High Speed Machining – Up to What Extent Suits to Your Industry?

One great rule in the Manufacturing industry is that automation applied to an efficient operation magnifies the efficiency. High speed machining is one process that has magnified efficiency in the engineering and automation sectors and is a vital element in virtually any operation. Machining of complex and large numbers of pieces is now a success through high technology machine tools available in industry.

Lathes for Heavy Machining Requirements

Certain features are critical for heavy duty machining, as the work pieces are larger than the normal diameters. Greater load capacity is achieved with a spindle bore of 130mm and more and a sufficient bed width for the machine capacity.

  • The carriages are also sufficiently wide and there is transverse arrangement of the saddle, cross slide, and top slide.
  • The faceplates must be sufficiently wide to handle large components facing work.
  • Sufficiently powered induction motor for the spindle drive
  • Varying spindle speeds and presence of anti friction bearings.
  • Rigid tail stock and hardened sleeve as well as in built rotating centers for better stability of the machine during operation.

WM Series Heavy Duty Lathe Machine

The extra heavy-duty Pedestal type lathes are highly demanded in the heavy machining industry due to their versatility in handling large work pieces efficient machining. High-speed operation is achieved through more than 15 horse-powered motors while the spindles are dynamically balanced to produce precise machining and high quality surface finish.

Extra heavy duty lathes – Planner type is also suited for heavy industrial operations and produces a perfect finish due to high precision in application. Some important features include the hardened bed ways, hardened and ground headstock gears, high tensile hardened steel headstock and spindle. The motor output is up to 22 kilowatts for maximum power delivery.

WM Series Extra Heavy Duty Lathe Machine

Benefits of High Speed Machining

Before technology advanced to the level it is today, there was the constant worry on the safety concerns of high speed turning operations. The biggest threat was the development of the centrifugal force that develops as the speed increases. This force leads to loosening of the work piece by the chuck, which leads to mis-alignment of the tool and work piece and poor quality work.

  • With the improvements in the gripping of the work piece such as counter balancing of the chuck, this problem has been solved and you can reduce the cycle times dramatically and therefore reduced work completion times.
  • Equipment and tool set up time is also dramatically reduced due to more “user friendly” controls on the heavy duty high speed lathes.
  • The invention of harder tools such as the diamond and carbide bits, which run for longer time without wearing off, has also been of great importance.
  • Elimination of subsequent grinding operations also lowers the time taken to achieve a good finish.
  • Management of heat during the process has been achieved through the cooling pump and the coolant system hence higher efficiency achieved.

The high speed machining is now a real innovation that has been adopted in many industries due to the high efficiency derived from the process. Your machining needs have been effectively covered through this process.

Application of the Radial Drill in Petroleum Industry

The radial drill is one of the most important equipment in industry. It is an enhanced drill machine with the following components; the drill head, the arm, the column and the base. The critical operational function of the equipment is the ability of the head to rotate about the column at a radius equivalent to the arm. The height of the equipment can also be adjusted depending on the size of the work piece.

It is therefore very versatile equipment, which has wide-ranging applications especially in the oil production and conveyance. The equipment is usually set on a workbench or table, while very large types are mounted on the floor.

Advanced uses of the machine include reaming, tapping, spot facing, counter drilling. Various models have been advanced for this equipment to serve the various industries.

Drilling Works In the Petroleum Industry

Drilling Works In the Petroleum Industry

The oil field and petroleum production industry poses certain special challenges. It is a heavy machinery industry, handling equipments exposed heavy corrosion and mechanical breakdowns sometimes in far off areas. Radial drill equipment is vital in numerous repairs handling very large work pieces associated with oil exploration. Some special applications include;

Countersinking

A conical cutter is fitted to the equipment to create a bevel shape or a tapered end. This process is important in creating the bore for flat-headed screws. Common angles of the counter screws are 82 degrees and 60 degrees.

Counter Boring

This is a process of enlarging the top end of a bore up to a certain depth, and creates a square shoulder on the produced bore. Counter boring is done to allow the heads of the screws to properly flush with the surface of work piece.

Spot Facing

This is a delicate process of smoothening off a round edge of the bore to create a level-sitting surface of the countersink. It is also used for surfaces such as washers, bolts and nuts to fit tightly below the surface of the work piece.

Tapping

This is also well achieved using the radial drill. This is a process of creating a thread in a drilled bore. During this process, the machine is not necessarily powered so that the chuck is turned by hand gradually until proper threads are created. Tapping of larger holes require positioning of the tap using the drill chuck and a tap wrench is used for greater power and grip to be achieved for tapping.

Reaming

This is the process of enlarging a small hole to the targeted diameter. In the petroleum and the oil field, precision is very important and this is a critical process used to achieve precision. The holes are drilled to smaller dimensions then rimmed to reach the required diameter. For greater precision, a bore should be drilled and reamed while still on the same set up.

The importance of the radial drill in the petroleum industry is critical and especially where high precision is required. The ability of the machine to accommodate different tool bits has also enhanced its applicability in the oil production and conveyance industry.

Use Grinders in Welding and Maintenance Workshops

Maintenance operations

The maintenance and repair of equipments and facilities is a major part of the modern commercial and industrial sectors. Virtually all industries require some aspect of operation and maintenance (O&M).

Two popular O&M activities are carried out in most workshops, preventive and emergency repairs. In the preventive strategy, components are repaired before they breakdown while in emergency method, they are repaired when they actually breakdown.

The main operations carried out during repairs include: grinding, replacement of worn out tools, machining of worn out parts among other operations. These activities rely on machines which require regular sharpening.

Drills, lathe, milling machines as well as the shaper, sheet metal machines utilize tools that require regular grinding to sharpen them and maintain their cutting angle and face.

Drill bits and Milling Cutters

Use Grinder in arc welding operation

The arc welding operation which is a common joinery process in the workshop is performed in numerous repair works. The slug formed on top of the weld after the process is normally extracted using a grinder that scraps the surface and allow for other finishing operation to be done. A wide range of grinders can be used in this operation.

Drill Point Grinder

Drill Point Grinder perhaps the most commonly applied machine in boring holes for fastening application. A wide range of drills are used in this application. When blunt, these drills require sharpening in order to maintain the cutting edge, lip, heel, point and chisel.

Special grinders with high speed and low material removal rate are used. Since drills are made from hardened high speed steel, these devices have high abrasion resistance that cuts through these hard surfaces.

Drill Point Grinder

Chamfering work pieces

A specially designed machine is used to produce curved edges on materials. They work on metals, marble, granite and other materials. They produce a smooth surface finish on complex shaped parts.

8

End mill sharpening

Numerous repair activities are done on the horizontal and vertical milling machine. Vehicle engines and other parts need regular resurfacing on mills. Specially designed grinders are used to sharpen these cutters which have specially formed edges.

End mill sharpening can be used for two flutes, three flutes, and four flutes sharpening of the nose cutters as well as in flat bottomed drills.

They have diamond disk which cuts the very hard and wear resistance ends of these cutters. They are able to effectively clamp the cutter collets and achieve well balanced cutting face and high tool tip concentricity which are essential when milling.

Tool Grinder

Tool Grinder

Screw Blade Maintenance

Saw blades Grinder are used in many repair operations. These blades, when blunt are sharpened using special devices that sharpen the front and back angles. In addition, they surface and sharpen edges.

Screw Blade Maintenance

Tool maintenance

Most workshop machines use various tools for cutting, turning, knurling, tampering, boring, surfacing, threading, tapping, lapping among others. A specially designed device is used to sharpen these tools. This equipment is able to work on big and small tools with varying degree of complexity and hardness.

Application of Press Brakes in Railway Industry Fabrication Processes

Nature of railway operations

This industry is one of the oldest and most relied industries in transportation of cargo and people. The use of sheet metal in this sector spans many centuries when trains were powered by steam to the present day magnetic levitation trains.

Press brakes are used in this industry to manufacture a wide range of structures used in trains and other components. Most corporations have central and regional shops dedicated to continuous production of components used and in maintenance.

This industry depends on large heavy duty press brakes to form most of the bends. These machines are long, hydraulic or pneumatic operated and specially designed to handle both small and large gauge materials.

Critical quality and cost in railway fabrications

To achieve high quality train cabins and other structures, good press brake need to be used. The equipments have structure with high mechanical strength and rigidity in order to withstand heavy compressive forces.

