Component
Rear Axle Housing (Banjo Beam)
Customer Requirement
The customer required a comprehensive machining solution for the Rear Axle Beam that could achieve all four-side machining in a single setup: – a challenging and first of its kind requirement in India.
Key challenges included:
- Performing complete four-side machining in one setup, which most machine tool builders considered unfeasible.
- Operating without cutting coolant, necessitating an effective air jet system for chip removal from cutting to zone conveyor
- Managing 80 component variants on a single machine with minimal setup change.
- Meeting a surface finish requirement of 6.3 Ra or better.
- Cycle time 180 Seconds/component
BFW’s Solution
BFW engineered a Customized CNC 4-Way, 11-Axis Horizontal Milling Machine integrated with gantry automation, designed to meet these complex and high-performance machining requirements. Ideal solution for replacing four machine with single machine
Solution Highlights:
- Four spindles in one machine, enabling simultaneous operations from all sides.
- Two spindles configured as 3+3 axes for facing and boring operations.
- Two spindles with 1 axis each for plunge face operations.
- 3 axes gantry
- 80 component variants were intelligently grouped into 17 variants, further classified into three fixture setups:
- Set up change by ensuring zero leakage by adopt screwing couplings
- Easy setup change by shadow board for easy identification
- Equipped with gantry automation for efficient loading and unloading.
- Component auto flipping arrangement for easy chip removal after machining
- Delivered a surface finish of 2.8 Ra, significantly better than the required 6.3 Ra.
Machine Specifications
| Parameter | Details |
| Machine Type | CNC 4-Way 11-Axes Machine |
| Ground Clearance | 80 mm |
| Component Weight | Max 100 kg |
| Material Hardness | ~270 BHN |
| Spindle Motor Power | 22 kW |
| Spindle Speed | Max 650 RPM |
| Spindle Taper | HSK C100 |
| Spindle Torque | Max 600 Nm @ 1500 RPM |
Conclusion
BFW’s 4-Way, 11-Axes Horizontal Milling Machine with Gantry Automation is a testament to precision engineering and innovation in multi-side machining.
By combining productivity, flexibility, and automation, BFW delivered a true turnkey solution for Rear Axle Housing components — setting new standards in manufacturing excellence.
