Category: Case Study

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.