LUBRICATING CARBON BARING

OBJECTIVE:

Bearing Group

Carbon-graphite bearings and thrust washers are used in high temperature applications because oil/grease lubricated, metallic bearings can start to have problems at temperatures above about 350ºF (177ºC). Oil/grease lubricants can start to melt, volatilize or carbonize above this temperature. When this occurs, oil/grease-lubricated metallic bearings start to experience high friction, high wear, galling, vibration and even seizing.
At high temperatures, plastic and composite bearings are subject to other problems such as softening, melting, deformation and may extrude out of the bearing area all together.
Carbon graphite bearings are ideally suited for applications at elevated temperatures because they rely on graphite for their self-lubricating properties. These solid homogeneous bearing materials do not contain oil/grease lubricants and they do not rely on oil/grease for lubrication. Thus, bearings manufactured from these carbon graphite materials are not subject to the shortcomings associated with petroleum-based lubricants at elevated temperatures.
Because the carbon graphite matrix is very strong, it is not subject to the deformation, melting, or even softening that can occur with plastic bearings at these elevated temperatures.
Room Temperature or Cold Temperature Dry Running Applications
Carbon-graphite bearings are also used for dry running at room temperature or cold temperatures. This occurs in applications where oil/grease lubricated metal bearings can not be used because:

1. Oil/grease lubricants volatilize in vacuum
2. At low temperatures, oil/grease lubricants can congeal, freeze, or solidify
3. In environments containing abrasive dust which is attracted by oil/grease lubricants to form a paste that increases bearing wear.
4. In high load, slow roll, start-stop equipment where oil/grease lubricants can be squeezed out of the rubbing surface and cause metal-to-metal contact.
5. Where the bearings need to conduct an electric current.
6. In sanitary or clean conditions where oil/grease lubricants could leak out and destroy product such as food, textiles, pharmaceuticals, paper, etc.

COPY LATHE MACHINE

OBJECTIVE

The lathe machine is the most common machine tool machinery. Which remove material by rotating the work piece against a single point cutter. Parts can be held between centers, attached to a face plate, supported in a jaw chuck. Although this machine is particularly adapted for cylindrical work, it may also be used for other operations.

COPY LATHE MACHINE

NEW HYDRAULIC PUMPS

OBJECTIVE :

Branch of science concerned with the practical applications of fluids, primarily liquids, in motion. It is related to fluid mechanics (q.v.), which in large part provides its theoretical foundation. Hydraulics deals with such matters as the flow of liquids in pipes, rivers, and channels and their confinement by dams and tanks. Some of its principles apply also to gases, usually in cases in which variations in density are relatively small. Consequently, the scope of hydraulics extends to such mechanical devices as fans and gas turbines and to pneumatic control systems.

Hydraulic Elements

In hydraulic-power systems there are five elements: the driver, the pump, the control valves, the motor, and the load. The driver may be an electric motor or an engine of any type. The pump acts mainly to increase pressure. The motor may be a counterpart of the pump, transforming hydraulic input into mechanical output. Motors may produce either rotary or reciprocating motion in the load.

Hydraulic Pumps

The pumps run constant speed, usually by an electric motor, take the oil from the supply reservoir and deliver it at sufficient volume and pressure to do the work required.

Types of pumps

• gear pumps
• vane pumps
• plunger pumps
• piston pumps

Gear pumps

The gear pumps is probably the simplest kind of commercial medium- pressure
Constant-delivery pump. This type of pumps has been used for many years for raising and circulating (pumping) various kinds of liquids. Its wide use in the hydraulic transmission power is due to:
a. The large volume at medium pressure of which it is capable
b. It’s quiet running at high speed, owing to ball bearing, helical gears etc
c. Its small dimension
d. Its simplicity, low first cost and unkeep.

Vane pumps

The vane type pump has advantages in size, weight, quiet running, and long life, and is highly efficient. The diagrammatic is term “hydraulically” balanced” because there are two diagrammatically  opposing pumping chamber which, being opposite each other, cancel out thrust forces imposed by the pumping action.

Plunger pump

The plunger type pump lends it self radialy to variable delivery, high presser, and smooth flow and, alone or together with a constant-delivery unit, is an important piston, or plunger, which fits closely in its cylinder, draw in the oil as it moves outward and expels the oil as it is pushed back. These pumps have five or more radial cylinders, each of course, with its plunger.

Piston pump

Piston pumps generate a pumping act by causing piston to reciprocate within piston bore.
The pumping mechanism of piston pump basically consists of a cylinder barrel, piston with shoes, shawsplate, shoeplate, shoeplate bias spring, and port plate.

