Machine Shop

The Machines shop of SRM Institute of Science and Technology (formerly SRM University)-Kattankulathur is located in the Main campus, Mechanical ‘B’ block at MEB103. The Machine shop was established from the advent of Mechanical department having Conventional Machine tools initially. Later, many sophisticated CNC machine tools were commissioned in a phased manner. Machine shop can produce small intricate featured parts to Medium-size and Large size precision components. Machining of all kinds of materials could be carried and the shop is able to manufacture just about anything from custom parts to metal. The regular and Part-time B. Tech students are practicing both Conventional and CNC Machine tools during their course of study.

Specifications

Heavy Duty Fixed Column Vertical Machining Centre (41/2 Axis)-BFW 51 TC24-Vayu
3axis vertical machining centre – PX10-Jyoti
3axis vertical machining centre – BFW 35 T12-Gaurav
CNC turning centre –DX150-Jyoti
CNC Turning centre-Uniturn 300-GEDEE WILER

No data was found

External Thread Cutting – Centre Lathe
Surface Grinding in Surface Grinding Machine
Single point cutting tool Grinding in Tool and Cutter Grinding Machine
Helical Gear Cutting in Gear Hobbing Machine
External Cylindrical Grinding in Cylindrical Grinding Machine
Spur Gear Cutting in Universal Milling Machine
Step and Taper Turning in CNC Turning Centre -Programming, Simulation and Machining
Profile Turning in CNC Turning Centre – Programming, Simulation and Machining
Contour Milling in CNC Milling Centre -Programming, Simulation and Machining
Circular and Square Pocketing in CNC Milling Centre -Programming, Simulation and Machining
Demonstration in Wire-cut Electric Discharge Machine.

Vertical Machining Centre (41/2 Axis)-BFW 51 TC24-Vayu

Features:

Machine configuration of fixed column
C frame structure machine with a moving table for easy access
The complete structure is FEA proven with stringent analysis.
Features like linear scale feedback, through coolant, high speed motorized spindle are available as options.

Specifications:

SPECIFICATIONS	UNIT	BMV 51 TC24
Table size	mm x mm	1000 x 510
Maximum safe load on table	kg	800
X-axis	mm	800
Y-axis	mm	510
Z-axis	mm	510
Feed rates	mm/min	1 - 10,000
Speed	rpm	-10,000
Taper		BT 40
Number of tools	Nos.	24
Positioning accuracy	mm	± 0.005
Repeatability	mm	± 0.003
controller		siemens-sinumerik828D

3axis vertical machining centre - PX10-Jyoti

Features

Broader base foot print and stiff column.
Precision linear motion guide ways.
High Performance 6000rpm rigid BT-40 spindle.
Twin arm type auto tool changer with 20 tools.
4th & 5th axis machining by using rotary table.

Specification:

Table		PX 10
Table Size	mm	660 x 360
Dist. From Floor to Table	mm	1020
Max. Load on Table	Kgf	400
Capacity
X-Axis Travel	mm	510
Y-Axis Travel	mm	410
Z-Axis Travel	mm	510
Dist. From Spindle Face to Table	mm	100-610
Feed
Rapid Traverse ( X, Y & Z Axis)	m/min	25
Cutting Feed	m/min	10
Main Spindle
Spindle Motor Speed	rpm	6000
Spindle Motor Power - Siemens	kW	8.25 / 5.5
Automatic Tool Changer
No. of Tools		20
Other Data
Machine Weight #(Approx.)	Kg	4000
Machine Dimension #(Approx.) :
Length	mm	3410
Width	mm	2120
Height	mm	2810

CNC turning centre –DX150-Jyoti

Features:

AC Spindle Drive
AC SERVO Digital Drive
M. Guide ways
Chucking
8 Station Bi-directional Servo Turret
Auto & Manual Coolant System
Centralized & Programmable Lubrication
Laser Calibrated Axis for Highly Precise
Positioning Accuracy and Repeatability

Specification:	DX 150
Capacity	mm	375
Swing Over Bed	mm	150
Std. Turning Diameter	mm	250
Max. Turning Diameter	mm	350
Max. Turning Length	mm	150
X-Axis Travel (Cross)	m/min	24
Z-Axis Travel (Longitudinal)	kW	7.5 / 5.5
Spindle Motor Power - Siemens	rpm	38
Spindle Bore Dia.	mm	50-4500
Max. Bar Capacity	mm	32
Spindle Speed Range	mm	20 x 20
Turret (Servo)	Kgf (Max.)	75
No. of Stations	mm	100
Max Boring Bar Diameter	mm	300
Tool Size	Kg	0.007
Quill Stroke	mm	1950
Weight (Approx.)	Kg	3000
Dimension Length:	mm	1950
Width	mm	1375
Height	mm	1950

CNC turning centre-Uniturn 300-GEDEE WILER

It can be used for machining a wide range of parts having a diameter upto 175mm.
Lengthy bars having diameter upto 50mm can be machined continuously using a bar puller and parts collector.

"UNITURN 300 HD" TECHNICAL SPECIFICATION
Swing over bed	mm	425
Swing over cross slide-dia	mm	225
Admit between Centers Min / MAX	mm	10 / 375
Maximum Turning dia & Length(without chuck)	mm	185 x 300
Max Bar Capacity dia	mm	32 dia
Chuck Size dia	mm	165 dia
Spindle Speed	mm	50 - 4000
Spindle Nose DIN 55026	mm	A2-5
Spindle through bore	mm	42
X axis travel	mm	155
Z axis travel	mm	340
Rapid Traverse X axis	mts./min	20
Rapid Traverse Z axis	mts./min	25
Feed Rate	mm	6000
No of tool Positions	no	12-Aug
Tool Shank Size	mm	20x20 / 16 x 16

CNC wire cut EDM Machine-EZ-01-EZEECUT

Features:

Closed loop x, y linear scales
Flexible job stand for job mounting
Variable speed DC motor for wire drum assembly
Steel driver for wire drive mechanism
Fine pitch screw for u, v movement
Coolant oil is used as die electric
Reciprocating brass and molybdenum wire

Tool Management solutions-ZOOLER

The ZOLLER tool management - for the economical organization of tools and machines

BRONZE Basic Solutions ensures the economical organization of entire tools, individual components and machines. All tools and tool components are captured at a single point, saved in the software and managed. This avoids duplicate and multiple data storage Tool management is based on the practice-proven

Highlights:

Transparent organization of your tool pool
Central data storage in one system - instead of duplicate data storage
Easy administration of relevant documents

Features:

Reducing setup times
Saving on stockroom costs
Increasing productivity

The highly precise machine tool includes high precision ball screw, wire rolling guide, high-speed –wire feed Mechanism
Tension controllable wire driving system keep constant wire tension.
Simple to use software RRAPT. Feature include DXF file interface, built in utility packages for gear and curves, built in functions like move , rotate, copy, mirror, multi cavity program generation
Automatic stop after end of job

UNIQUE Feature: wire is reused which drastically reduces machining cost

Control panel EZ-01		Machine tool
control mode	CNC close Loop	X,Y axis travel	320 x 400
controlled AXIs	X, Y, U, V	Maximum work piece size	360×600mm
control panel size(L×W×H)	650×560×1710mm	Maximum Z height	360/480mm
control panel weight	175kg	Maximum work piece weight	300KG
input program format	G code	Maximum taper cutting angle	±3/0100mm
Display	15” color CRT	Maximum tool size(L×W×H)	1500×1250×1700mm
minimum input command	0.001 mm	Maximum tool weight	1400kg
minimum increment	0.001 mm	wire diameter	0.2 to 0.25 mm(brass), 0.12 to 0.25 mm(Molybdenum)
interpolation Function	Linear and Circular	Best surface finish(Ra)	1-1.5um
power requirement	3phase, 415VAC, 50Hz	Maximum cutting speed	60sq.mm/min
		Maximum dry run speed	25mm/min

