An international supplier of axle assemblies was having troubles with machined chips obstructing the tube ID post operation. In turn the operator would need to perform a secondary operation to manually clear the debris. In addition to the added cycle time, they were unable to incorporate automated material handling because of the obstructed tube. Ultimately the customer was looking for solutions to reduce not only cycle time but the overall cost per unit (CPU).
ParePro was applied to the ID of the tube which resulted in four (4), four (4) inch scribe lines covering the machining length on the tube. The tube surface scribe depths ranged from 1 – 4mm varying on the finished cut geometry of the axle tube. By ParePro pretreating the axle tube prior to the machining operation enabled the manufacturer to use existing equipment without any capital cost changes.
By incorporating ParePro to the existing operation the manufacture was able to see the following benefits:
- Reduced number of passes to one pass
- Cutting speed was increased
- Eliminated secondary debris removal operation
- Net saving of 43% machining time
- Able to run without coolant
- Increased production on existing equipment
- Increased safety for operator
- Longer use of tooling
- Reduced cost of this operation by 27%
A truck manufacturer had trouble keeping scrap metal stringers off of the tooling and out of the stamping when they began to turn the finished surface. The issue created a loss of time and the need for a secondary operation to remove the chips. In addition, the stringer created a safety issue for the operator because of their sharp nature. The current production was 400,000 units a year and the issue was occurring on every part so the customer was having substantial lost time and potential for injury on the floor.
ParePro was installed and scribed in four (4) different areas on the part within the finished part parameters. ParePro cycle time was substantially less than the turning operation so ParePro was able to supply enough parts to feed multiple machining centers.
Process resulted in a number savings:
- Eliminated stringers
- Machining time reduced 14%
- Feeds/Speeds were changed for optimal performance
- Changed to less expensive tooling; 10% savings
- Eliminated stringer safety issue
- Increased throughput
- Abolished the need for stringer related rework
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Engineered Machining Systems
300 Detroit Ave Suite I
PO Box 606
Monroe, MI 48162