Hydraulic valves

The purpose of valves is to control the flow of oils. The flow is through passages called port, in through the suction (intake or inlet) port, out through the presser (outlet) port. Valves may be operated mechanically, electrically, or hydraulically, and for most action may be automatic. Very sensitive valves for controlling the slightest movement (inches) even 0.001 in. of heavy tables are not uncommon. Frequently two or more, and quite often several, valves are incorporated in the same hydraulic system.

Types of valves pilot valves

Pilot valves is operated usually by dogs on a sliding table (or by hand) to release a comparatively small amount of oil to actuate some larger valve.

2. Relief valve

A relief valve may be adjusted to open at a predetermined presser

3. Check valve

A check valve permits a one- way flow only.
4. Reverse valve
A reverse valve is for the purpose of changing the direction of the flow of oil to the driven unit.

5. Resistance valve (foot valve)

It offers resistance in one direction of the flow.

6. Control valve

It may cover a variety of uses, such as starting, stopping, speed changing, and quite often the movement of other valves for various purposes.

 Hydraulic drive system

A hydraulic drive system is a drive or transmission system that uses pressurized hydraulic fluid to drive hydraulic machinery. The term hydrostatic refers to the transfer of energy from flow and pressure, not from the kinetic energy of the flow.
A hydraulic drive system consists of three parts: The generator (e.g. a hydraulic pump), driven by an electric motor, a combustion engine or a windmill); valves, filters, piping etc. (to guide and control the system); the motor (e.g. a hydraulic motor or hydraulic cylinder) to drive the machinery.

Hydraulic Cylinder

Hydraulic cylinders (Also called linear hydraulic motors) are mechanical actuators that are used to give a linear force through a linear stroke. Hydraulic cylinders are able to give pushing and pulling forces of millions of metric tons with only a simple hydraulic system. Very simple hydraulic cylinders are used in presses; here, the cylinder consists of a volume in a piece of iron with a plunger pushed in it and sealed with a cover. By pumping hydraulic fluid in the volume, the plunger is pushed out with a force of plunger-area pressure.

VERTICAL DRILL MACHINE

VERTICAL DRILL MACHINE

OBJECTIVE:

Drilling is a process of machining with a rotary cutting motion, in which the tool only   allows a feed movement in the direction of the axis of rotation. Drill includes various production processes such as counter boring and reaming. Drilling purpose is to make hole from the solid by using twist drill.

Drilling Details

Drilling is the operation of producing circular hole in the work-piece by using a rotating cutter called DRILL.

• § The machine used for drilling is called drilling machine.
• § The drilling operation can also be accomplished in lathe, in which the drill is held in tailstock and the work is held by the chuck.
• § The most common drill used is the twist drill.

Drilling Machine
• It is the simplest and accurate machine used in production shop.
• The work piece is held stationary ie. Clamped in position and the drill rotates to make a hole.
Types
1) Based on construction:
Portable,
Sensitive,
Radial,
up-right,
Gang,
Multi-spindle
2) Based on Feed:
Hand driven
Power driven
Components of drilling machine
Spindle
The spindle holds the drill or cutting tools and revolves in a fixed position in a sleeve.
Sleeve
The sleeve or quill assembly does not revolve but may slide in its bearing in a direction parallel to its axis. When the sleeve carrying the spindle with a cutting tool is lowered, the cutting tool is fed into the work: and when it’s moved upward, the cutting tool is withdrawn from the work. Feed pressure applied to the sleeve by hand or power causes the revolving drill to cut its way into the work a fraction of an mm per revolution.
Column
The column is cylindrical in shape and built rugged and solid. The column supports the head and the sleeve or quill assembly.
Head
The head of the drilling machine is composed of the sleeve, a spindle, an electric motor and feed mechanism. The head is bolted to the column.
Worktable
The worktable is supported on an arm mounted to the column. The worktable can be adjusted vertically to accommodate different heights of work or it can be swung completely out of the way. It may be tilted up to 90 degree in either direction, to allow long pieces to be end or angle drilled.
Base
The base of the drilling machine supports the entire machine and when bolted to the floor, provides for vibration-free operation and best machining accuracy. The top of the base is similar to the worktable and may be equipped with t- slot for mounting work too larger for the table.
Hand Feed
The hand- feed drilling machines are the simplest and most common type of drilling machines in use today. These are light duty machine that are operated by the operator, using a feed handled, so that the operator is able to “feel” the action of the cutting tool as it cuts through the work piece. These drilling machines can be bench or floor mounted.
Power feed
The power feed drilling machine are usually larger and heavier than the hand feed ones they are equipped with the ability to feed the cutting tool in to the work automatically, at preset depth of cut per revolution of the spindle these machines are used in maintenance for medium duty work or the work that uses large drills that require power feed larger work pieces are usually clamped directly to the table or base using t –bolts and clamps by a small work places are held in a vise. A depth –stop mechanism is located on the head, near the spindle, to aid in drilling to a precise depth.
Sensitive or Bench Drilling Machine
• This type of drill machine is used for very light works. Fig.1 illustrates the sketch of sensitive drilling machine.
• The vertical column carries a swiveling table the height of which can be adjusted according to the work piece height.
• The table can also be swung to any desired position.
• At the top of the column there are two pulleys connected by a belt, one pulley is mounted on the motor shaft and other on the machine spindle.
• Vertical movement to the spindle is given by the feed handle by the operator.
• Operator senses the cutting action so sensitive drilling machine.
• Drill holes from 1.5 to 15mm
Fig.1. Sensitive Drilling Machine
Up-Right Drilling Machine
• These are medium heavy duty machines.
• It specifically differs from sensitive drill in its weight, rigidity, application of power feed and wider range of spindle speed. Fig.2 shows the line sketch of up-right drilling machine.
• This machine usually has a gear driven mechanism for different spindle speed and an automatic or power feed device.
• Table can move vertically and radially.
• Drill holes up to 50mm
Fig.2 Up-Right Drilling Machine
Radial Drilling Machine
• It the largest and most versatile used for drilling medium to large and heavy work pieces.
• Radial drilling machine belong to power feed type.
• The column and radial drilling machine supports the radial arm, drill head and motor. Fig.3 shows the line sketch of radial drilling machine.
Fig. 3 Radial Drilling Machine
• The radial arm slides up and down on the column with the help of elevating screw provided on the side of the column, which is driven by a motor.
• The drill head is mounted on the radial arm and moves on the guide ways provided the radial arm can also be swiveled around the column.
• The drill head is equipped with a separate motor to drive the spindle, which carries the drill bit. A drill head may be moved on the arm manually or by power.
• Feed can be either manual or automatic with reversal mechanism.
Drill Materials
The two most common types are
1. HSS drill
- Low cost
2. Carbide- tipped drills
– high production and in CNC machines
Other types are
Solid Carbide drill, TiN coated drills, carbide coated masonry drills, parabolic drills, split point drill. Fig.4 shows various types of drills
Fig. 4 Various types of drill
Drill fixed to the spindle
Fig. 5 Drill fixed to a spindle
Tool Nomenclature
Fig. 6 Nomenclature of twist drill
Tool holding devices
Fig.7 and Fig.8 shows the different work holding and drill drift device. The different methods used for holding drill in a drill spindle are
• By directly fitting in the spindle hole.
• By using drill sleeve
• By using drill socket
• By using drill chuck
Drilling operations
Operations that can be performed in a drilling machine are
Ø Drilling
Ø Reaming
Ø Boring
Ø Counter boring
Ø Countersinking
Ø Tapping
Drilling:
It is an operation by which holes are produced in solid metal by means of revolving tool called ‘Drill’. Fig. 9 shows the various operations on drilling machine.

PILLOW BLOCK BEARING

OBJECTIVE:

Type SA-PB Pillow Blocks and Flange Blocks are a uniquely designed compact unit (Patented) requiring minimum support space. These units are self-aligning, ruggedly constructed and suitable for non- lubricated heavy duty applications. Fitted with a variety of Metcar Self-lubricating Bearing Grades which can be operated dry or submerged to temperatures of 1000º F.
Special features of these heavy duty units are:

1. Completely self-aligning (compensate for shaft deflection and misalignment)
2. Can be used dry or submerged to temperatures of 1000º F.
3. Replaceable Bearing Cartridge can be rotated 180º for double life (no need to remove from shaft)
4. Interchangeable with most standard ball bearing pillow and flange blocks.
5. Operate freely and quietly under heavy loads
6. Can be modified for thrust loading
7. 10 sizes available for shafts up to 3-3/8″
8. 2 Standard Bearing Cartridge lengths available (A and A-Ext.) Bearing length (A) medium duty applications, bearing length (A-Ext.) heavy duty applications.
9. Unlimited Bearing Cartridge length available for unusual load and speed conditions.

