Product category:
Chucks and collets for rotational work
News Release from: Leader Chuck Systems | Subject: Hainbuch collet chuck
Edited by the Manufacturingtalk Editorial
Team on 30 July 2002
Accurate chucking ups transmission
reliability
Collet chuck's high accuracy clamping secures holding of short-length model racing car transmission parts in CNC lathe for machining within 0.004mm TIR.
Radio-controlled model car racing is serious business, with sponsored race teams and professional drivers competing every week at various events throughout the country and overseas, including world championships Schumacher Racing is a leading exponent of the sport, producing a wide range of battery and fuel (nitro methane) powered touring, off-road and sports cars for enthusiasts around the globe
This article was originally published on Manufacturingtalk on 3 Mar 2004 at 8.00am (UK)
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"It's Formula One in miniature," says managing director Robin Schumacher, "even to the extent that we are continually updating and enhancing our designs.
This is to extract maximum performance from the carbon fibre chassis, three-speed auto gearboxes, hydraulic suspension systems, traction and torque control as well as ABS featured on some of our 80 mph race cars." In addition, the company's Northampton site mirrors Formula Grand Prix team HQs, with Schumacher Racing's skilled and enthused 25 employees adopting an 'only the best is good enough' work ethic that is underpinned by a myriad of production equipment.
This includes toolmaking capability to complement in-house plastics injection moulding capacity and, more recently, investment in modern twin-spindle, bar-fed CNC turning technology via a Pollard Mori Seiki SL-154SY turning centre.
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"With each car needing around 1,000 components and 150 of these being metal parts (disregarding standard screws and nuts), until the installation of the SL-154SY we outsourced all our metal component machining," comments engineering manager, Vic Ababurko.
"But the lessons learned from satisfying our injection moulding needs in-house - the machine paid for itself within months - prompted us to do our sums in terms of the outsourced metalcut parts.
We soon realised that a new turning centre would pay for itself in no time." Having analysed available machines, it soon became clear that the Pollard Mori Seiki was the best fit in terms of specification, reliability and, thanks to the use of a Hainbuch chuck on the sub-spindle, accuracy.
"Coincidentally, we also noticed that a number of F1 teams were also using Mori Seikis," adds Vic Ababurko.
He continues: "The machine supplier, Fredk.
Pollard and Co, have a good reputation for customer care and, being first-time CNC users, this was important to us.
In the event, this has certainly been borne out." With live tooling on its 70mm Y axis, the SL-154SY boasts maximum turning diameters and lengths of 300mm and 350mm, respectively, and X and Z axes travels of 215mm and 490mm - more than adequate for Schumacher Racing's requirements.
It has a spindle speed range of 60 to 6,000 revs/min and a 12-station tool turret.
Supplied with Leader Chuck Systems' collet-style Hainbuch chuck on the second spindle, as recommended by Fredk Pollard and Co, the machine plays a key role in satisfying the company's demand for cost-effective, precision components.
"Although the tightest tolerance we work to is 30 microns, and the machine easily achieves that, everything we do is 'double-sided'," says Vic Ababurko.
"After parting off from the first chuck, the workpieces are held in the Hainbuch chuck for all the secondary and finishing operations.
"Without the Hainbuch chuck's high-accuracy clamping of up to 0.004mm TIR it would be true to say that our investment wouldn't have made sense.
"Sure, we need accurate clamping, but for the particularly small components we produce we also insisted on the ability to securely hold short component lengths.
Due to its positive pull-back and clamping action, where the clamping head is pulled into a perfectly mating taper, the Hainbuch provides exactly that." Processing mainly alloys - aluminium 6262, 2011 TF free-machining aluminium and some steel - the SL-154SY has so far been applied to shock absorber bodies, flywheels and differential components, for example, within a 13mm to 42mm diameter size range, producing batches of circa 1,500-off.
The first job on the machine was a 3mm thick by 42mm high motor plate, formerly purchased from an overseas supplier who manufactured the part in five operations on conventional milling machines.
With its live Y axis, the SL-154SY now machines the part in a single, unmanned setting by applying a sequence of milling, drilling and tapping operations.
"By doing this job in-house, we are not only achieving a piece part cost that is comparable with the original bought-in price, but we initially also gained a two-month advantage during the launch of a new car," confirms Vic Ababurko.
"Dealing with overseas suppliers is often fine in terms of price advantage, but sometimes it takes time for design changes to be implemented.
Today, with our new-found turning capability, we can see the results very quickly." More jobs are regularly being added to the SL-154SY - the machine will eventually produce around 75 different components - and within six months it had already saved more money than the company would have spent on bought-in parts.
Also, with its potential for single set-up machining, and unmanned running courtesy of the automatic bar feed system, the machine has not only attracted enquiries for sub-contract work but has now also spurred the company into looking at the remaining 70 or so machined items used on each car.
In the meantime, Robin Schumacher points out that the company - founded 22 years ago by his father Cecil, a former Cosworth design engineer - has built a reputation for high-quality, high-specification cars.
(Despite the Formula One successes of Michael and Ralf Schumacher, the German brothers - no relation - have not helped the company sell more cars!) "In this business, what wins on Sunday sells on Monday," concludes Robin Schumacher.
"So as well as having the best drivers, it is important for us to continue to produce top-quality cars.
And that means having the best people and equipping them with the best tools for the job.".
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