The 3 liner slides are controlled by worm reduction gear box AC induction motor routed through vector VFD to obtain stepless speed variation from 30 mmmin to 1000 mmmin. All slides have a DRO to find exact position of the slides. The ram type milling head mounted on the vertical carriage has extra rigidity than conventional slide mounted milling head due to its square box design locked in with taper jibs.

This SPM was made for one of our customer who required to drill four numbers of equidistant hole on a component simultaneously. This is essentially a mass production machine which can give high output. Similar machines of same configuration can be made to suite different jobs.

• Used a conventional lathe.
• Manual 3 jaw chuck.
• Feeding HSS pilot drill manually
• Feeding HSS finish drill manually. .
• Heat treating the material and then boring using a VMC
• Total machining time of 20-30 minutes.
• Features and Specs:
  
  • Heavily ribbed, fabricated and stress relieved structure.
  • Atop the base, a stationary fixture is provided. The fixture consists of V blocks and hydraulic clamps to clamp the component.
  • On one side the fixture, drilling head is mounted on hydraulic cross slides. Sliding surfaces is made of LM guideways and blocks. The slide has a stroke of 300 mm.
  • The drilling head is driven by a 20HP motor connected to the spindle through timer belt and pulley mechanism.
  • The drilling heads motor are routed through VFD for stepless speed variation from 300-1500 RPM.
  • The slide is driven through a servo motor which is coupled to a ballscrew through a 1:4 ratio servo reducer to provide feed rates of 10mm/min to 7500mm/min.
  • The machine is provided with spindle through coolant and chip flushing.
  • The machine will be provided with complete machine enclosure.
  • The machine will be provided with PLC programmed auto-cycle. A touch screen HMI will be provided for machine parameter setting and trouble shooting.
  • Sequence of Operation:
    
    • Load the component on the fixture and press auto-cycle.
    • The component gets clamped.
    • Through coolant is switch on. The drilling head spindle starts, drills the component with 3 pecking cycles and retracts. Spindle stops
    • The finish drilling head moves, drills the component to the finish bore and retracts. Spindle and coolant stops
    • The component clamp disengages.
    Cycle Time:

    The cycle time of the machine from component clamp to unclamp condition consider the bore diameter 44x220mm is 180 seconds

    Final Conclusion:
    Lathe:
    • Component setup time is high.
    • Machining time is high
    • Need of skilled operators.
    • Due to manual feeding, operation is prone to operators fatigue, which may lead to loss in efficiency of production.
    • Even though tooling cost is less, considering the machining time, operators salary, the overall cost is more.
    U-Drilling and Boring SPM:
    • No need of skilled operator. Cost of skilled operators is reduced.
    • Uses U-drills with indexable inserts. Cost of tooling is reduced.
    • The total drilling time is 3 minutes, instead of 15-20 minutes on a lathe. Efficiency is more than 6 times. Increases the productivity, increases profitability, increases the scrap generation rate.
    • Machine provided with adjustable V blocks and clamps, which can accommodate a variety of

The fixture, will be designed to rest, locate on the ID. The clamping will be through pneumatic swing clamp cylinders.Station 3 will be top chamfering station. This station will have a chamfering head with a counter sink drill mounted on it. The drilling head will have a vertical servo stroke for drilling feed.Station 5 will be back counter sink station. This station will have a unit head with counter sink drill mounted on it. The unit head will have a vertical servo stroke for feed.Station 6 will be inspection station. This station will have a pneumatic cylinder which will plunge into the drilled hole to check for hole.

Features & Specs:

