controls, part designs are developed using computer aided design software. The design is transferred to the machine software which re arranges the files in such a way as to direct the operation of the machine, movement of the tool and the machining operation.
In highly automated systems, one machining unit may have several operations combined on a work piece such that processes run sequentially. This also reduces the time required to complete a job and increasing the efficiency of the operation.
This method of manufacturing is used in batch manufacturing continuous process. Pieces to be milled are stationed on the machine and milling operations are run automatically from piece to piece until the raw material is completed and more is fed to the machine.
Parts manufactured through milling
A wide variety of parts is made through milling. They include transmissions, gearbox cases, transmission housings, engine cylinder heads, aluminium drive housings, flywheels, engine locks, piston rods, wheels, water pumps, and more of these equipments.
Manufacturing of parts such as fuel injectors requires very high precision. Camshafts’ grinding is also a core application of CNC machines and is achieved through computer-aided designing.
Rack and pinion systems machining
These systems have very wide applications in automobiles. Some basic applications in the car include the wind shield wiper system, hydraulic steering, power windows, electric hand brakes, wing mirror adjustments, and manufacture of small gear worms. The gears are made through the milling process. In form milling the shape of the tool takes the shape of the gap between the gear teeth. Each tooth is cut with cutter moving progressively until completion.
This process uses the turning machine or the lathe machine. It is used to make rotational parts through continuous removal of the unwanted parts. Apart from turning, the lathe does other processes such as facing, grooving, cut off and thread cutting. The machine also performs internal work piece operations such as axial drilling, boring, reaming, and tapping which is the creation of internal threads.
Automotive parts made through turning.
Manufacture of brake disks is the most common application of the lathe in the motor industry. In some cases , specialized brake lathes have been made due to the rapid demand for this particular part. Other parts made with the lathe include brake drums, rotors , the fly wheel and most parts requiring the threading and phasing operations.
This is also a process of milling using equipments such as the radial drill, cord drills and the pedestal drills. They are also very important in automotive workshops in making of slots as well as cutting threads.
The range of applications of the machine tools in automotive industry continues to increase exponentially. This has been enhanced by development of computer numeric controlled machines, which are able to transform design to completed product in a very short time frame. High-speed machining techniques have also enabled greater precision to be achieved.
Online shopping is a great alternative to regular walk in shopping for various reasons. Listed here is a list of the many advantages of using the online Bhavya machine shop to buy quality machine tools for your organization.
The Quality policy; the company is committed to delivering the highest quality products through upholding of quality management systems after sales services and focus on the customer.
Customer service; you get access to a live chat service with support on standby to sort out all your queries. You can also call or email and get immediate assistance.
High technology standards; the company has a team of highly qualified professionals who are involved in the development of machinery and equipments. The company products meet the workmanship standards.
Efficiency; the equipment are manufactured for optimum power consumption while delivering maximum performance. All equipment has robust design, with stability and performance enhanced. The equipment is also durable.
Clientele include learning institutions, as well as private and government bodies. The company has been able to retain this market share due to their innovation, quality and service delivery.
Terms and Conditions in Online Shops
Information used in making online transactions is held in strict privacy and is only used for the company reference in orders processing. The information may also be used to help the company better their services.
Online registration is optional during purchase but it helps if you intend to make repeated online purchases. Registration also makes the purchase process simpler and easier.
Security; data security is very important in all online transactions. At Bhavya online shop, sufficient effort has been made to ensure transactions are secure.
Secure sockets layer “SSL technology has been used to ensure data is not hacked during transmission. Order information is transmitted in encrypted format and only accessible to the company staff.
In credit card payments, the SSL technology creates a very high level of encryption making the online money transfer very effective.
Product return policy is in place in case you feel not satisfied with the product. Returns are done within seven days of purchase and the company makes a full refund of the payments within 15 days. Product can also be exchanged for another in case you prefer another model.
As a customer, you receive your products within seven days of order if we have the product in stock.
You are notified in case of extra shipping charges before shipping is done.
For international purchases, the only documents that you require are a copy of the purchase order, payment documentation such as swift transfer and the dispatch instructions.
Payments can be done on a “cash on delivery” terms which are available on every product.
The company handles claims of damages during transits as soon as they are launched.
Bhavya machine tool is one-step ahead in machine technology. The efficient online shopping and payment system has enabled global supply of their machine tools while making the purchase process very user friendly.
