A manufacturer of precision pumps produces components for high-performance applications in the automotive and motorsport sectors. Small series with high requirements for tolerance, process reliability and repeatability are part of everyday business. To enable these to be manufactured economically and automatically, AMF developed custom-fit clamping devices. These enable the unmachined parts to be clamped securely and lay the foundation for efficient, largely unmanned production.
 

Automated manufacturing requires new concepts 

As demand increased, the number of units quickly grew to several thousand components per year. Two pump housings and two covers made of cast aluminium were to be manufactured fully automatically on a 5-axis machining centre in the future. For this purpose, the machine was equipped with pallet automation and supplemented with new, specially designed clamping devices. Thanks to integrated zero-point clamping technology, the clamping devices can be changed in a few minutes and positioned immediately in a reproducible manner.

Reduced complexity increases process reliability 

The particular challenge lay in securely clamping the aluminium sand castings. Whereas previously several components were clamped per fixture, they are now machined individually. This reduces interfering contours, improves accessibility and significantly increases process reliability. After positioning, the unmachined parts are clamped hydraulically and securely fixed with high forces. This allows the machining centre to perform all necessary operations precisely and without collision.

Precise clamping for tight tolerances

Holes, counterbores, sealing faces and internal contours are machined with very tight dimensional, positional and shape tolerances. The clamping devices ensure that the workpieces are held stable and with repeatable accuracy throughout the entire machining process. Once machining is complete, integrated clamping and centring elements ensure safe transfer to the automation system before the parts are further processed.

Fewer staff, greater efficiency

Since series production began, manufacturing has been fully automated and reliable. The combination of automation and customised clamping devices has significantly reduced staffing requirements while increasing productivity and process reliability. The solution demonstrates how clever fixture technology can be used to manufacture even demanding small and medium series economically – even with the highest quality requirements.