This machine mills a taper on the connecting rod’s small end. The client used to do this machining operation on an VMC, which was a time consuming process. In order to reduce the time and deliver an output of one component every 15 seconds, we proposed a rotary table concept. Basic features and sequence of operation is given below:

FUNCTIES & SPECS:

• Rigid, stress relieved and fabricated structural.
• A rotary table of our own make will be mounted on the base.
• This rotary table will have 2 indexing positions at every 180°.
• Four fixtures will mounted on the rotary table at every 90°.
• Two fixtures will be designed for 1^st setup milling operation (1^st side angle milling of a fresh component) and two fixtures will be designed for 2^nd setup milling operation (2^nd side angle milling after the completion of 1^st side angle milling).
• Het 1^st setup and 2^nd setup fixtures will be mounted at every alternate positions, to come after one another, while indexing.
• The rotary table will be oriented in such a way that two fixtures (one fixture of 1^st setup and one fixture of 2^nd setup) will be facing the operator for 180° index of table.
• On the other end of the table, at the other two fixtures, two milling heads are mounted on a two axes servo driven slide system.
• One milling head will be used for milling 1^st setup and the other will be used for milling 2^nd
• The two axes slide systems consists of a horizontal servo driven slide for feed, and a vertical slide for setting depth of cut.
• The machine will be provided with complete machine enclosure.
• The machine will be provided with a recirculating coolant system and integrated chip conveyor system.
• LM guides will be used for slideways.
• Machine will be provided with centralized lubrication system for sliding surfaces.
• Machine will be provided with touch panel HMI, for easy parameter setting of feed and positions.

SEQUENCE OF OPERATION:

• For describing the sequence of operation, the fixtures will be named as Fixture-1, Fixture-2, Fixture-3 & Fixture-4, in clockwise direction.
• Fixture-1 and Fixture-3 are 1^st setup angle milling fixtures.
• Whereas Fixture-2 and Fixture-4 are 2^nd setup angle milling fixtures.
• At the start of the cycle, Fixture-1 & Fixture-2 will be facing the operator. Fixture-3 & Fixture-4 will be under the milling heads.
• The operator has to load a fresh component on the Fixture-1 and transfer the component (1^st side angle milled) from Fixture-1 to Fixture-2, for 2^nd setup operation.
• When auto-cycle button is pressed, the rotary table, indexes by 180°.
• Now Fixture-1 comes under one milling head and Fixture-2 comes under the other milling head, while Fixture-3 and Fixture-4 face the operator.
• Now the vertical slides of both the milling head, position the milling head for the required depth of cut. Horizontal slides move the milling heads at the set feed to mill the components (1^st setup and 2^nd setup) simultaneously.
• Now, while milling is going on at Fixture-1 and Fixture-2, the operator, has to unload the component from Fixture-4(both sides milled), transfer the component from Fixture-3 (Single side milled) to Fixture-4 and load a fresh job onto Fixture-3.
• After milling, the slides return to home.
• Repeat the cycle.