Gala Precision’s forte: Precise surface engineering solutions

September 11, 2018 5:12 pm

Gala Precision, serving the industry for over 25 years, is one of the one-stop solution provider for surface finishing needs such as de-burring, finishing, washing and cleaning of components and parts.

The company offers the whole gamut of machines, processing media, compounds and services for surface finishing and parts.
Gala has the capability to build large finishing & cleaning equipments for challenging needs of defence, atomic and aerospace sectors. The finishing machines are capable of achieving Ra value of 0.05 microns while precision parts cleaning machines are capable of achieving a millipore value of less than 1mg.

Deburring and finishing
The de-burring and surface finishing machines are used for mass finishing of metal, plastic, ceramic and rubber parts. Small parts weighing a few grams up to 25 Kg can be processed in a variety of machines available from Gala’s wide range of products. Use of de-burring and finishing machines is essential to achieve consistency and high production rates. In addition to finishing equipment, use of abrasive media and compounds is essential to achieve the desired process results. Abrasive media can be of ceramic, porcelain, steel or plastic materials. Compounds are used with water with concentration levels of 5 to 10 per cent.
Gala offers standard and customised products to suit specific customer needs.

The finishing machines are of different types. These are:
– Vibratory finishing
– Centrifugal barrel finishing
– Disc finishing
– Customised finishing systems
– Complete automation of surface finishing processes is possible by using component loading system, conveyors, vibratory trolleys and dosing system using PLC based control panels

Vibratory finishing
The 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 de-burring, edge radiusing, degreasing, de-scaling, polishing, mirror finishing and smoothening of a variety of components.

Gala offers the following types of Vibratory machines based on the shape of the working bowl.
• Round vibratory finishing machines: Used for small parts such as rivets & screws to bigger parts like turbine blades.
• Spiral machine: Modified version of round vibratory finishing machine; used to ensure 100 per cent separation of parts within a short time of 8 to 10 minutes.
• Elliptical vibratory finishing machines: Used where processing time is less than 10 minutes. This is used for removing light burrs and general finishing of small parts such as bearing cages, ceramic insulation tiles, etc.
• Trough vibratory finishing machines: are used for de-burring, degreasing and polishing of medium size parts like axles, shafts, rods, marble and granite tiles, turbine blades, aerospace parts, etc. Gala offers machines from 100 to 1200 litre capacity.
• Segmented machines: Used for bigger parts to avoid part to part hitting while processing; for parts such as machined aluminium die cast parts, parts of hydraulic industry and so on.

Centrifugal barrel finishing
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 process need. The surface finish achieved with this process is more uniform and even. Centrifugal barrel finishing is capable of achieving
high Ra values up to 0.06 microns for parts such as textile rings, reed valves, bearing rollers, etc.

Centrifugal disc finishing
This 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 vibratory finishing process. This machine consists of a tub or housing with a rotating disc at bottom driven by electric motor. Complete automation is possible with component loading, separation trolleys, and media reloading using PLC -based controls.

Customised finishing systems
Completely automated finishing systems can be offered along with vibratory finishing and disc finishing equipment. Automation results in achieving higher production rates and process consistency. Fully automatic finishing systems can be offered using component loading system, separation equipment, compound dosing system, conveyors and PLC- based control panel.

Parts cleaning
Parts cleaning is an essential process of the manufacturing industry used to remove all types of contaminants from the surfaces of components and also degreasing, de-scaling, removing metallic burr or particles and other solid particles of contamination. Gala offers complete range of aqueous parts cleaning equipment which includes spray cleaning, ultrasonic cleaning, rotary screw, single chamber multi-process and customised machines. The company also builds customised machines which include ultrasonic machines with material handling system, drying with centrifuge arrangement, single piece flow and so on. It is capable of building large machines as big as 5000 litre capacity ultrasonic cleaning machine for very big parts and 60 feet long conveyorised washers.
Gala equipment are preferred for precision cleaning of parts of industries such as aerospace, automotive hydraulic, engineering, electronics and many others. Machines can be built to meet stringent requirements of achieving gravimetric (millipore or NAS standards) values of less than 1 mg and particle size as per class A for precision cleaning.

Spray cleaning
Gala’s comprehensive manufacturing range also includes spray cleaning machines up to 100 bar spray pressure. 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. The spray cleaning machines are offered in the following configurations:
• Rotary basket: Compact machines suitable for small parts in batches; 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 indexing : Suitable for small and medium size parts. Component loading can be at the same or at 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 screw
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 1,500 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 washers, fasteners, small arms ammunition shells, etc.

Cabinet front loading
These washers can have fixed or rotating work table and is used 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 work table.

Conveyorised
Conveyorised washers are popular as they support continuous production and are easy to operate.

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.

Ultrasonic cleaning
Gala manufactures a whole range of ultrasonic cleaning machines from 20 to 5000 litre capacity.

The company can offer material handling system for multistage ultrasonic cleaning machines for ease of handling of parts. Multistage machines are customised to suit customer needs with options of multiple cleaning, rinsing and drying. They 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 class A. Ultrasonic cleaning machines are widely used for cleaning of precision parts of aerospace and automotive sector such as engine valves, pistons, turbine blades, fuel injection parts, coil springs, bearing cages etc. This technology is ideal for cleaning of electronic parts & PCB’s, moulds, optical parts and lenses.

Gala can provide ultrasonic transducers of tank bonded, immersible box and rod type, based on application. The machine types offered are table top, multistage and multistage with material handling system.

Single chamber multi-process cleaning machines (SCMP)
Single chamber multi process cleaning machines offered by Gala are compact in size. Spray, immerse flood wash and ultrasonic wash cycles are possible in this configuration. Vacuum drying also can be provided on customer request.

Customised
Gala also offers customised cleaning solutions to meet customer’s special requirements. It can build machines for Single piece flow or Robotic washing.

Phosphating plants
Gala also offers pre-treatment, passivation and phosphating plants which can be fully automatic with material handling system, PLC based control panel and SCADA system. These are offered with features such as basket rotation, auto dosing, walking beam material handling arrangement, etc.

Material handling
Gala also builds and offers material systems for conveying components. The range includes belt conveyors, inclined conveyors, component loading systems and vibratory trolleys.

Industrial dryers
Drying is a natural corollary in the process of components cleaning. Hence, Gala offers industrial dryers of various types such as vibratory, belt type, rotary screw, and centrifuge dryers.

Quantity, size or criticality doesn’t deter Gala from offering a solution to any industry to the utmost satisfaction of the ultimate customer.