PILLOW BLOCK BEARING

Metcar 1010 Babbitt–Dry or submerged applications up to 350º F. Metcar 1515 Copper–High temperature applications up to 750º F. Metcar 2500–High temperature applications up to 1000º F.

sheet metal U Channel

Channel Dimensions :

Thickness and Length of Channels

Johnson Bros U-Channel & J-Channel thicknesses can range from .003" thick up to .150" thick. On 1/4 & 1/2 hard Aluminum, thicknesses may be as much as .250" thick. Many different decorative pre-coated metals are not generally recommended when more than .030" thickness is required unless larger than normal corner radii can be used. Some coatings can be used, however, up to .125" thick such as a pre-finished Hot Dip Galvanized coating. Standard Tooling is available for most sizes. Our Capacities on U Channels and J Channels are: Using up to .075" maximum thickness, Legs can be up to 5.5" O.D. High and Web widths can be up to 19" O.D. wide. Using up to .156" maximum thickness, Legs can be up to 4" O.D. high and Web widths can be up to 14" O.D. wide. Aluminum U Channels & Aluminum J Channels will have higher maximum thicknesses.

U Channel

Some additional tooling costs may be required for: Special Corner Radii, Amco Bronze needed for highly polished stainless steel that is not allowed to be coated with a protective strippable PVC Covering, Legs bent more or less than 90 degrees, and other more sophisticated forming requirements.
Lengths may be from 3" thru 40 feet long with close tolerances. Many different lengths can be put on one purchase order.

Source www.machinecalmachinery.wordpress.com
Email:   aatifraees92@gmail.com

Sheet Metal Thickness

Gauge	Mild Steel	Aluminum	Galvanized Steel	Stainless Steel
3	0.2391	0.2294		0.2500
4	0.2242	0.2043		0.2344
5	0.2092	0.1819		0.2187
6	0.1943	0.1620		0.2031
7	0.1793	0.1443		0.1875
8	0.1644	0.1285	0.1680	0.165
9	0.1495	0.1144	0.1532	0.1562
10	0.1345	0.1019	0.1382	0.1406
11	0.1196	0.0907	0.1233	0.1250
12	0.1046	0.0808	0.1084	0.1094
13	0.0897	0.0720	0.0934	0.0937
14	0.0747	0.0641	0.0785	0.0781
15	0.0673	0.0571	0.0710	0.0703
16	0.0598	0.0508	0.0635	0.0625
17	0.0538	0.0453	0.0575	0.0562
18	0.0478	0.0403	0.0516	0.0500
19	0.0418	0.0359	0.0456	0.0437
20	0.0359	0.0320	0.0396	0.0375
21	0.0329	0.0285	0.0366	0.0344
22	0.0299	0.0253	0.0336	0.0312
23	0.0269	0.0226	0.0306	0.0281
24	0.0239	0.0201	0.0276	0.0250
25	0.0209	0.0179	0.0247	0.0219
26	0.0179	0.0159	0.0217	0.0187
27	0.0164	0.0142	0.0202	0.0172
28	0.0149	0.0126	0.0187	0.0156
29	0.0135	0.0113	0.0172	0.0141
30	0.0120	0.0100	0.0157	0.0125
31	0.0105	0.0089	0.0142	0.0109
32	0.0097	0.0080	0.0134	0.0102
33	0.0090	0.0071		0.0094
34	0.0082	0.0063		0.0086
35	0.0075	0.0056		0.0078
36	0.0067			0.0070

Sheet Metal Boxes

Electronic Wall Mount Boxes, Telephone Panel Boxes,etc.
Objective:

Our company offers design, engineering and fabrication for sheet metal boxes, such as Electronic Wall Mount Boxes, Telephone Panel Boxes, Telephone Shelf Main Boxes, etc.

We also offer other sheet metal enclosures and housings, for Communications, Networking, Medical Equipment, Aircraft, Military and other special applications.

Tell us what you need and we will provide you with a .

Our reputation for quality, service and competitive pricing have been primary factors in our continued growth over the years.

We can design, prototype and manufacture your product from start to finish and meet your production schedule. We work from casual or formal drawings and specifications utilizing the industry's latest computer aided technologies to ensure the highest in product quality.

Our manufacturing system is tailored to allow exceptional flexibility in handling  the varying volume demands that our customers have while maintaining the highest quality standards. In our quest to meet the most stringent customer demands we have implemented an efficient Management Information and Resource Planning System designed to ensure accurate and timely processing of information and effective execution and tracking of our manufacturing resources.

