Need Help!- Configuring for mass production

[sonnybiker]

i have order to make mass production for product like drawing in the attachment. i'm new in manufacturing process, can anyone help me with this set-up?
what should i do for the 1st process and 2nd, etc

thanks for the help for setting the production process

[Grish]

What machines do you have available to you?
Are the measurements metric ? (size does matter after all )
And what quantity are we talking about? (my mass production is 25 parts)

***sorry .. discovered later on that it was metric, so scrath that question

[sonnybiker]

Originally Posted by Grish What machines do you have available to you? Are the measurements metric ? (size does matter after all ) And what quantity are we talking about? (my mass production is 25 parts)

The measurement are in metric (millimeter) and i have 3 milling machine, 1 machining Center. the quantity per moth are 1600 pcs. do u any suggestion?

[Paulo E.]

My advice is get some one that knows how to set this job up, You are being penny wise and dollar folish. If you think that with out any manufacturing experience you will be able to capitalize on this job, for once there are several parts, different gometries and types of operation, you need to know the type of material. I dont mind helping someone with advice on a part but you dont need advice, you need salvation. There are plenty of machinist out there who can help you and in the process you will help yourself by learning from them, in the end it's a win, win situation.

Sorry if I sound harsh but in the end if you sit down and think about it, you will be the one benefiting from it.

[sonnybiker]

Originally Posted by Paulo E. My advice is get some one that knows how to set this job up, You are being penny wise and dollar folish. If you think that with out any manufacturing experience you will be able to capitalize on this job, for once there are several parts, different gometries and types of operation, you need to know the type of material. I dont mind helping someone with advice on a part but you dont need advice, you need salvation. There are plenty of machinist out there who can help you and in the process you will help yourself by learning from them, in the end it's a win, win situation. Sorry if I sound harsh but in the end if you sit down and think about it, you will be the one benefiting from it.

i tried to talk with other machinist in my town, but no one know the efficient process, an my output only 10 pcs/day..what a pitty

[Geof]

I would do these in three operations using a cold saw and a VMC equipped with a fourth axis rotary table.

One fixture would be needed: this would be two pieces of plate about 450mm by 150mm by 15mm. The 450mm depends on how big the VMC is Each plate would have grooves across them wide enough to accept the party with two bolt holes between each groove. A method of mounting these plates bolted together between the rotary table and a tail bearing would also be needed.

The parts would first be cut slightly long using the cold saw.

The cut parts would be placed in the square holes that are formed when the two plates are bolted together. This can be done with the plates on the rotary table with the square holes vertical and a stop block underneath on the machine table so the parts will rest on this while the bolts are tightened.

With the bolts tight and the stop block removed now the ends can be faced, spotted, drilled and tapped and one set of cross holes spotted, drilled and tapped. The rotary table is indexed around to get at all sides.

The cross holes would be done through holes drilled in the plates; the easy way to do this is using the program and a drill in place of the spotting drill to just drill through the fixture plates.

The second set of cross holes would be done by taking the parts out and putting them back in turned 90 degrees; in this operation the stop block needs to be higher and very accurate because this is what makes sure the cross hole position is accurate.

This procedure finishes several parts in only two machine operations. It is similar in idea to the fixture I show in the second picture in post #3 in this thread.

http://www.cnczone.com/forums/showthread.php?t=22125

[ImanCarrot]

erm.. what's the material?

Aluminium, Steel, Wood, Cheesecake?

Or am I being myopic in my dotage?

[jetpig1]

Specify machines/materials/tooling available

This is a gravy part. I would look at some form tools to cut operations down to one stop shopping. Some fixture plates need to be made, and you could do a 3 or 4 operation setup on your mill. Finished part comes off the mill.

If you are looking to do 1600 a month, I think you could easily do 1600 a week, that is, unless your mill doesn't go faster than 10 IPM. I am an application engineer, and wish a little part like this would come across my desk. I call these "bread and butter", the parts that are very easy and boring, but pay the bills.

-Geo

[jetpig1]

I've cut the cheese, but never cheesecake...

Anyone know the surface feed on cheesecake ?

[neilw20]

Originally Posted by jetpig1 I've cut the cheese, but never cheesecake... Anyone know the surface feed on cheesecake ?

Really fast, and use waterjet without he abrasive.

[sonnybiker]

Originally Posted by jetpig1 Specify machines/materials/tooling available This is a gravy part. I would look at some form tools to cut operations down to one stop shopping. Some fixture plates need to be made, and you could do a 3 or 4 operation setup on your mill. Finished part comes off the mill. If you are looking to do 1600 a month, I think you could easily do 1600 a week, that is, unless your mill doesn't go faster than 10 IPM. I am an application engineer, and wish a little part like this would come across my desk. I call these "bread and butter", the parts that are very easy and boring, but pay the bills. -Geo

so, i wanna set up a production line, 1st process come in my mind are face mill the area, 2nd process milling cutter with 30 mm diameter, and 3rd process, 4th process are creating slot, 5th process are drilling the holes, 6th process are tapping the holes, 7th process are face grinding the surface.

...so many process...i wonder, how could u make this part fr 3 or 4 process?

[sonnybiker]

Originally Posted by ImanCarrot erm.. what's the material? Aluminium, Steel, Wood, Cheesecake? Or am I being myopic in my dotage?

the material are SS400 or u can call it MildSteel