The part in question presented several challenges that impacted both time and resource efficiency in the CNC machining process:
- The requirement to remove a significant amount of raw material extended machining times considerably.
- The narrow gap of 3mm between heat sink fins, each 30mm in height, mandated the use of slender and elongated cutting tools. However, this compromised tool rigidity, slowing down machining speeds.
- Achieving the specified tolerance in the first machining operation is essential because there is no opportunity for rework. The thinness of the heat sink poses a high risk of fracture upon contact with the cutting tool, making it imperative to ensure accuracy and stability during the initial machining.
- The presence of numerous threaded holes on the side surface added complexity, requiring multiple machining steps. Fixture inaccuracies and potential abrasions during clamping exacerbated the challenges.
To address these challenges, the optimization focused on introducing advancements in machining techniques:
- Implementation of 3+2 axis milling on a CNC milling machine for machining the side holes significantly reduced processing time by approximately 10%. This approach allowed for more efficient tool paths, enhancing overall productivity.
The optimization strategies implemented yielded notable outcomes:
The introduction of 3+2 axis milling for side holes led to a remarkable 10% reduction in machining time, streamlining the overall production process.
The optimized approach not only lowered costs but also improved the precision and accuracy of the machined components, mitigating errors introduced during the clamping process.
By addressing the challenges associated with fine machining of the heat sink fins, the optimization ensured better tool utilization, minimizing wear and enhancing efficiency.