The ability of machine tools to perform repetitive
actions is a key factor that has made them best for the automobile
industry. Additionally, the machines have higher production rates
because there is very little down times and changeovers are
eliminated. With the invention of the computer numerical controls,
part designs are developed using computer aided design software. The
design is transferred to the machine software which re arranges the
files in such a way as to direct the operation of the machine,
movement of the tool and the machining operation.
In highly automated systems, one machining unit may have several operations combined on a work piece such that processes run sequentially. This also reduces the time required to complete a job and increasing the efficiency of the operation.
CNC Milling
This method of manufacturing is used in batch
manufacturing continuous process. Pieces to be milled are stationed on
the machine and milling operations are run automatically from piece
to piece until the raw material is completed and more is fed to the
machine.
Parts manufactured through milling
A wide variety of parts is made through
milling. They include transmissions, gearbox cases, transmission
housings, engine cylinder heads, aluminium drive housings, flywheels,
engine locks, piston rods, wheels, water pumps, and more of these
equipments.
Manufacturing of parts such as fuel injectors requires very high precision. Camshafts’ grinding is also a core application of CNC machines and is achieved through computer-aided designing.
Rack and pinion systems machining
These systems have very wide applications in
automobiles. Some basic applications in the car include the wind
shield wiper system, hydraulic steering, power windows, electric hand
brakes, wing mirror adjustments, and manufacture of small gear worms.
The gears are made through the milling process. In form milling the
shape of the tool takes the shape of the gap between the gear teeth.
Each tooth is cut with cutter moving progressively until completion.
Turning
This process uses the turning machine or the
lathe machine. It is used to make rotational parts through continuous
removal of the unwanted parts. Apart from turning, the lathe does
other processes such as facing, grooving, cut off and thread cutting.
The machine also performs internal work piece operations such as axial
drilling, boring, reaming, and tapping which is the creation of
internal threads.
Automotive parts made through turning.
Manufacture of brake disks is the most common
application of the lathe in the motor industry. In some cases ,
specialized brake lathes have been made due to the rapid demand for this
particular part. Other parts made with the lathe include brake drums,
rotors , the fly wheel and most parts requiring the threading and
phasing operations.
Drilling
This is also a process of milling using
equipments such as the radial drill, cord drills and the pedestal
drills. They are also very important in automotive workshops in making
of slots as well as cutting threads.
The range of applications of the machine tools
in automotive industry continues to increase exponentially. This has
been enhanced by development of computer numeric controlled machines,
which are able to transform design to completed product in a very
short time frame. High-speed machining techniques have also enabled
greater precision to be achieved.
