Rotary In-Gate Milling SPM
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, yang 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 RPM
Technical Specification:
Machining Capabilities | |
Milling Capacity in Steel (max) | Ø63mm cutter x 10 mm depth of cut |
Y axis – Vertical Slide | |
Stroke | 300 mm |
Guideway details | All cast iron sliding surface. |
Slide drive | Screw rod and phosphorus bronze nut |
Drive | Hand Driven (Manual) through wheel |
Bellow cover protection | Collapsible bellows |
Lubrication system for axes | Centralized lubrication system integrated with PLC |
Slide end stop limit switch arrangement | Will provide feed end limit switches. |
Wipers for slide | will be provided |
Z axis – Cross/Ram slide | |
Stroke | 300 mm |
Guideway details | Both male & female sliding surfaces are all-cast iron |
Traverse rate | 1000 mm/min |
Ram size | minimum 150 square |
Slide drive | rolled ballscrew coupled to servo motor through inline servo reducer |
Servo motor rating | 2.4Nm, 0.5kW |
Servo reducer ratio | 01:10 |
Auto Feed / Manual Feed Selection | Will be provided |
Lubrication system for axes | Centralized lubrication system integrated with PLC |
Slide end stop limit switch arrangement | Will provide feed end limit |
Wipers for slide | will be provided |
Spindle Head & Spindle drive |
|
Tool clamping taper of spindle | ISO-40 |
Tool Locking system | Automatic Arbour clamping through disc spring stack and hydro-pneumatic cylinder |
Capacity of tool holder (weight / size) | max Ø160 mm cutter |
Spindle Bearing configuration | Match pair angular contact bearings |
Lubrication system of head | Molybdenum Sulfide Grease packing for life (ISOFELX NBU 15 of Kluber make) |
Spindle speeds | 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 |
Main Spindle motor rating | 5HP |
|
|
Other Equipment | |
Rotary table speed and indexing | 0 kepada 15 RPM and indexing of 275° |
Rotary table drive | Servo driven |
Operators control station | Will be provided |
Electrical Panel | Will be provided |
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:
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- +91-80-28361725
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