CNC West Dec jan 2019

42 www.CNC-West.com CNC WEST December 2018/January 2019 gines per year,” said Ozmai. “That production includes engines for race and team test events, as well as those for internal TRD research and development. The dynamic development environment paired with a 40-hour-plus week schedule create an ever changing demand for preci- sion manufactured components in the shortest possible lead time. The added flexibility and precision of the MIK- RON machining centers within a new automated manu- facturing cell allows us to keep pace in such a dynamic manufacturing environment.” Within TRD’s automated manufacturing cell, one rail- guided robot works from 100 open pallet positions to serve nine full 5-axis MIKRON milling machines. Specif- ic models include the MIKRON HPM 450U, HPM 800U HD and the HPM 1350U. The high-performance MIKRON HPM 450U pro- cesses TRD’s smaller engine components. With a rotary/ tilt table, providing unencumbered, interference-free ma- chining, it is well suited for universal, automated produc- tion. On the MIKRON HPM 800U HD (High Dynamics) High Performance Machining Centers, that deliver 1G ac- celeration rates, TRD mills mostly engine cylinder heads. For heavy-duty machining of its cylinder blocks, TRD is in the final stages of qualifying the MIKRON HPM 1350U with 43.42” diameter rotary table and a load ca- pacity of up to 3,306.9 lbs. For both speed and torque, the machine packs a 50-hp spindle with 142.349 ft-lbs of torque. Part machining cycle times at TRD can range anywhere from a few minutes to as long as 15 hours. Average part sizes run between 1.000” and up around 20.000” in any one dimension, with tolerances as tight as 5 microns or less. Many parts require full simultaneous 5-axis machin- ing of contoured surfaces, while for others, 5-axis motion simply provides better part accessibility and fixturing for faster and more accurate production. The kinematics associated with the 5 –axis MIKRO- NS also allows for the use of shorter tooling, eliminating long overhang tooling. Shorter more rigid tools reduce vibration, ensure smooth surface finishes and help TRD achieve its tight part tolerances. Aluminum and cast iron are the dominant materials at TRD. Cylinder blocks are cast iron and cylinder heads are aluminum, both per NASCAR regulations. According to Ozmai, the MIKRONS can process just about any of TRD’s milled components, making all of the shop’s parts potential candidates for manufacture through the auto- mated cell. GF Machining Solutions together with System 3R provided TRD’s automation integration. The cell’s robot loads/unloads both parts and fixtures at four load/unload stations where finished work exits and raw part material enters. Previously, TRD had eight individual machines operating independently of one another, each with its own pallet system.