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Insight's Machining Solutions
Fixtures ● Tooling ● Power-packs

- Seamless, Synergic, Comprehensive, End-to-End

Subtractive Manufacturing, mostly across Machining arena, remains an important process of achieving required form, accuracy & finish of most engineering parts.

Machining, in a broader sense refers to material removal. When we talk about metal machining - be it ferrous or non ferrous, it all comes down to overcoming the threshold shear-resistance of work-piece material in a way that:
- Produces a clean post-machined surface topography
- Decreases friction through careful tool geometry
- Facilitates swift & clean chip flow
- Enables easy & quick heat dissipation
- Removes material with a brisk MRR

Robot Automation, Machine Tending, Pick and Place, Conveyors, Welding Automation

All this - whilst carefully minding the metallurgical make-up of work-piece material, and approaching near-real behavioural estimate of Tool to Work-piece interface. And in the scheme of all these, securing the part by arresting all DOF, ensuring minimal or no deformation of the part itself, channeling the flow of forces from the fixture to the machine bed - in an efficient way, are a few things that are critical to outcome in terms of Q-C-D. Tooling is another aspect - that is as important as the Machine & Fixture, not to forget the importance of right cutting fluid.

Insight's Turnkey Solutions' team, with a collective experience of installation of over 1000+ production lines, work in close conjunction with its customer from print-to-production.

End-to-End Turnkey Solutions


Insight's machining solutions are distinguished by the wealth of experience held by our domain experts and a proven track record of successful implementations over many years. Our machining solutions' experts bring deep knowledge of fixture design, tooling design, process optimization, and accessories' integration, ensuring that the solutions are tailored to meet specific machining challenges. With a history of successfully addressing complex machining needs for a wide range of industries, Insight's solutions are not only reliable but markedly innovative, driven by Insight's core commitment to continuous improvement and excellence in machining practices. Here's the repertoire of Machining Solutions:
Cutting Tools, Tooling Solutions
Machining Fixtures

Precise & repeatable positioning, meticulous clamping schema for vibrational attenuation & part distortional minima, robust yet light weight build, clear tool access, ease of L/UL, strategically designed wear-elements, quick change-over & set-up, are a few aspects that a make up high performance fixturing.

Cutting Tools, Tooling Solutions
Tooling Solutions

A good combo of fixture + machine - make up 2/3rd of the recipe. It is the Tooling that finally hits the chord. Clean cutting, low CPC, high productivity rate and a solid balance between flexibility & specificity - personify operational excellence. Right set of tools, in the right flow, are critical to process excellence.

Accessories, Hydraulic Power Units, Coolant Systems
Accessories

These are the enablers of high performance; Coolant Systems, Hydraulic Power Units, Rotary Production Systems, Chip Conveyors, and so forth, form the foundation on which a robust process can be established. When parametrized in the right way, a good set of accessories can tip returns up to +15~30%.

Overall Mark-up

What all does our machining solutions' group specialize in? Well here it is-
Fixtures: Types & Applications

Horizontal Machining Centers:
Tomb-stone | Indexer Type

Vertical Machining Center:
Stationery | Rotary | 4th Axis | 5th Axis

Turning Centers:
Manual | Hydraulic with Rotary Joint

Mode of Operation:
Hydraulic | Pneumatic | Manual

Tooling: Solution Set

Print-to-Production:
Complete Process Prove-out

Run-off:
Cycle time & Quality Establishment | Cp Cpk

Synergic Mix:
Best picks from the Gamut from Tool making

High Performance:
Least GPL | Clean Cutting | Consistent Quality

Accessories: Coverage

Coolant Systems:
External nozzle coolant & base flushing
Optional High Pressure Spindle Through Coolant

Hydraulic Power Units:
On-demand (Intermittent Duty) | Continuous Duty
High quality valve-stacks & Digital sensors

Rotary Production System:
High stiff-ness to weight ratio. Robust build.

A host of other accessories forming a holistic solution.

