Single-cycle production: Changing to five-axis machining methods on a horizontal machining centre has allowed Daimler-Chrysler to adopt single-cycle production techniques. Mike Nash reports

摘要

Changing to five-axis machining methods on a horizontal machining centre has allowed DaimlerChrysler to adopt single-cycle production techniques for finish machining its high-performance V-series Mercedes-AMG engines. The V-engines, produced at the Sirnau factory outside Stuttgart, were previously finished on a combination of transfer lines, special-purpose and machining centres involving multiple clamping. This led to geometric and tolerance error between different features in the block. The turnkey solution involved three Heckert machining centres, installed as part of a flexible manufacturing system (FMS) for producing up to 10,000 crankcases a year. The system had to accommodate assembly of caps to the crankshaft bearings, washing, honing of cylinder bores, pressing in of cylinder head covers, leak testing, measurement and inspection and mechanical handling.