GENERATOR COMPONENT
Electrical Generator Component
 

Part: Electrical Generator Component.

OLD PROCESS: FOUR MACHINE TOOLS WERE REQUIRED:

  • 2-axis CNC lathe to turn the ID and OD
  • 3-axis VMC for mill, drill, tap operations along with centerline (2 setups)
  • 4-axis HMC for machining perpendicular to the centerline
  • 3 + 2-axis VMC with rotary/tilt table for angled features (3 setups)

PRODUCTION LEAD TIME - 47 HOURS:
Estimating (8) hours of queue time between machines and (2) hours of setup time per operation.

NEW PROCESS: ONE MACHINE - MAZAK'S INTX e-420HS:

Machine Configuration:

  • Horizontal main spindle plus second opposed spindle
  • 240 degree rotating B-axis with 30 hp spindle
  • 80-tool automatic tool changer

Multi-Tasking Process Advantage:

  • A raw billet is chucked in the main spindle for Id, OD, face turning, plus machining of all drilled and tapped holes, pockets and angled features
  • Part is automatically transferred to second spindle, chucked on the ID and machined complete on the backside.

Results: LEAD-TIME REDUCED FROM 47 HRS. TO 7 HRS. - NEARLY 7 TIMES FASTER!

  • Only one initial setup - no part transfer between machines
  • Fewer fixtures, fewer cutting tools and holders
  • Machine can run unattended
  • Increase in shipping and billing frequency improves cash flow

This is a Level 5 Multitasking application