Bangalore, Karnataka, India
Our Product / Services
Hydro Pneumatic Presses are low cost options for mass production of small components, made of sheet metal, rubber, foam etc. The hydro pneumatic cylinders offer the twin advantages of (a) rapid positioning & retraction through pneumatic and (b) pressing of the component through hydraulic. Generally, a hydro pneumatic press is custom-built for specific application. The same press can be used for near similar applications by changing the fixture. Photo sensors are offered optionally at extra cost for preventing the possibilities of accident.Hydro pneumatic presses are quite simple and easy to install and they are generally maintenance free. Normally temperature and pressure variation problems are not there in a hydro pneumatic press.
We have manufactured a 3 axes Milling, Drilling and Tapping Machine, which can be used to machine i Beams, H beams, Box beams and other steel materials. The 3 liner slides are controlled by worm reduction gear box AC induction motor routed through vector VFD to obtain stepless speed variation from 30 mm/min to 1000 mm/min. All slides have a DRO to find exact position of the slides. The ram type milling head mounted on the vertical carriage has extra rigidity than conventional slide mounted milling head due to its square box design locked in with taper jibs.
Technical Specification of this machine is given below:
Reverse engineering is a misnomer to the word copying. One can physically copy a machine or a tool or a fixture; but he needs an engineering perception to copy the soul of that equipment. The soul or finer point of a machine is subtle and cannot be seen by one and all with their plain eyes. It needs an inner eye. The soul of a machine can be its metallurgy, hardness, manufacturing and assembly tolerances etc. It needs an in-depth knowledge of engineering principles, which is the fruit of years of hands-down experience in the shop floors.
We are equipped to accept challenging assignments in reverse engineering of machine tools.
We have developed a number of import substitutions like Universal Milling Attachment, Multi Angle right angle attachment, Stamping Press etc.
FOAM SLICING AND CUTTING CNC MACHINE
Foam slicing through a CNC band-sawing process is very fast and it produces the sheets of the same and controlled thickness. We have designed and have built a FOAM SLICING & CUTTING CNC SPM for the manufacturer of automobile filters, which are made of foam cubes or buns of different sizes. These cubes are to be sliced into long sheets of different thickness accurately. The CNC Slicing SPM is designed to perform this precision, long, thickness uniformly controlled, slicing operation, so that the maximum numbers of slices are sliced off from the cubes, repeatedly. The encoder based feed system ensures accurate positioning of the slicing saw blade to accurate position in the vertical axis continuously and repeatedly from one pass to the other and without variation. The linear motion guideways and ball lead screws for the vertical and longitudinal axes facilitate smooth sliding movements.
Metallic Bellow Forming Machine was developed to obtain uniform and accurate bellow with mechanical cold forming with an completely automated process. The machine has an hydraulic cylinder, which will open and close the bellow die. The bellow die expands to form the bellow. The actual bellow blank, a stainless steel sheet metal seam welded in cylindrical shape, rests on a rotary indexing table which inturn is mounted on a vertical indexing slide. This indexing slide, is driven by a servo motor connected to a ballscrew. The sliding surfaces are made of LM guides and blocks for smooth and fast indexing. The servo motor, hydraulic expansion and indexing table rotation is seamlessly integrated with a PLC for complete auto-cycle function. A 7 touchscreen HMI is provided, so that parameters such as bellow pitch, number of rotations and angle of rotation per expansion, speed of indexing, etc can be easily entered and set.
FEATURES & SPECS:
SEQUENCE OF OPERATION:
We have developed a 3 axes Milling Machine, which can also be used as a portable CNC milling machine. This machine has the capability of a large VMC at the cost of a small VMC. The machine is inbuilt with linear, circular and helical interpolation capability. Any kind of machining, be it slots, face milling, profile machining, thread milling, drilling or tapping can be executed on this machine. The technical specifications of this machine is given below:
Forged tubes have rougher, coarser, non-uniform, inner and outer diameters. We have developed a CNC turning SPM, which does the OD turning, ID trepanning and end threading in a forged tube. It can enlarge the bore and makes the existing bore deeper. The bore produced by the SPM is smoother, uniform, and concentric. No drifting of the centre occurs, unlike in gun drilling, due to the self-guiding type specially developed tooling. The machine and the tool are robust to withstand extremely high cutting forces. Other features & specs are as mentioned herebelow:
1) Suitable mounting arrangement, so as to make the attachment suitable for mounting on the tool post of your VTL.