Solutions' Efficacity

End-to-End Turnkey Solutions

Comprehensive | Fixtures, Tooling
Hydraulic Power-pack, TBS, Probing 

Synergic Process | Best Fit

Right mix of Tooling & Peripherals
Right Tools, Least GPL >Better Quality> Lower CPC 

Vast Knowledge Library | BKMs

Preloaded with Kaizen & Best Practices
Reliable Process | Consistent Quality 

High Performance & Reliability

High Quality BOPs | Clamps, Actuators
Uncompromising Manufacturing Quality 

Meticulous Design & Engineering

High Stiffness-to-Weight Ratio  
Ease of L/UL <> Low Operator fatigue 

Flexibility | Ease of Maintenance

Modular, Flexible, Quick-change <> Enhanced OEE
Design Standardization <> Lowered Inventory 

Let's take a look at a few:

Machining Fixtures

Hydraulic Machining Fixture | Stationery Type

Component: 2-Wheeler Engine Part
Material: Aluminium LPDC
Machine Type: Vertical Machining Center with APC
End-user: Auto-Component Manufacturer

Scope: Fixture, HPP, Tooling Engineering

Solution: End-to-End Turnkey | Comprehensive process prove-out | From Process Cycle Time Study to Quality & Production Prove-out

Hydraulic Bench Type Machining Fixture

Hydraulic Machining Fixture | Rotary Type | 4th Axis

Component: Outer Tube | 2-Wheeler Shock Absorber
Material: Aluminium GDC
Machine Type: Vertical Machining Center + 4th Axis
End-user: Auto-Component Major

Scope: Fixture, HPP, Tooling, Robotic Automation of Machining Cells

Solution: End-to-End Turnkey | Comprehensive process prove-out | From Process Cycle Time Study to Quality & Production Prove-out

Hydraulic Machining Fixture, Rotary Type

Hydraulic Machining Fixture | Rotary Type | 4th Axis

Component: Engine Intake Assy Part
Material: Aluminium GDC
Machine Type: Vertical Machining Center + 4th Axis
End-user: Auto-Component Major

Scope: Fixture, HPP, Tooling, Robotic Automation of Machining Cells

Solution: End-to-End Turnkey | Comprehensive process prove-out | From Process Cycle Time Study to Quality & Production Prove-out

Hydraulic Machining Fixture, Rotary Type

Hydraulic Machining Fixture | Stationery Type

Component: Drive Shaft
Material: Forged Steel
Machine Type: Vertical Machining Center
End-user: Manufacturer of Precision Cold Forged & Automotive Components

Scope: Fixture, HPP, Tooling

Solution: End-to-End Turnkey | Comprehensive process prove-out | From Process Cycle Time Study to Quality & Production Prove-out

Hydraulic Machining Fixture, VMC Fixture

Hydraulic Machining Fixture | Bench Type

Component: Oil Pump Front Cover for 4-Wheeler
Material: Aluminium LPDC
Machine Type: Vertical Machining Center
End-user: Auto-Component Major

Scope: Fixture, HPP, Tooling, Tool Breakage Detection, Coolant System + Chip Conveyor for VMC

Solution: End-to-End Turnkey | Comprehensive process prove-out | From Process Cycle Time Study to Quality & Production Prove-out

Hydraulic Machining Fixture, Rotary Type

Hydraulic Machining Fixture | Bench Type

Component: Oil Pump Front Cover for 4-Wheeler
Material: Aluminium LPDC
Machine Type: Vertical Machining Center
End-user: Auto-Component Major

Scope: Fixture, HPP, Tooling, Tool Breakage Detection, Coolant System + Chip Conveyor for VMC

Solution: End-to-End Turnkey | Comprehensive process prove-out | From Process Cycle Time Study to Quality & Production Prove-out

Hydraulic Machining Fixture, Rotary Type

Hydraulic Machining Fixture | Rotary Type

Component: Oil Pump Cover Bracket for 4-Wheeler
Material: Aluminium LPDC
Machine Type: Vertical Machining Center + 4th Axis
End-user: Auto-Component Major

Scope: Fixture, HPP, Tooling, Tool Breakage Detection, Coolant System + Chip Conveyor for VMC

Solution: End-to-End Turnkey | Comprehensive process prove-out | From Process Cycle Time Study to Quality & Production Prove-out

Hydraulic Machining Fixture, Rotary Type

Hydraulic Machining Fixture | Rotary Type | 4th Axis

Component: Crank Case for Industrial Air Compressors
Material: Cast Iron
Machine Type: Horizontal Machining Center with APC
End-user: General Engineering Industry Major

