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This is a transportation component that has previously been a welded construction.
In op.1 several slip fit reamed holes are widened which have to be in line 0.004"
after the part is released. This is achieved by a stress free location adapting
to the datum points. In op.2 all remaining features are machined.

This part was made in 6 operations plus an assembly step in between.
Now this part is made in two steps with the assembly being an integral part.
The machine is stopped and positioned, so that the operator can insert a bushing.
Previous problems with bulging after the bushing was inserted have been eliminated, and the precision of the part has increased significantly (squareness of better than 0.001" per 6" on all sides)
The scrap rate is reduced to less than 1%.

On a previous process there have been problems with the outside contour not cleaning up.
Since this is cosmetic there was either the option to give more material on the
casting (quite a hoop to jump through), or change the locating features.
The later was achieved by now having two location points on the long side
and one location point (comprised of the"swimming points") on
the short side. Total cost under $2000.- and the casting stays untouched.
Plenty of trouble was spared for a lot of folks who never even where bothered.

This part posed some challenge since all inside clamping components in op.1 had to be removed as one in order to achieve a 2 operation process, A wall thickness under 1/8" provided additional
challenge. Knowing there will be some adjustments necessary the fixtures were equipped with
enough meat to easily attach damping features where needed.

This part is made of copper; very soft.
The deign also does not give much to hold on to.
3 features share a common centerline and have to remain within 0.005"
Ten-thousands of parts machined; no dimensional failures.

This apparatus presses a spring pin into a shaft / wheel assembly thus eliminating
cumbersome hand work. The assembly is aligned by a retractable pin and the magnetic
die presses the pin in retracting its outer shell in the process.

This switch get holes drilled, which have to be within ±0.0015" of
a cast hole, which is warranted be the use of spring-loaded tapered pins.

High volume made it feasible to utilize hydraulics.
The fixture can quickly be changed for a family of 3 different parts
and the fixture itself is has a quick change interface to the machine.

To test vises under machine conditions they were to be submersed in coolant.
To have a universal setup there is a 2" grid system at the bottom of the tank,
and the input shat seal is adjustable up and down for different vises.
The tank is one piece, ergo no leaks.

The tops of the teeth have to be between 0.001" an 0.003" underneath
the top surface, which will be ground after heat treat.
This requires dead on machining of the height of the teeth, which is assured
by clamping them down.
A multiple part setup takes care of efficiency.

The need for only limited clamping force made this
an easy decision to cut cost by using manual clamps without loosing efficiency.

Whenever possible we use spring-loaded devices to ensure fail-safe locating.

This is another example of making a complete part in 2 operations
and introduce multiple parts at the same time to the machine.