The effective manufacturing and production of specially formed sheet requires the use of this machine. They perform bending operations fast, reliably and cost effectively. The devices used must allow for great variability when bending in order to make different shapes using one machine tool. This reduces the capital and operation costs.

CNC controlled types are also utilized to achieve precision and accuracy when positioning and bending to specified angles. Hydraulic operated ones are fitted with computerized control modules to run the whole system.

The back gauge is specially designed from cast iron and is long to ensure adequate positioning. The tool has advanced clamping and hydraulic system to increase the speed of cutting. They also have large throat and back gauge to hold and curve large pieces of up to 40mm thickness.

Manufacturing steel and aluminum to develop rail freight cars

When manufacturing train cabins; long and heavy gauge materials that require long dies and punches are used. The machines used are therefore large, long and with high strength parts.

These machines are used to make the outer casing for most train cabins. Rail freight cars that transport goods are fabricated with steel. These contain corrugated sheet which are curved using the press brakes.

Manufacturing steel and aluminum to develop rail freight cars

For the passage freight cars, there is an increasing use of aluminum to manufacture the body since they are lighter, aesthetic, withstands corrosion and are more durable (+30 years). These are extruded, cut, folded and used to make the structure. They use less welding when compared to steel types. Currently, both steel and aluminum rail cabin use these folding devices to achieve a variety of shapes that are assembled to for the final cabin.

Containerization in the rail industryContainerization in the rail industry

With increasing need to pack products in enclosed spaces, there is a rise in special containers used to store electronics, perishable goods and other materials. Most rail containers are rectangular shaped or cylindrical (for liquid materials). The manufacturing and repair of these containers require the use of press brakes to fold and shape the metal plate before welding.

Turret Milling Machine – Must Have for the Defense Department

Introduction

Milling machines have been used from time memorial in a large number of military functions. The first miller was used by Whitney Eli to mass manufacture 10,000 muskets in 1798. Their use in the military operations has continued to advance and they are currently used to manufactures parts for vehicles, aircrafts, tanks, weapons and other products.

Use in production of military tanks and equipments

The tank is common equipment used in attack and defense for many centuries. It comprises of the rotating turret body, turret ring, hatch, periscope, the chain track, the steel wheels, drive sprocket, solid steel body, machine gun muzzle, barrel and mantlet, propeller shafts, engine, gear box, exhaust system, transmission, radiator, air cleaner and exhaust system.

Each of these tank components must be made to great reliability, accuracy and high strength to withstand off road conditions and the enemy fire. Specially designed heavy duty and CNC turrets millers are used to produce at least 85% of all the components in tanks.

Use in production of military tanks and equipments

In addition, other vehicles used in defense require flat surfaces that are inclined at different angles. The turret enables this equipment to turn the spindle and hence angular flat surfaces can be achieved. Many engine, gear box, transmissions and vehicle accessories require a milling tool during their manufacturing processes.

There are also thousands of specially designed equipments for launching missiles, attacks, defense and combat. These devices have flat heavy surfaces which are sorely manufactured using special millers. This device is therefore a must have equipment so as to produce complicated surfaces that must have high flatness and levelness.

With great advances in high speed carbide tipped cutters, these machines are able to remove materials faster resulting to high accuracy, precision and production of durable materials suitable for the army.

Unlike other millers, the turret is compact and occupies less workshop space. It is also highly flexible and adaptable to a wide range of activities. It achieves 900 swing to the left – right and 450 to swing forward and backward. The ram can move forward and backward as well as make a 3600 turn. The tool allows the milling of complicated shapes inclined at any angles which aren’t possible without these tilts. All these factors increase the versatility of this tool in manufacturing and maintenance workshops.

Repair and maintenance of equipment

Repair and maintenance is part of any military station. Vehicles, tanks and other equipments that are exposed to rough terrain constantly require maintenance operations. These include shaping and smoothening engine surfaces, gears and other components, resurfacing and making new components. These operations require this machine tool.

Military aircraft fabrication and servicing

There are numerous combat planes specially manufactured for defense operations and have superior reliability and accurately manufactured components. The new computerized milling machines are used to manufacture their parts. Engines, fuselage and wings are accurately produced using this device.

In addition, repair and maintenance of these plane parts require precision machining of parts which use the miller and other machine tools.

