Bangalore 

For proper gasket seating applications in valve manufacturing industry and leak-proofing, serration-like, coarse machined surface finish is required in the butting surfaces of the enjoining parts. Shenoy Engineering Pvt Ltd, a Bangalore based SPM manufacturer, offer face mounting type, electro-mechanical flange facers, which are custom-built to individual requirement. Already many flange facers are designed, manufactured and successfully commissioned at the respective customer’s works. 

Electro-mechanical, in-situ flange facers are also offered for ID clamping or OD clamping, or face clamping, depending upon the job requirement. Standard flange facers are with manual clamping, using clamping jacks or studs. For ID clamping in smaller flange facers, a unique 4 jaw self centering chuck is being used. Hydraulic clamping system is offered optionally for automatic clamping. The flange facer consists of a rotary drive unit, horizontal arm, electrical control panel & operator’s console. Powered quill mechanism is optionally offered for depth of cut setting and for boring operations. 

The spindle (rotary drive shaft) is supported by a pair of heavy-duty taper roller bearings in the front and by a pair of ball bearings in the other end. Bearings are lubricated for life with molybdenum sulfide grease. The rotary movement is 2 to 20 RPM in a step-less range through vector VFD. The spindle is made of EN-24, hardened and ground. The box type ram and the ram housing are made of high-grade CI. Sliding surfaces are hand scraped and blue-matched for smooth sliding, but without slackness. All sliding & rotating surfaces are well lubricated.  

The optionally offered powered quill feed unit consists of a ram type quill, having 50 mm quill movement through a motorized quill mechanism. An extremely rigid, box type ram is the quill, which provides 50 mm powered feed movement to the ram for feed in boring and for depth of cut setting in facing. The drive is through an independent drive motor and worm reduction gear box. The feed range is 20 mm to 600 mm per minute in step-less range through a VFD. An imported brushless rotary connector ensures that the cross feed & limit switch cables do not get entangled in the rotary movement of the arm.   

Mounted on to the rotary drive unit is the cross-axis arm, providing cross axis feed to the tool post through lead screw & box nut. The stepless feed range is from 20 mm to 600 mm per minute through a VFD controlled motor and worm reduction gear box.

Tilting type tool post, mounted on the arm, can swivel ±45° for taper machining. The angle can be set through a graduated collar provided.

The clamping system consists of clamping arms/legs, which are rigidly clamped to the rotary drive housing. The sliding legs have provisions for variable lengths, depending upon the flange diameter. 

The electrical panel houses VFDs for rotary drive motor, cross feed motor & optionally offered quill feed motor, switch gear elements and the operator’s console contains the controls, speed/feed variation knobs & digital meters showing the feed & speed rates.

Electro-mechanical flange facers have many distinct advantages, when compared with the imported pneumatic flange facers. There is no need of compressed air. Just 3 phase power supply is sufficient. Plug-in type of socket is provided to the input cable. Secondly, cutting efficiency of pneumatic flange facer depends on the quality of compressed air supply. Leakage in the air lines is a recurring problem. Both the problems are avoided in electro-mechanical flange facers. Third, the rigid and perfectly balanced ram and the heavy rotary drive unit facilitate heavy material removal. Fourth, the optional feed mechanism is through a self-powered quill. Fifth, maintenance problems are the least in electro-mechanical flange facers and spares are easy to make or procure. Last, since indigenously developed by a small-scale SPM unit, these flange facers are highly affordable with short manufacturing lead time.