Sheet Metal

Monday, 10 June 2013

Laser beam cutting

Laser cutting uses a high powered laser to cut through sheet metal. A series of mirrors and lenses direct and focus a high-energy beam of light onto the surface of the sheet where it is to be cut. When the beam strikes the surface, the energy of the beam melts and vaporizes the metal underneath. Any remaining molten metal or vapor is blown away from the cut by a stream of gas. The position of the laser beam relative to the sheet is precisely controlled to allow the laser to follow the desired cutting path.

This process is carried out on laser cutting machines that consist of a power supply, laser system, mirrors, focusing lens, nozzle, pressurized gas, and a workpiece table. The laser most commonly used for sheet metal cutting is a CO2 based laser with approximately 1000-2000 watts of power. However, Nd and Nd-YAG lasers are sometimes used for very high power applications. The laser beam is directed by a series of mirrors and through the "cutting head" which contains a lens and nozzle to focus the beam onto the cutting location. The beam diameter at the cutting surface is typically around 0.008 inches. In some machines, the cutting head is able to move in the X-Y plane over the workpiece which is clamped to a stationary table below. In other laser cutting machines, the cutting head remains stationary, while the table moves underneath it. Both systems allow the laser beam to cut out any 2D shape in the workpiece. As mentioned above, pressurized gas is also used in the process to blow away the molten metal and vapor as the cut is formed. This assist gas, typically oxygen or nitrogen, feeds into the cutting head and is blown out the same nozzle as the laser beam.

Laser cutting can be preformed on sheet metals that are both ferrous and non-ferrous. Materials with low reflectivity and conductivity allow the laser beam to be most effective - carbon steel, stainless steel, and titanium are most common. Metals that reflect light and conduct heat, such as aluminum and copper alloys, can still be cut but require a higher power laser. Laser cutting can also be used beyond sheet metal applications, to cut plastics, ceramics, stone, wood, etc.

As previously mentioned, laser cutting can be used to cut nearly any 2D shape. However, the most common use is cutting an external profile or complex features. Simple internal features, such as holes or slots are usually punched out using other sheet metal processes. But highly complex shapes and outer part boundaries are well suited for laser cutting. The fact that laser cutting does not require any physical contact with the material offers many benefits to the quality of the cuts. First, minimal burrs are formed, creating a smooth edge that may not require any finishing. Secondly, no tool contact means only minimal distortion of the sheet will occur. Also, only a small amount of heat distortion is present in the narrow zone affected by the laser beam. Lastly, no contaminates will be embedded into the material during cutting. Although not a quality issue, it is worth noting that the lack of physical tool wear will reduce costs and make laser cutting cost effective for low volume production.

Capabilities

Sheet thickness: 0.02-0.50 in.
Cutting speed: 30-500 IPM (1000 IPM feasible)
Kerf width: 0.006-0.016 in. (0.004 in. feasible)
Tolerance: ±0.005 in. (±0.001 in. feasible)
Surface finish: 125-250 μin

Design rules

Edges - Burrs are minimal, but can be further reduced by using a thinner sheet stock.
Corners - Rounded corners are preferred to sharp corners. Interior corners must have a minimum radius equal to the laser beam radius.
Holes - Minimum hole diameter should be approximately 20% of sheet thickness, down to 0.010 inches. Laser-cut holes will have a slight natural taper.
Multiple sheets can be cut at once to reduce cost

Drill Size Chart

The drill size chart provides a list of standard size drill bits in several measurement systems, including fractional, metric, wire gauge number, and letter. The decimal equivalents of the diameters are shown in both English and Metric units. Fractional sizes are measured in inches, while metric sizes are measured in millimeters. The wire gauge and letter systems refer to tool diameters that increase as the wire gauge decreases from #107 to #1 and then continues from A to Z. The drill size chart contains tools up to 1.5 inches in diameter, but larger tools are also commonly used.