2) Required extension, so as to reach the bore in the work piece.
3) 2 HP/2800 RPM flange mounting type 3 phase motor.
4) Extension shaft supported by suitable bearings arrangement inside the housing.
5) Main spindle bearings are of RHP make matched angular contact bearings.
6) Bearings lubricated for life with German make molybdenum supplied grease.
7) Wear-resistant Polyurethane coated drive & driven pulleys, properly balanced.
8) Self aligning, spring loaded belt tension adjusting mechanism.
9) Emery belt of required grid for grinding the bores.
Surfaces of huge square or rectangular flanges can be linear machined, using a in-situ X-Y axes machine. This is basically a vertical machine, mounted on the horizontally resting square tubes through hydraulic cylinders. The hydro-motor driven milling head, with its quill movement for depth of cut setting, is mounted on the cross beam. The milling head moves along the cross beam left to right and right to left in X axis. The cross beam moves up and down (Y axis) along the two vertical beams on either side of the flange. The linear guideways are provided with linear motion guideways and the movements are motorized lead screws. This machine is under development.
These tools, unlike the conventional back spot facing tool, are made from a single solid metal structure. The single piece construction & the other design features are such that the tool will bear all the stresses and vibrations. It produces accurately controlled back spot face dimensions.
Structure:
Working:
Advantages:
We have manufactured a 3 axes CNC controlled Horizontal Mill/Drill Machine. The 3 liner slides are driven by Siemens make Sinamics Motors in combination with ball screw and ball nut. The motors are controlled by Sinumerik 808D advanced controller. The ram type milling head mounted on the vertical carriage has extra rigidity than conventional slide mounted milling head due to its square box design locked in with taper jibs.
| Longitudinal Stroke | 2500 mm |
| Vertical Stroke | 1500 mm |
| Spindle power of milling head | 5 HP |
| Spindle Output taper of ram head | ISO-40 |
| Cross axis stroke of milling head | 750 mm |
| Maximum cutter mounting possible | Ø 160 mm |
| Maximum solid drill possible. | Ø 20 mm |
| Maximum dia drill possible by step drilling. | Ø 50 mm |
| Maximum boring dia possible in steps | Ø 100 mm |
| Spindle run out on ID, OD and face | Within 10 µm |
| Geometrical Accuracies for liner slides | 10 µm for 300 mm |
| Linear Positional Accuracy | Within 10µm/300mm |
| Spindle Speeds | 100-1000 RPM in combination with lever operated gears & VFD interface |
| Ram Square size | 150×150 mm, |
| Maximum axis interpolation | 2 |
| Feed rates | 40-4000 mm/min |
| Rapid Speed | 4000 mm/min |
| Arbour Clamping of milling head | Hydraulic Clamping |
| Counter-balance mechanism | Mechanical Counterbalance with dead-weight |
| Chip Conveyor | Optional |
| Recirculating Coolant System with thru coolant | Optional |
| Pendant type | Overhanging swiveling type |
| Servo Motors, Drives and CNC controllers | Siemens – Sinumerik 808D Advanced |
| Ball Screws, Ball nuts, LM guides & blocks | HIWIN Make |
| Hydraulic Elements | Yuken, Rexroth and other reputed makes |
| Hydraulic Power Pack | Our own make |
| AC motors | KEC/ABB |
| Limit Switches | Teknic |
| Major Switchgear elements | Schneider/ Siemens |
| Cables | Finolex |
| Spindle Bearings | RHP/FAG |
A boring machine back rest which was not being used, was converted into a 3 axis machine with milling, drilling and boring capability.Existing vertical stroke of 1200 mm of boring back rest is made powered with worm reduction gearbox and motor.The back rest is mounted adjacent to a plano miller and table of the plano miller is used for longitudinal traverse.
Basic Features and Specs:
Plate Edge milling Machines are also called Plate Edge Bevellers or Plate Edge Beveling machines. This is a dedicated machine for preparing weld edge preparations by preparing various sections like J groves in dimensionally large plates, which cannot be accommodate by a Plano miller.
