Product category:
Robotics, Handling and Storage
News Release from: WDS | Subject: Sterling Hydraulics
Edited by the Engineeringtalk Editorial
Team on 11 March 2002
Workholding solution reduces machining
time
A complete workholding solution from WDS has enabled Somerset based Sterling Hydraulics to reduce the production time for its latest hydraulic valve manifolds.
A complete workholding solution from WDS has enabled Somerset based Sterling Hydraulics to reduce the production time for its latest hydraulic valve manifolds Where a conventional bed-clamp would only effectively accommodate one work piece, the twin-sided workholding stations supplied by WDS can accommodate two
This article was originally published on Engineeringtalk on 3 Sep 2008 at 8.00am (UK)
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The employment of bespoke cast iron towers and innovative Microloc clamping system has also allowed the 70 stage machining sequence to be completed in a single work-and-turn operation.
Paul Jennings, Manager for this project at Sterling adds: "We are machining a hard grade of cast iron at relatively high speeds and as a result, the stability of the work piece is crucial.
WDS use of a single casting for the workholding base and tower, rather than a fabricated structure has definitely contributed to us achieving consistent finished quality surfaces.
Their solution has been designed with a wealth of experience in this field and it shows, it has worked perfectly from day one, allowing us to meet production targets with a product that requires an absolute minimum of finishing work".
WDS Sales Engineer for the project, Bill Hawker comments, "Long experience in this type of application has enabled us to take the pressure off the client by supplying a well proven solution.
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The tower was cast specifically for the job and the Microloc clamping system is one of our most successful products.
We used two Microloc serrated pads and moving jaws to clamp the top of each work piece.
They give highly accurate datum points, allow very fast changes and provide up to two tonnes of clamping force from each unit.
We were able to reduce the machining operation for two complete blocks down to 110min - quite an achievement since there are 70 machining operations per block".
"The use of a conventional bed clamp arrangement would have resulted in just one work piece being machined on each pallet at a time, it would also require more than one turn during the operation.
Our solution ensures the maximum machine cycle time without the need for operator intervention.
By allowing a manifold to be secured on either side of the tower and machined while two more are being loaded onto the opposite pallet, we have reduced the overall machining time by at least half.
An additional 'feather in our cap' was our delivery; from the initial visit we were able to provide a complete solution within 8 weeks and the equipment was in fact delivered early".
A new manufacturing cell including two twin-pallet machining centres has been installed at Sterling Hydraulics to produce new custom manifold blocks (CMBs), which are for a large combine harvester contract.
Iain Corbin, Sterling's Continuous Improvement Manager, relates the contract success in part to the workholding solution: "Manifold blocks have become larger as our new designs incorporate more of the control circuit into the block itself.
Reductions in the amount of external pipe-work have improved reliability, reduced the possibility of leaks and resulted in a more compact control module, though consequentially, the machining has become far more complex".
"We needed to be sure that we could produce the new designs efficiently and in high numbers, that meant an innovative but reliable workholding solution was essential.
Our confidence in WDS has been drawn from prior experience, where a similar workholding solution using a cast grid block and Microloc clamping system helped reduce our set up times from 'twelve' to 'five' hours and achieves extremely accurate components".
Bespoke work holding solutions such as the one supplied to Sterling Hydraulics form part of WDS's comprehensive range of fixturing system solutions.
The range extends from machined profiles, machining beds and base plates to automated hydraulic and pneumatic clamping systems.
WDS's expertise in developing and supplying exclusively engineered products also extends to their range of standard parts where bespoke items are often created by incorporating additional features or using nonstandard materials and finishes. Request a free brochure from WDS ...
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