A rotary milling SPM used to mill ingates was developed for a foundry based company as a solution for the following problem:

• Inagates of castings had to be removed before machining on VTLs.
• They were previously being removed by hand grinding.
• This was a laborious process requiring a lot of man power.
• There was a lot of dust, which was hazardous and of no use.

Key points of the solution offered:

• The ingates are milling within minutes compared to the previous numerous man hours spent to hand grinding.
• Better tool life of the final machining as ingates are removed uniformly.
• Milling chips are generated which can be used again in castings. Earlier these becoming powdered chips which could not be collected or used.

Features and Specs:

• Rigid, heavily ribbed, stress relieved, cast iron structure for slides. Fabricated structure for base.
• Atop the base, a vertical column is mounted with vertical slide.
• Both the slides are made of LM guides and blocks.
• Atop the slide, ಒಂದು 5 HP all geared milling head is mounted.
• The cross slide is driven by ballscrewscrew, coupled to inline servo reducer and servo motor.
• The machine also has a rotary table mounted in front. The drive is motorized and routed through servo motor with variation between 0-15 ಪಿಎಂ

 

Technical Specification:

ಯಂತ್ರಗಳ ಸಾಮರ್ಥ್ಯಗಳನ್ನು
Milling Capacity in Steel (ಗರಿಷ್ಠ)	Ø63mm cutter x 10 mm depth of cut
Y axis – Vertical Slide
ಸ್ಟ್ರೋಕ್	300 ಮಿಮೀ
ಸೂಚಿಪಥವನ್ನು ವಿವರಗಳು	All cast iron sliding surface.
Slide drive	Screw rod and phosphorus bronze nut
ಡ್ರೈವ್	Hand Driven (Manual) through wheel
ಬೆಲ್ಲೋ ಕವರ್ ರಕ್ಷಣೆ	ಬಾಗಿಕೊಳ್ಳಬಹುದಾದ ತಿದಿ
ಅಕ್ಷಗಳ ನುಣುಪಾದ ಪದರಿನ ವ್ಯವಸ್ಥೆಗೆ	ಕೇಂದ್ರೀಕೃತ ನುಣುಪಾದ ಪದರಿನ ವ್ಯವಸ್ಥೆಗೆ ಪಿಎಲ್ಸಿ ಅಂತರ್ಗತವಾಗಿರುತ್ತದೆ
ಸ್ಲೈಡ್ ಕೊನೆಯಲ್ಲಿ ಸ್ಟಾಪ್ ಮಿತಿಯನ್ನು ಸ್ವಿಚ್ ವ್ಯವಸ್ಥೆ	Will provide feed end limit switches.
ಸ್ಲೈಡ್ wipers	ಒದಗಿಸಲಾಗುವುದು
Z axis – Cross/Ram slide
ಸ್ಟ್ರೋಕ್	300 ಮಿಮೀ
ಸೂಚಿಪಥವನ್ನು ವಿವರಗಳು	Both male & female sliding surfaces are all-cast iron
Traverse rate	1000 ಎಂಎಂ / ನಿಮಿಷ
ರಾಮ್ ಗಾತ್ರ	ಕನಿಷ್ಠ 150 ಚದರ
Slide drive	rolled ballscrew coupled to servo motor through inline servo reducer
Servo motor rating	2.4ಎನ್ಎಂ, 0.5kW
Servo reducer ratio	01:10
Auto Feed / Manual Feed Selection	ಒದಗಿಸಲಾಗುವುದು
ಅಕ್ಷಗಳ ನುಣುಪಾದ ಪದರಿನ ವ್ಯವಸ್ಥೆಗೆ	ಕೇಂದ್ರೀಕೃತ ನುಣುಪಾದ ಪದರಿನ ವ್ಯವಸ್ಥೆಗೆ ಪಿಎಲ್ಸಿ ಅಂತರ್ಗತವಾಗಿರುತ್ತದೆ
ಸ್ಲೈಡ್ ಕೊನೆಯಲ್ಲಿ ಸ್ಟಾಪ್ ಮಿತಿಯನ್ನು ಸ್ವಿಚ್ ವ್ಯವಸ್ಥೆ	Will provide feed end limit
ಸ್ಲೈಡ್ wipers	ಒದಗಿಸಲಾಗುವುದು
ಸ್ಪಿಂಡಲ್ ಹೆಡ್ & ಸ್ಪಿಂಡಲ್ ಡ್ರೈವ್
ಟೂಲ್ ಕದಿರು ಟೇಪರ್ ಕ್ಲ್ಯಾಂಪ್	ಐಎಸ್ಒ 40
ಟೂಲ್ ಲಾಕಿಂಗ್ ವ್ಯವಸ್ಥೆಯನ್ನು	Automatic Arbour clamping through disc spring stack and hydro-pneumatic cylinder
ಉಪಕರಣವನ್ನು ಹೊಂದಿರುವವರ ಸಾಮರ್ಥ್ಯ (weight / size)	max Ø160 mm cutter
ಸ್ಪಿಂಡಲ್ ಬೇರಿಂಗ್ ಸಂರಚನಾ	ಹೊಂದಿಕೆ ಜೋಡಿ ಕೋನೀಯ ಸಂಪರ್ಕ ಬೇರಿಂಗ್ಗಳು
Lubrication system of head	Molybdenum Sulfide Grease packing for life (ISOFELX NBU 15 of Kluber make)
ಸ್ಪಿಂಡಲ್ ವೇಗ	Stepped spindle speed of 200,360, 500 & 960 RPM as standard. Or 100-1600 RPM with VFD interface (Optional)
Spindle speed range selection	VFD interfaced(Optional) motor in combination with lever operated change gear
Lubrication of spindle drive gearbox	Recirculating oil bath
ಮುಖ್ಯ ಸ್ಪಿಂಡಲ್ ಮೋಟಾರ್ ರೇಟಿಂಗ್	5ಎಚ್ಪಿ
ಇತರೆ ಸಲಕರಣೆ
Rotary table speed and indexing	0 ಗೆ 15 RPM and indexing of 275°
Rotary table drive	Servo driven
ಆಪರೇಟರ್ಸ್ ನಿಯಂತ್ರಣ ಕೇಂದ್ರ	ಒದಗಿಸಲಾಗುವುದು
Electrical Panel	ಒದಗಿಸಲಾಗುವುದು
Major bought-outs
AC motors	KEC/ABB
Servo Motor, PLC and HMI	Mitsubishi
Limit Switches	Teknic, Siemens
Major Switchgear elements	Schneider/ Siemens
Cables	Finolex

SEQUENCE OF OPERATION:

• Load the first component.
• Adjust the milling head height with respect to the ingate pad height and milling cutter.
• Adjust the cutter depth.
• Press auto-cycle.
• The component gets clamped.
• The ram head moves to the milling depth.
• The rotary table rotates at feed to mill the first ingate.
• The rotary table indexes by 180° in rapid.
• The rotary table rotates in feed to mill the second ingate.
• The rotary table rotates back to home position in rapid.

Video of Working: