conventional/non conventional machining tools - iit...
Post on 17-Apr-2018
227 Views
Preview:
TRANSCRIPT
Conventional/non conventional
Machining tools
For industrial applications
Department of 4i – Laboratory IITKanpur
Machining facilities available
Rapid prototyping CNC
Water Jet Laser cutting
Lathe Drilling Milling
Other machining tools
Rapid prototyping is a group of techniques used to quickly fabricate a scale
model of a physical part or assembly using three-dimensional computer
aided design data. Construction of the part or assembly is usually done using
3D printing or "additive layer manufacturing" technology.
The fabrication facility available in 4i Lab
1. A CAD model is constructed, then converted to STL format. The
resolution can be set to minimize stair stepping.
2. The RP machine processes the .STL file by creating sliced
layers of the model.
3. The first layer of the physical model is created. The model is
then lowered by the thickness of the next layer, and the
process is repeated until completion of the model.
4. The model and any supports are removed. The surface of the
model is then finished and cleaned.
Output Functioning of Rapid prototyping
The reasons of Rapid Prototyping are :
To increase effective communication.
To decrease development time.
To decrease costly mistakes.
To minimize sustaining engineering changes.
To extend product lifetime by adding necessary features and eliminating redundant
features early in the design.
Abrasive jet Delivery System The abrasive jet delivery system consists of the high-pressure
plumbing and swivels, a high-pressure nozzle, and an abrasive feed
system (hopper).
The OMAX Jet Machining Center is a precision abrasive jet
machining tool operating under software control and able to cut
complex parts out of most materials including metal, plastic, glass,
ceramics, stone and composites using standard CAD drawing files.
Output Functioning of abrasive jet machining
Machine specification :
Table size of 5' 9" x 2' 6" (1753 mm x 762 mm)
Rapid water level control for submerged cutting
A work envelope offering an X-Y cutting travel of 4' 4" x 2' 2" (1321
mm x 660
The fabrication facility available in 4i Lab
Dry air or gas is filtered and compressed by passing it through the filter and
compressor.
A pressure gauge and a flow regulator are used to control the pressure and
regulate the flow rate of the compressed air.
Compressed air is then passed into the mixing chamber. In the mixing
chamber, abrasive powder is fed. A vibrator is used to control the feed of the
abrasive powder. The abrasive powder and the compressed air are thoroughly
mixed in the chamber. The pressure of this mixture is regulated and sent to
nozzle.
The nozzle increases the velocity of the mixture at the expense of its pressure.
A fine abrasive jet is rendered by the nozzle. This jet is used to remove
unwanted material from the workpiece.
The fabrication facility available in 4i Lab
(CNC lathe in 4 i lab) Manufactured by DMG Gildemeister (Germany)
Max. work piece diameter, mm 420
Max. work piece length, mm 635
Bar capacity, mm 52
Spindle speed range, rpm (25-5000)
Feed speed, mm/min 4000
Rapid speed, m/min: - X axis 15, - Z axis 10
Movement, mm: - X axis 212 , Z axis 640
Main motor power, kW 22
Control: Heidenhain CNC Pilot
Turret positions 12
Machine dimensions, mm 3800 x 1750 x 1750
Machine weight, kg 4900
Output
•CNC stands for Computer Numerically Controlled Machine. It is the
advanced version of Lathe movement of the tool and the workpiece
is automated by the computer using G codes and M codes. All the
functions and operations are automated except holding and
unholding the job.
Functioning of CNC lathe
A CNC Lathe is Controlled by G and M codes which are number values and co
Ordinates. Each number or code is assigned to a particular
Operation and these are typed in manually to CAD by machine operators.
G&M codes are automatically generated by the computer software.
Programmed instructions are converted into output signals
which in turn control machine operations such as spindle
speeds, tool selection, tool movement, and cutting fluid flow
By integrating a computer processor, computer numerical control, or
CNC as it is ow k ow , allows part a hi i g progra s to e edited and stored in the computer memory as well as permitting diagnostics and
quality control functions during the actual machining.
Specification:
Laser type : Gas Laser (CO2)
Power :35W
Working Area :X and Y axis ,24” X 12” or (609.6mmX304.8mm)
Working type :Engraving(Raster) and Cutting(Vector)
LASER (Engraving and Cutting )
Model : EPILOG MINI WIN 32
Output Functioning of laser machining
Carbon dioxide laser (CO2 laser) is used to cut materials.
Carbon dioxide lasers are the highest-power continuous wavelasers that
are currently available.
The CO2 laser produces a beam of infrared light with the
principal wavelength bands centering around 9.4 and 10.6 micrometers.
