On Mfg - September 2014

Columns From: 8/28/2014 Automotive Design & Production


Complex Part Machining Handled with Precision 

The machining of complex contours—think turbocharger wheels—can be handled by the Doosan FM200/5AX Linear from Doosan Infracore Machine Tools (doosanmachinetoolsusa.com), as it is a five-axis machining center that is designed and engineered for machining complex, precision parts. One notable feature of this machine is that the X, Y and Z axes are driven by high-precision linear motors. Not only does this mean quick accel/decel feedrates, but there is minimal backlash—at most. The 4th and 5th rotary axis tables are driven by direct-drive motors, again for purposes of speed and efficiency. The FM200/5AX provides a rapid traverse rate on all axes of 1,968.5 ipm. The cutting feedrate is 787 ipm. The travels on the machine are 7.9 in. X, 13.4 in. Y and 11.8 in. Z. The platen is 7.9 in. in diameter. The load capacity is 33.1 lb. The machining center is equipped with a 45,000-rpm, 19-hp, HSK E40 spindle. It can handle tools up to 2 in. in diameter, 7.1 in. long and 2.2 lb. in mass in its standard direct-drive, servo-driven, 24-tool capacity, automatic tool changer. Control is via a Heidenhain TNC CNC control. 

Surface Finish Gage for Cranks 

Jenoptik Industrial Metrology (jenoptik.com) has developed a crankshaft journal surface finish gage that reduces the time required to collect and assess measurement data of virtually any crankshaft, any of its journals. Called a “point-of-use” gage, the benchtop device is designed for use at the point of production, allowing manufacturers to check crankshafts immediately as they come off the grinders. Shafts can be checked as needed, an entire production run or a sampling. Skidded probes trace the diameters as the journal rotates. The probe arm is fully protected from damage. The data is collected in seconds and can be immediately uploaded through Jenoptik’s proprietary Turbowave surface finish software. In operation, the operator places any size crankshaft onto V-guides, locks the part into position and adjusts the articulating arm to the desired lateral measurement position, using a horizontal arrow pointer on the ruler guide mounted to the base of the device. An air lock allows easy movement or locks the slide in place. Next, the operator scissors the device “up and over” onto the designated diameter: pin, crank, post, pump, or seal diameter. Pressing the measurement button completes the measurement. 

Probe for High-accuracy Inspection and Measurement 

Hexagon Metrology (hexagonmetrology.us) has developed a non-contact scanning probe for high-accuracy measurement and inspection. Called the “HP-O,” the probe is an alternative to conventional tactile analog measurement and scanning probes. The HP-O puts no physical pressure on a part, delivering force-free measurement of not only parts with complex and/or difficult-to-reach geometries, but also parts that may be easily deformed. The probe has a 3-mm diameter and a measurement range of up to 20 mm. It works in both single-point and scanning modes. With an acceptance angle of ±30 degrees, the probe can measure difficult-to-access features at a scanning speed of 1,000 points per second for rapid throughput. When used with the Leitz PMM-C coordinate measuring machine, the HP-O probe delivers repeatability under 0.3 μm. The HP-O’s scanning technology is not affected by ambient light, and is based on frequency-modulated, interferometric optical distance measurement. The probe’s dense data acquisition does not suffer from degradation at higher speeds. The HP-O’s high throughput capability renders it ideal for scanning large parts and parts that are rotationally symmetric.