Shenoy Engineering Private Limited

Peenya, Bangalore, Karnataka

We specialize in custom-built machines in metal cutting. We offer CNC controlled SGPMs (Special Purpose General Machines). The machine that is being showcased is a custom-built machine, but is capable of doing all milling, drilling operations, apart from rigid tapping. It has a stationary bed, on which the table moves longitudinally (to and fro).LMhardened & ground guide way strips for male sliding surfaces, turcite for female sliding surfaces.Metallic, collapsible guide way covers for the table; bellows for the cross and vertical axes.

• The machine is suitable for milling and drilling upto 50 mm in 2250 mm long x 1250 mm wide x 25 mm thick plate with in-built rigid tapping capability.
• Working height: 600 to 700 mm
• Ram type drilling head with ISO-50 spindle; ram stroke to form the vertical axis.
• Ram: 250 mm square, having 350 mm vertical stroke
• Daylight: 500 mm
• Powered arbor clamping, declamping system
• Provision for external or thru- coolant (with geared pump), capacity: 40 bar/40LPM
• LM/hardened & ground guide way strips for male sliding surfaces, turcite for female sliding surfaces.
• Ball screws & nut for all the 3 axes
• Metallic, collapsible guide way covers for the table; bellows for the cross and vertical axes.
• Machine enclosure, if ordered
• T slots provided on the table to facilitate mounting of any type of fixture.
• Lapp cables
• Screw type chip conveyor
• Drag chain for cables
• Coolant filtration for 15 microns
• Spindle speeds: 30 to 3000 RPM
• Angular contact bearings for spindle support
• Positioning accuracy: 10 microns
• The Siemens CNC package for the 3 axes drive, spindle drive, PLC & HMI to contain the following:

1) Servo motor 1FK7 27 Nm / 2000 RPM with Natural cooling for 3 axes drive2) Compact Induction motor of 17 KW / 1000 RPM / 162.3 Nm with 43 Amps capacity3) CNC System Sinumeric 802D SL with Machine control panel & Full CNC keyboard3) Sinumeric module of PP 72 / 48 I/O4) Line Filter as well as Line Reactor for the Power module5) Sinamic Smartline Power module for 36 KW / 600 VDC6) Sinamic S120 Single motor module, Double motor module & Spindle module7) Profibus connectivity for the above8) Electronic Hand wheel

Floor type, duplex Plano miller against an export order, is the most challenging Plano milling SPM that we created in terms of accuracy, configuration, capacity and size. The basic configuration of the machine is almost similar to a plate edge milling machine or a floor type Plano miller. There are 2 moving columns on either side of the T slot bed. Since there is no top bridge, unlike in a gantry Plano miller, each station can be used independent of the other. Each column accommodates a side mounting type 20 HP milling head. The 13.55 mtrs longitudinal traverse of the column on either side, on a 17 mtrs long base, is through a rack and pinion mechanism. An extremely rigid base is provided for the longitudinal traverse of the column. The cross traverse is 350 mm and the vertical traverse is 700 mm. The segmented structurals of the machine are made from the stress-relieved, high grade cast iron. All the male sliding surfaces are provided with case-hardened guideway strips and the female sliding surfaces are provided with turcite lining for wear-resistance, smooth movement and torsion-load resistance. Job clamping is through specially designed, hydraulically operated fixtures. The X axis traverse on both the sides is powered by GE Fanuc servo system for accurate pitch selection and for rapid positioning. The vertical and cross axes traverses are through VFD controlled AC motor and they are DRO enabled.

Wehave developed a 8 axes CNC SPM, having the capabilities of HMC, VMC & VTL. The salient features of the machine are mentioned here below:

• VMC, HMC & VTL rolled into a single dedicated SPM with innumerable general purpose machining capabilities.
• A servo driven rotary table for accurate positioning of the job & for providing rotational feed to the job while boring.
• Self feeding vertical ram for boring & turning operation, mounted onthe top bridge with integral horizontal side.
• Separate 10 HP vertical ram type, mill, drill head for operations like milling, drilling etc
• For machining the sides, horizontally mounted mill, drill head, mounted on a 3 axes slide.
• All the linear axes and rotary table are servo controlled with Siemens advanced controllers.
• VFD controls for stepless spindle speeds in combination with lever operated gears.
• A combined function of VMC, HMC & CNC VTL facilitates any machining operation, be it boring, milling, drilling or tapping.

LIST OF MACHINING POSSIBLE:

1) Using the Boring Ram (VTL head), possible to do Straight Bore, Taper Bore, profile boring, Top facing, OD turning etc

2) Using 10 HP Ram Type Mill/Drill Head (VMC Config): Drilling, Milling, Hole milling through interpolation, Slotting through end mills, tapping through tapping attachment, boring, milling, drilling of inside bore walls through a detachable right angle attachment.

3) Using Horizontal Head (HMC Config): Drilling, Milling, hole milling through interpolation, slotting through end mills, tapping through taping attachment, boring.

Using interpolation feature of CNC system many more types of operations can be performed.