Application of Lathe Machines in Manufacturing Renewable Energy Machines

Renewable energy manufacturing

As the saying goes “we did not inherit the earth from our ancestors but we borrowed it from our future children” and “a healthy environment is synonymous to a livable planet and a strong economy ”. All the world leaders, celebrities, business and nongovernmental organizations are united in fostering the development and use of renewable energy.

Wind and water are naturally occurring elements with vast amount of untapped energy.  .

Manufacture of water turbines and subsequent repair

Water wheels have long been used to generate electricity from rivers. The most common types include the Pelton, Francis, and Kaplan turbines. Their use depends on the height (head) and volume of the liquid. Their main parts include a high strength, anti corrosion rotating wheels and the outside casing that directs the water.

Manufacture of water turbines and subsequent repair

All these machines have many cylindrical parts such as shafts, axle flywheels, fastening holes and other parts. The outer casings of these machines also require a huge cylindrical bore to house the wheel.

Heavy duty lathe machines are used to face and turn materials to exact diameter and length. They also perform operations such as vertical and horizontal drilling, boring, tapering, threading bolts and fasteners, knurling and internal boring.

Use of extra heavy duty lathe

Producing these wheels from large shaft and casting is impossible without extra heavy duty lathes.  To prevent rusting, erosion by river particles and corrosion by chemicals in rivers, these turbines must be made from extra high strength materials such through hardened steel, nitrided steel and carburized iron. These materials are difficult to machine and require special extra heavy duty all geared lathes.

Extra heavy duty lathe

These all geared type machine a wide range of heavy shafts and have good surface finish. They have sturdy high strength bed machined to absolute flatness. Their tail stock and tool post are specially designed for accurate positioning and tooling.

For big hydroelectric generation, very huge lathes are required. These are custom made and are able to turn, face and bore wheels and shafts.

Advanced wind turbine production

Wind turbines contain a three large blades, low and high speed shafts, yaw drives, nacelle, a spindle and gear box.

Advanced wind turbine production

Machining of shafts, nacelle spindle, hub and other parts require the use of modern precision lathes. These parts must highly reliable and these plants operate for 20 years with minimal repairs. Geared lathes , CNC and turret types are specifically suited for their production.

Trends in the renewable energy sector production

Hydroelectric power has a gradual but progressive growth at a local and international level. With most sites for large HEP be fully exploited; medium, small, mini and micro hydro plants are being installed. These are not labor and capital intensive and require less specialized machine tools.

Trends in the renewable energy sector production

Off shore and inland wind farms are being installed in areas with good wind profiles and their global utilization shows a stable rise from 1990. Exploitation at low scale is limited to remote villages.

Use of Bandsaw in Fabrication of Metallic Door and Widows

Introduction

It is said that a chain is strongest at its weakest link; therefore, it is imperative that all aspects of construction industry are taken to consideration. The manufacturing of strong durable building opening not only improves security but also increases the aesthetic appeal for most buildings. These opening must be constructed to accurate dimensions and the required curves. Modern doors and windows are made not only to prevent breakages but also enhance the beauty of the house, are fireproof and also weather resistant.

Band saws play a crucial role in the manufacturing process for both metal and wooden components. It is a vital tool that all small and large workshops must acquire. Primarily, they come as either horizontal or vertical types.

swing_beam_shearing_images04

Small and large fabrication processes

This equipment is normally characterized by a straight narrow endless saw that forms a circular path. The blade orientation may be vertical or horizontal.  The cutting action is achieved through continuous rotation of the blade while the work piece is pushed against the blade.

Small scale workshops primarily have numerous jobs with high variability.  The job done today may be completely different from the one done the next day.  Bandsaw device allows great variation in the work piece shape, size, material and the shape of the final product. It is therefore an ideal tool for such production centers.

Small and large fabrication processes

Large production centers on the other hand are characterized by huge volumes of repetitive work. This device is fast, reliable and accurate cutting to various sizes which makes it an ideal tool for mass production. Unlike the power and hack saw, these devices achieve high degree of variability since their blades can be tilted. This enhances their scope of utilization in modern machine shops.

