Overview
A leading automotive component manufacturer required a high-precision machining solution for wheel plate assemblies. The challenge was to deliver consistent machining performance across multiple variants with stringent accuracy requirements, high productivity, and efficient chip management.
To address this, a 2-Way Horizontal Machining Center with Turn Table & High-Speed Turret was deployed, designed to perform multi-operation machining with superior speed, rigidity, and process reliability.
Solution Highlights
Machine Configuration
- 2 Horizontal Machining Centers inclined to meet specific camber & toe angle requirements (1 LH side & 1 RH side).
- Each machine equipped with 3-axis CNC movement, tool magazine, and capability to perform a wide range of machining operations including:
- Milling
- Spot Facing
- Drilling
- Tapping
- Boring
- Chip-to-Chip Time: 3 seconds
- Total Cycle Time: 60 seconds achieved
- Rapid CNC Axes Movement:
- Fast forward speed capacity: 30 m/min or higher
Machining Capabilities
- Track width machining range: 1200 mm – 1600 mm, A 4-point probing system is used to determine the exact machining depth and to measure the complete track width of the component from left to right, ensuring all critical parameters are maintained
- Torque capacity: 250 Nm @ 400 rpm (S1 duty)
- Spindle speed: 8,000 rpm or higher
- Integrated Poka Yoke System to ensure error-proofing for tools, fixtures, angle adjustments, and CNC programs.
- For different components, the machine can automatically adjust to the required toe and camber angles (Manual Camber angle (2º) and Toe angle adjustment (1º))
Chip & Process Management
- Magnetic chip conveyor included for efficient removal.
- Design ensures no chip accumulation in horizontal zones or corners.
- Machine structure allows chip conveyor re-positioning (Left/Right).
- Process area equipped with LED illumination for better visibility.
Clamping System
- Hydraulic clamping with adjustable clamping force ensuring stability against lateral machining forces.
- Backlash-free clamping mechanism.
- Fixture design accommodates multiple wheel plate variants (disk/drum dimensions).
Project-Specific Machining Operations
- Face Milling
- Drilling with Chamfer
- Tapping
- Drilling & Chamfering (combined) – complete 60 sec total cycle time
Additional integration of 4-point probing ensures dimensional accuracy and repeatability for every cycle.
Impact Delivered
- Achieved cycle time reduction to 60 seconds per component increasing the productivity .
- Enhanced machining accuracy for multiple variants with a single fixture setup.
- Improved operator efficiency with LED-lit process zones and poka yoke system.
- Robust chip evacuation system ensured zero downtime due to chip accumulation.
- Increased flexibility with capability to handle multiple component versions.
This solution delivered higher productivity, accuracy, and reliability, perfectly aligning with the customer’s quality and throughput requirements in the automotive sector. It is comparable to German machines—Indian-made yet meeting global standards of quality and reliability.