The machine is designed keeping in mind, the optimum utilization of the man and machine. This machine has been designed and manufactured to perform all machining operations in large circular components like motor frames, magnet frames etc in one go. All machining operations are carried out, taking the reference from the center bore axis, which ensures a very high level of accuracy consistently. In fact, most of these components need multiple machines for performing hundreds of machining operations of many types. A single machine can now perform all the operations in one go, which drastically reduces the dependency on human skill, multiple machine operators, floor space etc. Fully CNC controlled machine reduces the possibilities human error and thus eliminates the rejections to the least.

Wehave developed a 8 axes CNC SPM, having the capabilities of HMC, VMC & VTL. The salient features of the machine are mentioned here below:

• VMC, HMC & VTL rolled into a single dedicated SPM with innumerable general purpose machining capabilities.
• A servo driven rotary table for accurate positioning of the job & for providing rotational feed to the job while boring.
• Self feeding vertical ram for boring & turning operation, mounted onthe top bridge with integral horizontal side.
• Separate 10 HP vertical ram type, mill, drill head for operations like milling, drilling etc
• For machining the sides, horizontally mounted mill, drill head, mounted on a 3 axes slide.
• All the linear axes and rotary table are servo controlled with Siemens advanced controllers.
• VFD controls for stepless spindle speeds in combination with lever operated gears.
• A combined function of VMC, HMC & CNC VTL facilitates any machining operation, be it boring, milling, drilling or tapping.

LIST OF MACHINING POSSIBLE:

1) Using the Boring Ram (VTL head), possible to do Straight Bore, Taper Bore, profile boring, Top facing, OD turning etc

2) Using 10 HP Ram Type Mill/Drill Head (VMC Config): Drilling, Milling, Hole milling through interpolation, Slotting through end mills, tapping through tapping attachment, boring, milling, drilling of inside bore walls through a detachable right angle attachment.

3) Using Horizontal Head (HMC Config): Drilling, Milling, hole milling through interpolation, slotting through end mills, tapping through taping attachment, boring.

Using interpolation feature of CNC system many more types of operations can be performed.

The machine is designed keeping in mind, the optimum utilization of the man and machine. This machine has been designed and manufactured to perform all machining operations in large circular components like motor frames, magnet frames etc in one go. All machining operations are carried out, taking the reference from the center bore axis, which ensures a very high level of accuracy consistently. In fact, most of these components need multiple machines for performing hundreds of machining operations of many types. A single machine can now perform all the operations in one go, which drastically reduces the dependency on human skill, multiple machine operators, floor space etc. Fully CNC controlled machine reduces the possibilities human error and thus eliminates the rejections to the least.

A discarded paner in dismantled condition with many parts missing is converted into in to a Plano milling SPM for machining the inner walls of the traction motor housing. A specially designed milling head reaches inner walls of the motor housing through an extended reach & a right angle attachment. An in-built 3 axes feed mechanism facilitates positioning as well and feed & depth of cut. The job clamping fixture is mounted on a rotary table for facilitating all the inner surfaces of the motor body. This converted Plano miller has saved our customer an expensive floor boring machine.

A virtual wreckage of a planing machine is converted as a 4 axes, special purpose planing machine against an export order. All sliding surfaces are hand-scraped for a very high level of blue-matching and all rotating parts, drive system are re-engineered. The ram type milling head facilitates very high level of accuracy in 800 mm bore. No need to say that the customer saved a fortune which he otherwise should have spent on an expensive and sophisticated machine. Whenever need arises, the customer still has the option of using this machine as a general purpose Plano miller.

MILLING HEADS are offered with the following optional features:a)MANUAL BACK PLATEfor 5 HP milling heads for (a) taper machining by manually setting the spindle axis 45?, (b) optimizing the available quill movement & (c) quick & easy alignment of the spindle with respect to the tableORb)MECHANICAL TILTING BACK PLATEthrough bearing supported worm shaft & integral sector gear for fatigue free manual tilting of the back plate for both 5 HP & 10 HP milling headsORc)PLAIN BACK PLATESonly for (a) optimizing the available quill movement & (c) quick & easy alignment of the spindle with respect to the table, but with no facilities for tilting the head.d)Right angle attachments are suitable for using max. 125 mm cutter. With 5 HP milling head, the right angle attachment is provided with ISO-40 input drive arbor; with 10 HP milling head, the right angle attachment is provided with ISO-50 input drive arbor. But the output spindle taper in either case is ISO-40.(Different spindle speeds in MHR series heads are through change gear pairs provided. Different spindle speeds in MHCL series heads are through lever operated system)FEATURES OF MILLING HEAD:

• Close grained, high grade, stress-relieved castings
• Taper roller bearings provide rigid support to the spindle
• Drive though ground splines in the spindle
• Gears, spindle, quill etc made of case hardening steel, case hardened & ground
• Bull gear and mating gears, helical for high torque transmission
• Gear teeth are ground for noise free rotation
• Spindle bearings are SKF/FAG make; Motors: NGEF/ABBK/KEC/SIEMENS
• Spindle bearings lubricated for life with molybdenum sulfide grease
• Self contained, cam operated automatic lubrication system for gear box
• Spindle run-out on face, ID & OD: within 10 microns