Scope: Fixture, HPP, Tooling

Solution: End-to-End Turnkey | Comprehensive process prove-out | From Process Cycle Time Study to Quality & Production Prove-out

Hydraulic Machining Fixture, Rotary Type

Hydraulic Machining Fixture | Rotary Type | 4th Axis

Component: Outer Tube | 2-Wheeler Shock Absorber
Material: Aluminium GDC
Machine Type: Vertical Machining Center + 4th Axis
End-user: Auto-Component Major

Scope: Unmanned Machining Line | Fixture, HPP, Tooling, Tool Breakage Detection, Part Loading-Unloading Automation

Solution: End-to-End Turnkey | Comprehensive process prove-out | From Process Cycle Time Study to Quality & Production Prove-out

Hydraulic Machining Fixture, Rotary Type

Hydraulic Machining Fixture | Rotary Type | 4th Axis

Component: 2-Wheeler Engine Inlet Comp
Material: Aluminium LPDC
Machine Type: Vertical Machining Center with APC + 4th Axis
End-user: Auto-Component Manufacturer

Scope: Fixture, HPP, Tooling Engineering

Solution: End-to-End Turnkey | Comprehensive process prove-out | From Process Cycle Time Study to Quality & Production Prove-out

Hydraulic Machining Fixture, Rotary Type

Hydraulic Machining Fixture | Rotary Type | 4th Axis

Component: Cylinder Head for 4-Wheeler
Material: Aluminium LPDC
Machine Type: Vertical Machining Center + 4th Axis
End-user: Auto-Component Major

Scope: Fixture, HPP, Tooling Engineering

Solution: End-to-End Turnkey | Comprehensive process prove-out | From Process Cycle Time Study to Quality & Production Prove-out

Hydraulic Machining Fixture, Rotary Type

Operational Accessories for Machining Centers

Rotary Production System | Cradle Assembly

Enables Rotary Fixture Arrangements on VMCs

Scope: Head-stock (Rotary or Indexing Table), Tail-stock (with or without brake), Rotary Joint (4 port or 6 port), Base-structure (for Table Mounting), L-plates or Face-plates for Fixture Mounting

Solution: High quality Rotary Unit, dynamically balanced with high stiffness & weight optimized. Tribological engineering between Head & Tail for smooth running and resulting in long life of Head-stock & Machine itsef.

Rotary Production System, Cradle Assembly, Rotary Fixture

Coolant System | External and/or Spindle Through Coolant

Designed for high performance in terms of Tool cooling, lubrication & heat dissipation, and clean evacuation of chips from Machine guard, bed & difficult to access area.

Scope: Coolant System, Internal piping for the Machine, Electrical Interfacing with the Machine, High performance Coolant Pumps, Sensors for functional awareness & control. Optional IIoT enablement features.

Solution: Topologically optimized for compactness, yet high performance. Multi-stage filtration. Optional filtration levels of upto 0.01mm. Rigidly built, hence maximizing the life of operating elements such as motors, pumps, sensors, and so forth.

Coolant System, Coolant Tank

Hydraulic Power Pack | Power Units for Fixture Actuation

Premium Series of Power-packs; IIoT ready; Visual panel for each functional parameter such as Pressure.
On-demand type & Continuous duty type, based on application needs.

Scope: Hydraulic Power Unit, Piping for the Machine, Electrical Interfacing with the Machine, High performance Hydraulic Pump, Sensors for functional awareness & control. Optional standalone control unit through PLC.

Solution: Topologically optimized for compactness, yet for ease of operational access. Rigidly built, hence maximizing the life of operating elements such as motor, pump, sensors, and so forth.

Hydraulic Power Pack, Hydraulic Power Unit

Hydraulic Power Pack | Power Units for Fixture Actuation

Economy Series of Power-packs.
On-demand type & Continuous duty type, based on application needs.

Scope: Hydraulic Power Unit, Piping for the Machine, Electrical Interfacing with the Machine, High performance Hydraulic Pump, Sensors for functional awareness & control. Optional standalone control unit through PLC. Optional IIoT readiness features. Optional upgrade to premium series.

Solution: Topologically optimized for compactness, yet for ease of operational access. Rigidly built, hence maximizing the life of operating elements such as motor, pump, sensors, and so forth.

Hydraulic Power Pack, Hydraulic Power Unit
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