24-09-2014, 02:29 PM
GPM ASSEMBLY GPM stands for General Purpose Machines. These are generally manually worked machines involving no computerized or numerical control. These machines are semi-automatic in nature and of its operation like table movement, job movement, tool movement etc can be carried out either automatically or even manually. These are operated by concerned operators manually. The concept of modern day machines originated from GPMs itself. These are the simplest form of the metal working machines. In HMT, Pinjore unit there primarily FOUR types of GPM are manufactured:- 1. FN2 Milling Machine 2. FN3 Milling Machine 3. Turret Ram Milling (TRM) Machine (Tool Room Machine) 4. Broching Machine
ABSTRACT
GPM ASSEMBLY
GPM stands for General Purpose Machines. These are generally manually worked machines involving no computerized or numerical control. These machines are semi-automatic in nature and of its operation like table movement, job movement, tool movement etc can be carried out either automatically or even manually. These are operated by concerned operators manually. The concept of modern day machines originated from GPMs itself. These are the simplest form of the metal working machines.
In HMT, Pinjore unit there primarily FOUR types of GPM are manufactured:-
1. FN2 Milling Machine
2. FN3 Milling Machine
3. Turret Ram Milling (TRM) Machine (Tool Room Machine)
4. Broching Machine
PROCESS LAYOUT OF MANUFACTURING OF GPM TABLE
Table is main part of machine tool. When manufacturing any component on machine then we need to rest our job or work piece at proper level and held rigidly to make various operations with accurately. We need a table which hold our job properly. In milling machine, planer, drilling machines, jig boring machine, boring machine, shaper etc need table to hold the job or work piece.
Here we study table no 1067 which is used in vertical milling machine. It is table of TRM machine.
Material of table - G3 greys cast iron.
Dimension - 1070×232×92
Weight of table- 110 kg
LAYOUT OF MACHINE TABLE
S NO.
OPERATION
MACHINE
1.
Marking
Surface plate
2.
Plano milling
Plano miller
3.
Planning
Planer
4.
Planning
Planer
5.
End milling
Boring machine
6.
Drilling
Radial Drilling machine
7.
Painting
Flore
8.
Grinding
Grinding machine
MARKING
Marking is a first step of every component. Marking is done manually by using of hand tools & machines. Marking is done on each & every casting component before initiating its machining.
In table marking is done on three side of table. First we need to lift the table with the help of overhead crane put it to on the surface plate, where three jacks are already placed
§ First need to adjust table on three jacks.
§ Check straightening of the place table on the jack with the help of try square.
§ Then check the drawing & see where we need to mark with respect to control dimension given in drawing.
§ Take height with HEIGHT VERNIER SCALE and steel rule.
§ Taking up to 5mm allowance for marking on component.
§ Mark on all the four side with scriber.
§ Again mark other four sides by changing the position of the table on jacks.
§ Again mark on other side.
§ Now there is marking on whole side of the component and there is cross marking which indicate extra material that is needed to remove by machining.
VERNIER HIEGHT GAUGE & SURFACE PLATE
INSTRUMENT USED FOR MARKING
§ Surface plate
§ Scriber
§ Height Vernier scale
§ Steel scale
§ Try square
PLANO MILLING
Operation - top & side milling
Machine name – Plano miller
Operation carried out- milling
Why we choose this machine- because in one setup we can make two sides simultaneously & there is time saving in loading and unloading of the job.
Component used on machine- thrust clamping, try square, butting from left hand and right hand side clamping,
Problem during machining- blow holes and there is chance of hard material due to casting defects. There remedies are pining & heat treatment respectively.
Plano milling machine is a very accurate machine it is two head one at the top and other at the right side of the machine. Both head have cutter which cut material simultaneously one head as planer machine and other is horizontal milling machine. Step takes while machining.
PLANO MILLING MACHINE
§ First place table on the machine with the help of overhead crane.
§ Make it thrust clamping & butting on the Plano machine table to hold the job.
§ Set machine feed and speed.
§ Make cut on work piece with respect to marking.
§ Take 2 mm allowance during machining.
§ First make cut on top side by operating first head of Plano milling machine.
§ Then make cut on front side by 2nd head of Plano milling machine.
§ Make size of front & top side.
§ 10 -12 mm cut has to make by Plano milling machine.
§ Front face 70 breath × 1070 length.
§ Top face 232 breath × 1070 length.
In Plano milling machine side & face cutter used & its diameter is 100mm. in this cutter carbide bit inserted. It is a left hand cutter.
TABLE AFTER FACE MILLING ON PLANO MILLING
PLANER
Operation - planning
Machine name - planer
Operation carried out – making dovetail
Tool used - Dove tail cutting tool, single point tool for facing.
Why we choose this machine – this is very accurate machine making for dovetail. & it’s table is long so that by setting one time machine we can make dovetail of three TRM table simultaneously.
Component used on machine – try square, dial indicator, clamp for butting, thrust clamp.
Problem during machining - blow holes
Here planning is done to make dove tail in the bottom side of the table.
Planer is used for cutting T-slot, dovetail and facing of plane surface. In the TRM machine table dovetail and side is made on this planer machine. This is very precise machine.
PLANER
§ Set up 1 piece per set up.
§ Mount on top pre machined face.