• Rigid, heavily ribbed, fabricated and stress relieved structural.
• Atop the base, a servo driven rotary table is mounted which is dived into 8 stations.
• The fixture, will be designed to rest, locate on the ID. The clamping will be through pneumatic swing clamp cylinders.
• Station 1 will be loading station. This station will have a pneumatic pick and place arm in combination with pneumatic cylinders to load the component.
• Station 2 will be clamping station, where the component is clamped.
• Station 3 will be top chamfering station. This station will have a chamfering head with a counter sink drill mounted on it. The drilling head will have a vertical servo stroke for drilling feed.
• Station 4 will be drilling station. This station will have aunit head with1.8mm drill mounted on it. The unit head will have a vertical pneumatic stroke for feed.
• Station 5 will be back counter sink station. This station will have aunit head withcounter sink drill mounted on it. The unit head will have a vertical servo stroke for feed.
• All unit heads of Suhner make.
• Station 6 will be inspection station. This station will have a pneumatic cylinder which will plunge into the drilled hole to check for hole.
• Station 7 will be job declamp station, where the job is declamped.
• Station 8 will be job unloading station. This station will be similar to loading station, but will unload the component into a bin.
• The Servo, drive, HMI, PLC will be of Siemens make.
• Each unit head will have a tool sensor to sense the breakage of the tool.
• Centralized lubrication system will be provided.
• The machine will have a recirculating coolant system to flush out the chips.
• The machine will be provided with splash guard.

Sequence of Operation:

• Load the components into the job feeding bin and press auto-cycle.
• The pneumatic cylinder moves the arm over the job, picks the job and places it over the fixture.
• Rotary table indexed, job gets clamped.
• The job gets indexed to station 3 and top chamfering takes place,
• The job gets indexed to station 4 and the 1.8mm drill, drills the component.
• The job gets indexed to station 5 and the bottom chamfering takes place.
• The job gets indexed to station 6, where the inspection will happen.
• The job gets indexed to station 7, where the job gets declamped.
• The job gets indexed to station 8, where the job is picked from the fixture and dropped into the chute leading to the bin.
• This process is continuous and when machining operation is going on at other stations, the job loading and unloading will be going on at other stations.

Rotary Coordinate Drilling SPM for dia 2, 000 mm is developed for an ancillary of L&T. This is a forced thru-coolant enable deep hole drilling machine for 35 mm x 400 mm deep holes. The servo motor driven rotary table with T slot has an accurate pitch positioning capability through the direct encoder feed back . The pitch selection, program selection, program editing etc are facilitated by a user-friendly HMI interface. The vertical axis movement and automatic job clamping, de-clamping are facilitated by hydraulic system.

The capacity of the above shown Knurling SPM is designed to accommodate shafts of 10 mm min. to 50 mm max x 500 mm long.

• Longer shafts can be accommodated either through suitable extension of admit between centers or through a hollow chuck.
• Cross traverse (traverse for the knurling wheel to plunge) is upto 150 mm through hydraulic cylinder.
• Ball screw & box nut for longitudinal axis movement, in combination with case hardened male sliding surfaces & turcite for female sliding surfaces will provide smooth, back-lash free smooth sliding movement, apart from wear resistance.

An AUTO-CYCLE, operated through the combination of direct, encoder based feedback of servo drive for the longitudinal axis, PLC, feed-end limit switches, sensors etc, ensures that the knurling operation takes place as programmed with repeat accuracy & with the least human intervention.

Coolant system, lubricants, machine enclosure, automatic chip disposal system, guide way protection etc will be provided at an additional cost. Job loading and unloading will be manual.

Customers Initial Machining Process:

• Used a VMC.
• Clamping sing a C washer and bolt mechanism.
• True the job which would take around 5 minutes.
• Machining cycle time for drilling of 31.75 mm for a depth of 56.3 mm using a U drill would take around35 minutes.
• A Total of40 minutesused to be taken up for one job to be completed.

Features & Specs:

• 2 servo controlled axes for (a) rotational movement of the rotary table, (b) cross axis movement of 10 HP drilling head, which can do drilling upto 36 mm drilling.
• Servo controlled linear axes movements & rotary movement are for accurate pitch selection & accurate indexing respectively.
• Drilling head with special angular contact bearings arrangement for high level of accuracy & rigidity. Head driven by a 10HP motor with a combination of gears and timer belt and timer pulley arrangement for obtaining required speeds without torque drop.
• Ball screw, box nut mechanism in combination with gear box for cross axis movements of the milling head.
• Hydraulically operated vertical movements of the drilling head.
• Swing clamp cylinder can be provided for automatic clamping.
• Touch Screen enabled HMI (Human Machine Interface) for quick on machine program selection, program editing by the operator & quick troubleshooting.
• Male sliding surfaces are with case hardened guideway strips and female sliding surfaces are with turcite lining for smooth axes movement & best wear resistance.
• Centralized automatic lubrication to lubricate all rotating & sliding parts at pre-set regular intervals.
• Machine enclosure & guideway protection
• Machine to have PLC program.
• High pressure coolant thru with rotary joint for quick chip evacuation
• Total machine enclosure, required for high pressure coolant dispensation.
• Chip conveyor for easy chip disposal.

