Precision Camshaft Machining for a Two-Wheeler OEM

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.