Component
Defence Part
Operations
Drilling, Milling, Finish Boring & Tapping
The Challenge
A leading player in the defence sector faced a critical machining challenge for a key component used in missile launching systems.
Their existing process required 4–5 setups across multiple machines, leading to:
- Complex material handling and frequent re-clamping (Component reference face and dowale hole damage due to multiple load and unload)
- Accuracy issues due to multi-machine operations
- Higher cycle times and inconsistent quality
- Lack of an integrated machining solution in the Indian market
- Critical accuracy requirement on component
BFW’s Solution
BFW provided a tooled-up solution on the TCM series machine that addressed these pain points effectively:
- Combined all operations into a single machine with only two setups
- Eliminated material movement between different machines, improving accuracy
- Used a tilting spindle configuration to enable vertical/ horizontal/angular operations in a single setup
- High Speed Tool magazine inside the column near the spindle to reduce tool-change time.
Key Machine Features:
- Large work area: Fixed Table size ~2000 x 800 mm, suitable for bigger components.
- Stroke X/Y/Z axes: 1600/825/1000 ,rapid traverse speed up to 30,000 mm/min
- Powerful spindle: BT-50 taper, 50 kW motor, 8000 RPM, 600 Nm torque for heavy-duty machining
- Tilting spindle head: Allows vertical and horizontal operations in a single setup (+-100 degree)
- Efficient tool management: 30-tool magazine inside the column near the spindle for 5-second tool changes
- High accuracy: Roller-type LM guideways and inbuilt absolute encoders for precise positioning
The Results
- Setups reduced from 4–5 to just 2
- Accuracy improved due to minimal material handling
- Cycle time reduced significantly with faster tool changes and fewer setups
- Productivity enhanced with simplified workflow and better-quality consistency
Conclusion
By understanding the client’s pain points and delivering a customized TCM machine solution, BFW transformed a fragmented, high-handling process into a streamlined, accurate, and efficient machining operation—setting a new benchmark for productivity in critical defence manufacturing segment.
