Fabrication processes
Fabrication processes
Rafay Emad Rizki
IMS Electric, Karachi
Internship
Maaz Ahmed Khan
Sep 27, 2023
Fabrication processes
Summary
This report will cover the machines currently in operation at IMS Electric, Karachi. I
visited the fabrication side of the manufacturing plant where Galvanized iron (zinc-coated
steel sheets), Aluminium, Mild steel, PVC, and polycarbonate sheets of thickness ranging
from 0.6mm to 5mm were being used. Three main categories of machines were being used
which are as follows: 1. Punching machine ( Finn-Powers E5 Turret Punch Press ), 2. Laser
cutting machine ( Senfeng ), 3.Bending machine ( Finn-Power E-Brake ).
Fabrication processes
Fabrication processes
Punching
In this particular manufacturing plant, the Finn-Powers E5 Turret Punch Press is being
used for the punching process. The procedure for the punching process is as follows; firstly as
per the client, the sheet material is selected from PVC, polycarbonate, GI, AL, and MS. The
thickness and size of the particular sheet is also specified. A programmer has to write down
the code files in the software called NC express required by the machine's software to be
used, the files are uploaded to the interface on the machine, and with the use of clamps, the
particular sheet is set onto the punching table. The program files are run and the machine
starts to operate. A typical run time is approximately 20 minutes. After the punching process,
the finish is not smooth and may cause an injury so a technician with a grinder smooths out
the edges. And finally, the parts are labeled and organized for the logistics team to pick up.
Fig1.0: Shows the Finn-Powers E5 Turret Punch Press.
Fabrication processes
Fig1.1: End product from punching machine.
Laser Cutting
In this manufacturing process, the Senfeng Metal Laser Cutting machine was used.
This machine uses oxygen and nitrogen gas to form a laser for cutting. For GI sheets nitrogen
gas is used while for MS sheets oxygen gas is used. This machine also uses the same
procedure first the program files from Autocad are uploaded to the Lasers interface and after
the files have been uploaded the machine is started and in a few moments the final finished
product is ready. One important thing is that Laser cutting is used for complex and finely
detailed parts as the cuts are smooth and already finished. But the downside is that the laser
machine takes a longer time to produce a cut piece.
Fabrication processes
Fig1.3: Senfeng
Laser cutting
machine in
operation.
Fig1.4: End product
from Laser Cutting
machine.
Fig1.5: Finished
parts ready to be
installed or bent.
Fabrication processes
Bending
In this manufacturing process, a Finn-Power E-Brake bending machine is being used.
After the parts have gone through laser cutting or punching the parts that do require bending
are sent to this machine where a technician using CAD files analyzes where the bends need to
be made. This machine has a bending force of 27 tons and a variety of different bending dies
which are replaced as required for a particular job. After calibrating the machine the bending
process is started and the operator adjusts the parts accordingly for each bend. After the
bending job is completed MS parts are sent to the paint shop to be painted while GI parts are
sent to the logistics department.
Fig1.6: Finn-Power E-Brake bending machine.
Fig1.7: Bracket formed from bending.