Plate Edge Beveling machine consists of the following main parts:
CONSTRUCTION:
Bottom base for the horizontal movement, plate resting platform etc are made of stress-relieved, fabricated steel. Vertical column, carriage, milling head housings etc are made of machine tool grade casting, stress-relieved.
FEATURES:
Both the top and the bottom edge of the plate can be machined in the same setting by moving the milling head vertically and in combination with the mechanically tilting mechanism. Alternatively, 2 separate side mounting milling heads can be provided one for top portion plate beveling and the other, for bottom portion plate edge beveling.
OPEN GAP EDGE MILLERS
The conventional, close-gap plate edge millers have an inherent design limitation it is not possible to mill the plates which are longer than the stroke length of the edge miller. To overcome this limitation, Open Gap Edge Miller is offered. The open gap edge miller in the picture is with 3 meters long stroke. But with proper end support, any length of plates can be edge milled in multiple setting. Open gap edge bevellers are cost effective and versatile for varying sizes of plates to be beveled. The barrier-free ends of an Open Gap Plate Edge Miller accommodate plates that are longer than the machine itself. This innovative design also conserves the precious shop floor space.
Shenoy Engg. Pvt. Ltd., known for tailor-made solutions in metal cutting, especially in milling, have developed a Quadruple Head Milling SPM for rapidly machining all the 4 sides of rectangular grates accurately, with repeat accuracy. Essentially a high speed, mass production milling machine, the multi head milling SPM is an economical & faster alternative to expensive VMCs.
The rectangular work piece is about 500 mm long (corresponds to LH & RH sides) and about 180 mm wide (corresponds to front & back).
The SPM consists of 4 numbers of 5 HP milling heads 2 horizontal heads for machining both the sides of the job simultaneously; 2 vertical heads for machining the front and back sides of the job individually. While the sides involve plain, horizontal machining, the front and the back sides of the job involve radius machining within the cavities. Total machining cycle time is around 90 seconds.
The milling heads are mounted on the compound slides for linear machining. The linear machining is through hydraulically operated cylinders. Combination of limit switch & PLC ensures an efficient auto-cycle without manual interruption, right from job clamping, complete machining and de-clamping. Combination of turcite and case hardened guideway strips ensures smooth slide movements and best wear resistance. An automatic lubrication system is provided for automatically lubricating all sliding and rotating parts in regular intervals. Tooling, cutters and inserts are all standard, affordable and easily available off-the-shelf. Slides are well protected and the Machine is provided with aesthetically designed guard. Machine control console is conveniently located, for quick access to the operator.
Fly cutter is the affordable and near ready-made answer when you need to tool up your milling spindle with large diameter cutter
Face milling cutters in standard range are generally not available beyond 400 mm. Larger dia cutters are tailor-made by the cutter manufacturers, which makes them unaffordable and with long delivery lead time. Fly cutters are found to be the answer.
Fly cutters are far simpler, faster and cheaper to make. Fly cutters can be for large diameters, say even up to dia 1 mtrs or beyond. Of course, a fly cutter cannot compete with a face milling cutter in material removal capabilities. But it can produce a large width of cut, having uniform surface with mirror finish, which is not possible for a face milling cutter.
Since there are fewer cutting edges in a fly cutter, heat generated during the cutting is less, thus making it the most ideal cutter for machining non-ferrous material like aluminium. Of, course, fly cutter can also be used for machining steel and cast iron for superior finish. In other words, fly cutters can be extensively used with the least tooling cost where the stock material is less and the requirement of finish on the machined surface is high.
The construction of a fly cutter is simple and parts are very few. Standard, centre clamping carbide inserts offer all the advantages of inserted carbide like multiple cutting edges, easy availability, heavy material removal etc.
While sending an enquiry, please let us know the diameter and number of cutting edges needed.
A ram type milling head in a converted Plano miller virtually throws innumerable possibilities like boring, grooving, facing etc, apart from all other normal milling operations. The sleek ram facilitates access to the cutter through narrow, deep passages and perform almost all kinds of machining operations.
