Summary
Toolcraft, a renowned provider of precision manufacturing solutions, designed and manufactured a high-performance Face Driver for an electrical motors company. This Face Driver is engineered to enhance machining precision and efficiency in industrial applications. This case study details the specifications, applications, manufacturing process, and quality control measures undertaken to deliver this specialized tooling system.
Project Overview
- Client: An Electrical Motors Company
- Product: Face Driver
- Industry: Automotive
Overall Specifications
- Material: M-2 Tool Steel
- Stock Dimensions: 4″ Diameter x 3-3/8″ length
- Heat Treatment: Rockwell C 62-65
- Finish: Sandblasted after hardening
- Surface Finish: 32 µ” AA cylindrical grinding after sandblasting
- Tolerance: Maintained within +/- .0001″
Uses and Applications
The Face Driver is designed for various machining tasks, including:
- CNC Turning Operations: Facilitates complete machining of parts in a single setup by holding workpieces by the face.
- Precision Machining: Ensures high precision in producing electric motor components and other intricate parts.
- High-Volume Production: Suitable for large-scale production runs while maintaining consistent quality.
Capacity
The Face Driver is capable of handling workpieces with diameters ranging from 50 mm to 150 mm, adapting to different machining requirements. Its robust design ensures prolonged use under high-stress conditions without significant wear, enhancing operational efficiency and productivity.
Quality Control
Toolcraft’s comprehensive quality control procedures ensured the Face Driver met stringent performance and reliability standards:
- Dimensional Inspection: Precision measuring instruments were used to verify all critical dimensions and tolerances within ±0.01 mm.
- Final Inspection: A thorough final inspection was performed to validate the overall quality and readiness of the Face Driver before delivery to the client.
Quality Control
Toolcraft’s comprehensive quality control procedures ensured the Brass Die scraper met stringent performance and reliability standards:
- Dimensional Inspection: Coordinate Measuring Machines (CMM) were used to verify all critical dimensions and tolerances.
- Material Testing: Metallurgical tests were conducted to confirm the material’s properties and compliance with specifications.
- Non-Destructive Testing (NDT): Techniques such as ultrasonic testing and magnetic particle inspection were employed to detect any internal or surface defects.
- Functional Testing: The assembled Brass Die scraper underwent rigorous functional tests to ensure proper operation and integration with Michelin’s manufacturing process.
- Final Inspection: A thorough final inspection was performed to validate the overall quality and readiness of the Brass Die Scraper before delivery to Michelin.
Manufacturing Process
Design & Engineering
Toolcraft’s production team collaborated closely with the client to understand specific requirements. Advanced CAD software was used to design the Face Driver, ensuring compatibility with the machining processes and optimization for the intended tasks.
Material Selection & Procurement
M-2 Tool Steel was chosen for its durability and wear resistance. Materials were sourced from certified suppliers to ensure quality and consistency.
Precision Machining
Utilizing Toolcraft’s state-of-the-art CNC machining capabilities, the Face Driver components were manufactured with tight tolerances to ensure precise fit and function. Multi-axis machining centers were employed to achieve complex geometries and features.
Heat Treatment
The Face Driver underwent hardening and tempering processes to achieve a hardness of 55 HRC, enhancing strength and durability.
Surface Finishing
A hardened and tempered finish was applied to protect the Face Driver from wear and corrosion, extending its operational life in demanding industrial environments.
Conclusion
Toolcraft’s expertise in precision manufacturing and commitment to quality enabled the successful development of a high-performance Face Driver. This specialized tooling system enhances the capabilities of machining operations, providing reliable and efficient solutions for a wide range of industrial applications. Through meticulous design, manufacturing, and quality control processes, Toolcraft ensured the delivery of a robust and versatile tooling solution tailored to meet the specific needs of their client.