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Tool Room Services |
Microrep Model MIL-201
2D Universal Measuring System with an accuracy of 0.0005 mm.
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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.
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Deckel Maho DMU - 50V
5 Axes CNC Milling Machine DMU-50 V with 24 ATC and Heidenhain 426 PA Control
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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
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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.
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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
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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.
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EDM MACHINES: A, B
1. CHARMILLES CNC EDM MACHINE.
Model - ROBOFORM 35P. SWISS MAKE.
Sr. No. 649196
64A
ISOPULSE GENERATOR with Rotary ‘C’ Axis
Traverse - 350 x 250 x 300 mm
Work table Size - 500 x 400 mm
Max.
Work piece wt. - 500 kg.
Dim. of Dielectric Tank - 800 x 550 x 370
Positioning Resolution - 0.5 Micron.
Surface Finish - Ra – 0.1 Micron.
Max.
Electrode Wt. with ‘C’ Axis - 50 kg.
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FORM 20 - CHARMILLES SPARK EROSION MACHINE:
Generator capacity 5 KVA, 64 Amps.
Worktank useful dimensions
(height x width x length) - 180 x 660 x 450 mm
Max.
workpiece weight - 200 kg.
Table Dimensions (Length x Width) - 400 x 300 m
Travel Longitudinal X - 300 mm
Transversal Y - 250 mm
Display Resolution - 0.001mm
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CHARMILLES D20 AND ISOCUT ELECTRICAL DISCHARGE MACHINE -
with ISOPULSE 80 Generator and having electronic digital readout of Mikron
accuracy - Swiss Make.
Work head back slide travel - 200mm
Work Tank dimensions - 650 x 450 mm
Max.
die electric level - 280 mm
Longitudinal
travel of the table - 250 mm
Transverse travel of the table - 170 mm
Reading Accuracy - 0.001mm
Best Surface finish - 0.4 um
Max.
Electrode weight - 30 kg.
‘ELEKTRA’ SPARK EROSION MACHINE:
Model - M 5030
Vertical Travel - 150 mm.
Work Tank dimensions - 530mm x 380mm x 330 mm
Table Transverse movement - 150 mm
Table longitudinal movements - 225 mm
Material removal rate for Copper Electrode (+ve) - 150mm3/min at 35 amps
cutting current
Best Surface finish - 0.7 micron CLA.
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WIRE EDM CHARMILLES
Model : Robofil 440 SLP
Maximum work piece size : 1200 x 700 x 400 mm
Maximum work piece dimensions : 020 mm
Maximum Work piece weight : 1.5 Ton .
X, Y, Z travel : 550 x 350 x 400
U,
V travel : 550 x 350
Maximum Taper : +- 30 / 400
Cutting Speed : 300 mm2 /Min.
Minimum Finishing : 0.22 µm Ra
Measurement resolution : 0.5 µm
CHARMILLES WIRE EDM
Model : Robofil 290
Maximum
Work piece weight : 500 Kg.
Maximum work piece dimensions : 850 x 500 x 200 mm
X - Y travel : 400 x 250 mm
U - V travel : 400 x 250 mm
Programmable Z Axis travel : 0 to 200 mm
Maximum Taper Angle : +- 30 degrees
Maximum Cutting Speed : 280 MM2 /Min.
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C N C MACHINES - C, D
1. HERMLE – 5 AXIS CNC MILLING M/C.
Model - U 740 with ITNC 530 Heidenhain Control.
Table Load - 700 kg.
Speed - 20 to 12000 rpm,
16 ATC
Travel - 740 x 500 x 500
Clamping Surface - 900 x 500
B axis Swivel - 5˚ / + 95˚
Main Spindle - Manual Swivel - 5˚ / + 95˚
Positional Tolerance - 0.010 mm
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HAAS Vertical Machining Centre
Model - VF - 6 /50
Travel - 1626 X 813 x 762 mm
Table - 1626 X 711
Table Load - 1.8 T
Spindle Speed - 7500 rpm (max),
Taper - 50, 30 ATC
Positional Accuracy - ± 0.0076 mm
Repeatability - ± 0.005 / mm
Model - VF - 9 /50
Travel - 2134 X 1016 x 762 mm
Table - 2134 X 914 mm
Table Load - 1.8 T
Spindle Speed - 7500 rpm (max)
Taper - 50, 30 ATC
Positional Accuracy - ± 0.0076 mm
RepRepeatability - ± 0.005 / mm
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DECKEL MAHO 5 AXIS MILLING MACHINE:>