The rate of advancement in the beverage industry is just phenomenal especially when we consider technological advancements. Globally, this is due to increasing population and the need to achieve efficiency in manufacturing. Certain equipments have become vital in this industry such as high-speed picking and packing machines, palletizing equipment, automatic inspection systems, filling equipments, capping machines, conveyors, shrink sleeving machines and movers.
Advantages of Packing Equipments
The machines help the manufacturer to lower operating costs, reduce dependence on human labor, economical utilization of material, maintenance of high and consistent quality, higher efficiency and productivity, flexibility in manufacturing and better implementation of health and safety procedures.
Importance of workshops in Manufacturing
A processing factory or plant with such machines is bound to experience down times due to servicing, breakages and machinery failures. A workshop is therefore crucial in such a setting to avoid extreme down times when unexpected failure occurs. One of the most important equipment that such as workshop must have is a lathe. This is because the equipment can handle numerous activities related to the installed equipments. These activities include;
Motor shafts machining
Damaged shafts are very common in motors and pumping equipments used in industry. Bearings attached to shafts are made of harder material than the shafts therefore, during continued use; the shaft may wear off leading to wobbling motion, which could be disastrous. The sunken areas are filled up with material and the machine is used to reduce the shaft back to the required dimensions.
Repairs for punching machine die forms
The punching mechanism is commonly used in erection of packaging boxes, and some containers. Regular wear and tear is therefore common on the punching die and hence constant recalibration may be required. In this case, accuracy is of utmost importance and this is possible with the lathe in the workshop.
Conveyor Belt Roller knurling Process
This is the process of creating tiny grooves on conveyor rollers to maximize friction and enhance the grip between the roller and the conveyor. The knurling tool is held firmly against the roller shaft on the lathe and it imprints the grooves. With the gradual usage, the grooves wear off and repair is required.
Liquid filling Machinery components servicing
Various filling equipments are used in bottling. They include overflow filling, gravity systems, pump filling, piston type systems and many others. Maintenance of this equipment requires very high accuracy in machining, surface smoothening, and repairs. This is achieved using sensitive machine tools, which can work to very small measurements and ensure accuracy.
Bottle Washing Machinery and Maintenance
These are critical equipments in the beverage industry. This is because some plants use reusable bottles, which are always re circulated. Cleaning machines are automated and may process in stages such as pre washing, detergent cleaning stage, sanitizing and final rinse. The washers are exposed to dirt and suspended particles, which can damage the pipes and ducts and therefore regular servicing is done using the lathe for greater productivity.
The important of fully equipped maintenance workshops in industry cannot be underestimated. Soft drinks making machine are exposed to certain cyclic problems such as wearing off shafts and rollers and conducting ducts. The lathe machine is useful equipment in repairs of these faults and efficiency and productivity is maintained.
Most foods and beverages are packed in bottles fitted with a metallic caps. Popular brands such as Coca cola, Pepsi, beers and other beverages have long be packed using metal sealed bottles. In addition, pharmaceutical products stored in the glass bottles also utilize the top covering to effectively seal the container.
Use of power press in making metallic bottle caps
Power press machine is part of a larger manufacturing unit made up of the die, the blank material and the accessories for feeding the material.
The press supplies a heavy force to the punch which squeezes against the die and workspace to produce the desired shape. Punches and dies are replicas of the product to be made.
Metallic bottle tops are inherently made by punching using the power press. A flat sheet steel materials is specially printed to match the brand be packed. Normally, one sheet will have 24 to 48 prints. The sheet is then passed to the device.
The device rotational motion is converted to reciprocating motion that pushes the punch against the die. This effectively forms the shape and also shears it off from the sheet. In one process, up to 48 products can be pressed and formed. Due to the rapid cyclic movement of the machine, very many bottle tops are made with a minute.
In addition, the machine is also used to develop lids used to cover and seal many packed foods. These lids have special formations which can be produced by punches and dies.
Critical parameters that must be achieved
Though there are different types of this machine, the most common are the Gap frame and straight side types. The Gap frame assumes a C shaped structure where the dies are put. Since there sides are open, the die can be accessed from three sides. This machine handle high loads (250 tons) and is less costly
Since the backside is open, wastes and scrap can be easily discarded and this makes it suitable for mass production of caps and other punched products.
The straight side type is widely used for inline mass production. It has two vertical arms on the sides. It has a strong housing on the top part that house the crankshaft. They have crankshaft and pulleys that change the type of motion.
