Automotive Parts Manufacturing
Ann Arbor, MI
An automotive parts manufacturer was struggling with circularity (ie. roundess) with two a thin walled powder metal parts for a transmission application. The level of distortion experienced by their 3-jaw chuck was in excess of 0.010”. This consumed the entire tolerance and prevented any SPC capability.
After reviewing the application and needs of the customer, the final solution alleviated close to 70% of the roundness error down to around 0.003”. The real benefit though really came about during the initial test cutting when a different sound came from the machine. Due to the improved rigidity of the workholding devise the production volume dramatically increased.
Before incorporating this workholding devise, each cutting inserts edge was only lasting 15~20 minutes. This part chatter was prematurely shortening the insert life. Once the new workholding devise was installed each insert edge began to last closer to (8)hrs. What benefits did the new workholding provide?
- Less scrap parts since the roundness feature was now under control
- 50% increase in part through-put was realized by reducing the down time of the machine for insert changes
- Thousands of dollars in cutting tools savings per year
