Month: November 2023

GESCO Healthcare – Complete Machining solution in one place

Posted on by supercode_cygnus

The Company

GESCO Healthcare is a prominent player in the medical industry, specializing in the design, development, and manufacturing of medical devices and healthcare solutions. The company is known for its commitment to quality, innovation, and customer satisfaction. Here’s a comprehensive look at GESCO Healthcare, including its products, services, and contributions to the healthcare industry. Medical Component Machining: Precision, Compliance, and Innovation Machining medical components is a highly specialised field that requires precision, adherence to stringent regulatory standards, and the ability to work with advanced materials. Here, we delve into the critical aspects of medical component machining, including the challenges, processes, and benefits.

Tools + Synergy Solution

Complete Process Machining Solutions: End-to-End Manufacturing Excellence Complete process machining solutions provide a comprehensive approach to manufacturing, covering every stage from design to final inspection. These solutions ensure high precision, efficiency, and quality, tailored to meet the specific needs of GESCO

Computer-aided manufacturing (CAM) enable precise design and efficient programming of machining processes. Comprehensive management of tooling inventories, including maintenance, calibration, and replacement . Utilization of Industry 4.0 technologies, including IoT and real-time data monitoring, to optimize machining processes. Continuous monitoring and inspection during the machining process to detect and correct issues early. A highly flexible and efficient clamping system from SCHUNK that significantly reduces setup times by allowing rapid changeover of workpieces. The SCHUNK Vice is a high precision clamping solution designed for a wide range of machining applications. Known for its robust construction, high clamping force, and flexibility, the Vice enhances productivity and precision in medical components machining .Renishaw probing system is designed to provide high-quality probing solutions for precision manufacturing. RENISHAW primo enhance their machining accuracy, reduce setup times, and improve overall process reliability without significant investment.

Duo Just-cut with a 3D chip breaker insert gives a tool life of 4X times

Posted on by supercode_cygnus

The Company: KUN Aerospace is a private limited company, certified AS910 & ISO901, offering  services to Aerospace, Medical, Oil & Gas and Energy. KUN Aerospace has a great degree of  experiencing solving complex engineering problems and offers a wide range of solutions at various  stages of product development processes and beyond. We are well-versed as a solutions provider of  Contract Manufactured Assemblies & Engineering services. Each of these solutions are strategically  aligned to each other to provide enduring value for all our Customers around the globe. 

Challenge: The Ti-6Al-4V alloy is an α–β titanium alloy that exhibits high strength, low density,  and good corrosion resistance. It is one of the most commonly used titanium alloys. The joining of  C/C and TiB whisker (TiBw) reinforced Ti-6Al-4V composite by brazing is more effective by using a  brazing material consisting of Cu–Ni alloy and TiB2 than one consisting of only the Cu–Ni alloy. The  shear joint strength is 56% higher for the former. The TiB2 particles in the brazing material react with  Ti, which diffuses from the TiBw/Ti-6Al-4V composite, resulting in the formation of TiB whiskers in the  brazing layer. The in situ synthesized TiB whiskers are uniformly distributed in the joint and provide  reinforcement and decreased residual thermal stress. 

Due to the machining complexity the current insert gave a tool life of 400 components which resulted  in lot of down time and a higher tool consumption. 

Solution: Secure insert clamping and strong insert design of Duo Just-Cut prevents insert breakage  when machining at high rates. Tungaloy(JXPG20R20F-15SH725) 

Double-ended parting inserts has a very sharp cutting edge with 0.8mm width insert with pressed-in  3D Chip breakers Provides reduced material waste and low cutting forces during parting-off  operations – Robust insert design withstands repeating bar feeder pressures, allowing the toolholder  to be used for workpiece positioning. 

Result: The total tool life has increased by 4x and thus resulting in reduction of tools per annum. The  total cost saving per annum is 4.00L approx.

Titanox series gives a tool life of 4X times

Posted on by supercode_cygnus

The Company

PMI Global Technologies is expertise in low and Medium volume complex part  manufacturing and adds value to the components by executing Special process and Precision  Assembly operations .PMI Global Technologies has been providing its clients total Product manufacturing solutions including engineering services since 2016. Strategically located in India,  Precision CNC machining (Milling, Turning and Turn Mill operations) able to hold tolerances down to  .0001 inch. Assembly of complex electro-mechanical subsystems. 