Model - DMU 50 V with 24 ATC & Heidenhain
426 PA Control.
Working Area - 500 x 380 x 380 mm
Main AC Drive Power - 15 KW
Machine Accuracy
a. Positioning - 0.002mm
b. Repeatability - 0.002
c. Speed - 0 - 8000 RPM (Stepless)
SPINNER TC 42 CNC LATHE
Control - 21i – TB- Fanuc
Max
Dia. - 280 mm
Centre Dist. - 550 mm
Swing Dia. - 400 mm.
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SPECIAL PURPOSE MACHINES - E, F, G
1. MIKRON GEAR HOBBING MACHINE - SWISS MAKE
Type - 102.05,
Max. Module - 2 (12.7 DP)
Maximum Diameter to be hobbed:
For Spur and Helical Gears - 120 mm
Max. Length to be hobbed - 130mm
MIKRON UNIVERSAL GEAR HOBBING MACHINE - SWISS MAKE
Model - 122 type
Max. D.P. Which can be hobbed - 26 (Module 1)
Max. Dia. - 40 mm
Max. Saddle Travel - 40mm
Max. length which can be hobbed with work arbon or collects - 35mm
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MIKRON UNIVERSAL GEAR HOBBING MACHINE - SWISS MAKE
Model - 122 type
Max.
D.P. Which can be hobbed - 26 (Module 1)
Max. Dia. - 40 mm
Max.
Saddle Travel - 40mm
Max.
length which can be hobbed with work arbon or collects - 35mm
SUNNEN HONING MACHINE -
U. S. A. MAKE:
Model MBB - 166
Hones bores up to 16” in length,
depending on bore diameter.
I. D. Range - 0.060” to 6.500
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WASINO JAPAN OPTICAL PROFILE GRINDING MACHINE
Model - 125A - 10
Grinding Dimension - 250 x 80 x 120 mm
Projector Screen size - 535 x 515 mm
Work Table Cross travel - 80 mm
Range of Receipro Strokes of wheel head - 0 – 120
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Dimensional Universal Measuring System :-
Microrep Model MIL 201. This is a machine attached with the Metrological microscope and digital readout Equipment “Quadra Check 2000” having resolution 0.001 mm for two co-ordinate measurement of external threads, internal threads, blind or through holes, taper, profile angles, circles and radii. The machine is designed to give an effective support to the verification and calibration of internal Micrometers, Dial Indicators, Micrometer Heads, Bore Gauges, Snap Gauges etc. This helps to achieve the quality requirements of the components manufactured in order to comply the requirements of ISO-9000
Machine Capabilities :
This includes different measuring methods both Contact and Non-Contact types, Profile comparison, the measuring range being X = 200 mm & Y = 100 mm, the working stage with an area of 800 x 240 mm, max. load up to 40 kg. adjustable centre cradle up to 750 mm, V-type supports adjustable up to 850 mm. The Tilting head has an angular movement of ± 15° for sharp focusing both with flanks of external threads. The microprocessor based digital readout system offers a resolution of 0.001 mm permitting a wide range of linear and circular calculations. PC-based software is coupled to facilitate gauge management.
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Electronic Height Gauge :
Tesa Make Electronic Height Gauge is having least count of 0.0001mm specially designed for length measurement in the form of internal, external, height, depth and distance dimensions on geometrical elements having either a flat, plane-parallel or cylindrical surface. Also able to capture the position of bores in two directions of co-ordinates with further output in either Cartesian or polar system. Their measuring capabilities can be increased with the use of an inductive probe that can be connected for the detection of perpendicularity errors. |
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Electronic Dial Calibration Tester :
The machine is having the least count of 0.0001mm and Used for calibration of plunger type,lever type Dial gauges and bore gauges. The unit is computer interfaced with a user-friendly software for statistical analysis of measured values. The range of the instrument is 0-25mm and it is suitable for all types of dial gauges and bore gauges with lowest Least Count. |