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Optimizing Body Machining Including Variable Casting Allowances

Gessner Andrzej

Management and Production Engineering Review

2021

Vol. 12, No. 2

65--74

The work contains the results of research conducted to optimize the machining of milling table castings. The possibility of reducing the total volume of machining allowances, reducing the wear of cutting tools, shortening machining time and eliminating idle machining passes was considered. The tests were carried out on two batches of castings supplied by two independent foundries. Casting geometry measurements were made using a structured light scanner. The analysis included machining with cemented carbide tools and tool ceramics at two machining centers: DMC200U and DMC270U. It has been shown that as a result of eliminating idle machining passes, it is possible to reduce machining time by 12% for the first and by 44% for the second casting supplier. The estimated annual savings for the production volume of 500 pcs of these castings can range from € 7388 to even € 23 346. The actual cost of cheaper casts was also calculated, taking into account the difference in machining cost resulting from larger machining allowances.