Trends in utilization of metallic caps in the industry
With the increasing number of foods, cosmetics and pharmaceutical industry requiring metal and plastic caps, the market is expected to rise gradually in the next 5 years. The use of metallic caps is however facing stiff competition from the cheaper plastic that contributes to over 80% of all the closures. In 2013, the closures market accounted for US$ 40 billion and this is expected to rise to US$ 43Billion (5.3%). US market closures consist of 80.6 % plastics and 9.8% metals. However, with the negative environmental impacts associated with plastics, the metallic closures are expected to take a larger portion.
Jewels have been used from time memorial for beautification and as precious gifts passed from one person to another. They are common among celebrities, famous people and even the ordinary folks as they bring a sense of class, elegance, luxury and happiness. They are manufactured from expensive durable materials such as diamond, gold, platinum, silver and bronze.
Due to their small size, complex shape and need to conserve the expensive materials, jewels must be made using special machines to produce high quality and good dimensional stability to ensure that customers are satisfied with them.
They must also have good aesthetic appeal and be durable. They must therefore be machined to perfect smoothness and flatness.
Precision jewel cutting using light duty lathes
Most rings are cast into cylindrical shapes and later machined using lathe and mill turns. They are also manufactured from rolled flat bars though this is not common for expensive products.
Due to the precision required, the production volumes are very low. In addition, most jewels are customized according to the client requirement which differ due to different physical dimensions e.g. size of fingers and neck.
Light duty lathe machines are used to fabricate most of these rings. The material is mounted on a chuck and various machining operations done. Turning of the internal surface is done to create an internal diameter that fits on the finger while outside diameter is turned to the specified size. Facing is done on the two opposite ends to smoothen them.
In addition, other processes such as drilling, tapping, chamfering and polishing and also done using this machine. A combination of these cutting operation results to the formation of the product. For example, chamfering gives the ring a wedge like edges while knurling results to a rough surface. All these operations are performed on light duty machines fitted with a small six jaw chuck to hold smaller work pieces without affecting the surface.
Contractors specializing in fabrication of many custom items have to make numerous rings that differ in design. This is achieved by using CNC machine. The jewels are automatically made by adjusting the tools and feed. In addition, these devices have the capacity of not only performing the turning, facing and other conventional lathe work but can also mill and perform cylindrical grinding.
The lathe allows a wide number of finishing operations to be done on the ring and jewels. In the lapping operation, the ring is rubbed continuously against another surface with an abrasive liquid between them. This removes a very tiny layer and smoothen the ring.
Features of light duty lathe machine
They are characterized by minute tool post and chuck which are designed to handle tiny work pieces. Their bed is machined to perfect straightness. They are also fitted with a plate chuck which assists in holding complex shaped work pieces. They have a smaller bed, tailstock, head stock and carriage. These machines also have low power consumption and are very efficient. They are compact, durable and have excellent functionality.
International and local transport has grown considerably due to globalization and internationalization. There has been a global increase in dependency on commodities manufactured from low wage countries such as China, India, Africa and Asian nations. This has driven the demand for better shipment.
The invention of containership by Malcom Mclean’s in 1956 was perhaps the most important innovation in the transport sector. Bulk and sensitive commodities are packed and sealed in strong durable steel or aluminum boxes. These were then loaded on trucks, ships and trains for transportation.
The shape of the container allows easy stacking on top of each other. Since they are manufactured from high strength materials and locked, they are intrusion free. They also have identification number allowing for easy tracking via GPS and RFID.
Essential Parts of a Container
Standard containers are manufactured from steel or aluminum. Their shape, sizes are standardized to allow easy handling and transport.
Steel containers are 20, 30 or 40 feet long, width of 7 and 8 ft and 8, 8 ½ and 9 feet high. The side and end walls are manufactured from paneled sheets. The frame is specially designed to withstand weight of other stacked containers on top. One end has door hinges, panels and locking bars.
Aluminum types are made of steel frames while the sides, front, back, roof and bottom are made with high strength durable aluminum.
Machines used in container manufacture
The container manufacture process utilizes a great deal of sheet metal machinery. First they are cut to their specific dimensions using the shearing machine. This device is sturdy and has the capability of cutting heavy gauge plates in a guillotine manner.
Square, rectangular and round grooves are then made on the flat materials using a specially designed heavy duty press brake. The machine is fed with material and it forms the square corrugations.
