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.
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.
Among the range of workshop machineries available a shaping machine stays very useful to shape the surface of metal, wood or steel surfaces to a desired shape or dimension. It is quiet easy to obtain good finishing in the surfaces of the instrument. Some of the popular predetermined shapes that can be acquired through shaping machines are flat surface, shoulders, and different types of grooves. it come in different sizes hence; it is easy to choose it for workshop based on the requirement of dimensions and sizes.
The significances and applications of shaping equipment
it is used for different applications in shaping, hence, it is considered as significant workshop equipment. The cutting is processed with a special single edged accessory where to and fro strokes help in cutting the desired dimension and shape. It is found to be useful in removing scaling from metals like cast iron, where a steel shaping device can be preferred to get smooth surface in the cast iron material. Long and heavy parts can also be cut into desired shapes by heavy duty. Similarly, a wood and metal shaping machine are also available for cutting wood and various metals respectively. For obtaining precise cutting, and quality smooth surface it will stay excellent workshop equipment.
Components of shaping device
The tools for a shaping machine differ according to the applications such as cutting, surfacing, etc. The selection of tools has to be determined in terms of the type of work piece that need to be shaped. Every component has specific function to perform in the machining process. Some of the important components that are installed with equipment are
Tool feed handle-Which carries the cutting tool to the machining material
Ram-helps the cutting tool to more to and fro
Vice- It is the part that hold the machining material strongly
Clutch Handle-Helps in starting the ram to function
Tips to select appropriate equipment for shaping requirements
Since, shaping requirements vary for different materials such as wood, metal and steel the cutting tools also has to be selected based on the thickness and volume of the machining material. For example, a straight or bent of swan-necked tool can be used for cutting in different angles and shank forms. Similarly for shouldering, grooving and hooking purposes specific tools are available. Thus investing on a shaping device brings multi-benefits for machining process. Read more about the shaping machine.
Some important suggestions to maintain the efficiency of Shaping Machines
Selecting the right kind of cutting tool is an excellent way to maintain the efficiency of the machining process. For example, it is possible to normalize the slotting tools with respect to the predetermined shape and dimension. In order to maintain proper function of the shaping device for a long run, it is better to keep the cutting edge properly sharpened. This will also save cost of cutting and shaping processes. In addition selecting the type of power source is also important, for example a v belt driven shaping are relatively less efficient than gear driven.
Investing on shaping equipment for workshop can be made more economical by choosing the right tools with respect to the desired machining process. This will also increase the efficiency of working with machineries.
Woodworking is basically a dangerous task; however the risk can be reduced by always using the proper safety equipments. Moreover, the power tools are very sharp, and can cause serious injury, if they are not used properly. Hence you can keep safe while using machinery by implementing the following safety habits.
First of all you should always wear suitable safety equipment. You must always wear your safety glasses and only take them off when you leave the woodworking room. Routers and surface planers are very noisy machines hence you should put on ear plugs for protecting the ears. Wearing latex gloves is also essential to protect the hands while applying various finishes. Also do not consume alcohol or drugs; or other intoxicants and stimulating drinks while performing operations as they are dangerous.
Moreover, you should not wear loose fitting clothes, and also remove neck chains or bracelets that hang from the body; as they may get trapped in a cutting head or saw blade. Wearing proper fitting clothes makes you feel comfortable and also helps to protect your body from any harmful wood chips during cutting tasks. Always check the work piece for nails, screws, staples, metals etc. before starting the machine. This may damage the work piece, cutting head, or the fast spinning saw blades; or cause the work piece to kick back and thus injure you.
Always disconnect the power connection before changing the blade or bit of a power tool. You should always use a heavy duty extension cord for all high voltage power tools in the woodworking room. Hence you will have to change the cord and also plug and unplug the power before using the tool. You must avoid using a dull cutting tool as the tool may kick-back or bend and harm you. Moreover the tool and the woodworker will have to work harder for completing a simple task. While a sharp cutting tool is quicker and safer.
Further, you should avoid distractions while using it. In case you get distracted; while performing any task with a power tool, you must always remember to finish the cutting operation safely before going away from the machine; or leaving the working room for any some reason.
While working on a bandsaw machine, table saw, miter saw, etc., you should never put your hands near the moving blade, particularly when you are removing the waste or cut-offs. Always wait for the blade to stop moving and thereafter touch the switch. It is advisable to use a scrap piece or a push stick for moving the waste away from the blade; only after the saw blade has stopped moving.
You must always work against the cutter. A saw blade or router bit must cut against the motion. Also the cutter should cut into the work piece. Hence all woodworking tools are engineered in such a way that the direction of the moving wood, and the direction of the moving tool, is in the opposite direction.
Milling machine is used in industries dealing in wood, metal, plastic etc. Solid hard materials can be formed into shapes of desire. With the advanced technology there is a great improvement in the working. Today they work much faster than what the speed was years ago.
It can execute many functions. It can drill, cut, rout etc. The machines are kept greased with a liquid which is dispensed on the location of cutting to clean away small pieces of metal.
Horizontal type is mainly used for cutting big and heavy material.
Column type is simple to use, with few parts. The mechanism for cutting is poised vertically and this can drill the materials.
The turret is very adaptable and can produce numerous products.
The C frame is commonly used in the workshops as it is very powerful.
The most accurate type of it is the CNC machine. As it works by means of computer and very intricate designs can be made on the work piece.
The size of the machines also differs, small machines that can be kept on a table and the big ones are as big as a room.
Tips for Buying the Milling Machine:
The type of Milling machine you buy depends largely on the kind of work you have to do. So first reflect on how simple or difficult and intricate the work is. The main conditions you must think about are:
Production needs – the capacity of it you wish to buy depends on your needs.
Frequency of use – if you are going to use the machine often then buy an industrial tools, and for less usage buy a commercial machine.
Axis – check how many axis the machine has.
Power – depending on the speed you require check the power of the electric motor, spindle, turbine and the engine power.
Speed – how fast the spindle head moves is the speed of the spindle, make a note of it.
Attachments – check how many attachments will come free with the machines, you might have to buy others.
Popularity – check online how popular that particular brand of machine is, read the feedback and comments of other people who are using the machine.
Safety measures to use while operating milling machines:
The operator must be trained well. The work piece must be clamped properly and the operator must make sure the clamps and vises are activated properly or it can lead to serious accidents.
He must check regularly if and when the tools should be changed. The machines must have the guards to protect any small pieces from flying away. Safety glasses must be used while operating it.
Thus, it becomes easy to buy a particular brand of machine after learning important facts about it. Check the credentials of the company and also the machine you wish to buy. It’s a big investment, so be very sure about the type of machine you need, before you buy one.
Metal materials are also applied for making creative ideas like art work, designer steel doors, window frames, etc. However, range of bending operation varies when compared to customary ones. The type of reforming that suits best for the above kind of application is channel bending. In some work requirements punch remains perfect choice of machining and in some die stays precise option because these two options support for machining requisites which must fit into pre-planned geometry. Special kinds of deforming is done by making use of exclusively designed die or punch formed by sheet metal channel. For example, “U” design can be made only by employing U shaped die and punch and similarly, semi rectangular or square designs are also made through exclusively pre-formed punch and die.
Description of Manufacturing Method
Spacer frame channel is the hot choice for modern construction requirements. Instead of tradition wood frames, channel forms offer greater as well as better benefits in terms of usability. It is created to add multiple provisions for glass fixture to make it easily slide between both directions. When it comes to manufacturing process, sheet metal bending equipment stays ideal to make such kinds of special bends using ferrous and non-ferrous ingredients. The following processes are included,
Series of V cutout elements are made through sheet metal tool
A corner is formed on each side of a flat strip so that when the channel is reformed on a transverse axis it is sent through apexes of V shaped cuts to provide perfect V design
Pairs of such cuts are set along the length and spacing is subsequently made.
The edges are fixed to remain parallel against one another.
For heavy weight applications the spacing arrangement is welded
Butt welding is also recommended to obtain perfect bondage from inside.
Merits in this Technology
This type of design helps to separate window panels and produce insulation. Consumer will be able to find one wall of window backed by second wall leaving space between the two. It prevents leakage and structurally provides good sealing. Customized requests can also be made by adding multiple channels. In recent days, people need flexible provision for ventilation including prevention of insect and dust entry. Presence of manifold channels are requested for in advance to add protective netted or plain glass or reflection preventing sheets as per their convenience or to suit climate.
Sheet bending equipment is a versatile tool that can be applied to meet our expectations for unique patterns. Automated devices of the same range are preferred in manufacturing industries for bulk production. For instance, construction and automobile sectors benefit highly through this while building works have heavy duty operations when compared to automotive industry.
Making channels from job material like steel aluminium through sheet forming device and bending to the desired dimension support for making window frames. This is an innovative production method that is performed using machining tool.
