specifically the horizontal HP5100, we discovered that we could hog the features from an aluminum block instead, result- ing in a cheaper process. In the end, we literally redesigned the part with better results, rather than simply re-machining one critical feature in a casting.” For a telecommunications com-
pany, HTPMI machined a complex part 24" (608 mm) in diameter from ABS plastic. “The part is rather complex with a lot of angles, pockets, grooves and required considerable 3-D ma- chining. Utilizing one of our Doosan HP 5100 horizontal machining centers, we were able to turn the part around before the customer had time to get a quote for doing the job via injection molding,” said Lonero.
“A larger volume part that has ben-
efited from our LPS is a family of sensor blocks used in air quality machines,” said Joe DeVargas, HTPMI production manager. The sensor block is 2 × 1¼ × 1¼" (50.8 × 31.7 × 31.7 mm) with a lot of holes and pockets. “Doing the part on the HP5100 gives us a much more precisely finished part. We’ve actually run thousands of these parts. It’s a part that is machined on every side, and to put that part on a vertical machine would require six different setups. “On the HP 5100 with LPS, it’s machined complete in just two setups. Best of all,when parts go through de- sign changes by the customer, we are able to turn that around and start mak- ing the new configuration within a day, because the part is all set up and the tooling is in the machine. To make simi- lar adjustments on a vertical machine would take weeks,” said DeVargas. “When I bring customers or potential customers into the plant, and they see all the Doosans running, they’re amazed that the entire system runs continually and only requires a single operator,” said Lonero.
“This typically leads to a discussion about the foolhardi- ness of outsourcing jobs half way around the world in an attempt to save costs through cheap labor. Here, we’ve reduced the labor content, guaranteed consistent part quality
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January 2015 |
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