The roof panels are made pressing using a specially designed press brake machine. This device punch presses the plate against the die to form the intended shape.
The floor frame is then made by cutting the plate using a shearing machine and these are folded using a press brake machine. This machine folds the material forming a U shaped bracket. A series of these brackets are welded to form a very strong base.
The door, sides and other parts are also fabricated by cutting the plates and square tubes using shearing equipment, folding the sheets using press brake and welding the parts. Fastening holes are also drilled on all parts.
Quality issues in sheet metal working
The containers must be made from good quality materials that don’t rust or corrode when exposed to harsh sea environment. The joints and other parts must be properly sealed to protect the commodities being transported.
Rising containerization process in international trade
The container market has continued to grow rapidly. In 2012, the global container fleet was 32.9 million TEU and 34.5 million TEU in 2013. This growth is expected to continue due to their global acceptance and high demand.
Human beings cannot live without food. For centuries, the agricultural industry has been thriving due to global rise in population that continues to grow exponentially and demand for more foodstuffs.
Traditionally, hand and manual tools were used but in modern time, agriculture is highly mechanized and computerized. Common equipments include tractors, combine harvesters, planters, ploughs (mould board ploughs and disc cutters), harvesting machinery, storage equipments, pest and herb control, hay making and processing equipment.
Use of radial machine in production workshops
The manufacture of tractor relies heavily on machine tools. These are used to bore holes on the engine block, gears and shafts. The devices have a large table and heavy metal base suitable for heavy duty work. The all geared type is suitable for making large precision holes on the engine block, wheel hub, gear box and other transmission and structural parts
Tractor engine (Inline and V type): numerous holes and attachments done with radial drill
Other specialized tractors such as the combine harvesters also use these devices to make holes oriented at different directions, angles and position.
Tractors essentially pull a wide variety of farm implements. Implements such as ploughs, harvesters, fertilizers, irrigation and planting equipments are manufactured through casting, machining and assembly of parts. During the machining process, heavy duty radial drill are used to make large and deep openings oriented at different angles. This machine is a must have for small and large scale production of these devices.
Farm produce must be processed to add value using a wide range of equipments. Farm processing industry has numerous equipments and this makes them an indispensable and imperative machine tools.
Special design features
The protruding arm allows the movement of the drill head and spindle horizontally. In addition, the radial arm moves 3600 about the column. Once the work piece is clamped, very many holes can be drilled at an instance.
The parts are through hardened fine grade steel that has extra strength and resist wear. The drill is able to withstand heavy forces during boring. The machine have double row roller and thrust bearing which withstand high forces and torque.
Trends in the industry
The global agricultural sector has been experiencing a yearly growth of 8 %. In 2010, it accounted for $ 56 billion and US$ 81 billion in 2015. The industry is mostly serviced by 50Hp tractors and combine harvesters.
The main drivers are increasing population, food demand and technological advancement.
High power tractor (>100Hp) are used in Europe, USA and Canada. In the EU the tractor market accounted for $18 million in 2010 and is expected to reach $ 23 billion in 2015. South America and Asia countries use medium (40-100 Hp) while Africa uses low horse power types.
The major drivers in pacific region are Asia and India. On average, India sells 150000 units of tractors (15 -75Hp) each year.
Repair and maintenance
The devices are also widely used in repair and maintenance of tractors, farm implements and in making processing equipment.
Air cons (AC) are widely used in residential, commercial and industrial systems to actively pump out heat and maintain a predetermined temperature and humidity. They create an artificial environment which suitable for machines, human and agricultural produce.
Air conditioning systems fabrication
Most modern house and industrial buildings comprise of many rooms that need HVAC (heating, ventilation, air conditioning system). Instead of using a separate split AC for each room, all the rooms are fitted with ducts and vents and one system is used to control multiple rooms. HVAC system regulates temperature and humidity and creates a fresh environment.
This ducted system is made up of numerous square or round pipes made from light aluminum of stainless steel sheets. They span the entire house and connect to a central duct that aerates the room.
Role of bending machines in fabrication of these systems
To manufacture these pipes and ducts, sheet bending machines are used to fold light and heavy gauge sheets. These machines are therefore found in contractor’s fabrication labs where folding sheets constitute 60% of all fabrication process.
The sheet material is cut at the required position and then fastened on the equipment. This device then folds the sheet to the required angle (normally 450 to 900 for most AC applications).
