Production of high precision welded frame for production lines
Research Jaroslav Miklušák - MECASYS, Matúš Madleňák - MECASYS Technology, Pavol Gužík - MECASYS Design, Dominik Zilka - MECASYS CAM Program
Summary
We design and apply technological processes based on the combination of heat treatment and 5-axis CNC milling in the production of precision load-bearing frames for high-speed machine lines.
We ensure that critical dimensional tolerances are maintained with a maximum deviation of 0.01 mm on a length of 930 mm.
The required tolerances (e.g. coaxiality up to 0.015 mm, perpendicularity up to 0.01 mm, parallelism up to 0.012 mm) are necessary to achieve high quality and reliability of the customer's final product. The support frames are the basic structural platform on which the other functional elements of the machine are subsequently mounted.
By carefully planning and optimizing all process steps, MECASYS has ensured that every process contributes to achieving high precision and repeatability. By adhering to a proven process, we guarantee the consistent quality of every part produced.
Description of the problem
A Swiss packaging machinery manufacturer approached us with a requirement to produce a high-precision welded frame for production lines producing packaging for the pharmaceutical and food segments, specifying very tight dimensional tolerances. He had worked with a number of suppliers across Europe in the past, but had repeatedly encountered problems - they were unable to ensure the accuracy of critical dimensions, leading to production delays and complications in the assembly of his final equipment.
After receiving the technical documentation, we thoroughly analyzed the assignment and prepared a proposal for a production solution. The customer then verified our technical and manufacturing capabilities, including available technologies, measuring equipment (CMM) and internal quality procedures. After successful validation of our capabilities, we received an order for the production of a test sample.
It was clear from the outset that the project required an exceptionally precise approach - not only because of the strict tolerances (e.g. perpendicularity within 0.01 mm, concentricity within 0.015 mm, parallelism within 0.012 mm), but also because of the interplay between these requirements. Each technological step had to be carefully planned to eliminate the risk of inaccuracies.
Solution
In the pre-project phase, before the start of the implementation, MECASYS thoroughly analyzed the specific requirements of the client and the submitted documents. At the same time, it also thoroughly identified the client's hidden expectations.
By analyzing the existing situation, the client's documents and perception of their expectations, MECASYS optimized the technological procedures and processes for the realization of load-bearing frames for high-speed lines in order to achieve the set goal - higher efficiency, productivity and quality of production, not only with regard to safety and cost savings, but also by taking into account other important aspects.
Based on the analysis of critical points, the MECASYS team created several scenarios for the production process, which were evaluated in terms of technological risks and their impact on the resulting accuracy. In this process, we have used the experience of MECASYS Labs, gained through participation in global projects for the production of critical components for various industry segments, such as pharmaceutical, aerospace or construction.
One of the key issues that had to be dealt with was the deformation of the structure after welding and the internal stresses in the support frame before chip machining.
In addition to the manufacturing process itself, we also designed stages to verify the actual design with the required dimensions and their tolerances. These verification stages on CMM measuring equipment were included in the manufacturing process and we established identical alignments on 5-AX CNC milling machines and for CMM measurements on HEXAGON METROLOGY Global S-series machines.
Ongoing verification and consultation of the responsible teams ensured that the quality objectives and dimensional parameters were met.
After planning and optimizing the technological, production and measurement operations, we proceeded to the realization of the prototype. During the realization, we systematically followed the proposed steps, especially the prescribed technological adjustments between each operation - heat treatment, surface treatment before machining, continuous dimensional verification and final surface treatment processes in order to achieve the final state of the product.
In MECASYS we have designed and implemented a technological process of welding, heat treatment, 5-AX CNC machining and verification of functional dimensions to achieve the required accuracy to 0.01 mm with final surface treatment. Part of the process was also the validation of the achieved parameters with the customer, which took place before the export of the realized product.
After 8 weeks of systematic work and development, we handed over the finished prototype to the customer, which met all the criteria without the need for additional modifications. The export also included the exchange and sharing of quality information with the customer, in particular certificates of verification of dimensions, heat treatment, materials used and adherence to prescribed processes.
Results and benefits
By applying the proposed procedure and a systematic methodological approach, we achieved:
1. Meeting the customer's criteria for the accuracy of the welded support frame for the high-speed line, especially the perpendicularity within 0.01mm, the coaxiality within 0.015mm and the parallelism within 0.012mm.
2. Verification of the reliability of the entire production process with guaranteed repeatability of results in the future.
3. Elimination of production downtime and slippage during assembly at the customer's site.
4. Reduce the cost of initial quality verification of a critical component by continuously exchanging and sharing quality data from CMM measurements.
Conclusion
A project to produce a high-precision welded frame for a Swiss customer has confirmed MECASYS' technological and process maturity. The successful implementation of a demanding assignment - including adherence to tolerances in the micrometer range and comprehensive production validation - proves that even extremely stringent technical requirements can be met with a high degree of repeatability.
Based on a precisely documented and proven procedure, we can ensure repeatable production without the need for new set-up. The customer is thus assured of consistent quality for future orders.
Our approach based on detailed analysis, in-house development of technology scenarios, precision manufacturing and controlled CMM verification enabled the customer to obtain a component that:
- significantly reduced risks during installation,
- eliminated the additional cost of the initial check,
- ensured the reliable operation of its high-performance lines.
This experience has also moved us forward in the field of unifying and optimizing technological processes for demanding and mission-critical applications.
MECASYS is ready to transfer this experience to other projects where precision, stability and reliability are decisive factors.
Your needs, Our expertise
Are you looking for a partner who can handle the high precision of 0.01 mm in the production of basic machine frames up to 400 kg and 1000 mm in size?
MECASYS will design and deliver the machines you need - reliably, flexibly and in accordance with the demanding requirements of your production.
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References
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