Client
A leading scooter manufacturer renowned for precision-engineered mobility solutions.
Component
Camshaft – A critical engine component that controls the opening and closing of intake and exhaust valves through cam profiles.
Customer Challenges
The customer faced the following production pain points:
- High loading and unloading time.
- Part orientation errors, leading to inconsistent machining.
- Difficulty in achieving tight tolerances and key dimensional accuracies.
- Elevated rejection rates, impacting productivity.
Project Objective
- Reduce part handling and orientation time.
- Eliminate orientation errors using Poka Yoke.
- Deliver consistently high dimensional accuracy and process reliability.
- Optimize setup and improve overall cycle efficiency.
Our Solution
We deployed Vertical Machining Centers (VMC) – Model: Dhruva HE 4050 with integrated 4th Axis for high-precision and multi-operation capability.
Machine Details
- Model: Dhruva HE 4050
- Table Size: 650 x 400 mm
- Axes Travel (X/Y/Z): 500 / 400 / 450 mm
- Spindle: BT40, 8000 rpm, Inline
Application Summary
Operation 1 – Facing, Centering, End Machining
- Machine: Dhruva HE 4050 with 4th Axis
- Cycle Time: 2 min
- No. of Setups: 1
- Fixture:
- Change plate for 6 camshaft variants
- Poka Yoke for orientation detection
- Slope cover for efficient chip evacuation
Operation 2 – Keyway Milling
- Machine: Dhruva HE 4050 with 4th Axis
- Cycle Time: 1 minutes
- Fixture:
- Hydraulic chuck for secure component clamping
- 1 Setup per component
Outcome
- Zero orientation error with Poka Yoke fixture design.
- Improved efficiency
- Achieved tight tolerance control and reduced rejections.
- Faster cycle time and consistent quality across all several camshaft variants.
Conclusion
BFW’s Dhruva HE 4050 High Speed VMC delivered a reliable, precise, and application-specific machining solution for camshaft components. With a combination of intelligent fixture design, compact footprint, and CNC precision, the customer achieved significant improvements in cycle time, quality, and productivity.