Swiss Turning Critical Brake Components

Swiss Turning Critical Brake Components
  • Industry: Contract Manufacturing, Automotive
  • Process: Swiss Turning, Turning
  • MGI Division: Rem Sales
  • Builder Tool: Tsugami BU26/BU38 ( Gang + Turret)
  • Customer: More Information
  • Outcome: Prince Industries realized a 41% reduction in cycle time while maintaining required tolerances.

 » Challenge

In early 2006, the Prince Industries continuous improvement team looked at the process for machining an engine brake component. Then- current procedure produced the part profitably with a 32µin finish and .0005 perpendicularity on both faces to the outside diameter of the part. "We knew that in theory it could be manufactured faster and more efficiently" explains Vice President of Manufacturing Mark Paluch "It was really an issue of cost and capability."

 » Solution

The keystone, and first step of the project was creating a program based on variables that utilized a custom macro feature in the Tsugami-Fanuc CNC. "We knew that it was possible to change over from one part to the next within the family by changing one variable and the identification roll on the roll stamp."

After meeting with Mr. Campbell and tooling experts from Sandvik Coromant who were willing to share their experience with producing these parts, the team began the work of developing a stable tooling process that extended tool life beyond the approximately 60 pieces that could be cut with the roughing tool and the 160 pieces that could be cut with the finishing tool. Mr. Murphy recommended an increase in the depth of cut to eliminate the multiple roughing passes. Utilizing the ruggedness of the Tsugami BU38SY and its 15HP main spindle, depth of cut was increased to .270 at 500 surface feet per minute with the front gang slide.

Prince Industries was able to achieve 470 linear inches of cut and 210 pieces before changing the roughing tool. Finishing tool life was extended to 782 linear inches of cut or 350 pieces, an improvement of 250% on the roughing tool and 194% on the finishing tool. All of this was accomplished while maintaining a 32µin finish on the face in both the main and sub spindles.

 » Assessment

With a length to width ratio less than 5:1, initial process reviews pointed to a gang tooled lathe. While discussing possible solutions, Rem Sales regional manager Dan Murphy and application engineering manager Steve Tragarz introduced a Tsugami BU38SY Swiss-turn as the best possible solution; it offered the possibility of producing the part complete from bar stock and removed inaccuracies induced by deflection on the gang tooled lathe. "Although no stranger to Swiss-turns, given the size and geometry of the part, we didn't even think that it was a Swiss application," commented Paluch.

Two parts needed to be turned complete from bar stock with differing lengths to their stems. Achieving increased tool life while eliminating the need for hard facing & hole deburring after heat treating were critical. "To improve upon the current cycle time the Swiss-Turn would need to remove a substantial amount of relatively hard material quickly - something that Swiss-turns are not known for" explains, Mr. Tragarz.

 » Results

While the Rem Sales team knew going in that the BU38SY was capable of removing serious amounts of metal quickly, everyone was surprised when the final process generated enough chips to fill a 55-gallon drum every four hours. After final approval of the process and installation of their new Tsugami, Mr. Paluch noted that Prince Industries realized a 41% reduction in cycle time while maintaining required tolerances.

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Keywords: brake component, tsugami, reduce cycle time, productivity, sandvik, prince industries