1. | Introduction and History

Dated back in 1947 small family of migrants from India witnessed a high caliber and intelligent person with extraordinary skills named Zafar Mahmood. He fought for freedom of Pakistan as fighting for freedom was in his blood “The Mongols”. Many of his family members killed by Indian forces but he among few survived and became the only consolation to his family.

He was very hardworking and passionate. He wanted to do something for his nation and family. In spite of glorifying his golden days in India he admitted the fact of his new birth in Pakistan. With no money and resources he struggled for his homeland for almost 7 years starting from a tea stall to Eagle Machinery Services in Badamibagh which afterwards became a Tycoon in Lathe Machine & Tools Manufacturing.  He died in 1992 and opened a space for his children and grand children to serve Nation.

Since 1953 Eagle Machinery Service (EMS) has been the sole pioneer in Lathe machine manufacturing in Pakistan.  EMS efforts set the standards in design, development, and quality control that are emulated to this very day.  EMS ability to match and even excel over the standards of many foreign built machines has been legendary throughout Pakistan to the extent that there is hardly a soul who is not familiar in some way with the name Eagle.

Today EMS continues to try and surpass not only our competitors’ standards but also the standards it set over the past 54 years.  It is for this reason that EMS commitment to serving the needs of the manufacturing and industrial communities has been renewed with a new vigor with the result that future developments in Lathe design are being investigated today to provide the end user with the most efficient and precise tool as possible. In EMS history it has the honor of working with some of the great industrial giants of Pakistan and has established a long and rich tradition of service to the manufacturing and industrial communities.

2. | EMS Current Status & Chronology

2.1 | Divisions and System

CREED (Center for Reverse Engineering & Emerging Technologies Development) has been established in association with RAD Federation to facilitate EMS for the production of latest technology and reverse engineering. CREED also act as Virtual Governance System backed by technical and theoretical knowledge base of best practices, qualitative and quantitative research in engineering, mechatronics and digital logic design.

EMS is the name of Personal efforts geared by knowledge, devotion to workmanship and investments of stakeholders. Since its inception no help has been taken from government for the development and upgradation of industry.

The EMS mechanical engineering team provides a complete engineering solution to meet the requirements of its clients. The engineers have broad-based multidiscipline skills and industrial experience from a variety of backgrounds.

Eagle Machinery Services is divided into the following distinctive divisions as mentioned above in Figure 1.1.

Division of Engineering Design: In engineering design is the process of solving problems. Traditionally EMS engineers design components and products with the help of systems such as CAD/CAM software systems. At EMS Engineering design typically include a precise statement of design requirements and constraints, determination and analysis of alternative solution ideas and selection, after several iterations, of the solution that best satisfies the constraints. EMS design steps usually include a precise definition of design requirements, determination and analysis of alternative possible solutions, selection after several iterations of a satisfactory solution that will be feasible in the technical, economic and time variables. Mechanical engineering design includes the use of theoretical and empirical knowledge relating to thermo-mechanical performance of machine and power system elements and synthesis of such elements to form machines, systems [including power] or controls.

Division of System Engineering and Operations Research: At EMS Systems engineering and operations research deal with modeling complex systems with a view to improving and optimizing performance. A small design team having expertise in Analytical Methods including Structural, machine, vehicle, fluid, control, chemical, human and human/machine, electrical and computer, manufacturing knowledge, Synthetic Methods including Sampling and testing, forecasting, simulation, reliability, economics Management, CAD/CAM, display, robotics knowledge and  System Theory and Techniques including Information theory, game theory, decision theory, programming, queuing and Markov processes, feedback, adaptive and learning control, simulation, testing and reliability, probability, numerical analysis and logic works under this division.

Division of Metallurgy and Metallurgical Engineering: This division deals with the science and engineering of metals and alloys. Alloys are combinations of metals but usage includes nonmetallic additives such as carbon in plain carbon steel.

Mechanical Engineering Division: This division deals with the use of mechanics, thermodynamics and materials properties in the synthesis and design of machines, systems and controls for power transportation, industry and other applications. The use of mechanics, thermodynamics and material properties implies booth experimental and theoretical aspects including related mathematical and numerical and computer techniques to determine which of various solution-ideas best meets the design specifications.

Division of Industrial and Management Engineering: This division deals with methods to make the workplace and production more effective: time and motion study, plan layout, quality control, inventory control, resource allocation; these aspects of productivity are analyzed in turn by the fields of human engineering and applied psychology, network analysis, statistics, queuing, programming. The objective of this division is creation of effective and efficient systems of management and industry for provision of engineering systems, products and services. The methods include those of systems engineering design and operations research. The approach is multidisciplinary and involves analysis, evaluation, synthesis, design and management of systems that range from a single component to very large and complex assemblages of resources of all types.

2.2 | Technical Status

Lathes: Lathes are used for the production of all kinds of components which are symmetrical about their axis of rotation.
Drilling Machines: Drilling machines are used for drilling, boring, counter-sinking, reaming and tapping operations.
Milling Machines: Milling machines are used to produce flat surfaces, sink, and slot.
Transfer Machines: A number of work stations (turning, drilling, milling, etc.) arranged behind each other, linked by the means of an automatic work transportation unit, which governs their positions and the timing cycle.
Grinding Machines: These machines are used to grind material. Basically, the cutting tool provides the cutting movement on grinding machines.
Honing Machines: Honing Machines are used for improvement in surface finish and dimensional accuracy.


2.3 | Machine Tool / Lathe Construction Components

Frame: The frame is a machine's fundamental element. This casting or fabricated section carries all the active and passive components- spindles, tables, and controls. Frames are made from welded steel, cast iron, or composite concrete. When constructing the frame, loads, damping, apertures, heat transfer, and noise are major design considerations.

Slides and Rails
Guild ways are frame elements that carry the workpiece table or spindles. There are two way types: box ways and roller ways.

Box way: This oldest and simplest of the two. It has high stiffness, good damping characteristics, a large surface contact area, and resistance to high cutting and shock load. The rail for this design is cast or welded onto the frame or bolted in place. Cast ways are difficult to repair and virtually impossible to replace.

Roller ways: This way type consists of a rail and a slide, but has a rolling-element bearing between the two. Roller ways are lighter weight and operate with less friction, so they can positioned faster and with less energy. Roller ways, however, take more space and is usually more costly.

Spindles and Motors
Electric motors are the prime movers for most machine tool functions. They mostly use 3-phase ac power supplied at 220 or 460 V. Spindles generally operate around 10,000 rpm or higher, ranges from 5-150 hp (3.7-112 kW).

Spindle motors: A spindle is a motor-driven shaft that both positions and transmits power to a tool or holds a workpiece. Spindle motors are the major motors on a machine tool, drive the spindle shafts.
Feed motors: Positioning motors drive the ball-screws that move the slides carrying spindles or worktables. Today's most popular positioning motor is technically called a dc brushless motor, more commonly known as an ac servo motor.

Linear motors: A linear motor is essentially a "straightened out" rotary motor. The rotor is the slide and the stator is a row of windings. It is very lightweight relative to the conventional motor, but less accurate in positioning.
 
Controls
Today, EMS engineers can create both parts design and the manufacturing programs to make them on a computer. First, an engineer designs a part using computer-aided design (CAD), and then the design goes to a computer-aided manufacturing program (CAM). CAM will generate the tool-paths. Finally, the CNC on the machine tool will execute the tool-paths commands.
 
Tools and Holders
Cutting tools remove metals from a workpiece are usually made of tungsten carbide which is form into inserts that are clamped onto a holder. In more recent times, in EMS high-speed steel are used for making tools. These steels are alloyed with chromium, tungsten, and cobalt to make them hard, strong, and resistant to mashing heat at the cutting edge.