Transporting vehicle needs excellent strength to bear load and support durability of usage. Cast or wrought iron are the most important raw ingredients considered for making cross sectional shapes of railway rail. These have to be set perpendicular to each other, therefore, symmetrical construction is mandatory. These are subject to extreme stresses and should be made from excellent quality of stuff to remain strong for several decades. There were different forms of tracks produced since earlier times like flanged rail with L cross section, baulk for light weight usage, Vignoles, double-headed, flanged and many more forms.
Difficulties in Shaping
Shaping or deforming sheets or blocks of tensile ingredients had been challenging as majority of work was done with manual support. Apart from that precision was also a matter of complication and reworking was also common until accuracy was reached. In most manufacturing processes where metal elements were regarded as basic ingredient, machining process remains top most requirements. Sheet metal equipment has replaced several contemplations regarding deforming needs. Profile making and bulk manufacture of gadgets made by using heavy duty basic elements have also become much comfortable with the above range of devices. Fabrication of rail profile is one among the kinds of jobs done easily with modern workshop tools.
Sheet Metal Device for Complete construction Support
This is considered as an exact device to achieve satisfactory cut and get sharp corners. The primary application of this instrument had been for cutting patterns over variety of textures like marble, wood, etc. However, later on its usage was felt to be appropriate for scratching stencils and for heavy duty jobs as well. Milling device is also employed in fabrication of rails. In addition to that, innovative machines like roll threading instrument and selection of corrosion resistant tensile material also remain important attributes for creating increased quantity of products at comparatively short time period.
Rapid Manufacture Support
When compared to traditional methodology of bulk production, this device provides scope for dimensional accuracy during multiple levels of production. Application of sophisticated assortment of machinery like CNC embedded instruments also makes production effective through easy operation. Diverse appearances of tracks can also be produced in accordance to purpose of usage. For example, light weight push trolleys appear like rails but they are meant for lifting wagons and heavy objects yet, these are durable, resistant to corrosion and strong in resisting abrasion also.
How Manufacturers Compete in Quality Management?
When it comes to quality assurance, producers will always look for higher grade ingredients because the produce needs to meet standard array of applications. The object also has to bear intense load capacities. Hence, based on the respective requirement such as rails in cement work, irrigation projects or sugar mills the dimensions change.
Heavy metal machining jobs are of various kinds, among them creation of profile rails for different sources vary between industries. However, with the shore up of profound duty apparatus creation process takes place in terms of fast, reliable and industry friendly performance.
Recently the craze for beautifying construction works has reduced the use of brick work and employs metals in artistic ways. Steel, cast iron, aluminium, alloy coated material are few among them that are considered for creative works. The need for suitable machining tools is also highly felt as they support a largely in easily achieving inspirational sculptures and consumer friendly forms. There are several types of shapes created using steel as base metal for enhancing purposes. The range extends from domestic space to commercial buildings and public places. Starting from light fixtures to art work, frames, and the list is unlimited.
Cutting –The Major and Mandatory Job
Creative outcomes made from tensile materials need strong force to bring them to the desired shape. Convenience in cutting varies based on thickness, width and type of ingredient. Components in the form of sheets remain comparatively flexible for deforming and those that are in rod shape have to be fed into suitable machinery for reshaping them as per preferred assortment of applications.
Unlimited Applications of Rods
Today, rod forms of steel are found have obtained majority likes from consumers because of its compatibility to adapt in infinite ways of creativity. Steel rods for instance are utilized for ornamental aspects for the following luxuries. For example,
They provide Aesthetic appearance when tried in varieties of designs
Bears smoothness when touched
If offers feel of sturdiness
These are pre formed and processed and polished before being sawed.
Stay supple for bringing out into elegant shapes.
Among the series of equipments applied for producing artistic patterns using rods, bandsaw plays prominent role in providing accurate cuts. Dimensional precision is most important to reach the desired outline; especially, metal components are quite complicate in this regard. Bandsaws help to achieve this in easier manner. Apart from that,
Application of automatic saws is economical
Provides better results in cutting
Convenient operation to transform into expected dimension for making it further designing
Featured with ease of machining setting options
Faster in performance
Suits best for bulk production
The non-corrosive property of this material makes it a smart and favorite choice of ingredient for making plethora of projects like ladders, door handles, railings, chairs, tables, and many more things. A bandsaw device comes with variable cutting capacities in terms of blade speed. It stays very supportive for carrying out complicated machining works on metal stock which then vary in thickness and shape. Today machine manufacturers are able to analyze its industrial importance and customize important features to make the equipment stay fit for industrial standards. In addition, this device is completed from strong material which makes it perform for long run.
A saw device with automatic features stays supportive to carry out multiplicity of art works made from high tensile elements. Apart from other machining equipments, this device proves to be friendly one to work for creative expectations.
Healthcare industry has extensive demand of minor to major gadgets made from metals. Machining equipments have significant roles to play in formation of metal based gadgets. These accessories range from small to moderate range of sizes and are applied for several purposes during the course of testing to treatment. Some of the related elements are forceps, scissors, pet’s first air kit, hoof testers, toe nail clipper, and many more.
Compatibility of Raw Material with Designing Source
Special metal called surgical quality steel is the one used for designing flawless pieces. This job material quality has amazing velocity impact which makes it perfect choice for machining with high speed CNC mill. Moreover, the maker is able to obtain uniform quality of produce that stays rigid for high temperature exposure. This material is recommended for usage in pharmaceutical and food sectors as metallic contamination is very less when compared to others. For body modification implants compliant steel is also considered due to its corrosion resistant and tooling compatibility.
Forging Basic Shapes
Forging is the primary method applied to achieve shapes using raw ingredients. Application of suitable dyes and hammers help to get elementary structure which will then be sent to varieties of complicated processes. However, periodical inspection of all steps is carried out by instrument specialists only.
Tooling Apparatus Used for Manufacturing
Dimensional accuracy is utmost important for creating medical friendly components. To get the desired thickness, shape, blend, cut and joining, there are many instruments involved in the process. When it comes to procedures involved between shaping to cutting, the part played by milling, drilling machine and welding becomes highly required.
How does Milling Enhance Production?
Mill is highly required for setting space for screwing. Automated mills have greater demand in this industry because best instruments are selected based on accuracy of holes provided in it. Every process is inspected and every machine employed for production is also inspected before it is used. The need for screwing in multiple measurements is another top requirement in creation of therapeutic devices. Compact drills are also considered for maintaining perfecting in hole as pairs of produce are joined to form a single apparatus. A slight variation in milling or boring will lead to wastage of raw stuff and time taken to carry over job.
The Process of Fitting
Welding device is equally required for binding two or more parts to form into a full apparatus. For example, gadgets like forceps which is made by binding more than one portion. The role of welding works out at this stage. However, the joints have to be perfectly combined to leave no space for further weld or leave any suspensions at particular spot. Scissors on the other hand, is designed with precise processes.
Pharmaceutical sector makes use of special form of un-contaminated metal for handling in operations and body part modification treatments. These elements are processed through series of methods with the help of workshop devices to obtain them in precise and accurate way.
Cooking utensils made of metal have great demand all over the world because of its durability and wear and tear resistant nature. Creating different shapes of utilities still have excellent reception from consumers. When it comes to applying metal as raw material, aluminium and stainless steel remain the prominent options other than power coated ingredients. Creation part requires accuracy in production without which convenience would be doubtful.
Equipments Considered for Production
Kitchen produce ranges from wood spatulas to premium steel vessels. They are available in different shapes and sizes in accordance with usability analysis. In earlier days wood turning process was considered as prime source of inspiration in creating cooking components. Turning device had been in existence since 12th century where many products were made including utensils, vessels, toys, etc. Wooden molds were also created using the above system. Cylindrical forms of job material were diagnosed as perfect for producing spherical shapes of elements. The speed of device was also found to be compatible to meet manufacturing requisite.
Transforming Basic Ingredient-Role of Press Device
Press has important role to play in transforming raw material into the expected thickness. Some factories make use of hydraulic and Power device with respect to their productivity requirement. Hydraulic device offers cost effective manufacturing and power provides efficient high speed performance in producing small to medium variety of cooking accessories.
Lathe was supposed to be the most convenient forms of machining tools through which manufacturers try out extensive array of products. It also stayed sufficient for carrying out bowl turning, making of carved vessels and many related objects at comparatively short time.
Sharpening and Finishing
Mill comes next in this role and this is highly relied upon for sharpening smaller range of tools. It provides perfect surface for the objects and make them prepared for adding fixtures like handle, screws, and steam vent with nut.
Making of Pressure Cooker
Pressure cooker is top priority element for cooking. It is composed of different metal parts including,
Pressure regulator is made from work piece.
Aliminium alloy, stainless steel are some of the suitable elements employed in manufacturing. These are reliable and cost effective material and provide good results for prolonged usage.
Copper is also used in minimal quantity as the base to add efficiency in absorbing heat.
Some utensils are made by using copper as main ingredient.
