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We routinely use our whole array of process capabilities to produce difficult parts that can’t be made by conventional machining processes alone. Here are just a few examples of what we have accomplished for our customers:
Case Study #1-Thermode
This part presented challenges both in material and structure. A thermode used in repair of very high-value circuit boards, it was made of 90% tungsten alloy. The material is machinable but brittle, in this case especially because of its skeleton like shape. We produced the part using conventional machining techniques as well as Wire EDM, then applied gold plating at the contacts. Our customer got a part that worked well at an affordable price!
Case Study #2-Pinion Shaft
Our customer needed a small quantity of pinion shafts to replace worn parts in an automated manufacturing cell. The quantity was too small to make hobbing the gear practical, and high hardness was required. We solved the problem using conventional machining processes, then grinding the journals on the heat treated blank and using wire and conventional EDM to produce the gear.
Bottom-line: high precision parts delivered quickly at a much lower price than the original equipment manufacturer wanted for the same parts.
Case study #3-Flipper
The difficulties with this part were two - it needed high hardness and the journals on the ends needed to be concentric within .001”. With the eccentric shape and amount of material removed it wouldn’t have been possible to make it by conventional machining techniques. We wire-cut the shape, made a special collet to hold the shape in turning, turned the journals, then removed the notch after heat treat.
Case study #4-Cam
This cam called for high hardness, corrosion resistance, and a cam surface with a .002” surface profile and a 16 microfinish. Using 420 stainless, we used CNC milling to make the pre-heat treat blank, then finished the d-hole with wire EDM and the cam profile with CNC grinding after heat treat. We topped it off with electropolishing for maximum corrosion resistance. |
