Conventional/non conventional

Machining tools

For industrial applications

Department of 4i – Laboratory IITKanpur

Machining facilities available

Rapid prototyping CNC

Water Jet Laser cutting

Lathe Drilling Milling

Other machining tools

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 fabrication facility available in 4i Lab

1. A CAD model is constructed, then converted to STL format. The

resolution can be set to minimize stair stepping.

2. The RP machine processes the .STL file by creating sliced

layers of the model.

3. 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.

4. The model and any supports are removed. The surface of the

model is then finished and cleaned.

Output Functioning of Rapid prototyping

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.

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.

Output Functioning of abrasive jet machining

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

The fabrication facility available in 4i Lab

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.

The fabrication facility available in 4i Lab

(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 (25-5000)

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

Output

•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.

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.

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)

LASER (Engraving and Cutting )

Model : EPILOG MINI WIN 32

Output Functioning of laser machining

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.

The fabrication facility available in 4i Lab

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.

Output of Laser Cutting System realized in 4i lab

Tiles Stamps

Leather belt design Wood Engraving Metal Engraving

Sunmica Engraving

Technical information

1. X-Travel 630 mm

2. Y-Travel 500 mm

3. Z-Travel 500 mm

4. Spindle taper SK 40

5. Spindle speed range 0-8000 rpm

6. Feed range 1-30000 mm/min

7. Rapid feed 30 m/min

8. Table clamping area 800x500 mm

9. Number of tools in changer 24

10. Max. tool diameter if magazine is full 80 mm

11. Max. tool diameter if both sides are free 140 mm

12. Max. tool length 300 mm

13. Max. tool weight 7 kg

14. Drive capacity 30 kW

15. Weight ca. 6500 kg

3 AXIS CNC VERTICAL MILLING MACHINE

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

EZEE DRILL

EDM Drill

Machine

EZEE drilling in hard metals

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.

Machine Tool EZEE DRILL

Work Table 440 X 320

X & Y Axis Travel 350 X 270

Z Axis Travel 320+300

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

Technical Specifications of EZEE DRILL:

EZEECUT NXG

CNC Wirecut EDM CNC Wirecut EDM

Features :

•� 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.

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CNC Pulse Generator EzeeWin

Technical Specifications

Machine Tool - EZEECUT NXG

Parameter EP EP EP

2532H 3240H 4050H

Worktable size mm 340 x 560 380 x 650 410 x 710

XY table traverse mm 250 x 320 320 x 400 400 x 500

Max Z height mm 300 300 300

Max workpiece weight Kg 200 300 450

Max taper cutting angle ±3/0100mm ±3/0100mm ±3/0100mm

Generator EzeeWin

Minimum input command 0.001 mm

Minimum increment 0.001 mm

Interpolation function Linear and Circular

Simultaneous controlled X, Y, U, V

Resolution for X, Y, U, 0.001 mm

Data input CD, USB Pendrive

Input power supply 3phase, 415VAC,

50Hz

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

PCB Fabrication Flow Chart

LPKF Protomat 95s/2

LPKF Contac RS

LAUFFER Press

LPKF ProMask

Green TRF LPKF UV Exposure

LPKF ProtoPrint LPKF ProtoPlace

LPKF ProtoFlow

If PCB is more than 2 layers

Thank You