Peizo Multi component Dynomometer

The multi component dynamometer provides dynamic and quasi-static measurement of the 3 orthogonal components of a force (Fx, Fy, and Fz) acting from any direction onto the top plate.
With the aid of optional evaluation devices the 3 moments Mx, My and Mz can be measured as well.
The dynamometer has high rigidity and hence high natural frequency. The high resolution enables very small dynamic changes to be measured in large forces
The highly precise machine tool includes high precision ball screw, wire rolling guide, high-speed –wire feed MechanismWire cut EDM:
Tension controllable wire driving system keep constant wire tension.
Simple to use software RRAPT. Feature include DXF file interface, built in utility packages for gear and curves, built in functions like move , rotate, copy, mirror, multi cavity program generation
Automatic stop after end of job

Technical information-Component Dynamometer Type 9257B…
Range Force application within and max.25 mm above top surface	F_x, F_y, F_z	kN	–5 … 5
Range when turning, force application	F_z	kN	–5 … 10
Calibrated partial range 1	F_x , F_y	N	0 … 500
Calibrated partial range 1	F_z	N	0 … 1 000
Calibrated partial range 2	F_x , F_y	N	0 … 50
Calibrated partial range 2	^Fz	N	0 … 100
Overload Fx and Fy ≤0,5 Fz	F_x, F_{y, Fz}	kN	–7,5/7,5
Overload Fx and Fy ≤0,5 Fz	F_z	kN	–7,5/15
Response threshold		N	<0,01
Sensitivity	F_x, F_y	pC/N	≈–7,5
Sensitivity	Fz	pC/N	≈–3,7
Linearity (all ranges)		%FSO	≤±1
Hysteresis (all ranges)		%FSO	≤0,5
Crosstalk		%	≤±2
Rigidity	c_x, cy	kN/μm	>1
Rigidity	c_z	kN/μm	>2
Natural frequency	f_n (x, y, z)	kHz	≈3,5
Natural frequency (mounted on flanges)	f_n (x, y)	kHz	≈2,3
Natural frequency (mounted on flanges)	f_n (z)	kHz	≈3,5
Operating temperature range		°C	0 … 70
Temperature coefficient of sensitivity		%/°C	–0,02
Capacitance (of channel)		pF	≈220
Insulation resistance at 20 °C		Ω	>1013
Ground insulation		Ω	>108
Protection class with cable Type		–	IP67
1687B5, 1689B5, 1677A5, 1679A5
Weight		kg	7,3

Technical Specification:

Control panel EZ-01		Machine tool
control mode	CNC close Loop	X,Y axis travel	320 x 400
controlled AXIs	X, Y, U, V	Maximum work piece size	360×600mm
control panel size(L×W×H)	650×560×1710mm	Maximum Z height	360/480mm
control panel weight	175kg	Maximum work piece weight	300KG
input program format	G code	Maximum taper cutting angle	±3/0100mm
Display	15” color CRT	Maximum tool size(L×W×H)	1500×1250×1700mm
minimum input command	0.001 mm	Maximum tool weight	1400kg
minimum increment	0.001 mm	wire diameter	0.2 to 0.25 mm(brass), 0.12 to 0.25 mm(Molybdenum)
interpolation Function	Linear and Circular	Best surface finish(Ra)	1-1.5um
power requirement	3phase, 415VAC, 50Hz	Maximum cutting speed	60sq.mm/min
		Maximum dry run speed	25mm/min

No data was found

The multi-component dynamometer provides dynamic and quasi-static measurement of the 3 orthogonal components of a force (Fx, Fy, and Fz) acting from any direction onto the top plate.

With the aid of optional evaluation devices the 3 moments Mx, My and Mz can be measured as well.

The dynamometer has high rigidity and hence high natural frequency. The high resolution enables very small dynamic changes to be measured in large forces.

Technical information-Component Dynamometer Type 9257B…
Range Force application within and max.25 mm above top surface	Fx, Fy, Fz	kN	–5 … 5
Range when turning, force application	Fz	kN	–5 … 10
Calibrated partial range 1	Fx , Fy	N	0 … 500
Calibrated partial range 1	Fz	N	0 … 1 000
Calibrated partial range 2	Fx , Fy	N	0 … 50
Calibrated partial range 2	Fz	N	0 … 100
Overload Fx and Fy ≤0,5 Fz	Fx, Fy, Fz	kN	–7,5/7,5
Overload Fx and Fy ≤0,5 Fz	Fz	kN	–7,5/15
Response threshold		N	<0,01
Sensitivity	Fx, Fy	pC/N	≈–7,5
Sensitivity	Fz	pC/N	≈–3,7
Linearity (all ranges)		%FSO	≤±1
Hysteresis (all ranges)		%FSO	≤0,5
Crosstalk		%	≤±2
Rigidity	cx, cy	kN/μm	>1
Rigidity	cz	kN/μm	>2
Natural frequency	fn (x, y, z)	kHz	≈3,5
Natural frequency (mounted on flanges)	fn (x, y)	kHz	≈2,3
Natural frequency (mounted on flanges)	fn (z)	kHz	≈3,5
Operating temperature range		°C	0 … 70
Temperature coefficient of sensitivity		%/°C	–0,02
Capacitance (of channel)		pF	≈220
Insulation resistance at 20 °C		Ω	>1013
Ground insulation		Ω	>108
Protection class with cable Type		–	IP67
1687B5, 1689B5, 1677A5, 1679A5
Weight		kg	7,3

No data was found

What It Is:

Friction welding is a solid-state joining process that produces coalescence in materials, using the heat developed between surfaces through a combination of mechanically induced rubbing motion and applied load. The resulting joint is of forged quality. Under normal conditions, the faying surfaces do not melt. Filler metal, flux and shielding gas are not required with this process.

Dissimilar Materials:

Even metal combinations not normally considered compatible can be joined by friction welding, such as aluminium to steel, copper to aluminium, titanium to copper and nickel alloys to steel. As a rule, all metallic engineering materials which are forgeable can be friction welded, including automotive valve alloys, maraging steel, tool steel, alloy steels and tantalum. In addition, many castings, powder metals and metal matrix composites are weld able.

Savings—Cost, Time:

Material Since dissimilar materials can be joined, a significant cost savings is possible because engineers can design bimetallic parts that use expensive materials only where needed. Expensive forgings and castings can be replaced with less expensive forgings welded to bar stock, tubes, plates and the like. Substantial time savings are realized since the process is significantly faster than more conventional methods of welding.

Technical Specification:

Maker-RV machine tools
Welding capacity-Ø8 to Ø25 mm in steel
Machine overall dimension-2200×1900×1000mm
Spindle tape-A26
Spindle motor-servo motor (MAD130C-0150) (REXROTH)
Feedback encoder-spindle servo motor in built (REXROTH)
Motor torque/max-117Nm/275nm
Spindle power-15Kw
Spindle speed-1500rpm (max 2500RPM)
Spindle drive-poly V-belt drive
FW chuck-3B- Ø250 FWC (GMT)
Hydraulic closed cylinder-CH-22-65(GMT)
Z-axis thrust force-10 ton
Z-axis travel-200mm
Z-axis motor-23Nm/2200rpm
Z-axis rapid speed-300mm/min
Z-axis gear box-8:1 right angle planetary
Z-axis ball screw-40×10R×6-4(REXROTH)
Z-axis LM guide-RG-H-45-CA-2-R-640-ZO-H-AA-DD (HIWIN)
Z-axis-15ton load cell (ADI ARTECH)
Max/min holding diameter – Ø50mm/8mm
No of cylinder-2
Cylinder diameter – Ø100mm
Rod diameter- Ø80mm
Stroke-15mm
Z-axis-200mm
Power pack-HYDRO SOLUTION

No data was found

Profile

The highlights of the machine shop includes Heavy duty CNC Vertical machining centre with 41/2 axis, CNC Wire EDM machine, NC Friction Welding machine and Peizo Multi component Dynamometer. Machine shop also consists of Professional Training Centre for Tool Management Solutions in which tool wear/life can be ascertained and online tool offset can be set off

No data was found

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