The chain case is a critical component within vehicles. It provides a covering for the chain responsible for power transmission from the engine to the wheels in vehicles. It is engineered to safeguard the chain from external factors such as dirt, debris, and moisture, and is pivotal in ensuring seamless and efficient power transfer.
Moreover, it aids in sustaining optimal chain tension, thereby reducing the necessity for frequent lubrication and maintenance, thus enhancing the chain’s lifespan. Additionally, the chain case contributes significantly to overall safety by preventing the chain from encountering the rider or other vehicle parts, mitigating the potential for accidents or injuries. Its sturdy construction and strategic placement render it an indispensable element for various vehicle types’ smooth functioning and prolonged durability.
Our client
Our client is a Japanese Die-caster and one of India’s leading Tier-1 suppliers to automotive companies.
Highlights of the case
The client sought a customised machining solution for chain cases to bolster productivity, streamline operations, and improve cycle time. The primary objective was to align with market demands, optimise output, and reduce complexity within their manufacturing operations.
Challenges and requirements of our client
The challenges and requirements identified by our client included inefficiencies within their current manufacturing process, where two face operations were distributed across two separate machines, leading to decreased productivity and heightened complexity.
Furthermore, cycle time presented a significant obstacle—meeting market demands necessitated reducing cycle time to boost output. The client’s specific requirements encompass the need for a single VMC equipped with a 4th-axis table and designed to accommodate two-component models. Additionally, they stipulated a precise loading height within specified limits.
The client’s specific requirements:
- One VMC with a 4th axis table and two-component model
- A particular height of loading within a specific limit
BFW’s solutions
BFW provided one VMC, Dhruva HE 3070 and two HMC 300MCR machines.
Solution specifications:
- Material: Aluminium
- Output required: 121 sec/components
- Cycle time:
- Setup 2: 163 sec/machine
- Setup 3: 126 sec/machine
- Setup 4: 160 sec/machine
- No. of component models: 1
VMC, Dhruva HE 3070 salient features
- Axes Strokes (X/Y/Z): 500/ 400/ 350 mm
- Rapid Traverse – 48/48/36 m/min
- Spindle Taper – BT 30
- Power: 3.7/ 5.5 kW
- Spindle Speed (Max.): 12,000 rpm
- Chip to Chip time: 1.9 sec
- 14 tool magazine
- Coolant through spindle
- Pneumatic fixture
HMC, 330 MCR salient features
- Axes Strokes (X/Y/Z): 500/350/300 mm
- Rapid Traverse – 50/50/50 m/min
- Spindle Taper – BT 30
- Spindle Type: Inline
- Power: 3.7/ 5.5 kW
- Torque: 36 Nm
- Spindle Speed (Max.): 8,000 rpm
- Chip to Chip time: 3.9 sec
- 20 tool magazine
- Coolant through spindle @ 40 bar
Impact
BFW collaborated with the client to create a custom machining solution tailored for chain cases in their manufacturing process. Through our solution, the client achieved the desired cycle time and their stipulated loading height. Our solutions helped enhance productivity and flexibility, boosting output and streamlining their manufacturing processes.
Conclusion
Integrating BFW’s tailored machining solution for chain cases our client’s manufacturing operations. Moreover, this collaboration further strengthened our long-term relationship with the client. As a customer-centric organisation, we remain committed to providing all our clients with dedicated support and handholding, prompt emergency assistance, excellent post-installation services, access to shop floor training, and streamlined pathways for further machining enhancements.
