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.
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.
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