Machining can be classified into various processes as far as creation of kitchen goods is concerned. It includes,
Cutting of raw ingredient into circular or cylindrical form or any other shape as per the desired outcome. In some factories they use guillotine shear to support bulk production.
Trimming of body is completed using press. Excess amount of material is removed to reach dimensional accuracy.
Notching is done using bench drill and it is required to make engravings like brand image and other details which manufacturer wishes to appear.
Holes are created to add handles and for fixing additional parts. Drill becomes highly required in this regard.
Buffing and polishing process provides perfect shiny outcome giving the object new and fresh look.
Machining tools are applied in wide range of industries. They are very supportive in manufacturing of kitchen friendly equipments and vessels.
Selection of specific apparatus stays the key point of achieving unusual kinds of shaping. Apart from implementing dies, addition of utensils can help in enhancing machining operation. This methodology also provides good results in terms of productivity. Combination of more than one device is required in certain industries during times of profile making is required.
Considerable Types of Standard Instruments
Pre-formed tool design is the foremost feature that has to be checked for before buying equipment. Each machine supplied by a manufacturer will have standard range of contrivances. Exception demand of determining like forming channel legs using metal components may require the assistance of additional instrument apart from average options.
How Grouping of Machining Gadgets done?
Grouping or combining normal accessories with specific accessory is the proper selection of punch and die. This method is further fortified depending on the work material thickness along with varieties of deforming basics. Optimum blending decided upon the above criteria will help to reach the necessary set up as well as precision in distorting.
Follow Stages in Shaping
As far as application of multiple gadgets for deforming is concerned, it is done through different stages. The effectiveness of blending more than the standard choice of instruments works worthwhile when done through stages. For example, the first stage the die is focused and punch action is focused during the second stage
Different Shapes Formed through Combination Tooling
Creation of Channel Legs
Acute angled winding
R, Offset, tube, U, V, Closing and beading types of bending
Total contact form, etc
Changes Affecting Performance of Machining
A press brake is a versatile apparatus which works over the geometrical principle of punch angle and radius also called as top and bottom tool. Successful and precise results are possible only if the mixture of both remain compatible for work piece. Strategic assortment of gadgets considering supporting factors like material strength, width, thickness, die shape, etc offers the following advantages.
Increases capacity of device, like press brake
Manufacturers can manage higher productivity at balanced investment
Quick and accurate results obtained
Eliminates high cost and repetitions
Reduces possibilities of changes
Create products without any instrument impressions
Choosing a flexible die can help for better performance through replacing damaged ones without causing any changes in the already completed deformation.
Rare Happenings of Multi-breakage
Multi-breakage is a condition that occurs in R-bending. It results in prior winding before the actual machine starts its motion due to the pressure spreading in both directions. However, in heavy duty and high tensile strength materials this kind of actions occurs rarely. It should be tactically avoided by managing proportionate ration of sheet thickness and inside radius.
Extraordinary shaping needs are not possible with standard forms of devices. It can be done only with the support of additional components. An apparatus like press is one that can be accommodated with multiple gadgets to create unique shapes.
Lathe is versatile equipment that works worthwhile for several operations starting from cutting, to turning and deforming. Professional performance brings specific results in productivity because there are ample possibilities of faults to happen while staging a cutting action. The errors vary in mechanism in accordance with the type of materials such as metal or wood. Below are some of the
Rotating Speed Adjustment
It is mandatory condition to be checked for before feeding exertion material. Though it may appear a common criterion, it is highly advised to ensure material thickness, tool and speed compatibility to achieve accuracy.
Material Feed Rate
Heavy setting starts to slow down the process and diminish the quality of machining. During such conditions, the headstock gets disengaged before it meets the stop point. Professionals or skilled operators will be able to find out this error. For those who start with heavy settings, it would be better to apply small amount of hand feed and then try out with reversing the carriage and begin the next step. Checking the dial through the help of lock screw is another way to achieve precise metal working
Cutting Depth-Preventing Short Bytes
The depth of engraving goes in tune with toll selecting, pace, metal texture etc. For bigger depth requirement setting with small value of cutting and enhancing later gives better results. Therefore prefer machining with moderate velocity, lower depth and gradual increase of job portion supply.
Improper Tool Arrangement
Fixing the engraving device in an improper position with imbalanced height balance causes damage to dimension of slashing. The recommended pose is fitting at the centre of chuck as this will ensure accuracy of cuts and keep the work stuff free from damages. However, fixing can be done by running the lathe gradually so that the chuck is not fast on rotation.