Sequence of Operation of Machine:

• Load the job onto fixture manually
• Close the door and press auto cycle.
• Job Clamps.
• The servo driven horizontal slide moves from home to required distance to obtain the pre-fed PCD.
• Spindle ON, coolant ON, Vertical hydraulic slide having head mounted moves in rapid to the cutting zone and slows down to the required feed rate while cutting.
• Vertical slide retracts out of the hole and table indexes to the next pre-fed angle for drilling next hole.
• Same indexing & drilling is followed upto 360.
• The slide and table moves back to home.
• Job unclamps, unload job.

HMI Enabled Easy Programming:

• One of the setbacks in owning a VMC is requirement of CNC programming knowledge to alter or change the program.
• In our machine with a HMI, programming knowledge is not at all required. Simple instructions can be followed on screen to modify or change the program.
• Working as shown in the upcoming slide.

High precision deep holes with critical tolerances on dia, roundness, hole location, taper, concentricity and finish usually need secondary operations like reaming, honing, boring, grinding etc. Gun drilling can produce an accurate deep hole economically in a single operation at unbelievable speed. Since a gun drill has a carbide cutter at its cutting edge, it can effortlessly drill through hard material like forging, alloy steel components etc which cannot be economically machined with other types of drilling. The length of a gun drilled hole can be several times its diameter and holes will be bur-free. A rotating gun drill is slowly fed into the work piece at a high RPM. High pressure cutting oil is delivered to the cutting zone from a specially designed coolant pumping system through a rotary joint and an in-built coolant passage in the gun drill. The coolant not only cools the heat at the cutting zone, but also it removes and carries back the chips through the flutes provided in the gun drill to the chip box. Before the coolant reaches back the coolant tank for re-cycling, chips are filtered.

The 3 liner slides are controlled by worm reduction gear box AC induction motor routed through vector VFD to obtain stepless speed variation from 30 mmmin to 1000 mmmin. All slides have a DRO to find exact position of the slides. The ram type milling head mounted on the vertical carriage has extra rigidity than conventional slide mounted milling head due to its square box design locked in with taper jibs.

This SPM was made for one of our customer who required to drill four numbers of equidistant hole on a component simultaneously. This is essentially a mass production machine which can give high output. Similar machines of same configuration can be made to suite different jobs.

• Used a conventional lathe.
• Manual 3 jaw chuck.
• Feeding HSS pilot drill manually
• Feeding HSS finish drill manually. .
• Heat treating the material and then boring using a VMC
• Total machining time of 20-30 minutes.
• Features and Specs:
  
  • Heavily ribbed, fabricated and stress relieved structure.
  • Atop the base, a stationary fixture is provided. The fixture consists of V blocks and hydraulic clamps to clamp the component.
  • On one side the fixture, drilling head is mounted on hydraulic cross slides. Sliding surfaces is made of LM guideways and blocks. The slide has a stroke of 300 mm.
  • The drilling head is driven by a 20HP motor connected to the spindle through timer belt and pulley mechanism.
  • The drilling heads motor are routed through VFD for stepless speed variation from 300-1500 RPM.
  • The slide is driven through a servo motor which is coupled to a ballscrew through a 1:4 ratio servo reducer to provide feed rates of 10mm/min to 7500mm/min.
  • The machine is provided with spindle through coolant and chip flushing.
  • The machine will be provided with complete machine enclosure.
  • The machine will be provided with PLC programmed auto-cycle. A touch screen HMI will be provided for machine parameter setting and trouble shooting.
  • Sequence of Operation:
    
    • Load the component on the fixture and press auto-cycle.
    • The component gets clamped.
    • Through coolant is switch on. The drilling head spindle starts, drills the component with 3 pecking cycles and retracts. Spindle stops
    • The finish drilling head moves, drills the component to the finish bore and retracts. Spindle and coolant stops
    • The component clamp disengages.
    Cycle Time:

