Case Studies

Overall Efficiency gains through ADV MFG application means a win for CNC machining business.

How a company overcame the need for operators to manage difficult to calculate machine offsets at the micron level. Without stopping production.

The problem: Company secures contract for complex machined components. Needs opportunity to eliminate costly and difficult downstream operations, and needs the ability to handle offset adjustment in-process to accomplish this. Human intervention becoming too costly in both time and variability of math involved.

Specifics: 32 fixture stations of various operations exist in a 4 axis pallet changing Machining Center.

Cycle time: 6 hours. 

Features Managed: 300 unique dimensions per part. Multiple features stacked and calculated to provide product function. Post heat treatment surface grinding operation desired to be eliminated.

SCOPE

Material Conditions Adjusted

Automation Package Implemented

Renishaw Equipment installed, calibrated and lightly maintained

Coding re-configured for flexibility

Coding re-configured for cycle reduction, cost per cut reduction

Material Condition: Our engineers discovered that downstream operations and complex post-heat treat steps could be eliminated by applying a special process to the incoming material. This did not compromise the end properties, maintained print compliance, and was cost effective (Value-ADD).

Utilizing the Machining Automation Package #3 and #4 from Advanced Manufacturing Solutions. Company eliminated thermal growth:

Complete removal of Z length offsets, R offsets automated , Automatic in-machine inspection of key features complete, Automatic adjustment of features and datums through dynamic custom calculations, missing work piece detection and broken tools detection. Programs re-coded to mid-nominal feature measurement conditions.

Utilizes Renishaw Inspection Plus Macros. Custom calculations and implementation by Advanced-MFG.

Code Package added: All fixtures stations switchable to on/off 

Custom offsets possible for individual features via macro adjustment

Cycle and cost per cut reduced by applying scientific cutting approaches. Quality increased through perfected cutting parameters. 

Down time decreased. Value Increased. Predictability achieved. Overall win for the client, customer, and end user with a better product.