To perform a series of perpendicular and angular folds on the same work piece, these devices utilize a back gauge and specially formed dies. The back gauge accurately positions the metal sheet so that the bend is put at the precise location. This allows precision and accurate fabrication of multiple folds on the same work piece.
To fabricate folds fast and effectively, this equipment must allow continuous and precision folding of these tubes. Light and medium sized bending machine are applied in the operations since the ducts must be light in weight but durable.
Modern CNC types are becoming common. These allow accurate and precision feed, easy clamping, bend monitoring, folding as well as automatic calculation of the back gauge position based on the angle of bending. They have high ramming speed and are suitable for high throughput industry.
For small jobs on residential and commercial areas, smaller devices with less tonnage are used. These are versatile and flexible and allow folding of smaller work pieces to different angles and shapes.
Bright market for this machine in this industry
The AC market is on the rise in most parts of the world due to emerging cities and need to have a controlled internal environment.
With the rapid rise in middle income earners and high growth rate in the construction of commercial and residential houses, machine tools used in fabrication and installation of these equipment will increase.
In 2012, the global AC market was valued at US$86.8 billion and US$91.6 billion in 2013. The Asia pacific region has the highest demand due to rising industrial, commercial and residential sectors. The main units demanded are roof tops, indoor packaged, chiller plants and central ducted types.
Lathes are referred to as the mother of all machines due to the numerous engineering functions they perform and their application in nearly all industrial sectors. As the proverb goes, there is profit in all hard work; lathes are at the center of all profitable production and maintenance centers.
They provide a wide range of mechanical engineering functions suitable for all manufacturing and maintenance workshops. Teaching technical students on lathe machine operations not only impacts them with practical skills but also enable students engage in profitable ventures after college.
Nature of educational lathe machines
With the rapid increase in the number of universities and tertiary education centers offering quality engineering education, students must be trained on practical hands on experience on these equipments. Sturdy, high precision and accurate equipments are therefore used.
Educational equipments are developed to provide extra safety during operation since they are operated by untrained people. The bed, spindle, chuck and other components are made to high strength and durability and are must be produced to precision and accuracy.
Special training features for educational lathe
Trainer equipments must incorporate operations such as threading, horizontal boring, turning, facing, horizontal drilling, knurling and other functions. This ensures that trainers attain skills and experience in all machine tool operations. Three and four jaw chucks can be mounted on this equipment and this increases their versatility.
Safety is at the heart of every process and device. To enhance safety, they have automatic turn off switches and foot brake pedal that stops the device immediately. They also incorporate ergonomics to ensure that the user does not strain when operating the device.
CNC lathes are at the heart of modern training. Most operations in these devices are automated and have computerized feeds. It is possible to program these machines and are compatible with CAD and CAM software’s. Using CAD, drawing and other materials can be imported and used during operations.
Educational institutions are centers of excellence and quality. As a result, trainer machine tools must achieve high precision and accuracy. Their beds are manufactured to high flatness, robustness and smoothness. This is achieved high strength materials to manufacture the bed, carriage, tailstock, headstock, and tailstock. The feeds and lead screw are specially constructed to reduce backlash which results to inaccuracies.
Use in Education Institutions
The use of these machines in engineering college has increased due to the rapid need to produce well trained graduates and technologists in many countries. Currently most education facilities use CNC lathes since the train the student on both manual and computerized control. Over 95% of engineering learning institution have these equipments and is therefore imperative that institutions acquire them to aid in practical training.
Educational training equipment replicates modern machine tool used in production and maintenance centers. The machine tools used for teaching must have high strength and provide numerous functions to enable students gain all skills required. In addition, CNCs trainers are programmable, versatile and easily linked with design centers utilizing CAD and CAM software’s.
Iron and steel are the most common fabrication material in manufacturing and repair shops. They are widely used in construction, assembly, vehicle manufacture, processing and packaging industry. Large metal plates are produced in form of foils, rolls and plates that are then used for numerous applications. Bending is a common operation done in production centers. The component is plastically deformed along a given axis and this result to a change in geometry and shape. Various sheet metal bending equipments have been developed and are used during production. Essentially, this equipment folds the object into various angles and also produces various shapes during manufacturing. In this process, the material is first feed into the device. Manual or automatic controlled clamping that positions the components on the equipment is done. Then, the front plate of is then lifted to bend the plate to the required angle. Other forming methods can be accomplished using this instrument.
Use of the device in iron sheet manufacturing
Iron comes in various sizes and shapes depending on its utilization. During their production, the folding machine is utilized to produce various shapes and structures. Edge folding is the most common bending process performed using manual and automatic devices. The component is bent at the edges to various angles. The materials are first feed to the device such that the part to be bent protrudes from the equipment edge. They are then clamped such that the protruding part is cantilevered about the clamping edge. A wiping die is then used to apply a vertical force that bends the component to the required angle. This method is used to produce a variety of bends on iron plates.
A channel folding is another process performed using specialized equipment. In this case, the machine has an upper and lower die. The two are made to various geometries that resemble the part to be developed. For example, a square punch will produce square shaped bend while a V or U shaped dies develops V and U groves respectively. The die is made such that the punch fits into it and is clamped on the lower surface of the device. Upon lowering the punch, the component is formed to resemble the curvature of the forming dies. This is a quick and economical method to develop most components. The use of this equipment is therefore very important in fabrication processes.
Corrugation is another common bending process. In this process, a special tool is used to produce a series of symmetrical grooves on the entire surface of the component. Corrugations have increased resistance to twisting and fracture. Depending on the shape of the die, different corrugations such as U, V or square corrugations can be made on the component. In the corrugation process both the punch and die are identical but one part is held stationary while the punch moves vertically. The metal plate is mounted between the two dies and subsequent pressing forms the corrugations. The device is also used to develop other complex sheet structures.
Milling tools are used to perform numerous engineering operations prevalent in the manufacturing sector. They perform a number of complex mechanical operations such as gear cutting, plane, drill, shape, rout and cut slots. The machine utilizes a rotating cutter which remains stationary while the work piece is mounted on the table and moved along the cutter. The device has a stationary spindle that moves vertically upward or downwards. On the other hand, the work piece is moved perpendicular and parallel to the spindle. The knee of the machine is also moved to provide cutting in Z direction.
Uses of turret mills in food production industry
The food manufacturing industries utilizes a number of devices which are used in handling raw materials, conveying different materials to processing equipment, actual processing of raw materials to finished products and packaging the products. These equipments are widely applied in manufacturing different machine components used in this sector. Most precision cuts require this type of device since it can be rotated to different angles and positions. The machine can be swung through 3600 which makes the applicable for inclined or angular milling. In this industry, this device is used to develop gears that control rotary motion during processing and packaging. They are also used to plane flat metal pieces which form assemblies for most equipments. Due to their versatility, they perform most of the mechanical engineering operations required during the manufacturing of edible products. They are able to cut work pieces as well as drill holes through them. They are also widely used to produce accurate, regular areas on parts used to develop equipments used in this industry. For example, conveyors require regular surfaces underneath them and these are developed through milling. These devices are also used to cut slots and keyways that are used in transferring motion between the shaft and gears as well as pulleys. These devices are used to develop complex machine parts which require level angular areas. In addition, the hexagonal regular surfaces of bolts and nuts used as fasteners for most equipment are manufactured through milling.
Turret Milling Machine is also widely applied in most repair workshops in this industry. Normally, processing and packaging machinery require a wide range of preventive and breakdown maintenance operations. These operations entail resurfacing level areas, milling work pieces, hobbing new gears, grinding flat surfaces, grinding angular surfaces, cutting slots on new shafts and planning parts. All these operations are done during repair and maintenance operation in food processing industries and require this type of miller. Therefore, most processing companies normally have technical and servicing department where repairs using these equipments and other machines are done.
Turret mills are widely applied in this industry to manufacture tools and equipments. They are more versatile as compared to other mills since they can e used to develop complex and angular surfaces as well as performs a range of engineering activities such as rebating, slotting, gear cutting and drilling.
Radial drilling machine is one of the most versatile equipment used in manufacturing and production centers. They essentially punch and ream through or blind holes on work piece. They are also used to enlarge already punched holes. A protruding arm characterizes these equipments. On this arm, the spindle is attached so that vertical and horizontal movements can be attained. In addition, the large radial arm where the spindle is attached swings, move vertically as well as make radial movement. These movements enable the machine to perform operations on complex and odd shaped work pieces. They are therefore more versatile as compared to the pillar drill. The spindle can be tilted and swiveled and this makes it possible to bore through work pieces inclined at an angle.
Application in pharmaceutical machines
The production of medicine relies heavily on intricate equipments that are used to manufacture, process and pack medicines. The main devices used to manufacture drugs include reactors, bio-reactors, agitator vessels, mixers, homogenizers, fermentation equipment, pressurized tanks, storage tanks, centrifuges and other equipments. These are mainly manufactured from aluminum and cold rolled stainless steels. In addition, other devices are used to move and pack the liquid and solid medicines in containers. The making of pharmaceutical machinery greatly relies on devices such as drills. They bore opening on parts which assist in fastening using bolts and rivets. Equipments used to produce drugs have intricate shapes with numerous bores used to fasten the parts to others as well as to the production lines. The boring process requires versatile and computerized radial drills that can make vertical and inclined holes. The radial projections allow this device to make a range of complex openings on the parts being manufactured. These devices also allow for precision and computerized control that results to accurate and precision drilling of holes.
Application in medicine packaging
Medicine manufacturing industries have numerous equipments used to process, transport, separate and pack medicines. Wide ranges of devices are used in the packing products. Conveyor belt system transport drugs to and from the packaging machines. In addition, systems such as carton forming systems, shrink wrappers and automatic packaging systems are also used. All these equipment require fastening using bolts and rivets. Subsequently, drills are used to punch through holes for fastening with bolt and rivets while blind openings are tapped to allow fastening with a threaded bolt. Conveyor belt systems and wrapping equipment are intricate in nature since they must sort and pack different products with high precision. The complex nature of these parts requires more precision and accurate drilling to allow precision fastening and assembly of the whole equipment.
Application in repair and maintenance
These drills are also used in maintenance of both production and packaging machines. The repair of worn out parts necessitates the development of an alternative parts which must be drilled with precision. Most drugs manufacturing centers have a separate maintenance workshop dedicated to repairing the production equipment. These workshops have drilling tool to perform intricate drilling operations.
The shaper is one of the most versatile and important devices used in production and maintenance centers. It is an important production machine along with milling and lathe machines. The primary role of this tool is to produce surfaces that are at different planes. The equipment contains powerful motor that develops the rotary motion. This motion is the changed to reciprocating movement . The reciprocating feed is then connected to the cutting tool such that the cutter moves forward and backwards. During the forward stroke, the specially shaped cutter makes an incision along the workspaces but does not cut on the backstroke. Vertical feed is provided automatically so that the groove made by the cutter continuously deepens to the required depth. During the backward stroke, the vertical position of the cutter changes so that it removes some material during next cycle. The vertical feed and cutting speed are adjusted to match the type of metal, depth of cut and type of operation.
Use of shaping machine in gear manufacturing
Gears are an important constituent in vehicles, machines and other parts. The main types include: bevel, spur, helical and worm gears. The main methods used to manufacture different types of gears include: hobbing, milling, shaping, broaching and grinding. This shaping process has been used for a long time to manufacture them. The blank or a round work piece is mounted on the equipment table. The tool resembling the tooth to be cut is mounted on the tool clamp on the device. The reciprocating motion of the tool forms a single tooth on the round work piece. Once completed, the blank is rotated using an indexing head. The indexing head is set such that it accurately rotates the blank to a position where the next tooth will be formed. This process is used in manufacturing both internal and external components. Shaping machine and broaching are very much similar and are used on very large work pieces that require extra force to manufacture.
For manufacturing plants that require high production runs, cutting of one piece at a time is not convenient. In this case, pinion shaped cutters are used. They are mounted on the shaper while the blank is clamped on the equipment table. As the cutter moves forward and backwards, the whole gear is formed in a single operation. In addition, this equipment is also widely used to form keyhole, slots and internal splines that fasten pulleys on the shaft.
Use in pulley manufacture
Pulleys are used in many industries to transfer rotary motion between different components. The increase or decrease speed depending on the ratio of the diameter of the driver and driven wheels. The shaper is used to produce internal slots and keyways which are used to assemble the pulley wheel on the shaft. The slot is made on the internal radius of the pulley using this device. Therefore, the shaper plays a fundamental role in the development of rotary components.
The importance of machine tools can never be underestimated industry and one of the most critical of these tools is the lathe machine. The equipment is basically used in shaping metallic pieces such as tubes, engine shafts, bolts and nuts. The effectiveness of using this machine is based on the ability to hold the work piece firmly by a vice clamping mechanism and calibrate the machining to very precise measurements.
Another major and recent innovation of the lathe is that new designs have been developed that have incorporated computer numeric controls. This allows a particular design to be prepared by the engineering software and fed to the machine for execution.
There has also been an improved level of safety in using this equipment, with the latest models operated remotely, the work piece being enclosed in a chamber.
Challenges in Oil Drilling and Production Machinery
Oil drilling and exploration is usually a complex process involving so many operations happening at the same time. This process involves using a lot of chemicals and solvents which in turn lead to very fast degradation of machines and equipments. Specialized equipments have to be on standby especially machine tools such as the lathes for quick replacements of these special parts. It is also worthy to note that most oil drilling operations are far away from industrial areas and may take long while, if there are no stand by equipments.
Special Machining Features of Oilfield Pipes
The rethreading process is one of the major challenges in oil field machining. The frequent breakdown of piping systems in oil fields has caused machine tools manufactures to work strategically to deal with this problem. Oilfield lathes have also been developed which are able to handle very large diameter pipes as those in the drilling and conveyance sections. Special features such as automatic coupling cells have been incorporated for ease of handling pipe sections during machining.
Some Of The Critical Innovation Areas Requiring Constant Maintenance Include;
Oil couplings for enhancing efficiencies through process automation
Down hole instrumentation systems for handling tough material
Pumps used for the hydraulic fracturing process.
Various components of the pump jacks such as sucker rods, and stanchions.
Special Features of Oil Field Lathes
There are very unique threading requirements in the oil exploration industry and innovations have been made to support this process. These include;
Thread phase harmonizing. This has been done through the automatic operation of CNC lathes. Once a work piece is placed in the machine, it can automatically locate the threads and start the threading process. This allows faster machining and maintenance of the important tolerances. Accuracy and consistent quality is also maintained.
The “variable spindle speed threading” This is an application for machining pieces with thin walled gauge, without previous threads on the work piece. This component actively controls the feed axis due to the changing speeds of the spindle. This forward feeding technology realizes very high accuracy on threading.
The importance of the lathe machine can never be underestimated in the oil field operations. This is due to the constant need for repairs and maintenance of piping and conveyance systems. Special machines have been constructed specifically for these processes which have increased efficiency and production.
Research and development has led to the availability of many new and better products across many industries throughout the world. This has resulted in designing and producing a vast range of innovative machinery including tool room units for the local and global market. Hence, a broad variety of tools are now produced in order to fulfill the growing needs of various manufacturing industries.
Today there are several tool room equipment manufacturers in India and abroad. Each tool is built to perform a particular function and different models with specific characteristic are readily available at reasonable rates. Although all the producers supply good products; there are always certain distinctive features, even in the same type of equipments, manufactured by different producers.
Hence, choosing the right tool room device is definitely the key to control the overall costs. It helps to minimize input and maximize output; mainly in terms of expenditure, quality and quantity. First of all one should select a reliable and reputed tool manufacturer. The selected machine must have various salient features such as: user-friendly design, robust structure, higher dimensional accuracy, noise less, low maintenance, economical components etc.
Other essential characteristics include: top grade materials, highly secure, flexible, perfect timing, simple to operate, rust free, precise settings, corrosion resistant, longer working life, higher cutting capacity, vibration free, globally adaptable, highly tolerant, better surface, faster setup time, lesser wear and tear, standard parameters, higher tool life, uniform output, better finishing, consistent speed, fully tested, highly efficient, constantly updated, higher throughput, good quality spares, durable parts etc.
Some of the most versatile and widely used tools include the milling, bandsaw, grinding, shaping and slotting machine.
Milling machines are utilized for easy and complicated cutting, shaping and drilling operations. There are two categories of milling equipments such as horizontal milling and vertical milling. These are available in three models; namely manually operated milling equipment, mechanically automated milling and digitally automated CNC milling.
Bandsaw machines are utilized for cutting long metallic or wooden pieces into various irregular or curved shapes. It has a horizontal metal band and a blade. Basically two types are available such as horizontal bandsaw and double column bandsaw.
The grinding device is a tool used to grind the workpiece into different shapes and sizes, using an abrasive wheel. It involves precisely chipping the metal to finish the rough metal surfaces into smooth objects. Both manual and hydraulic grinders are easily available.
Shaping machines are utilized in several industries to shape straight and flat metal surfaces made from steel, aluminum, ferrous and non-ferrous metals; into various curved or angular shapes. A slotting unit is a tool used for shaping or cutting materials and for making slots in objects made from wood, metal etc.
Hence, the chosen tool room machine must be versatile, safe and efficient in order to control costs and achieve optimum value for money.