Department of 4i Laboratory IITKanpur. Conventional/non conventional Machining tools For industrial applications

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1 Department of 4i Laboratory IITKanpur Conventional/non conventional Machining tools For industrial applications

2 Machining facilities available Rapid prototyping CNC Water Jet Laser cutting Lathe Drilling Milling Other machining tools

3 The fabrication facility available in 4i Lab 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 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. Functioning of Rapid prototyping A CAD model is constructed, then converted to STL format. The resolution can be set to minimize stair stepping. The RP machine processes the.stl file by creating sliced layers of the model. 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. The model and any supports are removed. The surface of the model is then finished and cleaned. Output

4 The fabrication facility available in 4i Lab 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. 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 Output Functioning of abrasive jet machining 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.

5 The fabrication facility available in 4i Lab 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. (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 ( ) 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 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. Output

6 The fabrication facility available in 4i Lab LASER (Engraving and Cutting ) Model : EPILOG MINI WIN 32 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. 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) Output Functioning of laser machining 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.

7 Output of Laser Cutting System realized in 4i lab Tiles Metal Engraving Sunmica Engraving Leather belt design Stamps Wood Engraving

8 3 AXIS CNC VERTICAL MILLING MACHINE Technical information 1. X-Travel 2. Y-Travel 3. Z-Travel 4. Spindle taper 5. Spindle speed range 6. Feed range 7. Rapid feed 8. Table clamping area 9. Number of tools in changer 10. Max. tool diameter if magazine is full 11. Max. tool diameter if both sides are free 12. Max. tool length 13. Max. tool weight 14. Drive capacity 15. Weight ca SK x mm mm mm rpm mm/min m/min mm mm mm mm kg kw kg

9 Output of 3 axis CNC vertical milling machine realized in 4i lab

10 EZEE drilling in hard metals EZEE DRILL EDM Drill Machine 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. Technical Specifications of EZEE DRILL: Machine Tool EZEE DRILL Work Table 440 X 320 X & Y Axis Travel 350 X 270 Z Axis Travel 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

11 EZEECUT NXG CNC Wirecut EDM Features : CNC Wirecut EDM 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 Generator EzeeWin 2532H 3240H 4050H Minimum input command mm Worktable size mm 340 x x x 710 Minimum increment mm XY table traverse mm 250 x x x 500 Interpolation function Linear and Circular Max Z height mm Simultaneous controlled X, Y, U, V Max workpiece weight Kg Resolution for X, Y, U, mm Max taper cutting angle ±3/0100mm ±3/0100mm ±3/0100mm Data input CD, USB Pendrive Input power supply 3phase, 415VAC, 50Hz

12 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

13 PCB Fabrication Flow Chart If PCB is more than 2 layers LAUFFER Press LPKF Contac RS LPKF Protomat 95s/2 LPKF ProMask LPKF UV Exposure LPKF ProtoPrint Green TRF LPKF ProtoPlace LPKF ProtoFlow

14 Thank You