Sensing Blunders through Noise
With the inception of superior ranges of lathe models like vibration free, high speed, etc the point of finding mistakes is possible if only the equipment is managed by inexperienced operator or wrong substance feed position. However, there is a smart hint for the inexperienced to tactically grasp wounding mishaps is from high sound created during processing. If there is too much rotation speed or vibration the sound differs and this could help the operator to guess processing drawbacks.
Things to confirm before Turning
Turning is of different varieties such as facing off, tapering, facing to the length, boring, etc. The mechanism also differs wherein, the work object rotates and the instrument is fed against. Inaccuracies are identified through ensuring discoloring or ragging of job piece. Unmatched texture or surface forming on substance also indicated inappropriate operation. Such happening is likely when tempo or ingredient supply is incorrect.
Any workshop apparatus is designed only by means of reaching perfection and accuracy. However, errors may appear in most cases due to inexperienced trials. For successful results avoiding mistakes from operational aspects can help productivity in multiple ways.
Most of the workshop tools are featured with multifaceted operational aspects. Single equipment may be defined for specific operation like cutting, drilling or surfacing, yet, as far as flexibility is concerned, the same device is eligible for varieties of machining works. Machines like drill, press, mill, lathes machine, etc come under this category as they are meant for more than the specific form of working. Creation of cone shaped hole is one among the most required works, this is called countersinking. A drill is the prime apparatus that stands suitable the above work, however, lathe, mill; drill press can also be applied to same purpose.
Creating holes on work materials ranges may not be questionable unless the kind of material or position in which hole is required may remain complicated. Countersinking is a right method to manage tricky forms of drilling. Yet this process should be managed in a strategic method to avoid the possibilities of complications which vary in accordance with material.
Material Issues and Recommended Strategies
Titanium– Metals like Titanium remains a challenging raw ingredient during the process of backing off the cutting edge. This can be solved through the selection of spring in drilling equipment. The harder the work piece is, the stiffer and special the spring should be selected.
Application of sharp tools suits best to attain smooth dimension in wood. Apart from that, ensuring screw head and high rake angles works better to obtain better cut angles.
Drill is best equipment suitable for cone type drilling in plastics such as acrylic, Teflon, fiber, etc. It is found to bring our better results by using a drill than other eligible equipments for the above kind of operation
Acrylic is also a challenging material in forming conical holes is concerned. Simultaneous contraction of opposite sides of the hole had been the trouble during the application and the strategy remained in pressing the hole contour and apply lighter cut. Next, the numbers of RPMs were also determined in accordance with removal of residues to reach precision.
Important Rules Which May Help to Restrict Issues
In order to prevent disturbances, apart from countersinking, even chamfering also required special considerations. This will help in preventing burrs forming in between layers and from forming fuzzy edges and achieve good joints.
The application is done without leaving any obvious burr, tearing out, etc
While handling with plastics, the temperature may be noted for compatibility to stop melting
Slow feed rate is recommended for fragile range of components
Removing chips is a favorable condition for precise tooling.
Strategic way of handling complicated hole making operations helps to obtain precise performance. In addition, the ideas differ in tune with the type of work material because tool selection must be compatible with the ingredient chosen. In the same way, there are many devices which can be used for performing similar range of actions and they need to be selected based on how they go matching with work component.
Deforming work materials into the determined dimension is quite expensive. If there is change in dimension, it leads to wastage and loss. In addition, manual bending process with the help of compact tools is complicated and challenging when it comes to obtaining precision. However, with the inception of special kinds of dies and machines deforming work piece can be managed cost effectively.
Matching the Template
For perfect bowing creation of template is more important as this would make the job easier and costs comparatively less. Though it is not necessary to produce templates for every sort of tooling requirement, this method is of great use for larger productivity requirements.
Ensure the Yield Strength of Work Component
Check out the type of material that must be shaped. This will help the operator to choose the right die or device that remains compatible, easier, faster and minimal wastage. For example, there is difference between deforming pipes and sheets. Next, materials like steel tubes, pipe, channels, bars, etc are some of the work materials which are liable for easier deforming when processed through turning operation
Economic Bending for Heavier Materials
As far as heavy range of job pieces are concerned, press stays the right choice of apparatus to do the twisting application. It runs on the basis of pressure that is provided until the desired dimension of twisting is reached. This technology is very effective to handle heavier beams, channels, tubes and bars. The maximum thickness and negotiable radius has to be considered for good machining result.
A bending device is an appropriate option for handling flat range of sheet materials wherein, the operation is carried over dotted lines around a straight axis. A press brake offers reciprocating motion to and away and at right angles as well. The punch and die are supporting features for creating twists using a press. Therefore, matching the device as per the production demand is one more way of obtaining economic tooling.
Operation Sequence Management
There exists a position of winding operation until which the action takes place without interference. Splitting the steps of sequence in the following is a great way to organize professional tooling,
First, the length of material is to match the total bend dimension required and must stay correspond to the gaps on both sides of the twist.
Secondly, avoiding part tool impact on either side of shaping point and with adjacent levels.
Planning the Process in tune with Budget
There involves a series of actions for planning the deforming process in the desired budget. They are,
Picking the appropriate tool
Calculation of blank length
Estimation of shaping force
Verification of Tolerance level similar to selected tools
Determination of sequence
Planning set up time,
Machine position up, material feed, etc
There are certain influencing features which may be followed to make the process influencing and stay in budget limits. These features will also support to minimize overall production span and bring in optimized style of machining at moderate investment.
Vehicle Manufacturing – the Major Sector that depends on Machining
Automobile companies are the major metal product users for producing different parts. Steel and aluminium are two major components. Apart from this, fibre and plastics are also considered for making varieties of transport. Major luxury motor making companies are making cars aluminium for body that gives a classic look for the transport product. Manufacturers use this ingredient because it is strong and is affordable in the market and moreover, product can be engineered in different shapes and need of crash safety. Approx 65% of vehicle parts are made up of metal products. Steel is a kind of element which has flexibility and qualities that leads to its usage in affordable way. There are machines that are used by manufacturing companies to create the required design for manufacturing.
Machines to Design Metal
Industries use various machines for forming different components required for manufacturing, one such is lathe device. Automobile industry are using this tools to get the desired shape and cut of components. Different types of lathes are used for shaping plus cutting the raw material such as, engine, turret, and special purpose lathes. Today, bigger range of workshop tools is used by makers.
The user uses these devices as per the requirement and how these modern styles of tools can be used.
Varieties in Machined products Applied
Steel: Most part of the auto product including steering and suspension are made from this. Moreover, stainless steel is also used for auto built-up because of non-rusting property.
Aluminium: There is a big transition happening from the above material to this one in vehicle production. Though this raw ingredient cost double than the one made from the top component, but it brings a major change in the design. The reason behind this change is its light weight. Parts that are completed by using aluminium are engine and wheels.
Iron: This is next big material used in creation after the top preferred ones. Moreover, the weight of iron makes the usage more sufficient.
Titanium: This is strong, light weight and corrosion resistant. It is quite hard to manufacture, but is generally considered for intake and exhaust valves.
Making of Luxury Cars
Car manufacturers are now using advanced high-strength steels to make strong body. Luxury car makers are also using aluminium which is less dense material and saves 11% on making the body. For this base material, the market is very competitive for car manufacturing. Presently, advanced high potency form is largely used materials in automotive business. Metal industry has evolved greatly, and so the makers are using different forms of such products to manufacture high class design travelling product structure with the help of machining tool and lathe is one among the important requirements which is preferred for majority of creation requisites by makers.
There is no doubt that metal is an important component in designing the means of transport structure. Automobile engineering is evolving dramatically and so are the machining trade introducing versatile tools for long run and getting desired shapes of the same.
Mill is one of the priority equipments for metal industries and fabrication jobs. It helps it getting the toughest metal components ready to be composed for final produce. It is one of the main devices that prepare the raw materials to be taken to the next level of assembly. Industries which depend on metals like automobile, machine manufacturing, construction and aerospace, etc find more advantageous machining aspects through this kind of equipment.
The Art of Grinding Simplified
Grinding harder ranges of work pieces requires focus on precision and there are obviously many pitfalls if the process is done manually. A grinding device can resolve the pitfalls through the improved technical features it is equipped with.
How about In Depth Metal Processing?
In depth grinding or drilling deep into hard materials is certainly hard. For manufacturing sectors which depend on produce through processing metals has to consider precision as one of the foremost qualifications. When it comes to in depth grinding to the desired length or dimension, it can be done only with perfect machinery like grating equipment.
Is it possible to precisely crush deeper portions?
It is possible to achieve deep cut with the help of technically improvised turret mill. Since, this device is designed with quill unit that permits the work table for flexible movement and carry on different deep cuts in the metal. This functional feature helps the manufacturing sector to create complicated machining parts.
Flexibility of Operation at various Angles
It depend a large on the reachable options provided for quill and knee when it comes to obtaining machining operations at various angles. In smaller range of mills the operator can change the angle at the time of machining and in heavy duty models; the operator has to pause the operation for a while in order to reach grinding at different angles.
Check out the Milling Head Specification
If the device is featured with universal head it would be best thing for manufacturers to achieve complex angles of operation as the universal head is flexible for tilting movement up to 180⁰.
Determine the Depth of Cut
This can be done by checking the amount of feed that will be fed into the basic unit. It should not cross the depth of the teeth that is applied for grinding and it is usually controlled by the cutter diameter, side crush cutter is advisable for deeper cuts.
Ensure direction of feed
For best performance and precise results, ideal feed of components is recommended by experienced professionals. They have the following observations regarding this,
The material feed direction and dimension has to match the equipment capacity and the machinability of the work piece.
The rate of feed and the depth of grinding should be compatible with the thickness of work material.
If thickness of tool head is not adaptable to the material thickness, it may cause bad grinding and diminish the quality of machining.
Choose the right axis through which the desired tooling can be done.
Check the clearance level
Allowing suitable clearance level between the tool, work piece and the machining bed is one of the major concerns of successful machine set up. It helps for managing deeper grinding in smooth way.
When it comes to metal work materials, milling device has an important role to play in terms of providing required dimension for stronger connectivity with other components. For heavier and deeper grinding, this equipment remains a good solution provided the operator follows the above steps for perfect machining management.
Traditional press brake setup was found to be with hydraulic principle and the usage can be traced back to ancient Mesopotamia and Egypt. Later as years went on Greeks introduced some changes into the provisions considering suitability and ease of working. However, inception of electronic or motorized tool was also introduced during traditional times in which electric servo motors were used in addition to pulleys and belts. Scott Ottens, Manager of Amada America Inc, observes about this bending tool that “In Hydraulic system there will be acceleration. It takes a little bit of time to get up to speed where in an electrical system it is almost instantaneous”
Why setup of equipment is mandatory?
Traditional press brake setup was found to be with hydraulic principle and the usage can be traced back to ancient Mesopotamia and Egypt. Later as years went on Greeks introduced some changes into the provisions considering suitability and ease of working. However, inception of electronic or motorized tool was also introduced during traditional times in which electric servo motors were used in addition to pulleys and belts. Scott Ottens, Manager of Amada America Inc, observes about this bending tool that “In Hydraulic press brake system there will be acceleration. It takes a little bit of time to get up to speed where in an electrical system it is almost instantaneous”
Why setup of equipment is mandatory?
Setup or tooling alignment is a mandatory aspect if you are looking for precise work for long term. There are certain kinds of mistakes which can be identified as general issues in metal working apparatus like press brake. However, these things depend a lot in setting up the arrangement of device parts.
Mechanism and Machining alignment in conventional Press Devices
1. Tool Selection for Process
Selecting of tooling options is one of the mistakes that need to be reduced when it comes to obtaining precision in tooling work. It will also have impact on the working bed, hence the tooling components has to be consistent without bends or flanges as frequent operations may worn the components and may lead to cause bends or damages on the working beds. This could be one of the mistakes that lead to imperfect press mechanisms.
2. Creation of set up procedures
Set up procedure depends a lot on overall specifications. Every aspect of assembling has to go in tune with one another to reach maximum compatibility. For example,
The Ram gibs should be maintained in parallel position to avoid twisting movement. This will lead to cause imperfect machining and would become tough to reach perfection.
The return pressure should be maintained without increasing ram stroke.
Strictly following the recommended clearance for gibs is yet another way of achieving successful set of connections.
3. Failure in Lubrication
Lubrication is one of the major issues found both in earlier times as well as today. Successful working of equipment depends on how the operator follows instruction for lubricating all the moving parts of the apparatus. The manufacturers have a big role to play in this because a good manufacturer should provide all the instructions concerning lubrication and other maintenance features.
4. Layout strategy
Layout strategy deals a lot with incorporating equipment set up, maintenance of equipments and following the recommendations in the same way as provided by the manufacturer.
5. Ram Set Up
Ram provision is one of the most commonly made mistakes when it comes to imperfections in brake technology. It has to be compatible with the work material load as overload can lead to deflection of ram. If overloading ends up in machining deflection it can be set right only through re-machining the work material placing platform or bend and the ram. However, this can become a hectic process and disturb production.
Press Brakes are important equipment which had been in existence since earlier times. However, successful production can be reached by avoiding the above mentioned list of common errors.