How to enhance efficiency of machining process

January 6, 2016 12:05 pm

An analysis on the need for enhancing the efficiency of machining process
Why the need?“The continuing advances in production methods in manufacturing industries such as automotive components, pumps and valves have created a need, not only for precision work holding devices but also for efficient machining process.  This is true for hard-to-hold and non-cylindrical components,” believes K Jagannathan, Executive Director, Sales & Marketing, Guindy Machine Tools.
Jagannathan explains his statement with an example – the production and machining of components with intersecting axes, has, for a long time involved high processing expenditure. These components were either processed on special machines, transfer lines or on conventional lathes in several chucking operations. This is a time consuming process and we have to retain accuracy during each chucking operation.
To machine such components efficiently and to save time yet retain accuracy, ideal solution would be to machine the component in a single setting on a standard machine. This calls for a special chucking system which can perform multiple operations in a single setting. This will result in enhanced production and cut machining time often by factors as high as four times, according to Jagannathan.
Talking on the need of efficient machining process for an OEM Nitesh Gupta, GM – Product & Business Development, Haas Automation says, “Efficient machining processes for industrial production lines at OEMs is crucial as it results in an improved production and utilisation of available resources.”
Factors contributing to production line efficiency are manpower utilisation and machine efficiency. Measuring the machine efficiency and man power utilisation should be on-line, accurate and truthful. The management should be able to look for relevant production data and to accurately interpret these data in order to identify the various faults at production level and to immediately take steps to improve efficiency.
Enhancing efficiency of machining processExpressing his views on how to enhance overall efficiency of machining process, Jagannathan says, “One of the ways to enhance the machining process is to use custom work holding devices. Since these work holding devices are built for a particular component, it takes care of any anomalies in the component, such as an overhang, by providing a balancing arrangement like Turbine Housing. But after a detailed study of the component we arrived at a work holding solution with Universal Ball Lock Chuck including a special balancing arrangement.”
Machine efficiency is one of the factors that are frequently overlooked by the management and this can lead towards losses which reduces the Overall Equipment Efficiency (OEE). Improper maintenance of machines will result in low standards of produced parts and increases the maintenance of machines. Machines are meant to work efficiently, but in some circumstances machines can be less productive due to improper preventive maintenance.
Gupta observes, “Preventive maintenance is a key factor that keeps the machine running efficiently through the production process. Total Productive Maintenance (TPM) is the need of the hour wherein unpredicted downtimes can be reduced and optimum usage of machineries can be achieved which will inherently result in higher profitability for the OEM.”
GMT’s SolutionsSpeaking on the products and solutions offered by GMT, Jagannathan proudly boasts, “A special team of designers, experienced machinists and manufacturing engineers work closely with our customers to provide custom work holding solutions to enhance production.”
Jagannathan has chosen three case studies at random where there are solutions to enhance production, such as components with extruded stock, non-cylindrical parts, eccentric, off-center and non-traditional applications. The case studies are as follows:
Machining bodygateThis is a typical example of machining of components with intersecting axes. Guindy Machine Tools Limited (GMT) has developed Indexing Power Chucks to meet the persistent problems in machining components with intersecting axes in a CNC Lathe.
Indexing chucks of different sizes are designed for machining typical parts like Universal joints, tripods, spider and valve bodies, etc. Power operated power indexing chucks are offered with index position:4 x 90°,3 x 120°,2 x 180°
Clamping, de-clamping, indexing and locking of index drum are performed by integral hydraulic cylinders. The oil is fed to the different cylinders through a pipe bundle running through the spindle bore.
Machining lifting connectorUniversal Ball Lock Chucks (UBLC) is designed to provide an axial force to pull the component against chuck face and ensure face butting. This chuck is typically used for first operation for clamping forged or casting surfaces. These power operated ball lock chucks have certain distinctive advantages over wedge and lever type chucks. Main advantage is that a higher cutting parameter can be used as it provides a rigid and positive clamping.
Machining bushThe customer required a chuck to machine the above component. This was to be used for second operations. The aim was to achieve closer concentricity and parallelism. Our design team studied the component and designed a 2 jaw grip down chuck (pull down chuck) with air sensing.
This chuck is ideal for the finishing operation. The radial pull back function of the chuck ensures that there is a positive resting of the component after clamping. It also has a high gripping force, repeatability and is ideal for machining auto components.
Solutions offered by HAASHAAS which has been in existence in India from 1995 and with more than 5000 installations across the country, the focus has always been for long term relationships, says Gupta.
“The key for our success has been ontime customer service leading to increased customer satisfaction levels. With our focus more centred towards customer satisfaction, customers tend to have higher expectations from us – with faster machines, reduced cycle times and automation with robots to name a few. Increased effort in terms of technical shows like HAASTECs and demo days bring our products much nearer to our customers wherein they can feel the machines by themselves and have actual components cut during their presence. Providing Preventive Maintenance (PM) to machines being used at customers, we provide the much needed platform to our customers wherein their machines are maintained by our service engineers as per the standards set by HAAS so that the machines keep producing chips which eventually mean higher profits for our customers,” concludes Gupta. ——————–Efficient machining processes for industrial production lines at OEM’s is crucial as it results in an improved production and utilisation of available resources.
Nitesh Gupta, GM – Product & Business Development, Haas Automation
————————-One of the ways to enhance the machining process is to use custom work holding devices.
K Jagannathan, Executive Director, Sales & Marketing, Guindy Machine Tools.