Automated Part Processing with Sub-Assembly on CNC Turning Center
The subject metalworking facility is a mid-sized die caster. Their facility being somewhat dated and seeking markets other then the traditionally slim margin die cast business, this company was actively pursuing the more lucrative precision machining market. The core of
their business, near net castings, allowed them to offer precision machining as added value to their customer base.
To compete in this market they recognized that not only would they need to deliver precision, they also would need automated processing. The labor cost associated with individual piece processing was prohibitive. Automated workhandling was a key component of their process guidelines. They felt that precision machining in an unattended environment was a huge but attainable challenge.
The inclusion of a sub-assembly process was not a vague consideration to this company.
Recognizing the need for engineering assistance to tackle the challenging issues of work presentation, work handling, work holding, and finally machining, the company invited bids for a full turn key process.
The subject piece was an a-cylindrical, aluminum automotive component. The bid winner Amada Wasino provided two things, a precision CNC turning center with on board automation and seasoned engineering support that made automation simple and effective.
The project was built around a model G-6 Gang Type Turning Center with on board automation. Working in tandem, Amada Wasino engineers were allowed to see the entire scope of the manufacturing process including what was viewed as a post-assembly and secondary machining process of the subject part. Knowing both the limitations and the capabilities of their automation, Amada Wasino offered a process, which presented the workpiece complete including subassembly and secondary machining. Their comfort level with their automation enabled Amada Wasino to present a completely processed part including secondary operations that were not even on the table because of their unconventionality.
The process flow was unique, simple and most importantly answered the question, ". If I only had a third hand." Selecting an off the shelf, two hand, 90? robotic part exchanger, and a "grafted on" third hand, Amada Wasino engineers were able to pick up two items at the same time, bring them into the work area, exchange a fresh for a finished part and place an assembly bushing into an insertion actuator. What followed was precision machining including a boring operation with PCD, insertion of a hardened steel bushing into the bore and finally, precision boring of the hardened bushing with CBN. A completely automated process of a fully machined and assembled component. The process included presentation, work handling, work holding, machining, assembly, secondary machining and unloading. The bushing was bored to a 1.67 Cpk.
While the ingenuity of the three fisted robot draws most of the attention, two other factors weighed heavily in the success of this installation.
The Amada Wasino G-6 gang type, 2-axis turning center provided the foundation that enabled close tolerance production turning of the subject part. Also foundationally, a highly seasoned application engineering staff addressed the highly difficult task of designing workholding for an a-cylindrical die cast part.
Amada Wasino provided a (a)turning center (G-6) with an in-line gantry robot, (b)pallet shuttles with custom pallets, (c)a bowl feeder system for the steel bushings, (d)a two handed robot for part exchange, (e)a third hand for the bushings, (f)a sub-assembly device for injecting bushings, (g)a diaphragm chuck for work piece holding, and a fully tooled machining process.
All the accessories for this process were stock items supplied by Amada Wasino accept for a bowl feeder system, a sub-assembly device, and a diaphragm chuck. Amada Wasino engineers designed all workholding tooling.
This manufacturer has a truly complete manufacturing process on line. The completed part exits the process fully machined assembled and finish bored in the assembled bushing holding 0.000,4" to a 1.67 Cpk.
To compete in this market they recognized that not only would they need to deliver precision, they also would need automated processing. The labor cost associated with individual piece processing was prohibitive. Automated workhandling was a key component of their process guidelines. They felt that precision machining in an unattended environment was a huge but attainable challenge.
The inclusion of a sub-assembly process was not a vague consideration to this company.
Recognizing the need for engineering assistance to tackle the challenging issues of work presentation, work handling, work holding, and finally machining, the company invited bids for a full turn key process.
The subject piece was an a-cylindrical, aluminum automotive component. The bid winner Amada Wasino provided two things, a precision CNC turning center with on board automation and seasoned engineering support that made automation simple and effective.
The project was built around a model G-6 Gang Type Turning Center with on board automation. Working in tandem, Amada Wasino engineers were allowed to see the entire scope of the manufacturing process including what was viewed as a post-assembly and secondary machining process of the subject part. Knowing both the limitations and the capabilities of their automation, Amada Wasino offered a process, which presented the workpiece complete including subassembly and secondary machining. Their comfort level with their automation enabled Amada Wasino to present a completely processed part including secondary operations that were not even on the table because of their unconventionality.
The process flow was unique, simple and most importantly answered the question, ". If I only had a third hand." Selecting an off the shelf, two hand, 90? robotic part exchanger, and a "grafted on" third hand, Amada Wasino engineers were able to pick up two items at the same time, bring them into the work area, exchange a fresh for a finished part and place an assembly bushing into an insertion actuator. What followed was precision machining including a boring operation with PCD, insertion of a hardened steel bushing into the bore and finally, precision boring of the hardened bushing with CBN. A completely automated process of a fully machined and assembled component. The process included presentation, work handling, work holding, machining, assembly, secondary machining and unloading. The bushing was bored to a 1.67 Cpk.
While the ingenuity of the three fisted robot draws most of the attention, two other factors weighed heavily in the success of this installation.
The Amada Wasino G-6 gang type, 2-axis turning center provided the foundation that enabled close tolerance production turning of the subject part. Also foundationally, a highly seasoned application engineering staff addressed the highly difficult task of designing workholding for an a-cylindrical die cast part.
Amada Wasino provided a (a)turning center (G-6) with an in-line gantry robot, (b)pallet shuttles with custom pallets, (c)a bowl feeder system for the steel bushings, (d)a two handed robot for part exchange, (e)a third hand for the bushings, (f)a sub-assembly device for injecting bushings, (g)a diaphragm chuck for work piece holding, and a fully tooled machining process.
All the accessories for this process were stock items supplied by Amada Wasino accept for a bowl feeder system, a sub-assembly device, and a diaphragm chuck. Amada Wasino engineers designed all workholding tooling.
This manufacturer has a truly complete manufacturing process on line. The completed part exits the process fully machined assembled and finish bored in the assembled bushing holding 0.000,4" to a 1.67 Cpk.
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