Drill size	Diameter (in)	Diameter (mm)
#107	0.0019	0.0483
0.05 mm	0.0020	0.0500
#106	0.0023	0.0584
#105	0.0027	0.0686
#104	0.0031	0.0787
#103	0.0035	0.0889
#102	0.0039	0.0991
0.1 mm	0.0039	0.1000
#101	0.0043	0.1092
#100	0.0047	0.1194
#99	0.0051	0.1295
#98	0.0055	0.1397
#97	0.0059	0.1499
#96	0.0063	0.1600
#95	0.0067	0.1702
#94	0.0071	0.1803
#93	0.0075	0.1905
0.2 mm	0.0079	0.2000
#92	0.0079	0.2007
#91	0.0083	0.2108
#90	0.0087	0.2210
#89	0.0091	0.2311
#88	0.0095	0.2413
#87	0.0100	0.2540
#86	0.0105	0.2667
#85	0.0110	0.2794
#84	0.0115	0.2921
0.3 mm	0.0118	0.3000
#83	0.0120	0.3048
#82	0.0125	0.3175
#81	0.0130	0.3302
#80	0.0135	0.3429
#79	0.0145	0.3680
1/64 in	0.0156	0.3969
0.4 mm	0.0158	0.4000
#78	0.0160	0.4064
#77	0.0180	0.4572
0.5 mm	0.0197	0.5000
#76	0.0200	0.5080
#75	0.0210	0.5334
#74	0.0225	0.5715
0.6 mm	0.0236	0.6000
#73	0.0240	0.6096
#72	0.0250	0.6350
#71	0.0260	0.6604
0.7 mm	0.0276	0.7000
#70	0.0280	0.7112
#69	0.0292	0.7417
#68	0.0310	0.7874
1/32 in	0.0313	0.7938
0.8 mm	0.0315	0.8000
#67	0.0320	0.8128
#66	0.0330	0.8382
#65	0.0350	0.8890
0.9 mm	0.0354	0.9000
#64	0.0360	0.9144
#63	0.0370	0.9398
#62	0.0380	0.9652
#61	0.0390	0.9906
1 mm	0.0394	1.0000
#60	0.0400	1.0160
#59	0.0410	1.0414
#58	0.0420	1.0668
#57	0.0430	1.0922
1.1 mm	0.0433	1.1000
#56	0.0465	1.1811
3/64 in	0.0469	1.1906
1.2 mm	0.0472	1.2000
1.3 mm	0.0512	1.3000
#55	0.0520	1.3208
#54	0.0550	1.3970
1.4 mm	0.0551	1.4000
1.5 mm	0.0591	1.5000
#53	0.0595	1.5113
1/16 in	0.0625	1.5875
1.6 mm	0.0630	1.6000
#52	0.0635	1.6129
1.7 mm	0.0669	1.7000
#51	0.0670	1.7018
#50	0.0700	1.7780
1.8 mm	0.0709	1.8000
#49	0.0730	1.8542
1.9 mm	0.0748	1.9000
#48	0.0760	1.9304
5/64 in	0.0781	1.9844
#47	0.0785	1.9939
2 mm	0.0787	2.0000
#46	0.0810	2.0574
#45	0.0820	2.0828
2.1 mm	0.0827	2.1000
#44	0.0860	2.1844
2.2 mm	0.0866	2.2000
#43	0.0890	2.2606
2.3 mm	0.0906	2.3000
#42	0.0935	2.3749
3/32 in	0.0938	2.3813
2.4 mm	0.0945	2.4000
#41	0.0960	2.4384
#40	0.0980	2.4892
2.5 mm	0.0984	2.5000
#39	0.0995	2.5273
#38	0.1015	2.5781
2.6 mm	0.1024	2.6000
#37	0.1040	2.6416
2.7 mm	0.1063	2.7000
#36	0.1065	2.7051
7/64 in	0.1094	2.7781
#35	0.1100	2.7940
2.8 mm	0.1102	2.8000
#34	0.1110	2.8194
#33	0.1130	2.8702
2.9 mm	0.1142	2.9000
#32	0.1160	2.9464
3 mm	0.1181	3.0000
#31	0.1200	3.0480
3.1 mm	0.1221	3.1000
1/8 in	0.1250	3.1750
3.2 mm	0.1260	3.2000
#30	0.1285	3.2639
3.3 mm	0.1299	3.3000
3.4 mm	0.1339	3.4000
#29	0.1360	3.4544
3.5 mm	0.1378	3.5000
#28	0.1405	3.5687
9/64 in	0.1406	3.5719
3.6 mm	0.1417	3.6000
#27	0.1440	3.6576
3.7 mm	0.1457	3.7000
#26	0.1470	3.7338
#25	0.1495	3.7973
3.8 mm	0.1496	3.8000
#24	0.1520	3.8608
3.9 mm	0.1535	3.9000
#23	0.1540	3.9116
5/32 in	0.1563	3.9688
#22	0.1570	3.9878
4 mm	0.1575	4.0000
