How Customized Fixturing and Sensing Technologies Boost Machining Efficiency

Our team undertook an intricate and challenging workholding project that involved machining highly complex castings. These parts were previously completed through two separate, labor-intensive operations, presenting several inefficiencies in the manufacturing process. Our customer faced ongoing challenges related to frequent repositioning, excessive handling time, increased risk of error, and overall diminished productivity. They sought a solution that could eliminate these operational hurdles, streamline their workflow, and significantly improve overall efficiency.

To meet these ambitious objectives, our expert team developed an innovative and comprehensive machining solution, incorporating a state-of-the-art 4th-axis rotary table combined seamlessly with a custom-engineered trunnion fixture. This advanced setup enabled the entire casting to be machined in a single, uninterrupted operation, drastically reducing production time and eliminating unnecessary handling.

Achieving precision and repeatability was critical to the project’s success. To ensure consistent accuracy, reliability, and secure workholding, we integrated a sophisticated combination of specialized components:

• Vektek clamps provided robust and adjustable clamping capabilities, precisely accommodating the complex and varied geometries of the castings. These clamps were carefully chosen for their durability, versatility, and capacity to securely hold parts with diverse shapes and sizes, maintaining optimal positioning throughout machining processes.
• Vektek part-sensing components added an essential layer of quality assurance by continuously verifying that each casting was correctly positioned and firmly seated before machining began. This advanced sensor technology proactively prevented misalignments, significantly reducing potential errors and subsequent rework or scrapping.
• Custom-developed air gap sensors were meticulously designed and incorporated by our in-house engineering team, delivering an additional validation mechanism. These sensors confirmed optimal contact and secure engagement of each casting with the fixture prior to clamping. By ensuring precise alignment and eliminating gaps, these sensors substantially enhanced operational reliability and product quality.​

Through the integration of these advanced automation technologies, our innovative solution not only eliminated an entire machining operation but also achieved substantial improvements across various performance metrics. Cycle times were dramatically reduced, manual intervention was minimized, and part consistency was significantly enhanced, resulting in greater overall productivity.

As a direct result of our strategic and technologically advanced approach, our customer realized substantial operational efficiencies, lower production costs, and enhanced competitive advantage within their industry. They now have the capability to undertake higher-volume orders with increased confidence and efficiency.

Are you facing similar operational challenges in your production processes? Connect with us today and discover how our customized workholding and automation solutions can help transform your manufacturing processes, drive efficiency, and maximize your competitive edge.