Page 33 - AMTDC Annual Report 2019-20flipbook

Manufacturing of such machines comes with its own
challenges like the development of critical parts and its
assembly. One of the critical parts of the machine tool is the
rotary table and its bearings which bears the load of the
workpiece while providing high stiffness, stability and An Astonishing Range of
accuracy during machining. Hydrostatic rotary tables Application
provide very high accuracy, stiffness with minimal friction
and power. For the development of hydrostatic rotary table,
a systematic analysis has been followed. Numerical models The 5 axis CNC Universal Machining Centre
of the bearing pad and flow controller are prepared with the is a Mother Machine having 5-axis
help of COMSOL Multiphysics, involving a 2-way Fluid simultaneous machining capability and facility
Structure Interaction (FSI) analysis on the flow controller to machine large prismatic components in a
and laminar flow analysis on the bearing pads, after the single setup. These machines are used to
selection of type of bearing/ flow controller, design produce components with complicated profiles
parameters and operating parameters. Result of the FSI are and design features along different
taken as inputs for the laminar flow analysis for the pads orientations, which otherwise would require
while keeping the film thickness constant. The results from multiple machines. The uniqueness of this
the analytical and numerical analysis on the flow controller, machine lies in machining highly complex
thrust pad and the radial pad are used to prepare CAD model geometric structures in a single setup, high
based on the dimensions obtained from the numerical accurate parts with better surface finish and
study.
increased productivity leading to time saving.
On the other hand, structural design of bed, traverse,
column, head stock, slides are done by analytical modelling The machine finds application from
of individual component through load calculations, stiffness general machining of machine frames, machine
and damping considerations. Next, FEM analyses have been beds to machining of jet engine casings & rings,
used to optimize the structural design for energy efficiency, wing rib, bulkhead for Aerospace and Aviation
better dynamic and optimum performance of the machine. industries to Energy generator components
The manufacturing analyses are carried out in terms of such as impellers, bearing housing, turbine &
machine tool setting, tooth surface topography generator parts to automobile parts like
optimization, process design & tooling, etc. cylinder head, engine block, axle housing to

The manufacturing of the components and assembly is machining of train coach side and roof panels,
underway. The system will undergo design modifications wheels, frames for the locomotives to
and fine tuning after the testing and calibration. manufacturing of missile housing, tank turret

head for defence sector.

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AMTDC Annual Report | 2019-20