Shenoy Engineering Private Limited

Peenya, Bangalore, Karnataka

Chamfering, immediately after drilling, with no changes either in job setting, spindle speeds or direction of spindle rotation. No special skill is required. the bottom side of a drilled hole is deburred or chamfered, after mounting the same job upside down. The automatic duplex deburring & chamfering tool, in one go, deburrs and produces a chamfer in a drilled hole both at the top as well as at the bottom. No change either in the spindle speed or in the direction of spindle rotation or in the job set-up is required.

Mounting flange of the unit is specially designed to suit to the existing machine.The sleek ram, in combination with a detachable right angle head, permits machining of the inner walls of the housings which have narrow openings, Unique box type construction of the ram ensures least clearance between the sliding surfaces for the linear movement, thus ensuring a tight fit and the maximum rigidity. Inherently, the square sliding surfaces have extremely large contact area with the housing, thus ensuring maximum rigidity and the least vibrations during traverse and heavy material removal.Ram feed unit consists of a ball lead screw, box nut and the drive is through a VFD controlled motor and worm reduction gear box.

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.Heavily ribbed, robust construction to withstand heavy intermittent cutting.Auto-cycle through the combination of PLC & limit switches for logic controlled, sequential & automatic plate positioning, clamping, machining, de-clamping, plate retraction, homing, chip disposal etc.

This machine mills a taper on the connecting rods 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.A rotary table of our own make will be mounted on the base.Two fixtures will be designed for 1st setup milling operation (1st side angle milling of a fresh component) and two fixtures will be designed for 2nd setup milling operation (2nd side angle milling after the completion of 1st side angle milling).The 1st setup and 2nd setup fixtures will be mounted at every alternate positions, to come after one another, while indexing.The two axes slide systems consists of a horizontal servo driven slide for feed, and a vertical slide for setting depth of cut.Machine will be provided with touch panel HMI, for easy parameter setting of feed and positions.

This machine chamfers the bore on connecting rods small end. The client used to do this machining operation on an VMC, The chamfering head, at start of each cycle, will be positioned at the center, in between the fixtures.Machine will be provided with touch panel HMI, for easy parameter setting of feed and positions.

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.Being a CNC SPM, it offers all the advantages of a CNC machine like operator friendly, HMI enabled quick & easy part programming, very high level of positioning accuracy & repeatability.High pressure, through coolant & generously large gashes in the cutter facilitates rapid chip evacuation from the cutting zone.

The chamfer had controlled depth for rivet seating. The depth control on the chamfer had to be mainatained within 30 microns for correct. The sustomer was using an hand operated drilling machine with mechanical dead stop. The depth control was very difficult in this setup and was set up time was. This now has been replaced by our machine which has a 1.5HP spindle with 500-2800 RPM stepless speed variation through VFD interface. The depth, feed and rapid return of the tool is by the servo motor coupled to ballscrew. The touch screen HMI can be used to program the spindle speed, drill feed, rapid return and dwell. This machine can be used for even tapping with a compensatory tapping chuck. Different fixtures have to be made to align the hole position to the spindle position. After fixture setup, the machine can be used in continuous auto-cycle for mass production.

The RH for the fixture, a hydraulic longitudinal slide is mounted with a vertical milling head having woodruff cutter.The the longitudinal slide of the LH moves in to plunge the end mill into the job. Then the cross slide moves the end mill to trace the profile of the notch and the longitudinal slide returns back.

Each station has 2 sets of compound slides with servo driven cross and longitudinal axes. One set of compound slide does facing while the other will be used to bore.Many innovative design features for reducing the cost, without diluting the stock removal capabilities within the specified time.Slides made of male, heavy duty, extra rigid, case hardened guideway strips and female turcite lining.

A longitudinal slide with an automatic fixture is mounted on the centre of the base.At station 2, two end milling heads are mounted diametrically opposite to each other on either side of the fixture slide.Coolant System for chip removal, heat dissipation & fine surface finish.

Flange Facer is a multi-utility machine and it can also be used for doing other machining operations like drilling, boring, thread cutting etc by adding a self-powered unit head and using proper tooling and axes synchronization.Flange Facer consists of a rotary drive unit and clamping arms. Power cables from the rotary table are routed through an imported brushless rotary joint connector with an universal joint which permits the flange facer to do the operation in vertical, horizontal and in any angular position without the danger of cables getting entwined with rotating parts.The rotary drive unit consists of a pair of pre-loaded, extra heavy duty taper roller bearings, located in an accurately dimensioned, forged alloy steel body. The rotary drive is through a gear box and a motor. A vector VFD provides step less rotational speeds. The main body and the cross axis ram are made of high grade CI casting, heavily ribbed and stress-relieved. The box type ram is quite unique in design, perfectly balanced, light in weight, robust in construction to withstand the deflection. The cross feed drive is through a worm reduction gear box & VFD controlled motor. Proper balancing and additional care in design ensure smooth cutting even when the cutting takes place in the extreme end of the ram. The rotational drive and feed axis are synchronized through a PLC. Adjustable feed end limit switches are provided for the ram movement.