#21	0.1590	4.0386
#20	0.1610	4.0894
4.1 mm	0.1614	4.1000
4.2 mm	0.1654	4.2000
#19	0.1660	4.2164
4.3 mm	0.1693	4.3000
#18	0.1695	4.3053
11/64 in	0.1719	4.3656
#17	0.1730	4.3942
4.4 mm	0.1732	4.4000
#16	0.1770	4.4958
4.5 mm	0.1772	4.5000
#15	0.1800	4.5720
4.6 mm	0.1811	4.6000
#14	0.1820	4.6228
#13	0.1850	4.6990
4.7 mm	0.1850	4.7000
3/16 in	0.1875	4.7625
4.8 mm	0.1890	4.8000
#12	0.1890	4.8006
#11	0.1910	4.8514
4.9 mm	0.1929	4.9000
#10	0.1935	4.9149
#9	0.1960	4.9784
5 mm	0.1969	5.0000
#8	0.1990	5.0546
5.1 mm	0.2008	5.1000
#7	0.2010	5.1054
13/64 in	0.2031	5.1594
#6	0.2040	5.1816
5.2 mm	0.2047	5.2000
#5	0.2055	5.2197
5.3 mm	0.2087	5.3000
#4	0.2090	5.3086
5.4 mm	0.2126	5.4000
#3	0.2130	5.4102
5.5 mm	0.2165	5.5000
7/32 in	0.2188	5.5563
5.6 mm	0.2205	5.6000
#2	0.2210	5.6134
5.7 mm	0.2244	5.7000
#1	0.2280	5.7912
5.8 mm	0.2284	5.8000
5.9 mm	0.2323	5.9000
A	0.2340	5.9436
15/64 in	0.2344	5.9531
6 mm	0.2362	6.0000
B	0.2380	6.0452
6.1 mm	0.2402	6.1000
C	0.2420	6.1468
6.2 mm	0.2441	6.2000
D	0.2460	6.2484
6.3 mm	0.2480	6.3000
1/4 in	0.2500	6.3500
E	0.2500	6.3500
6.4 mm	0.2520	6.4000
6.5 mm	0.2559	6.5000
F	0.2570	6.5278
6.6 mm	0.2598	6.6000
G	0.2610	6.6294
6.7 mm	0.2638	6.7000
17/64 in	0.2656	6.7469
H	0.2660	6.7564
6.8 mm	0.2677	6.8000
6.9 mm	0.2717	6.9000
I	0.2720	6.9088
7 mm	0.2756	7.0000
J	0.2770	7.0358
7.1 mm	0.2795	7.1000
K	0.2810	7.1374
9/32 in	0.2813	7.1438
7.2 mm	0.2835	7.2000
7.3 mm	0.2874	7.3000
L	0.2900	7.3660
7.4 mm	0.2913	7.4000
M	0.2950	7.4930
7.5 mm	0.2953	7.5000
19/64 in	0.2969	7.5406
7.6 mm	0.2992	7.6000
N	0.3020	7.6708
7.7 mm	0.3032	7.7000
7.8 mm	0.3071	7.8000
7.9 mm	0.3110	7.9000
5/16 in	0.3125	7.9375
8 mm	0.3150	8.0000
O	0.3160	8.0264
8.1 mm	0.3189	8.1000
8.2 mm	0.3228	8.2000
P	0.3230	8.2042
8.3 mm	0.3268	8.3000
21/64 in	0.3281	8.3344
8.4 mm	0.3307	8.4000
Q	0.3320	8.4328
8.5 mm	0.3347	8.5000
8.6 mm	0.3386	8.6000
R	0.3390	8.6106
8.7 mm	0.3425	8.7000
11/32 in	0.3438	8.7313
8.8 mm	0.3465	8.8000
S	0.3480	8.8392
8.9 mm	0.3504	8.9000
9 mm	0.3543	9.0000
T	0.3580	9.0932
9.1 mm	0.3583	9.1000
23/64 in	0.3594	9.1281
9.2 mm	0.3622	9.2000
9.3 mm	0.3661	9.3000
U	0.3680	9.3472
9.4 mm	0.3701	9.4000
9.5 mm	0.3740	9.5000
3/8 in	0.3750	9.5250
V	0.3770	9.5758
9.6 mm	0.3780	9.6000
9.7 mm	0.3819	9.7000
9.8 mm	0.3858	9.8000
W	0.3860	9.8044
9.9 mm	0.3898	9.9000
25/64 in	0.3906	9.9219
10 mm	0.3937	10.0000
X	0.3970	10.0838
Y	0.4040	10.2616
13/32 in	0.4063	10.3188
Z	0.4130	10.4902
10.5 mm	0.4134	10.5000
27/64 in	0.4219	10.7156
11 mm	0.4331	11.0000
7/16 in	0.4375	11.1125
11.5 mm	0.4528	11.5000
29/64 in	0.4531	11.5094
15/32 in	0.4688	11.9063
12 mm	0.4724	12.0000
31/64 in	0.4844	12.3031
12.5 mm	0.4921	12.5000
1/2 in	0.5000	12.7000
13 mm	0.5118	13.0000
33/64 in	0.5156	13.0969
17/32 in	0.5313	13.4938
13.5 mm	0.5315	13.5000
35/64 in	0.5469	13.8906
14 mm	0.5512	14.0000
9/16 in	0.5625	14.2875
14.5 mm	0.5709	14.5000
37/64 in	0.5781	14.6844
15 mm	0.5906	15.0000
19/32 in	0.5938	15.0813
39/64 in	0.6094	15.4781
15.5 mm	0.6102	15.5000
5/8 in	0.6250	15.8750
16 mm	0.6299	16.0000
41/64 in	0.6406	16.2719
16.5 mm	0.6496	16.5000
17 mm	0.6693	17.0000
43/64 in	0.6719	17.0656
11/16 in	0.6875	17.4625
17.5 mm	0.6890	17.5000
45/64 in	0.7031	17.8594
18 mm	0.7087	18.0000
23/32 in	0.7188	18.2563
18.5 mm	0.7284	18.5000
47/64 in	0.7344	18.6531
19 mm	0.7480	19.0000
3/4 in	0.7500	19.0500
49/64 in	0.7656	19.4469
19.5 mm	0.7677	19.5000
25/32 in	0.7813	19.8438
20 mm	0.7874	20.0000
51/64 in	0.7969	20.2406
20.5 mm	0.8071	20.5000
13/16 in	0.8125	20.6375
21 mm	0.8268	21.0000
53/64 in	0.8281	21.0344
27/32 in	0.8438	21.4313
21.5 mm	0.8465	21.5000
55/64 in	0.8594	21.8281
22 mm	0.8661	22.0000
7/8 in	0.8750	22.2250
22.5 mm	0.8858	22.5000
57/64 in	0.8906	22.6219
23 mm	0.9055	23.0000
29/32 in	0.9063	23.0188
21/23 in	0.9130	23.1913
59/64 in	0.9219	23.4156
23.5 mm	0.9252	23.5000
15/16 in	0.9375	23.8125
24 mm	0.9449	24.0000
61/64 in	0.9531	24.2094
24.5 mm	0.9646	24.5000
31/32 in	0.9688	24.6063
25 mm	0.9843	25.0000
63/64 in	0.9844	25.0031
1 in	1.0000	25.4000
25.5 mm	1.0039	25.5000
1 1/64 in	1.0156	25.7969
26 mm	1.0236	26.0000
1 1/32 in	1.0313	26.1938
26.5 mm	1.0433	26.5000
1 3/64 in	1.0469	26.5906
1 1/16 in	1.0625	26.9875
27 mm	1.0630	27.0000
1 5/64 in	1.0781	27.3844
27.5 mm	1.0827	27.5000
1 3/32 in	1.0938	27.7813
28 mm	1.1024	28.0000
1 7/64 in	1.1094	28.1781
28.5 mm	1.1221	28.5000
1 1/8 in	1.1250	28.5750
1 9/64 in	1.1406	28.9719
29 mm	1.1417	29.0000
1 5/32 in	1.1563	29.3688
29.5 mm	1.1614	29.5000
1 11/64 in	1.1719	29.7656
30 mm	1.1811	30.0000
1 3/16 in	1.1875	30.1625
30.5 mm	1.2008	30.5000
1 13/64 in	1.2031	30.5594
1 7/32 in	1.2188	30.9563
31 mm	1.2205	31.0000
1 15/64 in	1.2344	31.3531
31.5 mm	1.2402	31.5000
1 1/4 in	1.2500	31.7500
32 mm	1.2598	32.0000
1 17/64 in	1.2656	32.1469
32.5 mm	1.2795	32.5000
1 9/32 in	1.2813	32.5438
1 19/64 in	1.2969	32.9406
33 mm	1.2992	33.0000
1 5/16 in	1.3125	33.3375
33.5 mm	1.3189	33.5000
1 21/64 in	1.3281	33.7344
34 mm	1.3386	34.0000
1 11/32 in	1.3438	34.1313
34.5 mm	1.3583	34.5000
1 23/64 in	1.3594	34.5281
1 3/8 in	1.3750	34.9250
35 mm	1.3780	35.0000
1 25/64 in	1.3906	35.3219
35.5 mm	1.3976	35.5000
1 13/32 in	1.4063	35.7188
36 mm	1.4173	36.0000
1 27/64 in	1.4219	36.1156
36.5 mm	1.4370	36.5000
1 7/16 in	1.4375	36.5125
1 29/64 in	1.4531	36.9094
37 mm	1.4567	37.0000
1 15/32 in	1.4688	37.3063
37.5 mm	1.4764	37.5000
1 31/64 in	1.4844	37.7031
38 mm	1.4961	38.0000
1 1/2 in	1.5000	38.1000

