The average car comprises around 30000 components, and each component needs to work flawlessly with other components. Precision and serial production of components are critical to the supply chain. This has been made possible through CNC Swiss machining for production of repeatable components. Multiple designs fly off the design phase, and the machines turn out prototypes that are tested and validated, before moving to serial production phase. The role of these machines is of paramount importance, enhancing the safety and performance of vehicles. Components such as brakes, suspension, gear and steering knuckles are all manufactured through Swiss machining services.
Precision for form, fit and function
FFF, abbreviation for Form, Ft and Function, is a key criteria in manufacturing processes. Swiss turned components ensure high precision cutting and shaping, thereby exactly matching the CAD designs in the shopfloor. Every single component that comes off the shop floor needs to be identical to the components of same category. This ensures that mounting, or installation of the components is easy and correct.
Fit in FFF – Components need to fit in with other parts flawlessly, without any tradeoff in performance. The nestling of components with each other, into each other will determine the performance and reliability of the final product. The major components are around 5000, including sub-assemblies. The remaining components are relatively smaller, including seals, wiring etc. Regardless of the size, or category, every single component needs to be precise. This determines the functioning and performance of the vehicle. This is largely possible through micro Swiss machining.
Function in FFF – Components are subject to stress, heat and repetitive motion. The mechanical, structural and thermal properties of machined components need to withstand these forces. Swiss turned components ensure that every single component is not only identical, but meets the functional requirements. For instance, smoothness of the surfaces, sharpness of the edges, and moving action need to be consistent with design requirements.
Chamfering is another key requirement in specific components. While a smooth surface or a sharp edge in a component can be considered as relatively easy to achieve, meeting the chamfering requirements, is considered challenging. This is where micro Swiss machining plays a very important role. The programmed toolpaths cut the angled edges with a precision that is virtually impossible to achieve manually. The machine possesses capabilities to control the angle, the depth and the position of the component, to chamfer it as per requirement.
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Types of CNC machines in automotive segment
Typically, CNC machines in automotive sector can be classified into the following. Each category has its own specific purpose and deliver components accordingly. Each category presents distinct advantages towards manufacturing processes in the shop floor. Categories include:
• CNC Milling for Engine blocks, casings.
• CNC Turning for Shafts, axles, discs.
• CNC Plasma Cutting for Chassis, thick sheet metal.
• CNC Laser Cutting for Trims, body components.
• CNC EDM Dies for injector parts.
• CNC Waterjet Cutting for Composites, interiors.
• CNC Grinding for Crankshafts, rotors.
• Multi-Axis CNC Machines for Complex engine parts.
Range and complexity of components manufactured at supplier facilities
The primary assessment of supplier facilities is to understand the range and complexity of components that can be manufactured. This gives a clear indication of the capabilities of the supplier. For instance, a facility that has multi-axis Swiss machining services indicates that turbo housings can be manufactured. Similarly, CNC turning and grinding capabilities at a supplier facility indicates that crankshafts and cam shafts can be manufactured. At advanced facilities, the entire range of machining allows manufacture of components under a single roof. This smoothens supply chain processes, and eliminates bottlenecks in production. This also helps QA processes and traceability.
Process control documents at facilities and compliance with standards
Various process control documents at facilities ensure that Swiss turned components meet the stringent standards of the sector. From Process control, PFMEA, to tool life monitoring sheet, the various documents ensure that components and manufacturing facilities are compliant with standards.
From IATF 16949 to APQP, the automotive industry demands compliance with multiple standards. This ensures that various requirements are met, from dimensions, tolerances, appearance, to traceability and risk identification. Audits of CNC machining facilities involve various standards that are sectoral or OEM-specific. Facilities of companies with extensive experience and processes meet audit requirements smoothly.