Challenge

The Ti-6Al-4V alloy is an α–β titanium alloy that exhibits high strength, low density,  and good corrosion resistance. It is one of the most commonly used titanium alloys. The joining of  C/C and TiB whisker (TiBw) reinforced Ti-6Al-4V composite by brazing is more effective by using a brazing material consisting of Cu–Ni alloy and TiB2 than one consisting of only the Cu–Ni alloy. The  shear joint strength is 56% higher for the former. The TiB2 particles in the brazing material react with  Ti, which diffuses from the TiBw/Ti-6Al-4V composite, resulting in the formation of TiB whiskers in the  brazing layer. The in situ synthesized TiB whiskers are uniformly distributed in the joint and provide  reinforcement and decreased residual thermal stress. 

Due to the machining complexity the current endmill gave a tool life of 400 components which  resulted in lot of down time and a higher tool consumption. 

Solution

The Titainox and Superalloys range represents the innovative proposal for machining  stainless steels, titanium and superalloys, capable of achieving cutting parameters that are much  higher than those offered by high-end items. The innovative superior-quality cutting edge, the specific  rake angle surface treatment, together with Silmax 4S superfinishing process allow to combine an  extraordinary finish (surface roughness below 1 micron), while maintaining the maximum cutting  performance.  

Result

The total tool life has increased by 4x thanks to the the PVD Balzers Latuma ® coating  currently represents the best proposal for machining titanium and stainless steels. The total cost  saving per annum is 3.50L approx. 

OLP40 Helps in reducing the CMM dependability by 90%

Posted on by supercode_cygnus

The Company:

KUN Aerospace is a private limited company, certified AS910 & ISO901,ofering services to Aerospace, Medical, Oil & Gas and Energy. KUN Aerospace has a great degree of experiencing solving complex engineering problems and offers a wide range of solutions at various stages of product development processes and beyond. We are well-versed as a solutions provider of Contract Manufactured Assemblies & Engineering services. Each of these solutions are strategically aligned to each other to provide enduring value for all our Customers around the globe.

Challenge:

Inspecting a component on machine with OLP40 is a straight application but when it is on CNC lathe and the component is small the complexity increases. Every component requires inspection on CMM, since almost every company does not hold a CMM for one component the queue up time has increased due to which the production comes at halt at times affecting the machining OEE. Non-productive work of queue up time and component movement has resulted in not able to meet the production demands.

Solution:

OLP40 is a versatile multifunctional optical work probe that does not only work setting but also inspection on the component after machining. With help of a 2mm ruby styli, 11 parameters are inspected including both outer and inner diameter.

Result:

The CMM dependability has reduced by 90% and other non-productive activities for the component has resulted in increasing the OEE by 18%.

OLP40 helps in auto selecting the right program as per the variant

Posted on by supercode_cygnus

The Company:

KUN Aerospace is a private limited company, certified AS910 & ISO901,ofering services to Aerospace, Medical, Oil & Gas and Energy. KUN Aerospace has a great degree of experiencing solving complex engineering problems and offers a wide range of solutions at various stages of product development processes and beyond. We are well-versed as a solutions provider of Contract Manufactured Assemblies & Engineering services. Each of these solutions are strategically aligned to each other to provide enduring value for all our Customers around the globe.

Challenge:

Inspecting a component on machine with OLP40 is a straight application but when it is on CNC lathe and the component is small the complexity increases. Every component requires inspection on CMM, since almost every company does not hold a CMM for one component the queue up time has increased due to which the production comes at halt at times affecting the machining OEE. Non-productive work of queue up time and component movement has resulted in not able to meet the production demands.

Solution:

OLP40 is a versatile multifunctional optical work probe that does not only work setting but also inspection on the component after machining. With help of a 2mm ruby styli, 11 parameters are inspected including both outer and inner diameter.

Result:

The CMM dependability has reduced by 90% and other non-productive activities for the component has resulted in increasing the OEE by 18%.

Achieving visual finish at overhang of 240mm and to reduce cycle time

Posted on by supercode_cygnus

The Company:

Allison Transmission is an American manufacturer of automatic transmissions for commercial and military vehicles. The company is known for its pioneering work in the field of automatic transmissions, particularly in the medium and heavy-duty vehicle markets. Their transmissions are used in a wide range of vehicles, including buses, trucks, emergency vehicles.

Challenge:

Sieving visual finish at overhang of 240mm and to reduce cycle . There are 4 variants and each have different program that needs to be selected manually, One wrong input of program can impact the total supply chain right from cost, OEE, rejection, scrap, rework and more. In simpler terms this will affect the entire supply chain.

Solution:

DO Force Tri is used to achieve visual finish at long overhang because the cutting edge is configured with a large curve with an optimal inclination which generate low cutting force in light depth of cut. Every cutting edge is built with a wiper and innovative flank design. Optimized cutting edge ensures smooth entry and good surface finish.

Result:

Reduced cycle time from 13mins to 6.1mins and improved tool life from 450mins to 500mins.