Manual vertical milling machine

Manual vertical mailling mchine

The above components of the milling machine can be oriented either vertically or horizontally, creating two very distinct forms of milling machine. A horizontal milling machine uses a cutter that is mounted on a horizontal shaft, called an arbor, above the workpiece. For this reason, horizontal milling is sometimes referred to as arbor milling. The arbor is supported on one side by an overarm, which is connected to the column, and on the other side by the spindle. The spindle is driven by a motor and therefore rotates the arbor. During milling, the cutter rotates along a horizontal axis and the side of the cutter removes material from the workpiece. A vertical milling machine, on the other hand, orients the cutter vertically. The cutter is secured inside a piece called a collet, which is then attached to the vertically oriented spindle. The spindle is located inside the milling head, which is attached to the column. The milling operations performed on a vertical milling machine remove material by using both the bottom and sides of the cutter.

Milling machines can also be classified by the type of control that is used. A manual milling machine requires the operator to control the motion of the cutter during the milling operation. The operator adjusts the position of the cutter by using hand cranks that move the table, saddle, and knee. Milling machines are also able to be computer controlled, in which case they are referred to as a computer numerical control (CNC) milling machine. CNC milling machines move the workpiece and cutter based on commands that are preprogrammed and offer very high precision. The programs that are written are often called G-codes or NC-codes. Many CNC milling machines also contain another axis of motion besides the standard X-Y-Z motion. The angle of the spindle and cutter can be changed, allowing for even more complex shapes to be milled.

Manual vertical milling machine

Standard Manufacturing Chart Thickness's

Standard Manufacturing Chart Thickness's

Gauge (or gage) sizes are numbers that indicate the thickness of a piece of sheet metal, with a higher number referring to a thinner sheet. The equivalent thicknesses differ for each gauge size standard, which were developed based on the weight of the sheet for a given material. The Manufacturers' Standard Gage provides the thicknesses for standard steel, galvanized steel, and stainless steel. The Brown and Sharpe Gage, also known as the American Wire Gage (AWG), is used for most non ferrous metals, such as Aluminum and Brass. In the UK, the Birmingham Gage (BG) is used for a variety of metals and should not be confused with the Birmingham Wire Gage (BWG), which is used for wires. Lastly, a standard exists for Zinc in which a higher gauge number indicates a thicker sheet. The chart below can be used to determine the equivalent sheet thickness, in inches or millimeters, for a gauge number from the selected gauge size standard. The weight per unit area of the sheet can also be seen in pounds per square foot and kilograms per square meter.


