The customer’s previous process of manufacturing the shell was complicated, labor-intensive, and energy-demanding. It included 10+ operations in various machine-tools, without achieving consistent workmanship.
The part is most critical, material-intensive, and high-accuracy-demanding. Shells with a critical internal diameter ratio are the most difficult ones to make; at the same time, they are widely used in engineering.
Information about the project:
The new technological solution allowed performing all the machining in one Weiler (Germany) turning centre. The uniqueness of the solution consists in turning of a solid piece followed by cutting it into sectors along the axis of rotation. The ultimate cutting (one of the most complicated machining steps) involves use of special-design attachments, which allow cutting without the risk of cut-off sectors falling down when the piece rotates. A special head was also designed and manufactured for cutting with a side mill.
The manufacture labor hours cut by two thirds The part quality is 100% consistent.
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