We have an integrated deep-hole drilling system on the tailstock and a turret could perform parallel turning while the tailstock was drilling.
This would dramatically reduce cycle time. And the center drive machine could turn the ID immediately after drilling was completed without any unclamping/clamping being needed.
This would give an excellent CPK result.
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Key Problem
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The output shafts were forged and solid, part was bent and it was difficult to find a good reference and setup for machining. A standard OP10 process was to be used for a hydraulic clamping fixture for milling and drilling both ends at same time. However, it was difficult to obtain stable run-out, and adjusting the machine alignment was extremely time consuming.
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The output shaft was required to be hollow for transmission purposes, so a deep hole drilling process was needed. This meant more space was required to accommodate a deep hole drilling machine in your production line, and the shaft needed to be transferred to another machine for ID turning.
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Solution from FastCut
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By clamping the part and turning the OD, we could hold the part OD run out to within 0.01mm (depending raw material condition). A two center hold would also give high concentricity. This was a simple operation for the OP20. By using a standard process, you might need to have an expensive compensating chuck system to overcome the run-out problem. However, a simple high precision chuck on our Center drive lathe would give a stable and precise outcome. We could clamp one OD which was completed on Center Drive Machine, instead of using the driven center which did not have a strong enough clamping force. And the shaft could be turned using an extra deep cut to reduce turning passes and decrease cycle time.
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