Tool Room Services
Microrep Model MIL-201 2D Universal Measuring System with an accuracy of 0.0005 mm.	TOOL ROOM AND WORKSHOP Besides rendering its services to the industries in the areas of Calibration & Testing, Training, Design and Development the Institute has a full fledged Tool Room equipped with the state of art machines and technology. The Tool Room also has the back-up of a Tool Design Section and a modern Dimensional Metrology Laboratory. The Tool Room is endowed with various types of conventional machines and special purpose machines. It specialises in manufacturing of precision jobs, moulds and dies for a variety of engineering components, jigs and fixtures, pressure die-casting dies, batch production of components etc. The tenor of this paper is to highlight the capabilities of the Institute in the specialised areas of Hi-tech machining. In what follows, some of these facilities are enumerated in detail.
Deckel Maho DMU - 50V 5 Axes CNC Milling Machine DMU-50 V with 24 ATC and Heidenhain 426 PA Control	AXES MACHINING CENTRE The recent acquisition of the Deckel-Maho Model DMU-50V with 24 ATC and Heidenhain TNC-426 Control combines the capabilities of Universal Milling, Boring and Vertical Machining Center. This Ultra-Modern Machine has 5 axes machining capabilities such as X, Y, Z, C and B axes with 24 Automatic Tool Changer. Confluencing the multiple and prevalent state of art technologies in building this machining-center, it has produced an ultimate workhorse of perfection keeping in view precision in machining and productivity.Its two-axes N.C. Rotary / Tilting table enables complete 5-side machining in a single setting. The machine has a state of art Digital Technology rendering High Speed and Hard Metal Machining up to 55 HRC. Specifications : 1. Longitudinal Traverse550 mm 2. Transverse Traverse350 mm 3. Vertical Travel330 mm 4. Spindle Power15 KW 5. Spindle Speed20 – 8000 RPM 6. Rapid Speed & Feed30 m / min. 7. Table Clamping Area500 mm x 380 mm 8. Overall Work-piece Description for :        a) 3 axes Machining800 mm x 400 mm (300 kg)        b) 4 axes & 5 axes Machining 500 mm x 390 mm (200 kg) Applications :                   1. Precision Machining Operations                   2. Cavities and Inserts for Dies and Moulds                   3. Precision Co-ordinate Boring                   4. Precision Co-ordinate Milling                   5. Precision Component Production
Charmilles Robofil 290  5-axes CNC Wire EDM	II. SPARK-EROSION MACHINES The Tool Room is equipped with two Spark Erosion Machines Charmilles Models Form-20 and D-20 with ISO PULSE 80 Generator with electronic digital readout some of the salient features of D-20 are as follows: -Work head back slide travel - 200 mm -Work Tank Dimensions - 650 x 450 mm -Max. Dielectric level - 280 mm -Longitudinal travel of table - 250 mm -Transverse travel of table - 170 mm -Reading accuracy - 0.001 mm -Best surface finish - 0.4 m - 0.6 m Max. -Electrode weight - 30 kg.                           The machine has orbital movement i.e. ISOCUT 3 R System with the help of which we can increase the cavity by 4 mm in diameter. This attachment also has sine bar arrangement with the help of which one can give positive or negative taper on cavity or projection. Angular translation is also rendered possible with an increment of 10° with one electrode cavity can be finished by giving sufficient diametrical spark gap according to the cavity profile and size.The machine has orbital movement i.e. ISOCUT 3 R System with the help of which we can increase the cavity by 4 mm in diameter. This attachment also has sine bar arrangement with the help of which one can give positive or negative taper on cavity or projection. Angular translation is also rendered possible with an increment of 10° with one electrode cavity can be finished by giving sufficient diametrical spark gap according to the cavity profile and size. Applications : Generally used for moulding Tools and Die-Casting dies, and three dimension profile cavity with high accuracy and aesthetic finish. Noteworthy of mention is the job carried out for M/s. Bhilai Steel Plant involving wherein the 100 m rail had various types of square and rectangular cavities and minute holes of f 1.0. This was used for Ultrasonic testing of rails. Spark erosion of the engine body of fuel pump (Boeing Aircraft) was also done for Air India to increase the fuel efficiency. The operation was 250 mm in depth with diameter of approximately 200 mm. Inlet oil port was open with dimensions typically of 3 mm (t) x 20 mm (w). This was a critical job and had the approval of DGCA. Various audio components dies hitherto imported have al so been completed for M/s. Philips India Ltd. and several moulding tools for M/s. Siemens Ltd., Kalwa.
Charmilles Model Form-20    Spark Erosion Machine	III. OPTICAL PROFILE GRINDING           An important asset to the Tool Room is the Optical Profile Grinding Machine Model 125-A-10 of Wasino Japan. Specifications : -Grinding Dimension - 250 x 80 x 120 mm -Projector Screen size - 535 x 515 mm -Work Table Cross Travel - 80 mm - Range of Reciprocal Strokes of Wheel Head - 0 - 120 This machine is basically for precision profile grinding of flat and circular workpieces. The machine is equipped with cylindrical grinding attachment to accommodate 200 mm dia cylindrical work piece and flat form of grinding of 250 x 80 x 120 mm (h). The profile accuracy of the workpiece is achieved by 50 x magnification on a screen of 500 mm. Applications : 1. Form of rollers for container manufacturing units 2. Profile punches and die-segments 3. Circular and flat form tools 4. Precision cylindrical form and flat form grinding of commissioning the latest State of art 5-axes CNC Wire EDM Charmilles Model Robofil 290. Robofil 290 is a high quality wire EDM with five programmable axes. The programmable Z axis is fully automatic. The accuracy is ensured both by measuring the rotation angle of the leading screw and by directly controlling the actual movement of the slide with the adaptation of a precision linear scale. The Robofil 290 can accept workpiece weighing up to 500 kg and the dimensions being 850 x 500 x 20 mm. The machine has exceptional inclination possibilities up to 400 mm x U travel and 250 mm YV travel, with maximum taper cutting of ± 30° for a full travel of the Z axis. The machine accuracy that can be achieved is 5 microns over the entire height of the workpiece. Applications : 1. Ultra-precision wire EDM of punch and die profile with no cutting clearance 2. Electrode machining for spark erosion machines 3. Moulding inserts for involute gear, spur and helical gear 4. Machining of cavities and cores for injection moulds and die casting dies.