Utilizing bandsaw in attractive metal door fabrication

Modern door and widow fabrication is characterized by attractive designs manufactured through cutting complex shapes and welding them together. To cut these shapes, this machine tool is most ideal as the blade is narrow and hardened such that it can be bent to a large degree before breaking. This enables the operator to make complex curves such as circular, parabolic, ellipses which are all used in beautifying the end products.

Utilizing bandsaw in attractive metal door fabrication

In addition, these devices are used to make straight and angular cuts on metallic rods, tubes, angle lines, rectangular hollow section, and solid bars. All these are constituents of modern entrances.   

Facts and statistics on utilization in small and large scale workshops

The Bandsaw market is set to increase as the construction industry develops around the world. The demand for doors and windows and other metallic products is set to increase with construction. Subsequently, the bandsaw market is set to increase so as to respond to the urgent need for these products.

There is already an increasing trend in the demand for these devices since machine cut products have high dimensional stability, are accurate and produce aesthetic products. In addition, machines increase the quality and quantity of the end product resulting to increased productivity and profitability.

Achieving Reliability in Construction of Marine Equipment Using Turret Mills

Introduction

It is said that one machine can perform the job of over hundred men and the work done by these machines has countless advantages as compared to manual tasks.  The marine sector is one of the most important sectors in international trade. It account for over 80% of all the goods transferred from one nation to another.

Due to the heavy nature of the machines used in ship building and the need to incorporate reliability, all marine metal construction works can only be achieved using heavy duty machine tools. These machines are widely popular in this sector and are inevitable in the construction of modern boat components.

marine parts

Manufacturing precision marine parts

These components require heavy duty gang milling operations. In addition, machine centers comprised of both horizontal and vertical millers are installed. The horizontal types have an arbor which can house one or many cutters. The turret essentially has a rotating cutter held vertically against a moving work piece.

The modern hull (the part under the water) and super structure- the part above the water are manufactured by cutting large steel plates, machining them on miller to specific shapes corresponding to the hull and finally welding the plates to for the ship hull and the superstructure above it. Since the hull must be water tight, precision is crucial and is achieved through careful machining and welding.

marine_diesel_engine_crankshaft_crankcae_assembly_ship_repairs_parts_salvage

The parts of the ship propulsion system are largely dependent on accurate and precision machining of large elements. Modern propulsion is achieved through the use of large V type diesel engines which are coupled through a gear box or a shaft to the propeller.  The manufacturing of these engine blocks require large machines that can fabricate all components to accurate flatness and good surface finish. Due to the heavy pressure, these parts must be made reliable and resist imposed loading.

In addition, these devices are also used to produce countless parts. A number of operations such as flat milling, leveling, surfacing, gear cutting and cutting slots are achieved using this device. Therefore, these devices are imperative in improving the reliability of parts produced.

Repairing and maintenance of marine equipment

Mills are virtually all ship maintenance workshops. The device has wide application in this sector since the swivel and turret can be adjusted through 3600C to make any type of cut. The turret and other millers play a significant role in repair of old engine blocks and cylinder head that require constant leveling. The equipment also performs countless operations in repair works such as gear cutting, grinding and bolt head shaping.

Conclusions

The boat building and repair industry is one of the most thriving sectors in many countries such as the UK, USA, China, Europe (Netherlands) and India. It comprises of both small and large scale operators. In the UK, for example, the industry employs over 105,000 people and generated over £7.6 billion annually. This industry heavily relies on machine tools such as turret mills in production and maintenance.

Mass Produce Corrugated Iron Sheet using High Quality Shearing Machine

Introduction

It is said that the roof of a building increases its aesthetic appeal in addition to serving its protective role. Philosophers have always said that whatever good structures we set up, they end up developing us.

Though a variety of modern roof materials have been introduced in the last two decades, corrugated iron still remain an important roofing product at a local and international scale. These materials are manufactured through a range on sheet metal fabrication techniques such as rolling to reduce their diameter, folding or pressing to form corrugations and cutting to the required lengths.

The roofing products are made from galvanized iron which is cold rolled and sheared to the specific dimensions.

Statistics on corrugated iron sheet manufacture

Due to the growing demand in the real estate and construction business, there has been a tremendous increase in demand for these products. In India, zinc and aluminum corrugated sheets are in high demand.

