Instrumentation/Sensor/Transducer Manufacturer
APPLICATION: Machining Stainless Steel with Precise
Tolerances
BACKGROUND: A Jergens customer manufactures differential
and straight pressure transducers, precision measurement instrumentation and sensors
for industrial, civilian and military aviation and defense applications, as well
as for space exploration.
ISSUE:
The manufacturing division specializes in the machining of stainless steel to precise
tolerances, with very short lead times from initial order receipt to product shipment.
Much of the parent company’s prototype development is also provided internally
by this division. Common machining methods requiring indicating were used for decades
on an aging Matsuura MC500v vertical machining center, and long set-up times were
an everyday matter. “We were spending much more time setting up than machining,
and we found ourselves falling behind in our commitments to internal customers as
a result,” said the division’s senior CNC programmer. It was clearly
time to upgrade our machining capability, points out the programmer, “and
reducing set-up times.
- A typical lot size of 30 parts required a two-step process and 4.75 hours of machining
time
- Combined set-up times were 4 – 5 hours
- Total machine time to set-up and run 30 parts averaged 9.5 hours
SOLUTION:
After extensive field research and exhaustive comparisons, the manufacturer
purchased a new Mori Seiki NV5000A/40 vertical machining center with a high-speed
spindle and high-pressure coolants to help minimize cycle times. With the concurrent
need to reduce set-up times, the division also explored various “quick changeover”
systems offered by leading suppliers, but found that the tooling costs per workpiece
using many of these systems were prohibitive.
The simplicity and precision of the Jergens Ball Lock Mounting System provided the
most appealing, costeffective alternative. The manufacturer purchased precision
fixture plates from Jergens, pre-drilled with liner bushings in place to match subplates
manufactured by Jergens with receiver bushings already installed. With the Ball
Lock system, this Jergens customer’s changeovers became significantly faster
as fixtures were removed with a single 1/8-inch T-handle hex key, and the next job
was fastened down and ready to cut in less than 10 minutes. Major
improvements in the machining process were realized:
- Machining time reduced to just under 2.5 hours for 30 parts – second operation eliminated
- Improvement: Nearly 1/2 the machining time
- Changeover time reduced to 18 minutes, with no need for establishing location or
squaring
- Improvement: 90% reduction in set-up time
- Total machine time decreased from an average 9.5 hours to less than 3 hours to produce
30 pieces
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ABOVE: Ball Lock System in action |
|
 The
productivity advances achieved with the
Ball Lock Mounting System allowed the manufacturer to quickly recoup their machine
and workholding investment.
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