TAIWA NUMBA WAAN
Aluminum
- Joined
- Mar 9, 2021
I've recently gotten some strange requests from customers. They have parts being made in fairly large qts, 30,000 to 60,000 annually, that have difficult features to machine. I can't post the drawings here but, I'll try to describe the parts:
50-54 Rc steel,
30mm to 67mm diameter
Length about 1.5x diameter
Has a big through hole off center by a few mm, so the wall thickness varies.
The thicker walled side has more axial through holes from 3mm to 7mm (high length/dia ratio)
There are a lot of slitting saw crescent cuts on both the inside and outside.
Worst of all, the tolerances on the OD, off-center ID, are 0.015mm! This requires grinding since it's full hard.
The customer has/had them made in China with 60 to 100 percent reject rate - passed Chinese QC and the customer paid for them all, but scrapped when inspected independently after delivery to the western company..... Yes, I know this is as dumb as it sounds, keep in mind I'm not the one doing this.
So the customer now wants to bring the manufacturing in-house in a mill turn setup with a rough op, heat treat, then finish grind with in process probing as preliminary QC.
I am skeptical of putting a production grinding process in a machine that also does regular turning and milling, but I'm kind of obligated to help this particular customer, so if anyone has any advice please let me know!
50-54 Rc steel,
30mm to 67mm diameter
Length about 1.5x diameter
Has a big through hole off center by a few mm, so the wall thickness varies.
The thicker walled side has more axial through holes from 3mm to 7mm (high length/dia ratio)
There are a lot of slitting saw crescent cuts on both the inside and outside.
Worst of all, the tolerances on the OD, off-center ID, are 0.015mm! This requires grinding since it's full hard.
The customer has/had them made in China with 60 to 100 percent reject rate - passed Chinese QC and the customer paid for them all, but scrapped when inspected independently after delivery to the western company..... Yes, I know this is as dumb as it sounds, keep in mind I'm not the one doing this.
So the customer now wants to bring the manufacturing in-house in a mill turn setup with a rough op, heat treat, then finish grind with in process probing as preliminary QC.
I am skeptical of putting a production grinding process in a machine that also does regular turning and milling, but I'm kind of obligated to help this particular customer, so if anyone has any advice please let me know!