Case Studies

Case Study #1

Background
The customer was using a box turning attachment to turn a .487" diameter 2" long on a steel part. The process was desirable but resulted in intermittent scrap parts, due to the turned diameter being .015" out of concentric with the bar stock diameter. The customer had to solve this problem immediately.

What We Did
Precision Components engineered a support bridge that traveled along the bar stock diameter and a prototype was produced within days. The result was concentricity within .002" and better finish due to less vibration during the cut.

The Result
The Customer has implemented this design on several other parts and now produces these parts without concentricity issues.

Case Study #2

Background
The customer needed to broach an external involute spline with tight tolerances during screw machining. A conventional 1pc. broach could only be sharpened once due to the tolerance required and was very expensive to replace on an ongoing basis.

What We Did
Precision Components designed a 2pc. insertable broach that had the following benefits:

Savings of 25% since the consumable is much smaller
Faster replacement when dull
No adjustment on change overs

The Result
The customer has lowered tooling costs and uses this method exclusively on a large family of parts.

Case Study #3

Background
The customer specialized in screw machining aluminum parts. Small formed grooves posed a major problem with the danger of cutting chips curling and wrapping around the groove. This affected 60% of parts produced. But, a finished bad part was visibly indistinguishable from a good one as the chip curled tightly around the bottom diameter of the groove. The problem had to be solved immediately.

What We Did
Precision Components designed a special clamp that follows the contour of the form tool close to the cutting edge. It breaks the chip before it has a chance to wrap around during machining. The clamp reduced this problem which now only affects 1-5% of parts produced.

The Result
The customer now requires this concept be used on all form tools to be used for their aluminum parts.