The fabrication facility available in 4i Lab
The point where the laser (the terms "laser" and "laser beam" may be
used interchangeably) touches the surface should be on the focal plane
of the laser's optical system, and is usually synonymous with its focal
point.
The energy delivered by the laser changes the surface of the material
under the focal point. It may heat up the surface and subsequently
vaporize the material, or perhaps the material may fracture (known as
"glass" or "glass up") and flake off the surface. This is how material is
removed from the surface to create an engraving.
Output of Laser Cutting System realized in 4i lab
Tiles Stamps
Leather belt design Wood Engraving Metal Engraving
Sunmica Engraving
Technical information
1. X-Travel 630 mm
2. Y-Travel 500 mm
3. Z-Travel 500 mm
4. Spindle taper SK 40
5. Spindle speed range 0-8000 rpm
6. Feed range 1-30000 mm/min
7. Rapid feed 30 m/min
8. Table clamping area 800x500 mm
9. Number of tools in changer 24
10. Max. tool diameter if magazine is full 80 mm
11. Max. tool diameter if both sides are free 140 mm
12. Max. tool length 300 mm
13. Max. tool weight 7 kg
14. Drive capacity 30 kW
15. Weight ca. 6500 kg
3 AXIS CNC VERTICAL MILLING MACHINE
Output of 3 axis CNC vertical milling machine realized in 4i lab
EZEE DRILL
EDM Drill
Machine
EZEE drilling in hard metals
Features:
• Small hole drilling in any hard metal.
• Both brass and copper electrode tubes can be used.
• Large drilling range.
• Tab water is used as dielectric fluid.
• Granite work table ensures longer life.
• Precision stepper drive control.
• Compact footprint.
Machine Tool EZEE DRILL
Work Table 440 X 320
X & Y Axis Travel 350 X 270
Z Axis Travel 320+300
Max Electrode Length 400mm
Size of electrode dia 0.3 to 3.0 mm
Max Drill Depth 300 mm
Max coolant pressure 6 MPA
Max weight of the work piece 350 kg
Work tank 800 X 480mm
Net weight 750 kg
Connected load 2 KVA
Input power supply 3 phase, AC 415 V, 50 Hz
Max matching current 20 amp.
Machine Footprint 950 X 770 X 1950
Technical Specifications of EZEE DRILL:
EZEECUT NXG
CNC Wirecut EDM CNC Wirecut EDM
Features :
•� Lowest running cost
•• Full Closed loop X, Y (linear scale) with error compensation
•• Reciprocating Brass / Molybdenum wire
•• Avg. Cutting speed
• 80 mm 2/ min on steel (HCHr / WPS)
•• Mutipass and Multicavity facility
•• Best surface finish 1.5 Ra
•• Taper ± 3 / 100 mm (Higher degrees optional) •• Inbuilt 2 axis DRO
•• Coolant used as dielectric.
��
CNC Pulse Generator EzeeWin
Technical Specifications
Machine Tool - EZEECUT NXG
Parameter EP EP EP
2532H 3240H 4050H
Worktable size mm 340 x 560 380 x 650 410 x 710
XY table traverse mm 250 x 320 320 x 400 400 x 500
Max Z height mm 300 300 300
Max workpiece weight Kg 200 300 450
Max taper cutting angle ±3/0100mm ±3/0100mm ±3/0100mm
Generator EzeeWin
Minimum input command 0.001 mm
Minimum increment 0.001 mm
Interpolation function Linear and Circular
Simultaneous controlled X, Y, U, V
Resolution for X, Y, U, 0.001 mm
Data input CD, USB Pendrive
Input power supply 3phase, 415VAC,
50Hz
Electrical Discharge Machining (EDM)
General Aspects of EDM
EDM is a machining method primarily used for hard metals or those that would be very
difficult to machine with traditional techniques.
EDM typically works with materials that are electrically conductive, although methods for
machining insulating ceramics with EDM have been proposed.
EDM can cut intricate contours or cavities in hardened steel without the need for heat
treatment to soften and re-harden them.
This method can be used with any other metal or metal alloy such as titanium, hastelloy,
kovar, and inconel.
Also, applications of this process to shape polycrystalline diamond tools have been
reported.
EDM – Schematic EDM – Working Principle
PCB Fabrication Flow Chart
LPKF Protomat 95s/2
LPKF Contac RS
LAUFFER Press
LPKF ProMask
Green TRF LPKF UV Exposure
LPKF ProtoPrint LPKF ProtoPlace
LPKF ProtoFlow
If PCB is more than 2 layers
Thank You
top related