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Machine Rebuilding is a comparatively new technology in the industrially developed countries. It should not be mixed with machine tool repair and maintenance and overhaul. The main characteristic of Machine Rebuilding are:
- The rebuilt machine has same performance and accuracy as a new machine.
- The warranty period is same as for a new one.
- Cost of Rebuilding is one-third of the price of new equivalent machine.
PMTF has established this machine rebuilding facility in 1994 with the assistance of UNIDO experts from UK and since then has undertaken the rebuilding activity with targeted output set for 10 to 12 machines per annum.
Quality Control:
Inspection and Testing is carried out according to procedures established for ISO 9001 Quality Assurance System. The inspection activities are backed up with the facility for calibration of measuring and testing devices.
| Design Centre: | |
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Computer Aided Design & Manufacturing (CAD/CAM) facilities were installed for Product Design and Tools/Jigs/Fixtures Design and CNC Shop in 1990. Engineering software from Computer vision (USA) and Autodesk namely:
- CADDS 5
- Design View
- Personal Designer
- Personal Designer/Personal Machinist
- Micro draft
- Personal Data Extract
- Mechanical Desktop power pack (with Auto Cad 2000)
are used for design of products, tools, jigs, fixtures, cutters, forging & die casting dies, gears, equipments, mechanical devices.
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| Machining: | |
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The works facility consists of variety of conventional and CNC machine tools capable of performing various machining operations such as turning, planning, milling, drilling, jig boring, thread grinding, deep hole drilling, gear hobbing, shaping and shaving, gear grinding, spiral bevel gear cutting, broaching to the close tolerances specified in the design. The maximum machining capabilities are as follows:
| Turning | : Max. 1000 mm dia x 4000 mm length x 800 kg wt. |
| Shaping/Planning | : Max. 6000 mm length x 1500 mm width x 2000 kg wt. |
| Boring/Drilling | : Max. 600 mm dia/50 mm dia max. |
| Gear Cutting | : 10 module x 700 mm dia max. |
| Grinding | : Max. 400 mm dia x 2500 mm length x 500 kg wt. |
| Pressure Die Casting | : Max 650 ton locking force x 12 kg wt. |
Besides above facilities special purpose machines are available for die-sinking, spark erosion, thread grinding, jig boring, spline rolling, vertical turning, copy milling for intricate precision components.
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| Tool Room: | |
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The factory has a fully equipped Tool Room facility capable of manufacturing jigs & fixtures, special tools like drills, gauges, cutters and holding devices, special high precision machine tools like jig boring, thread grinding, die sinking, relieving lathes, vertical copying lathes, precision milling machines and special purpose tool grinding of Swiss and German origin suppliments the facility and ensures that all specifications and tolerances essential for tool room accuracy is met. The Tool Room is linked with Tool Design Section fully equipped with omputer Aided Design facilities and supported by Metrology section located in same area for precise calibration and control of tool room products. All recommended international standards are followed for toolings.
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| Material Testing: | |
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a. Metallography:
Complete Evaluation of :
Macro and Micro Structure
Non - Metalic Inclusion & segregation
Case Hardening and Case Depth
Photo Micrograph of Structure
Failure Analysis
b. Mechanical Testing:
Facilities to determine:
Mechanical Properties
Stress - Strain
Tensile and Compressive Strength
Shear and Impact Test
c. Chemical Testing:
Complete Analysis of:
Metals and Alloys
Ferrous and Non Ferrous Elements
Paints, Chemicals, Ores, Oils Greases etc
d. Non-Destructive Testing:
Determination of:
Internal Cracks by Ultrasonic Testing
Surface Cracks by Magnaflux and Dye
- Penetration
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| Heat Treatment: | |
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The Heat Treatment shop is the largest and the most well equipped in the country. The equipment is of French, German and Italian origin.
The Facilities has :
- For Carburising and Case Hardening :
Five Sealed Quench Furnaces
Three Gas Fired Pit-type Muffle Furnaces
Two Rotary Hearth Furnaces with Quenching Press
Electrically Heated Tempering Furnace
For Induction Hardening :
Three High Frequency and Medium Frequency Induction Hardening Machines
For Surface Hardening :
Flame Hardening Machine
For Hardening High Speed Steel :
Salt Bath Furnaces
Hydraulic Presses, Shot Blasting Machines, Sand Blasting Plant are available for post-
heat treatment process.
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| Forging: | |
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The Forging shop is equipped with two drop hammers of 3000 kg and 1500 kg Pneumatic hammers of 600 kg and 300 kg, Tremming press of 320 tons and 1000 tons, Friction Screw Press of 480 tons, Heating of stock for forging is done in rotary hearth furnace. Furnace car-bottom type is installed for normalising the forged components. Removal of scales is done in Tumbler & Table type shot blasting machines. The forge shop is capable of production of forgings upto 20 kg and 200 mm in diameter.
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| Machine Rebuilding: | |
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Machine Rebuilding is a comparatively new technology in the industrially developed countries. It should not be mixed with machine tool repair and maintenance and overhaul. The main characteristic of Machine Rebuilding are:
- The rebuilt machine has same performance and accuracy as a new machine.
- The warranty period is same as for a new one.
- Cost of Rebuilding is one-third of the price of new equivalent machine.
PMTF has established this machine rebuilding facility in 1994 with the assistance of UNIDO experts from UK and since then has undertaken the rebuilding activity with targeted output set for 10 to 12 machines per annum.
Quality Control:
Inspection and Testing is carried out according to procedures established for ISO 9001 Quality Assurance System. The inspection activities are backed up with the facility for calibration of measuring and testing devices.
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