Product category:
Vertical machining centres (VMC)
News Release from: 600 Centre | Subject: Fanuc Alpha T14i Robodrill vertical machining cntr
Edited by the Manufacturingtalk Editorial
Team on 23 December 2003
VMCs up engineering subcontractor's
efficiency
Following investment in three VMCs, an engineering subcontractor has been able to gain valuable orders in the fiercely competitive automotive market.
Following investment in three Fanuc Alpha T14i Robodrill vertical machining centres Gloucester based Sapa Pressweld has been able to gain valuable orders in the fiercely competitive automotive market According to engineering director, Drew Moore: "We have achieved this welcomed expansion through the phased introduction over the last two years of Fanuc Robodrills, from 600 Centre of Shepshed near Loughborough
This article was originally published on Manufacturingtalk on 22 May 2001 at 8.00am (UK)
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He maintains: "We needed to be more competitive in our production of a number of new automotive trim products where our existing CNC machines were just not cost-effective both from a batch size point of view and from a capability aspect".
He then explains how initially the company obtained details of some 14 different machining centre suppliers and quickly whittled them down to a shortlist of just two.
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"It was the rapid movements, particularly the fast acceleration to 54m/min rapid traverse and two second tool change coupled with versatility for short cycling operations, accuracy and price that concluded the deal," he says.
The final specification included the high speed 15,000 revs/min spindle option and the extended guarding enclosure in order to accommodate longer extruded components.
Formally known as Pressweld UK, the company was acquired by the Swedish SAPA group in November 2002.
It employs 110 people and is a medium volume manufacturer specialising in the design and manufacture of high quality, trim-type components which are mainly produced from aluminium.
Main customers are from the automotive sector which accounts for around 65 per cent of the business with the balance made up from leisure, domestic appliance and home heating industries to which it supplies in typical batch quantities of between 1,000 and 5,000 parts.
As well as all its machining equipment, the company also operates a range of power presses and press brakes and has a well-equipped finishing department and a large bright trim anodising plant.
Following the purchase routine, the first Fanuc Alpha Robodrill was installed in 2000 and such was its immediate success on a range of aluminium trim components that the company bought another T14i the following year.
In 2002 a third machine was acquired from 600 Centre and as Sapa Pressweld's production capability increased, this was repaid with a new contract to produce curved ash tray lids for an executive car.
However, in order to machine the end sections of stiffening ribs which formed part of the extrusion, the company found it really required an additional fourth axis and in consultation with the 600 Centre, it was decided to retrofit a Nikken index unit and tailstock to the original T14i Robodrill which would then create a rotary axis machining capability.
In addition, a special fixture was also developed which would hold four ashtray lids at a time, on a trunnion-type unit, which is indexed sequentially by the Nikken unit to enable the excess rib section material to be milled away.
Measuring 215mm long by 80mm wide by 2mm thick, these curved aluminium extrusions are now produced in batches of 1,500.
Each extrusion has three stiffening ribs along its length but these 3mm wide sections need to be machined away for a distance of some 19mm at both ends in order to allow a wood veneer to be fixed and the ends of the lid formed.
The main fixture also comprised two sub-fixtures in order that parts can be easily loaded away from the machine while the other sub-fixture is being processed through its two minute production cycle.
The removal of unwanted areas of extruded aluminium profiles is the key machining function of the other Robodrill operations.
For instance, on another recently won automotive contract involving the production of a 345mm long by 150mm wide by 1.6mm thick curved passenger airbag deployment door, which looks similar to a glove compartment lid, the extruded aluminium form is modified to allow the door to be securely anchored by two special polyester straps.
When the air bag is activated, this method of fastening ensures the door is able to swing away and be safely retained.
The straps are located at two points and each of the 25mm wide sections have to machined through a 10mm outside diameter extruded tube which has a 6mm diameter bore and runs along the complete length of the door.
This form, which has tolerances of +/-25 mm enables the two anchors to be slotted into the tube and secured via a pin which runs through the entire length of the tube, rather like a hinge.
Mounted four at a time on two, special curved fixtures, the location sections along with some end machining work are finished in a cycle time of just 75 seconds each.
Batch sizes can be up to 2,500.
A further automotive example completed on the latest Robodrill T14i are batches of 3,000 tread plates which are fitted to the sill inside the door of a car.
Produced for an American customer, this extruded aluminium section measures around 645mm long by 75mm wide and is 20mm thick.
Operations include: machining an angular and bevel form on each end, recessing a large 1.8mm deep rectangular pocket to locate a badge plate, and the production of a 0.5mm deep sub-pocket in the centre.
Three holes of 7mm diameter are then drilled and counterbored to 15mm diameter by 4mm deep.
Multi-fixtured three at time, these components are produced within a cycle time of 1.8 minutes using six different tools for each type of tread plate.
As Drew Moore reflects: "The purchase of each of the Fanuc Robodrills has had a big impact on our production capability and especially our efficiency.
Such is the productivity we can now achieve, the machines have undoubtedly helped us win new business.".
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