Single point cutting by a flange facer is not only time consuming, but also it needs a separate machine for drilling the pitch drill holes. Conventionally, this is done by laborious, manual blue-matching, using hand grinders. Conventional flange facers, cannot do the drilling operation. A single flange facer cannot face all the sizes of flanges upto diameter 6.5 meters or even above. Radial Arm Mill, Drill Centre, also called Flange Miller, can radially mill on the diametrical surfaces of dia 6.5 meters flanges and can produce close pitch drills, effortlessly and in considerably less time.Central rotary drive unit of the radial arm mill, drill center consists of extra heavy duty, preloaded pairs of taper roller bearings or slew bearings.It is possible to use the same machine for radially grinding the top flange as well by mounting a cup wheel grinding attachment on the opposite, counter balancing ram, which is meant for counter balancing milling ram.

CONSTRUCTION & FEATURE

• Though popularly named Flange Miller, more aptly called Radial Arm Mill, Drill Center
• Flange Miller consists of a Central Post, on which a rotary drive unit is located.
• Cross axis arm & counter balancing arm are located on the sides of the rotary housing.
• Cross traverse mechanism in the arm to position the milling head to the varying diameters of the flanges.
• 20 HP milling head is mounted on a vertical slide unit for setting the depth of cut.
• Different sizes of detachable center blocks to suit to the varying lengths/heights of the flanges.
• Central rotary drive unit of the radial arm mill, drill center consists of extra heavy duty, preloaded pairs of taper roller bearings or slew bearings.
• Common VFD controlled cross feed traverse and vertical feed traverse.
• Rotary drive through a AC servo motor for repeatedly accurate pitch selection in drilling, after radial milling through HMI (Human Machine Interface).
• A unique, self-adjusting, self-compensating counter balancing mechanism for continuous balancing for the moving ram.
• While the rotary drive bearings are lubricated for life, the other rotating and sliding surfaces are continuously lubricated at regular intervals by an automatic or manual lubrication system.
• It is possible to use the same machine for radially grinding the top flange as well by mounting a cup wheel grinding attachment on the opposite, counter balancing ram, which is meant for counter balancing milling ram.

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:

• Custom manufactured as per your requirement. Mention the required hole and counter-bore diameter and we will manufacture it for you.
• Offered with tapered or straight shank.
• Standard ISO grade indexable carbide carbide inserts used. Replacement inserts can be bought from a local tool shop.
• Double or triple cutting edges provided so that feed per tooth can be increased for better speed and finish.
• Guide pilots used to guide the tool and provide sufficient rigidity while cutting.
• Guide pilots result in better concentricity.
• Guide pilots are detachable type. You can use one counterbore tool for multiple holes by changing the guide pilot.
• Detachable guide pilots can be easily replaced after getting worn out.
• Engineered relief, typical to flutes of a drill provided for chips to flow out.
• Manufacturing lead time of maximum 20 days.
• Shipped to your door though air logistics.

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:

• Custom manufactured as per your requirement. Mention the required hole and counter-bore diameter and we will manufacture it for you.
• Offered with tapered or straight shank.
• Standard ISO grade indexable carbide carbide inserts used. Replacement inserts can be bought from a local tool shop.
• Double or triple cutting edges provided so that feed per tooth can be increased for better speed and finish.
• Guide pilots used to guide the tool and provide sufficient rigidity while cutting.
• Guide pilots result in better concentricity.
• Guide pilots are detachable type. You can use one counterbore tool for multiple holes by changing the guide pilot.
• Detachable guide pilots can be easily replaced after getting worn out.
• Engineered relief, typical to flutes of a drill provided for chips to flow out.
• Manufacturing lead time of maximum 20 days.
• Shipped to your door though air logistics.

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:

• We tailor-make the machine with tooling for bore upto 400 mm & bore length upto 3 meters. Material removal capability: 4 mm radial depth of cut.
• Being a CNC SPM, it offers all the advantages of a CNC machine like operator friendly, HMI enabled quick & easy part programming, very high level of positioning accuracy & repeatability.
• High pressure, through coolant & generously large gashes in the cutter facilitates rapid chip evacuation from the cutting zone.
• The BTA type tool has multi-lipped cutting edges with unique, self-guiding features through carbide bushes.
• Hydraulically operated, self-centering chuck & steady rest to ensure the job remaining in steady, concentric line.
• Between center job clamping facility for OD turning.
• Aesthetic machine enclosure and automatic chip conveyor.
• End threading of the pipe using single point cutting
• Job-rotating & cutter-stationary.

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:

It is possible to add slide-way grinding capabilities to the planer by mounting a cup wheel grinding attachment on the clapper box of the tool post. The existing tool post traverse mechanism is used for setting the depth of cut. Alternatively, grinding heads are also offered with graduated collar enabled manual quill movement for fine depth of cut setting (least count: 0.05 mm per div). The same grinding attachment, when tilted to LH or RH 90°, can be used for peripheral grinding application. Existing LH/RH tilting mechanism of the tool post is to used for the grinding head also. SKF/RHP angular contact, matched pair bearings are used for high spindle accuracy.

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.

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: