Developing a high-volume solution for a horizontal machine

We recently tackled an exciting challenge—developing a custom tombstone fixture to handle uniquely shaped forgings for a horizontal machining center. These forgings presented a particularly tricky problem due to their irregular and inconsistent dimensions, which often lead to difficulties in maintaining accuracy and efficiency during machining processes.

Understanding the complexity involved, our team took a strategic approach. We began by analyzing the challenges posed by these forgings and quickly recognized the need for specialized tooling to securely hold and precisely position each piece. To overcome these obstacles, we designed custom fixtures specifically tailored for this project. These fixtures were engineered to ensure the forgings could be reliably and repeatedly positioned, eliminating the inconsistencies previously experienced in machining.

​A key component of our innovative solution was the integration of Carr Lane’s robust spring locating pins. These spring-loaded pins provided dynamic, self-adjusting clamping forces, adapting automatically to minor variations in the forgings' dimensions. This adaptive feature significantly reduced setup time, minimized operator intervention, and dramatically improved repeatability and accuracy throughout high-volume production runs.

Additionally, to ensure the highest levels of rigidity and durability required for continuous operation, we constructed the tombstones from single-piece castings. This manufacturing approach provided enhanced structural stability and rigidity, which was critical for sustained precision under demanding machining conditions.

By further integrating these custom fixtures within an automated pallet pool system, we enabled the customer to execute unattended machining cycles—effectively introducing lights-out production capabilities. This automation significantly boosted spindle uptime, increased productivity, and optimized part density per setup, achieving remarkable production efficiency.

The outcome of our innovative approach speaks volumes: streamlined workflows, enhanced accuracy, reduced downtime, and increased profitability for our customer.

Are you facing similar production challenges? Connect with us today to learn more about how our custom machining solutions can optimize your operations and elevate your manufacturing capabilities.