To be able to manufacture the components of electro-pneumatic valves in production batches of millions, Nass Magnet (Hanover, Germany) invested in a new machining center with a rotary transfer machine with eight stations for double-sided machining, which came with drills from another supplier.
Nass Magnet member of the Kirchheim group that employs about 500 people who develop and manufacture electromagnetic pilot controls and valves for air, natural gases, liquids and other media as well as electromagnetic drives for valves on mobile applications.
The company’s goal was to specifically increase the capacities and simultaneously reduce the manufacturing costs by a high margin. Rather than being satisfied with the delivered, turn-keyed multi-stage machining process, the goal was to use a single machining process from barstock without any secondary post machining processes. Despite thorough technical modifications and agreements with the machine tool builder, no long term satisfactory process could be achieved.
Then, Carsten Schulze, Nass Magnet supervisor of parts production as well as process development, and Hans Pauck in the tool planning and purchasing department, contacted Schwanog. Schwanog sales representative Michael Klingner summarized the requirements on site and consulted with Schwanog’s engineering team in Obereschach, Germany. The continuous investment in recent years in personnel and in the design department is paying off. Despite the complex requirements, the engineers quickly found a solution, which was developed based on the Schwanog PWP-D insertable form drill system .
Because of the extra wide inserts, the PWP-D system enables the machining of bore diameters as large as 28 mm. The bore tolerances and precision required could be guaranteed by the especially wide locating surfaces and Schwanog’s system accuracy.
Nass Magnet thoroughly tested the recommended Schwanog system and expressed how much the result impressed them in regard to the superior surface finish as well as tool life, the company says. With several hundred thousand drilling operations per insert, even the greatest expectations were surpassed by far.
Mr. Pauck was also impressed by the excellent collaboration of the Schwanog solution competence: “The Schwanog team is working highly efficiently, and because of their tremendous know-how, offered us a perfect solution in the shortest amount of time.”
Producing a keyway, spline or similar longitudinal feature on a turned part usually necessitates an additional, time-consuming, secondary operation on a broaching or slotting machine. That means moving the part to and from a secondary operation, an extra setup, additional labor and hourly machine costs and all of the other headaches that go with secondary operations.
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