Case Studies

Cam Carrier

Client: Major Power Tool Manufacturer

Background:
Traditionally many cordless drills have been used for driving screws, an application for which they are not ideally suited. To address this market many manufacturers have introduced new drivers that are far more effective for this application. Innovatech has worked with Black & Decker design engineers to improve the manufacturability of some of the key components and has developed and implemented manufacturing systems for production. Innovatech now produces key components for DeWalt's full line of cordless impact drivers and wrenches.

Manufacturing Challenge:
The components in question start as investment castings. The machining involved is complex and includes both milling and turning operations. The machined features include 4 axis contours, 5 micron tolerances to 1.33 CpK's and concentric ground diameters. Secondary processing includes heat treatment, free-abrasive-media deburring, cleaning and preservation. The critical machining features, such as the 4 axis cam path, must be gaged and the annual requirement is well in excess of 100,000 pieces.

Solution:
Innovatech processes this part on 6- and 8- axis dual spindle CNC turning centers. The machines have two spindles and automatically transfer the workpiece from spindle to spindle so the part is complete in a single handling. Milling and turning is done simultaneously in a single machine. Innovatech has met and exceeded the process capability requirements of the customer.

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