Case Study:

Customer’s Initial Process:

One of our client was making a component, made of mild steel. The component was a rectangular box of rough dimension L:240xB:120xT:44 mm, which had a ‘U’ Shaped slot inbetween of size 66. The bottom of the slot has to be taper milled with a 0-5 mm taper.

The customer was doing this on a knee type milling machine with manual clamping and tilting the head. We was getting a cycle time of more than 5 minutes per component.

Our Solution:

We offered him a machine which had a dedicated spindle and gearbox design for milling this taper. A specially custom designed hydraulic fixture for automatic taper orientation and rigid clamping for higher feeds. The promised cycle time was within 3 minutes, which was a 40% increase in his productivity.

Conclusion:

The customer accepted our proposal. We designed and delivered the machine

Final Finding:

• The cycle time achieved was 2 minutes 20 seconds because of which the production increased by 2 times.
• Since this was PLC programmed machine with automatic job clamping and declamping, the client could engage an unskilled labour to load and unload the job instead of a skilled miller.
• The tool life doubled due to a dedicated spindle and gearbox design.