Anand Kaundanya, COO - Surface Engineering Solutions, Gala Precision Engineering Pvt Ltd
Gala Precision Engineering is a vibrant organisation with a young team that follows the spirit of entrepreneurial professionalism. The Gala Group serves global markets with its high end technology solutions in the fields of surface engineering and high performance springs. Anand Kaundanya, COO – Surface Engineering Solutions, Gala Precision speaks to Machine Tools World at length about the activities of Gala in the sphere of surface engineering. He also explains the numerous process options & mass finishing and Parts cleaning equipment available which are customised as per customer specific needs for enhancing the operational efficiency of the smart manufacturing sector which leans heavily on automation. Excerpts:
Gala is a ‘one stop solution provider’ for surface finishing needs of deburring, finishing, cleaning and phosphating equipment. We have more than 25 years’ experience in building standard and customised machines. We offer a comprehensive range of solutions that includes equipment and media & compounds for surface finishing and parts cleaning needs.
We have the capability to build large finishing & cleaning equipment to meet the challenging needs of defence, atomic energy and aerospace sectors. Our finishing machines are capable of achieving Ra value of 0.05 microns and precision parts, cleaning machines achieving Millipore value of less than 1mg.
Deburring and surface finishing machines are used for mass finishing of metal, plastic, ceramic and rubber parts.
These equipment are used for removing burr of metal parts, descaling & degreasing, edge radiusing of thin parts, sizing of pins, polishing of surfaces, pickling & brightening of non- ferrous parts, deflashing of rubber & plastic parts. Surface roughness (Ra value) of 0.05 microns can be achieved.
Small parts weighing a few grams to parts weighing up to 25 Kg can be processed in a variety of machines available from Gala. Use of deburring and finishing machines is essential to achieve consistency and high production rates.
In addition to finishing equipment, use of abrasive media & compounds is essential to achieve the desired process results. Abrasive media can be of ceramic, porcelain, steel or plastic material. Gala offers standard and customised products to suit specific customer needs.
A Vibratory Finishing machine consists of a bowl lined with polyurethane material which is mounted on springs and uses vibratory motor and unbalanced weights to achieve gyroscopic motion to the workload. Vibratory finishing is used to achieve Deburring, Edge radiusing, Degreasing, Descaling, Polishing, mirror finishing and smoothening of a variety of components.
This is the most common method used for deburring and polishing of components which includes sheet metal, machined, cast, forged and moulded parts. A wide range of components of Automotive, Aerospace, Defence and consumer products can be processed using vibratory finishing machine.
We offer the following Vibratory machines based on the shape of the working bowl:
Round Vibratory finishing machines are the most common type of machines used in manufacturing industry for a wide range of components. This machine can be used for small parts like rivets & screws to bigger parts like Turbine blades.
We offer machines from 70 to 1500 litre capacity. Standard and Auto Separation models are available.
Spiral machine is a modified version of Round vibratory finishing machine. This type of machine is used to ensure 100% separation of parts within short time of 8 to 10 minutes. Due to Spiral shape of bowl, the process efficiency is better as compared to round vibratory machine.
We offer Spiral machines from 120 to 1800 litre capacity. Spiral vibratory finishing machines are used for parts of bearing industry, fasteners & washers, precision auto parts.
Elliptical vibratory finishing machines are used where processing time is less than 10 minutes. This is used for removing light burrs and general finishing of small parts like bearing cages, ceramic insulation tiles, etc.
We offer Elliptical machines up to 250 litre capacity.
Trough vibratory finishing machines are used for deburring, degreasing and polishing of medium sized parts like axles, shafts, rods, marble & granite tiles, turbine blades, aerospace parts, etc. We offer machines from 100 to 1200 litre capacity.
Segmented machines are used for bigger parts to avoid part to part hitting while processing. Segments are provided to make compartments in working bowl where one or more parts are loaded for finishing. Normally 3 to 8 compartments are provided.
We offer segmented round and trough vibratory finishing machines as per the customer needs. These machines are used for parts like machined aluminium die cast parts, parts of hydraulic industry, etc.
This is a more aggressive form of finishing as compared to Vibratory finishing. This machine uses 3 or 4 barrels mounted on Turret assembly. The high rotation speed of turret results in high centrifugal forces which results in faster process. These machines are often used with variable frequency drives to adjust the rotational speed as per the process need.
The surface finish achieved with this process is more uniform and even. These machines are used in various industry sectors such as jewellery, bearing, textile, compressor, automotive and aerospace. The Centrifugal barrel finishing process is capable of achieving high Ra values up to 0.06 microns for parts like textile rings, reed valves, bearing rollers, etc.
Centrifugal Disc finishing is the most aggressive form of surface finishing as compared to Vibratory finishing or Centrifugal barrel finishing. The resulting forces are at least 10 times higher as compared to the Vibratory finishing process. This machine consists of a tub or housing with a rotating disc at the bottom driven by electric motor. Complete automation is possible with component loading, separation trolleys, and media reloading using PLC based controls.
These machines are popular in processing parts like coin blanks, medical implants, fine blanked components and precision components of automotive & aerospace sector.
Yes of course. Gala is the market leader in offering customised finishing systems.We offer automated finishing systems for Vibratory finishing and Disc finishing equipment. Automation results in achieving higher production rates and process consistency.
