Customer Challenge
A leading automotive manufacturer in Mexico required a machining solution for a frame (chassis) component involving multiple precision machining operations. The application demanded high productivity, excellent surface finish, and consistent dimensional accuracy while maintaining a competitive cycle time.
Additionally, the customer sought to reduce non-productive loading and unloading time and improve overall machine utilization.
BFW Solution
BFW provided a Single Spindle Horizontal Machining Center (HMC) integrated with a rotary table, Automatic Tool Changer (ATC), and a specially designed tombstone fixture.
The fixture was engineered with two machining faces, allowing loading and unloading activities to take place simultaneously while machining was performed on the opposite side. This arrangement significantly minimized idle time and maximized productivity.
The solution was designed to accommodate two variants of the component with identical overall dimensions, enabling flexible manufacturing without compromising efficiency.
Engineering Highlights
Dual-Face Tombstone Fixture
The hydraulic fixture is mounted on a rotary table with a rotary joint on top of the tombstone to facilitate independent clamping and decamping for two components. This configuration enables concurrent machining and loading/unloading operations, reducing downtime and improving machine utilization.
Integrated Clamping System
All fixture clamping cylinders are internally connected, eliminating exposed hydraulic lines and preventing chip accumulation around the fixture. This results in improved reliability, cleaner operation, and reduced maintenance requirements. Cutting chips are directly discharged from the cutting zone through the rear chip conveyor positioned below the machining area.
Component & Fixture Cleaning System
A series of air jets is provided to clean the component and fixture after machining while indexing the tombstone by 180°. This ensures that the finished component is thoroughly cleaned before moving to the next process. An independent air vessel is provided to deliver the required air volume for effective cleaning.
Chip Containment & Machine Protection
X-axis lamella protection is provided to contain cutting chips within the machining zone and prevent chips from travelling beyond the spindle face. This ensures a cleaner and safer machining environment while protecting the surrounding machine areas.
Operator Safety & CE Compliance
The machine is designed in accordance with CE norms, considering the export-oriented application. A complete safety fence with safety switches is provided around the machine to protect the operator during operation.
The loading and unloading area is additionally protected with a light curtain, ensuring operator safety during component handling and machine operation.
Optimized Support & Clamping Arrangement
The component includes projected sections that require additional support during machining. Specially designed support and clamping mechanisms ensure rigidity throughout the machining cycle, enabling the achievement of the required surface finish and dimensional accuracy.
The support and clamping elements are integrated in a manner that does not interfere with component loading and unloading, ensuring operator convenience and process efficiency.
Machining Operations
- Boring
- Front Face Machining
- Drilling
- Tapping
- Precision Machining Operations
Machine Specifications
| Parameter | Specification |
| Machine Type | Single Spindle HMC |
| Motor Power | 22/37 kW |
| Spindle Taper | HSK A100 |
| Maximum Spindle Speed | 6,000 rpm |
| Rapid Traverse Rate | 40,000 mm/min |
| Tool Magazine Capacity | 24 Tools ATC |
| X-Axis Travel | 1200 mm |
| Y-Axis Travel | 1200 mm |
| Z-Axis Travel | 500 mm |
Results Achieved
Cycle Time : 113 Seconds
Key Benefits
- Reduced non-cutting time through simultaneous loading/unloading and machining.
- Increased machine utilization and overall productivity.
- Consistent dimensional accuracy and superior surface finish.
- Enhanced fixture reliability through internally routed clamping systems.
- Capability to machine multiple component variants using the same setup.
- Improved operational efficiency and reduced operator intervention.
Conclusion
By combining a high-performance Single Spindle HMC with an innovative dual-face tombstone fixture, BFW delivered a solution that significantly improved productivity and machining efficiency for an automotive manufacturer in Mexico. The optimized fixture design, robust clamping arrangement, and advanced machining capabilities enabled the customer to achieve faster cycle times, superior quality, and reliable production performance.
