A flywheel is a component that by spinning around its axis can store energy that can subsequently be used by interacting with the axis. In order to let the flywheel spin freely, there has to be a cover that will prevent any intruder from coming too close to the spinning wheel and can safely add lubrication. This type of component is normally made in aluminium; in this case it was AlSi 132 GD and the demo part was from Piaggio in Pontedera, Italy.
This shape of component, which is very common in the automotive and parts manufacturing industries, is normally worked on a high-volume machine such as the Makino Slim3n. However, depending the part, it may need to be worked on a horizontal machining centre such as the Makino a61nx.
In this case we used an a61nx with a hydraulic fixture. The parts were clamped automatically in the pallet change area and when the axis came inside, we had:
On B= 0° and two parts ready for operation one
On B= 180° and two parts ready for operation two
Tools and result
For the process to be accepted, the CMK should be over 1.33. Our applications engineers therefore analysed the process and selected the best tooling to enable machining in the shortest time possible. Using PCD inserts we were able to cut as fast as possible and at the same time managed to have a stable process.
With machine rigidity, fixturing and tooling all counted, the final CM was 1.35-1.43 and the cycle time 7 minutes and 6 seconds.