Sheet Metal Frames & Chassises

Objective :

Our company offers design, engineering and manufacturing for sheet metal frames and chassises, made of various metals, and finnishes.

Please see below some of our products:

1.  Back Frames for IT and Telecom industries
2.  Metal Frames for Cabinets
3.  Conveyor Frames 
4.  Sheet Metal Frame Parts
5.  Titanium Frames
6.  Sheet Metal Chassises for Electronic Equipment 
7.  R ack Mount Chassises
8.  Government Contracts
9.  Aerospace & Military Chassises

Sheet Metal Bending &Forming

Objective:
Our company employs some of the best craftsmen in the sheet metal industry at forming and the precision tools necessary to process close tolerance precision sheet metal bends.
In our workshop we have press brakes capable of doing most any job from prototype to production with accuracy.

We have a wide range of both standard and non-standard press brake tooling available. That allows us to produce many types of complex sheet metal bends.

Sheet Metal Bending - Wide range of bending capabilities with a very large inventory of bend dies/tools

We feature CNC and mechanical benders that bend in material range from 3/8" to 6", from .028" wall to .250" wall in carbon steel, stainless steel, aluminum, copper and brass.

We bend rounds, ovals, squares, rectangles and special shapes.

Quality mandrel and non-mandrel, crush, draw and press bends. we have capabilities to bend complex shapes.

Sheet Metal Cabinets

Objective:


Metal Dynamix offers design, engineering, prototyping and fabrication of various sheet metal cabinets & metal enclosures, for a wide variety of industries, such as Telecom, Medical, Industrial, Consumer Goods, Mil Spec, etc. We employ a  system for standard and custom sheet metal cabinets & metal enclosures, which we invite you to ask for.
Please see below some of the sheet metal cabinets & metal enclosures that we can supply from stock or custom made:

Sheet Metal Cabinets:

 Server Cabinets & Mobile Carts,   Rack Mount Server Cabinets, 19" Server Cabinets  Data Center Cabinets  Computer Cabinets  Equipment Cabinets, Network Cabinets  Copper Bus Bars  Metal File Cabinets  Metal Storage Cabinets  Wall Mount Metal Cabinets  Rack Mount Metal Cabinets  Metal Tool Cabinets  Utility Metal Cabinets  Metal Shelf Assemblies  Cabinet Accessories Metal Dynamix will satisfy your precision sheet metal fabrication requirements with the very best in cost effective engineering, layout, design, and production. From initial consultation right through to final delivery, our experienced professional staff will be with you every step of the way t0 ensure consistent, top quality work.
If your next job requires metal fabrication, be sure to talk with us before you start.

Sheet Metal Design

Objective :
Our company has a complete set of software tools for sheet metal design. We efficiently create and manage sheet metal parts based on knowledge of material properties and manufacturing processes.

The CAD suites we use include features and utilities that incorporate material and process information and allow the model to represent multiple stages in the sheet metal fabrication cycle - such as bends, flanges, cutouts, and other formable features.

The sheet metal design tools allow us to apply defaults and standards to the values used in creation of sheet metal parts, based on both industry or company best practices. For example, bend radii values may be fixed within a certain range for a given material thickness based on known manufacturing quality issues.

Folded and unfolded views of sheet metal components can be used in both the 3D environment as well as downstream in 2D documentation and for manufacturing. We use CAD packages, that enable the full interaction of other parametric modeling operations with sheet metal features within the context of a single part.


summary of our operations:

1. Sheet Metal Sheering /Sheet Metal Cutting
2. Sheet Metal Punching / Sheet Metal Piercing
3. Sheet Metal Grinding /Sheet Metal Polishing
4. Sheet Metal Welding: Mig, Tig, Resistance (Spot Weld)
5. Sheet Metal Forming / Sheet Metal Bending
6. Sheet Metal Drilling
7. Sheet Metal Notching 
8. Sheet Metal Milling
9. Sheet Metal Sawing
10. Sheet Metal Hardware Insertion
11. Sheet Metal Pressing
12. Sheet Metal Rolling
13. Sheet Metal Tube Bending
14. Sheet Metal Powder Coating
15. Sheet Metal Plating
16. Sheet Metal Silk Screening
17. Sheet Metal MIL Spec Painting
18. Programming & Precision Machining
19. Sheet Metal Inspection
20. Packaging / Shipping

Source: www.machinecalmachinery.wordpress.com
Email:     atifraees92@gmail.com
Cell No. 03452641467