    The cycle time of the machine from component clamp to unclamp condition consider the bore diameter 44x220mm is 180 seconds

    Final Conclusion:
    Lathe:
    • Component setup time is high.
    • Machining time is high
    • Need of skilled operators.
    • Due to manual feeding, operation is prone to operators fatigue, which may lead to loss in efficiency of production.
    • Even though tooling cost is less, considering the machining time, operators salary, the overall cost is more.
    U-Drilling and Boring SPM:
    • No need of skilled operator. Cost of skilled operators is reduced.
    • Uses U-drills with indexable inserts. Cost of tooling is reduced.
    • The total drilling time is 3 minutes, instead of 15-20 minutes on a lathe. Efficiency is more than 6 times. Increases the productivity, increases profitability, increases the scrap generation rate.
    • Machine provided with adjustable V blocks and clamps, which can accommodate a variety of

The fixture, will be designed to rest, locate on the ID. The clamping will be through pneumatic swing clamp cylinders.Station 3 will be top chamfering station. This station will have a chamfering head with a counter sink drill mounted on it. The drilling head will have a vertical servo stroke for drilling feed.Station 5 will be back counter sink station. This station will have a unit head with counter sink drill mounted on it. The unit head will have a vertical servo stroke for feed.Station 6 will be inspection station. This station will have a pneumatic cylinder which will plunge into the drilled hole to check for hole.

Features & Specs:

• Rigid, heavily ribbed, fabricated and stress relieved structural.
• Atop the base, a servo driven rotary table is mounted which is dived into 8 stations.
• The fixture, will be designed to rest, locate on the ID. The clamping will be through pneumatic swing clamp cylinders.
• Station 1 will be loading station. This station will have a pneumatic pick and place arm in combination with pneumatic cylinders to load the component.
• Station 2 will be clamping station, where the component is clamped.
• Station 3 will be top chamfering station. This station will have a chamfering head with a counter sink drill mounted on it. The drilling head will have a vertical servo stroke for drilling feed.
• Station 4 will be drilling station. This station will have aunit head with1.8mm drill mounted on it. The unit head will have a vertical pneumatic stroke for feed.
• Station 5 will be back counter sink station. This station will have aunit head withcounter sink drill mounted on it. The unit head will have a vertical servo stroke for feed.
• All unit heads of Suhner make.
• Station 6 will be inspection station. This station will have a pneumatic cylinder which will plunge into the drilled hole to check for hole.
• Station 7 will be job declamp station, where the job is declamped.
• Station 8 will be job unloading station. This station will be similar to loading station, but will unload the component into a bin.
• The Servo, drive, HMI, PLC will be of Siemens make.
• Each unit head will have a tool sensor to sense the breakage of the tool.
• Centralized lubrication system will be provided.
• The machine will have a recirculating coolant system to flush out the chips.
• The machine will be provided with splash guard.

Sequence of Operation:

• Load the components into the job feeding bin and press auto-cycle.
• The pneumatic cylinder moves the arm over the job, picks the job and places it over the fixture.
• Rotary table indexed, job gets clamped.
• The job gets indexed to station 3 and top chamfering takes place,
• The job gets indexed to station 4 and the 1.8mm drill, drills the component.
• The job gets indexed to station 5 and the bottom chamfering takes place.
• The job gets indexed to station 6, where the inspection will happen.
• The job gets indexed to station 7, where the job gets declamped.
• The job gets indexed to station 8, where the job is picked from the fixture and dropped into the chute leading to the bin.
• This process is continuous and when machining operation is going on at other stations, the job loading and unloading will be going on at other stations.

Rotary Coordinate Drilling SPM for dia 2, 000 mm is developed for an ancillary of L&T. This is a forced thru-coolant enable deep hole drilling machine for 35 mm x 400 mm deep holes. The servo motor driven rotary table with T slot has an accurate pitch positioning capability through the direct encoder feed back . The pitch selection, program selection, program editing etc are facilitated by a user-friendly HMI interface. The vertical axis movement and automatic job clamping, de-clamping are facilitated by hydraulic system.

The capacity of the above shown Knurling SPM is designed to accommodate shafts of 10 mm min. to 50 mm max x 500 mm long.

• Longer shafts can be accommodated either through suitable extension of admit between centers or through a hollow chuck.
• Cross traverse (traverse for the knurling wheel to plunge) is upto 150 mm through hydraulic cylinder.
• Ball screw & box nut for longitudinal axis movement, in combination with case hardened male sliding surfaces & turcite for female sliding surfaces will provide smooth, back-lash free smooth sliding movement, apart from wear resistance.

An AUTO-CYCLE, operated through the combination of direct, encoder based feedback of servo drive for the longitudinal axis, PLC, feed-end limit switches, sensors etc, ensures that the knurling operation takes place as programmed with repeat accuracy & with the least human intervention.

Coolant system, lubricants, machine enclosure, automatic chip disposal system, guide way protection etc will be provided at an additional cost. Job loading and unloading will be manual.

Customers Initial Machining Process:

• Used a VMC.
• Clamping sing a C washer and bolt mechanism.
• True the job which would take around 5 minutes.
• Machining cycle time for drilling of 31.75 mm for a depth of 56.3 mm using a U drill would take around35 minutes.
• A Total of40 minutesused to be taken up for one job to be completed.

Features & Specs:

• 2 servo controlled axes for (a) rotational movement of the rotary table, (b) cross axis movement of 10 HP drilling head, which can do drilling upto 36 mm drilling.
• Servo controlled linear axes movements & rotary movement are for accurate pitch selection & accurate indexing respectively.
• Drilling head with special angular contact bearings arrangement for high level of accuracy & rigidity. Head driven by a 10HP motor with a combination of gears and timer belt and timer pulley arrangement for obtaining required speeds without torque drop.
• Ball screw, box nut mechanism in combination with gear box for cross axis movements of the milling head.
• Hydraulically operated vertical movements of the drilling head.
• Swing clamp cylinder can be provided for automatic clamping.
• Touch Screen enabled HMI (Human Machine Interface) for quick on machine program selection, program editing by the operator & quick troubleshooting.
• Male sliding surfaces are with case hardened guideway strips and female sliding surfaces are with turcite lining for smooth axes movement & best wear resistance.
• Centralized automatic lubrication to lubricate all rotating & sliding parts at pre-set regular intervals.
• Machine enclosure & guideway protection
• Machine to have PLC program.
• High pressure coolant thru with rotary joint for quick chip evacuation
• Total machine enclosure, required for high pressure coolant dispensation.
• Chip conveyor for easy chip disposal.

Sequence of Operation of Machine:

• Load the job onto fixture manually
• Close the door and press auto cycle.
• Job Clamps.
• The servo driven horizontal slide moves from home to required distance to obtain the pre-fed PCD.
• Spindle ON, coolant ON, Vertical hydraulic slide having head mounted moves in rapid to the cutting zone and slows down to the required feed rate while cutting.
• Vertical slide retracts out of the hole and table indexes to the next pre-fed angle for drilling next hole.
• Same indexing & drilling is followed upto 360.
• The slide and table moves back to home.
• Job unclamps, unload job.

HMI Enabled Easy Programming:

• One of the setbacks in owning a VMC is requirement of CNC programming knowledge to alter or change the program.
• In our machine with a HMI, programming knowledge is not at all required. Simple instructions can be followed on screen to modify or change the program.
• Working as shown in the upcoming slide.

High precision deep holes with critical tolerances on dia, roundness, hole location, taper, concentricity and finish usually need secondary operations like reaming, honing, boring, grinding etc. Gun drilling can produce an accurate deep hole economically in a single operation at unbelievable speed. Since a gun drill has a carbide cutter at its cutting edge, it can effortlessly drill through hard material like forging, alloy steel components etc which cannot be economically machined with other types of drilling. The length of a gun drilled hole can be several times its diameter and holes will be bur-free. A rotating gun drill is slowly fed into the work piece at a high RPM. High pressure cutting oil is delivered to the cutting zone from a specially designed coolant pumping system through a rotary joint and an in-built coolant passage in the gun drill. The coolant not only cools the heat at the cutting zone, but also it removes and carries back the chips through the flutes provided in the gun drill to the chip box. Before the coolant reaches back the coolant tank for re-cycling, chips are filtered.