Fully automatic finishing system uses PLC based control panel which can be offered using component loading system, separation equipment, compound dosing system, conveyors, inline washing, etc. Customised systems are popular in applications like processing of coin blanks, medical implants, fine blanked parts, drive chain components, bearing rollers & cages and so on.
Cleaning of parts is an essential process of manufacturing industry. Parts cleaning machines are used for degreasing, descaling, removing loose metallic particles and other solid particles of contamination. Parts cleaning can be achieved by using Immersion, Spray and Ultrasonic technique or a combination of all these.
The other criteria are type of cleaning agent used. It can be Solvent or Aqueous based cleaning.
The selection of process and equipment is based on
Machines can be built to meet stringent requirements of achieving Gravimetric Millipore values of less than 1 mg and particle size as per requirement for precision cleaning.
We offer spray cleaning and Ultrasonic cleaning machines.
We also offer customised cleaning solutions where we use a combination of Spray & Ultrasonic cleaning techniques.
Ultrasonic cleaning machines are used for precision cleaning of parts which are complex in configuration and geometry and / or which require stringent gravimetric values and particle size count as per defined levels. Operating frequency can be 25 KHz or 30 KHz or 40 kHz to suit the cleaning application.
Ultrasonic Cleaning machines offered are of Table top, Multistage or Multistage with material handling system. Ultrasonic cleaning equipment with automated material handling system helps to increase production rate and improve consistency of cleaning.
Ultrasonic cleaning machines are widely used for cleaning of precision parts of aerospace and automotive sector like engine valves, pistons, turbine blades, fuel injection parts, coil springs. It is also used for consumer parts like Jewellery, furniture fixtures etc. We manufacture Ultrasonic cleaning machines from 20 litres to 5000 litre capacity.
Spray cleaning machines are widely used for washing of components such as machined parts, stamped parts, cylinder heads, cylinder blocks, connecting rods, crank shafts, housings, bearing parts, fasteners, transmission parts, ammunition shells, containers, etc.
We build spray cleaning machines in the following configurations:
The spray pressure can range from 2 bar to 500 bar as per the application. Spray cleaning machines offered are of different configurations like Rotary basket, Conveyorised, Cabinet type, Rotary Screw etc.
Rotary basket washers are compact machines suitable for small parts in batches. These machines are simple to use with Wash, Rinse and Dry options.
Spray pressure is in the range of 2 to 4 bar and basket rotation speed is in the range of 3 to 6 RPM. Rotary basket machines are suitable for general cleaning of small components such as machine parts, sheet metal parts, fasteners, and springs, etc.
This is suitable for medium size parts. Component loading can be at the same or different locations.A single part is indexed in cleaning, rinsing and drying zone and follows single piece flow. Component loading and unloading can be manual or automatic with pick & place device or with Robots. Rotary indexing machines are suitable for cylinder liners, shells, and machined cast parts.
Rotary screw spray cleaning machines are suitable for continuous production. The cleaning and drying stages can be customised. Machines are available from 30 Kg/hr to 1500 Kg/hr capacity. These washers can be integrated with other production equipment to maintain production flow in a uniform manner. These washers are popular for components such as stamped rivets, washers, fasteners, small arms ammunition shells, etc. Cabinet Front Loading These washers can have fixed or rotating work table. Spray pressure can be from 5 bar to 14 bar. This is suitable for cleaning of medium and heavy parts such as housings, axle box, brake drums, machined castings & forgings. Parts can be loaded in basket or can be placed on the work table. Wash, Rinse and dry cycle can be offered.
Conveyorised washers are popular as they support continuous production and easy to operate. They are used where production requirement is on higher side.
Components travel on conveyor with or without trays and pass through enclosed chambers. Spray, rinse and dry sections can be customised based on the cleaning requirements.
Conveyor can be made of steel wire mesh and chain & rod type. Conveyorised washers are suitable for parts like aluminium or brass shells of ammunition, connecting rods, containers, housings, wheels, machined castings, Aluminum Die cast parts, Metal Cylinders, plastic bins etc.
We also offer customised cleaning solutions to meet customer’s special requirements. We can build machines such as Single piece flow where we can use a combination of Ultrasonic cleaning and Spray rinsing & Drying.
Most of the mass finishing systems use PLC based control panels and HMI’s. We can offer features like basket rotation, auto dosing, walking beam material handling arrangement. Multistage ultrasonic & phosphating plants can be fully automated with material handling system. PLC based control panel and SCADA systems are offered to monitor and record the process details and output. Also all safety interlocks are provided to ensure smooth functioning of machines. HMI displays major process parameters and errors if any.
Yes indeed. We offer both zinc and manganese phosphating plants. We have a number of installations across the country.
It’s a long way to go. Currently 5% of our customers discuss about offering IIoT features in the equipment we build. They are mainly Tier I automotive sector customers. Its growing rapidly in automotive manufacturing sector where Robots and high tech CNC machines are employed. SME and MSME customers are talking about low cost automation and they will move towards IIoT after reaping benefits of investments in low cost automations.
State-of-the-art Internet of Things (IoT) can make the manufacturing sector smarter and effective. Such technologies can potentially and radically enhance visibility of the manufacturing process such that every unit of production can be monitored at each step. The revolution of smart manufacturing is well and truly on its way as more and more cost-effective options are available in the market.
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