Component
Banjo Beam (1000-2000 mm Length)
Operations
Milling, Boring, Drilling & Taping
The Customer Challenge
A leading automotive OEM was facing a significant machining challenge while working on the Bango Beam — a long and heavy component critical to both commercial and passenger vehicle platforms.
The existing process allowed machining on only one face at a time, as the component could not be rotated due to swing diameter limitations.
This led to:
- Multiple setups and frequent re-clamping
- Increased cycle time
- Larger components with end operations require a bigger machine for adequate swing clearance.
- Reduced overall productivity
BFW’s Solution
BFW engineered an innovative high-speed two-way horizontal machining solution tailored for large and asymmetric components like the Bango Beam, developed to overcome the above challenges.
Key design enhancement:
- The component is positioned at the center of the table.
- The machine table remains fixed, allowing easy access to both faces of the component.
- This setup eliminates the need to re-clamp or manually rotates the component, ensuring higher accuracy and reduced cycle time.
The result: Smooth machining with single setup precision.
Performance Highlights
| Parameter | Specification |
| Machine Type | CNC Two-Way Horizontal Machining Center |
| Component Loading Height | 1350 mm |
| Machine Weight | ~15,000 kg |
CNC Axes Configuration
| Axis | Stroke (mm) | Rapid Rate (mm/min) |
| X1 & X2 | ~650 | 40,000 |
| Y1 & Y2 | ~500 | 40,000 |
| Z1 & Z2 | ~500 | 40,000 |
Spindle & Tooling Details
| Feature | Specification |
| Power | Max 18.5 KW |
| Speed | Up to 5000 RPM |
| Torque | Max 350 Nm |
| Taper | HSK-A63 / HSK-A100 |
| Tool Capacity | Max 40 Tools |
Result & Customer Benefit
- Reduced cycle time due to simultaneous face machining
- Enhanced accuracy and repeatability
- Flexible machining setup for different component lengths:
- HSK A63: 1000–2000 mm
- HSK A100: 1200–2500 mm
- Higher productivity for both commercial and passenger vehicle variants
Customer Impact
The solution significantly improved throughput while maintaining accuracy for long components.
The customer reported:
- 40-45 % reduction in machining time
- Improved process reliability
- Better floor space utilization with reduction of 40-45 % with our TWH with reduced connected (30-35%) load
- Single Lift Machine
Conclusion
BFW’s customized Two-Way Horizontal Machining Center(TWH) for the Banjo Beam demonstrates our expertise in delivering precision engineering with practical innovation.
By rethinking the machining process, we supported the customer achieve higher productivity, reduced cycle times, and improved operational efficiency—a perfect example of “Engineering the Future of Manufacturing.”