Thickness
Weight Per Area
Gauge	in	mm	lb/ft²	kg/m²
3	0.2391	6.073	9.754	47.624
4	0.2242	5.695	9.146	44.656
5	0.2092	5.314	8.534	41.668
6	0.1943	4.935	7.927	38.701
7	0.1793	4.554	7.315	35.713
8	0.1644	4.176	6.707	32.745
9	0.1495	3.797	6.099	29.777
10	0.1345	3.416	5.487	26.790
11	0.1196	3.038	4.879	23.822
12	0.1046	2.657	4.267	20.834
13	0.0897	2.278	3.659	17.866
14	0.0747	1.897	3.047	14.879
15	0.0673	1.709	2.746	13.405
16	0.0598	1.519	2.440	11.911
17	0.0538	1.367	2.195	10.716
18	0.0478	1.214	1.950	9.521
19	0.0418	1.062	1.705	8.326
20	0.0359	0.912	1.465	7.151
21	0.0329	0.836	1.342	6.553
22	0.0299	0.759	1.220	5.955
23	0.0269	0.683	1.097	5.358
24	0.0239	0.607	0.975	4.760
25	0.0209	0.531	0.853	4.163
26	0.0179	0.455	0.730	3.565
27	0.0164	0.417	0.669	3.267
28	0.0149	0.378	0.608	2.968
29	0.0135	0.343	0.551	2.689
30	0.0120	0.305	0.490	2.390
31	0.0105	0.267	0.428	2.091
32	0.0097	0.246	0.396	1.932
33	0.0090	0.229	0.367	1.793
34	0.0082	0.208	0.335	1.633
35	0.0075	0.191	0.306	1.494
36	0.0067	0.170	0.273	1.335
37	0.0064	0.163	0.261	1.275
38	0.0060	0.152	0.245	1.195

New Brakets Draft

Brackets

Sheet Metal Table

Gauge size standard:

	Thickness		Weight Per Area
Gauge	in	mm	lb/ft²	kg/m²
000000	0.5800	14.732	8.185	39.962
00000	0.5165	13.119	7.289	35.587
0000	0.4600	11.684	6.492	31.694
000	0.4096	10.404	5.780	28.222
00	0.3648	9.266	5.148	25.135
0	0.3249	8.252	4.585	22.386
1	0.2893	7.348	4.083	19.933
2	0.2576	6.543	3.635	17.749
3	0.2294	5.827	3.237	15.806
4	0.2043	5.189	2.883	14.076
5	0.1819	4.620	2.567	12.533
6	0.1620	4.115	2.286	11.162
7	0.1443	3.665	2.036	9.942
8	0.1285	3.264	1.813	8.854
9	0.1144	2.906	1.614	7.882
10	0.1019	2.588	1.438	7.021
11	0.0907	2.304	1.280	6.249
12	0.0808	2.052	1.140	5.567
13	0.0720	1.829	1.016	4.961
14	0.0641	1.628	0.905	4.417
15	0.0571	1.450	0.806	3.934
16	0.0508	1.290	0.717	3.500
17	0.0453	1.151	0.639	3.121
18	0.0403	1.024	0.569	2.777
19	0.0359	0.912	0.507	2.474
20	0.0320	0.813	0.452	2.205
21	0.0285	0.724	0.402	1.964
22	0.0253	0.643	0.357	1.743
23	0.0226	0.574	0.319	1.557
24	0.0201	0.511	0.284	1.385
25	0.0179	0.455	0.253	1.233
26	0.0159	0.404	0.224	1.096
27	0.0142	0.361	0.200	0.978
28	0.0126	0.320	0.178	0.868
29	0.0113	0.287	0.159	0.779
30	0.0100	0.254	0.141	0.689
31	0.0089	0.226	0.126	0.613
32	0.0080	0.203	0.113	0.551
33	0.0071	0.180	0.100	0.489
34	0.0063	0.160	0.089	0.434
35	0.0056	0.142	0.079	0.386
36	0.0050	0.127	0.071	0.345
37	0.0045	0.114	0.064	0.310
38	0.0040	0.102	0.056	0.276
39	0.0035	0.089	0.049	0.241
40	0.0031	0.079	0.044	0.214

Friday, 24 May 2013

Machine Rebuilding:

Machine Rebuilding:

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:
	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.

Machining:

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.

	Tool Room:
	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.

	Material Testing:
	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 .

	Heat Treatment:
	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.

	Forging:
	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.

	Machine Rebuilding:
	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.

Material Testing:

	Design Centre:
	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.

Machining:

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.

	Tool Room:
	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.

	Material Testing:
	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 .

	Heat Treatment:
	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.

	Forging:
	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.

	Machine Rebuilding:
	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.

Manufacturers of Special Welding Alloys for Private Label Resellers

	Design Centre:
	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.

Machining:

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.

	Tool Room:
	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.

	Material Testing:
	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 .

	Heat Treatment:
	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.

	Forging:
	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.

Machine Rebuilding:

	Design Centre:
	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.

Machining:

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.

	Tool Room:
	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.

	Material Testing:
	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 .

	Heat Treatment:
	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.

	Forging:
	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.

	Machine Rebuilding:
	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.