Reducing setup time for turning and milling combined precision machining of connecting shafts requires careful planning, efficient processes, and the use of appropriate tools and techniques. Here are several strategies to help you achieve this:
Preparation and Planning:
Detailed Work Instructions: Develop comprehensive work instructions that outline every step of the setup process, including tool selection, workpiece fixturing, and alignment procedures.
CAD/CAM Software: Utilize computer-aided design (CAD) and computer-aided manufacturing (CAM) software to create detailed machining plans and toolpaths. This can help in visualizing the setup and identifying potential issues before they arise.
Tool Presetters: Use tool presetters to measure and set tool lengths and offsets accurately offline, reducing the time required for tool changes and adjustments on the machine.
Tool Organization: Implement an organized tool storage system that allows quick and easy access to the required tools. Tool cribs or tool carts can be useful for this purpose.
Fixturing and Workholding:
Quick-Change Fixturing: Invest in quick-change workholding systems that enable rapid clamping and unclamping of workpieces. This reduces the time spent on setting up and securing the workpiece.
Modular Fixturing: Use modular fixture components that can be easily reconfigured for different workpiece geometries. This minimizes the need for custom fixtures for each job.
Machine Features and Accessories:
Automatic Tool Changers: If your machine has automatic tool changers, ensure they are well-maintained and optimized for quick tool swaps.
Renishaw Probing Systems: Implement probing systems for on-machine part measurement and tool setting, allowing for real-time adjustments and reducing setup errors.
Standardized Workholding and Tooling:
Standardization: Standardize tooling and workholding components wherever possible to reduce the variety of setups needed.
Tool Crib Management: Maintain an organized tool crib with preset tool assemblies for common machining operations.
Cross-Training: Train your machine operators to be proficient in both turning and milling operations. This enables them to set up and switch between operations more efficiently.
Continuous Improvement: Encourage operators to identify and share time-saving techniques and best practices within the team.
Single Setup: Whenever feasible, aim to complete as much machining as possible in a single setup to avoid repositioning the workpiece.
Simultaneous Machining: Explore the possibility of simultaneous turning and milling operations, especially for complex geometries.
Value Stream Mapping: Apply lean manufacturing principles and conduct value stream mapping to identify and eliminate non-value-added activities in your setup process.
Maintenance and Calibration:
Regular Maintenance: Ensure that your machines are well-maintained to prevent unexpected breakdowns that can disrupt the setup process.
Calibration Checks: Periodically check and calibrate machine tools and measurement equipment to maintain accuracy.
Kaizen: Foster a culture of continuous improvement, where employees regularly review and refine setup processes to reduce time and increase efficiency.
By implementing these strategies and continuously seeking opportunities for improvement, you can significantly reduce setup times for turning and milling combined precision machining of connecting shafts, ultimately improving productivity and cost-effectiveness.