This leak testing machine is developed on a rotating giant wheel principle, which accommodates multiple components to be leak tested to the machine. It also helps to minimize the mess generated by the conventional leak testing machines by splashing of leak testing liquid. On rotating wheel, 4 fuel tanks are mounted. As one fuel tank gets immersed in the liquid for identifying the leaking welding joint, previously tested tank is to be removed from the wheel and a new tank is to be mounted. Like this, there is a provision for mounting 4 tanks in the wheel. The tank, wheel and other vital parts of the machine are made of stainless steel.
a single point cutting planing machine with its huge bulk, frequent break-downs and low productivity is an eye-sore in shop-floor. Yet for larger jobs, you have no choice but to retain the planer. We convert your inefficient planer into a money spinning work-horse with our plano milling conversion kit. We are one of the pioneers in the field of low cost plano milling conversion. We have converted more than 2000 planers into plano millers in india and abroad in the past 20 years. Our milling heads are known for heavy material removal capabilities, ruggedness and affordable prices. Different types of feed systems are offered to suit your budget.after plano milling conversion, older planers receive a new lease of life and the newer planers last longer. After plano milling conversion, not only the table speed is drastically reduced, but also the cutting load is taken over by the self-powered milling head.drastically reduced break-down rates & negligible wear & tear in a converted plano miller, due to slow feed rates.
We being a Special Purpose Machine manufacturing setup, design custom made fixtures for our machine. Having this know-how of designing custom made fixtures for our machine, we are venturing into the field of custom made hydraulic, pneumatic and manual fixtures for HMC and VMC.
We have an in-house design facility with the latest 3D and 2D CAD tools. A sound design background in SPMs and custom made machine manufacturing gives us a not only a perspective of job clamping, but also the finer aspects of tool approach, machining and machine interference.
We can design tombstone type of fixtures for HMC and fixtures for cradles in VMC.
We also provide design solutions for fixtures.
We are venturing into the field of custom made hydraulic, pneumatic and manual fixtures for HMC and VMC.We have an in-house design facility with the latest 3D and 2D CAD tools.but also the finer aspects of tool approach, machining and machine interference.
Direct, tool post mounting type, self powered grinding attachment is developed for facilitating quick mounting and dismounting the grinding attachment to the tool post of a lathe, like any other tool holders.
Tool Post grinders are commonly available grinding attachments for the lathe. For mounting conventional tool post grinders, tool post has to be removed and, in its place the tool post grinder has to be mounted with the help of a height block. After the grinding operation, the attachment has to be physically removed for mounting the tool post. This is quite cumbersome & time consuming.
Our tool post mounting type grinding attachments can be mounted directly on the existing square or quick change tool post of a lathe, just like any other tool holder, without the need for removing the tool post. The grinding attachment consists of a standard 2 HP/1440 RPM motor, L shaped holding arrangement and an add-on driven unit. The add-on driven unit supports the drive shaft extension with the help of matched pair angular contact bearings & grinding wheel mounting arrangement. The entire grinding attachment measures 350 mm in length, including the grinding wheel & the motor. The overall height of the attachment is 200 mm. The grinding attachment is suitable for mounting a grinding wheel of 250 x 25 mm width maximum.
This attachment is most ideal for heavy duty lathes and for intermittent OD grinding applications.
Video Of the Tool Post Grinder:
Counter bore tools offer the advantages of throwaway index able carbide inserts. Counter bore tools are offered in any size with single, double or triple cutting edges based on the size. Freely available standard carbide inserts are used. Pilots are detachable types, which permits the use of different dia of pilots for the same dia of counter bore. This feature also enables an easy replacement of damaged /worn-out pilots. To facilitate easy chip flow, well-designed gashes and relief are provided on the tool shank.
FEATURES & SPECS:
Counter bore tools offer the advantages of throwaway index able carbide inserts. Counter bore tools are offered in any size with single, double or triple cutting edges based on the size. Freely available standard carbide inserts are used. Pilots are detachable types, which permits the use of different dia of pilots for the same dia of counter bore. This feature also enables an easy replacement of damaged /worn-out pilots. To facilitate easy chip flow, well-designed gashes and relief are provided on the tool shank.
FEATURES & SPECS:
We have designed and developed many welding fixtures, especially for Automobile industries mainly for sheet metal components, which are vulnerable to thermal distortions during welding.
Stand alone type flange facers function without outside support. They get clamped to the job. If you have regular production type of jobs, we have other semi-insitu technology. Our regular milling head, if mounted on a supporting structure, can perform milling, boring and facing operation.