Global trends show that in most countries, approximately 10 – 25 % of all residential buildings roofing is done with this material. Though there is stiff competition due to other roofing materials, they remain the most viable option for developing countries.

With population increase, urbanization and the possibility of using these materials for both horizontal and vertical cladding; their utilization is expected to increase in the next ten years.

SHEARING MACHINE

Use of hydraulic and CNC machines

Continuous production is achieved through cold rolling, galvanizing, continuous bending to form corrugations and cutting to the specified sizes.

Hydraulic or CNC shears are used to cut the products to lengths that ranges from 8, 10 and 12 feet while the width ranges from 24 to 39 inches. The equipment used must be able to handle the different gauges and therefore, the shearing device must have high strength and rigidity. Common roofing materials gauges range from 32 which is very thin to 18 which is very thick. As the gauge increases, the tonnage of the equipment increases.

In the industrial set up, these machines are automated, pneumatic of hydraulic to reduce the force required to cut the materials. They are specially designed to clamp and shear with minimal damage to the product and achieve a straight edge.

corrugate sheet manufacturing

Shearing machines utilization in corrugate sheet manufacturing

Modern industrial shears are pneumatic and hydraulic. These are automatically controlled as they sense the length of material, clamp and shear it. They have cutting line illumination for accurate work piece positioning. They have accurate back gauge to assist in folding and have adjustable stroke and length.

CNC controlled shearing devices are now used to achieve more accurate positioning of the material and subsequent shearing. They can be programmed achieve high demand, quality and efficiency when operating. They also have increased safety features to reduce operator accidents. These type achieves rapid blade gap adjustment, faster clamping, quick blade depth adjustment, has cutting line illumination and other safety features. Therefore, these equipments will continue to play a significant role in the construction industry.

Uses of Press Brake in Fabrication of Outer Casing for House Hold Appliances

Introduction

House hold appliances are required in every home. They are manufactured by small, medium and large sized firms and come in different varieties, sizes, color and shapes. They range from cook tops, ranges, ovens, refrigerators, heaters, microwaves, water dispensers among others. The external protective casings of these equipments require iron covers that are extensively manufactured using sheet metal.

Durability, aesthetics and usability are crucial components of most products. In line with this, well formed metal coverings are applied for most home based electronic and electrical appliances. Even desktop PC processors have an external sheet worked casing.

Uses of Press Brake in Fabrication

Fabrication of outer covering of house hold appliances

The formation of this outer casing primarily involves bending specially treated metals to the required shapes. Most industries rely on modern, advanced brake presses to develop these casing at very economical rates. These machines guarantee quality at cost effective production costs and should therefore be the part of all sheet metal workshops.

The process entails accurately forming bends on metal so as to achieve the required shape of the device to be formed. For example, microwaves have a rectangular outer covering made by progressively folding the sheet material.

Fabrication industry

In addition, the folding process is easy, fast and economical. This makes this equipment suitable for small scale productions where most parts differ as well as large scale manufacture where single repetitive units are made.

Use of press brakes in fabrication process

These machines have been used widely in workshops. Materials of various gauges are folded to the right angle and shape through plastic deformation. Over 80% of all fabrications using low gauge material require a press brake.

Ever since there invention, these equipments have continuously developed to accommodate modern trends, improve ergonomics, meet the current industrial demands and increase the aesthetic value of developed products.

While old devices were manually operated with low tonnage, modern ones use hydraulic and pneumatic systems as well as computerized control to achieve precision.

Press Brake for Large Steel Fabrication

Advantages of press brake in performing multiple bending during fabrication

These equipments are cheap, affordable and easily form the product to the required shape. These are therefore preferred in most production centers. They perform a range of folding operation which is a primary metal forming method.

Since most of the house hold equipments require complex and repetitive bends to be made, back-gauges are used to locate the position of the material, assist in making the bend as well as allowing multiple bending.

Performing complex bending to suit different appliance covers

Modern devices have back-gauges that position and move the material so that two or more bends are made consecutively to achieve the device structure. The bending process also incorporates other small bends that improve the appearance and aesthetics of the item being manufactured.

Conclusion

Press brakes are widely used in mass production and small scale manufacture of external covering of most appliances. They are economical, ergonomic, fast, reliable and produce high quality covers with good dimensional stability.