Key Features of our 100 Ton+ Rotary Friction Welding Machines

  • Spindle driven by AC servo motor
  • Rapid stopping of spindle by regenerative braking which saves energy
  • Welding force provided by servo hydraulic cylinders in closed loop control system
  • Pressure transducer/ load cell and linear scale feedback for load and displacement control
  • On-line plotting of important parameters like axial thrust, spindle speed, loss of length and spindle torque during weld cycle
  • Archival and retrieval of weld data
  • Remote customer support through internet

100T - Horizontal Machine integrated with Robot for Spindle loading

This tie-rod constructed 100 tonne capacity Rotary Friction welding machine has a steel fabricated frame on which all sub-assemblies such as Spindle head, Tail stock carrying Servo hydraulic cylinder, Welding slide carrying clamping vices, Locating fixture and Stopper systems are mounted. The entire welding force is contained within the tie-rod and does not transmit to the machine frame for better stability. This single head machine is used for welding Spindle part to the Axle housing of automobile. A fixture unit mounted on welding slide allows proper location of axle housing, which is done manually. Two clamping vices, mounted on the slide hold the axle housing in position. A robot integrated with the machine picks the Spindle parts form the loader unit and places it into the machine spindle chuck for welding. On completing welding cycle at one end, the welded axle is removed, rotated 180 degree and located and clamped on the machine again for welding at the other end. The robot loads the spindle part again in to the welding spindle chuck. On completing the second weld, the welded axle housing is removed manually.

  • Max. forge force : 1000kN
  • Max. OD of spindle : 150mm
  • Max. length of spindle : 380mm
  • Max. length of axle : 2300mm

Designed for welding live and dummy Axle housings (Spindle to Axle Housing)

Automotive
6T - Machine With built-in deflash, deflect and auto loading / unloading

125T - Twin Head Machine One head fixed and the other moving for simultaneous welding at both ends

This tie-rod constructed 125tonne capacity twin head machine has a steel fabricated frame on which all sub-assemblies such as Spindle heads, Tail stock carrying Servo hydraulic cylinder, Welding slide carrying clamping vices and Locating fixture are mounted. The entire welding force is contained within the tie-rod and does not transmit to the machine frame for better stability. This machine is used for welding Spindle part to the Axle housing of automobile. The LH spindle head is rigidly mounted on the frame, while the RH spindle head is mounted on a slide unit. A fixture unit mounted on welding slide allows proper location of axle housing. Component loading and unloading are done manually. Two clamping vices, mounted on the slide hold the axle housing in position. The spindle parts are clamped in LH and RH spindle head chucks manually. After loading the parts and pressing cycle start button, welding cycle takes place simultaneously at both ends of the axle housing. The machine has a PLC based control system integrated with IPC and software for capturing real time weld data.

6T - Vertical Machine for Smaller Foot Print
  • Max. forge force : 1250kN
  • Max. OD of spindle : 160mm
  • Max. length of spindle : 380mm
  • Max. length of axle : 2500mm

Designed for welding live and dummy Axles (Spindle to Axle Housing)

Automotive

150 Ton Rotary Friction Welding

This 150 Ton sliding single head Rotary Friction Welding machine has a steel fabricated frame on which all sub-assemblies such as Spindle heads, Tail stock carrying Servo hydraulic cylinder, Welding slide carrying centering vices and radial clamping units are mounted. The entire welding force is contained within the tie-rod and does not transmit to the machine frame for better stability. This machine allows welding long rods or pipes like drill pipes, without a back stopper. It has a standalone hydraulic power pack and electrical cabinet. The machine has a PLC based control system integrated with an IPC and LabView software for capturing real time weld data.

  • Max. forge force : 1500kN
  • Max. OD of rotating piece : 150mm
  • Max. length of rotating piece : 450mm
welding unlimited pipe

Designed for welding unlimited length of Pipe / Rod with heavy duty hydraulic clamping system

Automotive
6T - Slant Bed Machine

200T - Horizontal Machine with built-in CNC Deflash Unit

This 200 Ton Horizontal Rotary Friction Welding machine is used for welding rod-eye to piston rod of a Hydraulic Cylinder with built-in deflash unit. It is a direct drive single head machine with manual loading and unloading. It has a steel fabricated frame on which all sub-assemblies such as Spindle heads, Tail stock carrying Servo hydraulic cylinder, Welding slide carrying centering vices and stopper systems are mounted. Control system is provided through a high performance Industrial PC and records more than 500 types of weld parameters.

6T - Vertical Machine for Smaller Foot Print
  • Spindle speed : 0-450 rpm- Infinitely variable
  • Spindle motor : 250kW, 800 rpm, 2986 Nm
  • Chuck : 2 jaw chuck- dia. 600mm -hydraulically operated
Rod -eye
  • Max. height of Rod-eye : 280mm
  • Bore dia. : 140mm
  • Max. dia. of Rod-eye : 280mm

Rod

  • Rod dia. : Min. 50mm / Max.130mm at weld
  • Rod length : 750mm to 3500mm

Designed for welding rod-eye to rod of piston rod of hydraulic cylinder

Automotive

Advantages

  • Very short cycle time (few seconds)
  • Ideal for mass production
  • Savings in costly material if bi-metallic component is used (Eg. Drills- HSS/MCS)
  • Low heat -affected zone and hence semi finished components can be welded
  • Low energy consumption
  • No edge preparation, filler material, shielding gas, spattering, fumes and radiation
  • Excellent welding: Joint as strong or stronger than parent material
  • Metals as diverse as Cu to Al, Cu or Al to steel, Titanium to stainless steel etc. can be welded
  • 100% in-process quality check

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