2.4 | Current Production Status

Eagle Machinery Services have manufactured large quantity of lathe machines and tools since 1953 in which some of Lathe Machines data sheets are mentioned. Each lathe is tested at all loads and speeds under strict supervision according to Dr. Schlesinger’s limits to make the Lathe dependable and durable under all working conditions. Many other models have been deleted because of poor socio-economic conditions. Under very tight circumstances EMS is now able to produce few models as under:

Model GL-32

From the single machine workshop to the largest factory setups Eagle’s “Golden Lathe” Model GL-32 has historically provided solid service and reliability since 1953. It has been designed and manufactured according to our highest standards to provide ample power, speed, precision, and high efficiency for light duty tooling tasks. So durable and dependable is the Lathe’s overall design that today, throughout the country, many of our original production models are still in service. With it’s unique size we have shown that a light duty machine can be employed for simple heavy duty tasks also not limiting the user to small jobs.
Specifications:

Standard Equipment: Face Plate, Steady Rest, Follow Rest, Switch, 2 Couplings for 3 Jaw and 4 Jaw Chucks, Motor Pulley, Solid Legs and Full Cabinet.
Extra (Optional) Accessories: 4 Jaw Chuck 6” dia China made, 3 Jaw self centering Chuck 6” dia, 3 phase 1 HP Motor w/ 1420 rpm

Model GL-28
Eagle’s Model GL-28 is our most popular design.  It is used in some of the largest factory setups in Pakistan and has continued its service to the industry with a sparkling record.  Eagle’s “Golden Lathe” Model GL-28 has provided solid service and reliability since 1953.  It  has been designed and manufactured according to our highest standards to provide high power, speed, precision, and high efficiency for the heavy duty tooling tasks common to large workshops. 
Specifications:

Standard Equipment:Face Plate, Steady Rest, Follow Rest, Switch, 2 Couplings for 3 Jaw and 4 Jaw Chucks, Motor Pulley, Solid Legs and Full Cabinet.
Extra (Optional) Accessories: 4 Jaw Chuck 8” dia China made, 3 Jaw self centering Chuck 6” dia , 3 phase 1 HP Motor w/ 1420 rpm

Model GL-43
Eagle’s “Golden Lathe” Model GL-43 has been designed and manufactured according to the requirements of modern machine tools in respect of greater power, speed and high efficiency. It is strong and rigid in roughing operation and capable of maintaining accuracy and precision for the finishing operation. The headstock is a strong constant section casting. It houses the main spindle and geometric progression train. The main spindle is bored to pass 1 ¾” diameter bar and there are six spindle speeds ranging from 30 to 600 rpm. The main drive is equipped with Taper Sleeve clutch. The main spindle is mounted on anti-friction bush-bearing system for ensuring smooth and accurate running over the full speed range. The carriage, Norton gear box, apron and tailstock have been designed to ensure easy handling with high accuracy in different operations.
Specifications:      

Standard Equipment: Face Plate, Steady Rest, Follow Rest, Electric Coolant Pump, Switch and Automatic Trip Starter, 3-jaw self-centering chuck 8” dia mounted on Chuck Plate, 4 jaw chuck 12” dia mounted on Chuck Plate, Motor 2 HP (3 phase)
Optional Equipment:Taper Turning Attachment, Grinding Attachment

EMS CNC Successful Experiment
Backed by the expertise of CREED, EMS divisions are now able to produce a full fledge CNC lathe machine. Details in analogous manner are given below.
The first benefit will be offered by all forms of EMS CNC machine tools is improved automation. The operator intervention related to producing workpieces will be reduced or eliminated. Many CNC machines will run unattended during their entire machining cycle, freeing the operator to do other tasks. This will give the CNC user several side benefits including reduced operator fatigue, fewer mistakes caused by human error, and consistent and predictable machining time for each workpiece. Since the machine will be running under program control, the skill level required of the CNC operator (related to basic machining practice) is also reduced as compared to a machinist producing workpieces with conventional machine tools.
The second major benefit of EMS CNC technology is consistent and accurate workpieces. Today's CNC machines boast almost unbelievable accuracy and repeatibility specifications. This means that once a program is verified, two, ten, or one thousand identical workpieces can be easily produced with precision and consistency.

2.5 | Production Statistics Since 1953 to 2005
Production statistics are divided as per 7 years average spanning 1953-2005. Details are given below:

2.6 | Infrastructure and Architectural Spending Since 1953 to 2005
Since its inception Stakeholders injected major revenues streams into business establishing strong credibility and symbol of quality. To date no major or minor mechanical industry exists without the lathe machine of Eagle. Following are the details: