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AMKONaut®
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Truck rear-axle grinding machine |
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Several well-known machine builders attempted to solve the problem of fettling or deburring of cast pieces by constructing special CNC-machines. Some tried this by simple application of CNC machine tool technologies, which were ment to produce parts corresponding to the CAD drawings in size and shape. However, they always overlooked the fact that each cast piece, even from mass- production, is UNIQUE because it exhibits unavoidable deviations from the ideal CAD form. In the majority of all cases, these deviations (often creating over-material) do not effect the usability of the pieces. Ergo, they can remain and in many cases they have to remain in place – only the burrs should be removed. Removing of this over-material could ruin the entire piece immediately or later because of mechanical stress. A very good example, of the truth of these statements, is the truck rear-axle: A Standard-CNC-Program would remove the material outside the technical ideal shape of a slightly bent or warped thin wall axle. The result would be: The thin wall would become intolerably thin, the cast skin is damaged so that later (because of physical/mechanical use) cracks will start from this point, and oil will no longer stay inside the gear. The result ia that the entire piece is absolutely useless. In contrast, our INDUVIDUAL-CNC-program guarantees that this TOO MUCH removing of material will NOT happen. The tools will follow the real contour exactly and create NO damage. The tool-offset to the surface of piece/part , meaning how much of the burr should be left after grinding, can be defined by the user. The task of fettling is to remove excess material while maintaining the desired form/shape of the part. The desired part is a deviation of the norm. A FETTLING-CNC-Program has, in the majority of all cases, to reproduce this deviating outline without manufacturing the ideal CAD form. The production of the ideal CAD dimensions may be necessary at some positions of the cast piece/part. However, in this case, a mechanical treatment is needed with machine- tools or via the employment from auxiliary- tools by our fettling/grinding/cutting machine. The results, of all attempts to fulfill this task of fettling, were always insufficient and and unacceptable. Additionally, you always had to accept a product of low-quality. Exactly this happened with a SPECIAL-Machine before AMKON was asked to help! What happened ? A German automobile and truck manufacturer, headquartered in Stuttgart, bought two Special-CNC-Machines for precise deburring of the outlines of the poured truck rear- axles . These machines were developed by an also well-known German machine manufacturer. From the onset, these 2 Special-CNC-Machines never obtained any satisfying results! As a result, enormous remachining costs and lack of any substantial production created production bottlenecks in other company divisions of the truck builder. After 2 years of permanently unsuccessful attempts, by the machine builder, to make these two machines work, the following decision was made: In order to save the millions in expensive bad investments, AMKON (normally not acceptable for DaimlerChrysler because of a too small business) received the following order: AMKON should undertake ALL necessary technical and electrical changes. Thus, AMKON should remove the entire existing CNC-control system and substitute the complete AMKONaut®-System ( software and hardware) in order to insure immaculate, economical, and fully automatic axle deburring. Click HERE for Photos ! AMKON fulfilled these tasks in all points completely ! Please see: Final Acceptance Certificate More information about this very sophisticated fettling/grinding project is provided by copies of DaimlerChrysler's originals: Includes job-specifications, system comparison with cost savings, and more DaimlerChrysler confirmations of full accomplishment of all tasks. Additionally there are more details about this DaimlerChrysler project and its - very strange exit - despite 100 % task fulfillment by us! Interested ? For more information about this issue please contact us personally.
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