Maximum Efficiency Enhancement in Aluminium Machining
To further optimise the production of aluminium components, a high-performance 5-axis milling machine was required. The previous manufacturing process took too long, necessitating a more efficient solution. This is where the FOOKE application engineers came into play. By implementing innovative manufacturing technologies and an optimised process strategy, a significant reduction in machining time was achieved. With the new FOOKE ENDURA® 715LINEAR and a tailored milling and clamping strategy, the production process was taken to a whole new level.
The Path to a Successful Collaboration – From Scepticism to Enthusiasm
The challenge was clearly defined, with the goal of sustainably improving the manufacturing process. Initial time studies revealed an enormous potential for optimisation—so significant that it initially seemed almost inconceivable. However, with the right strategy and machine configuration, even the most demanding requirements were met.
Precise Analysis & Customised Strategy
In intensive discussions with all stakeholders, existing challenges were thoroughly analysed to develop targeted solutions. The following key questions were at the forefront:
- How can machining times be significantly reduced?
- Which machine configuration ensures maximum efficiency?
- How can the entire process be automated and stabilised?
Through detailed simulations and analyses, a strategy was developed that enabled a significant increase in performance.
The Proof: Practical Testing for Clarity
To confirm the optimisation potential, a test milling operation was conducted on a comparable machine. The results were impressive: The newly determined machining times were not only realistic but also reliably reproducible. The efficiency gain exceeded all expectations, ultimately validating the developed solutions.
Turnkey Solution – More Than Just a Machine
FOOKE provided not just a state-of-the-art milling machine but a complete, customised solution:
- Optimised processes with guaranteed machining times
- High-end tools with specially developed solutions
- Postprocessor for maximum machine performance
- Comprehensive training and production support
Right from the planning phase, the primary focus was on developing the best possible solution. Every idea was evaluated to realise the optimal combination of machine performance, tool strategy, and automation.
Developing the Right Machining Solution Together
Even during the quotation phase, it was always a key concern to select the right solution in collaboration with the customer. No idea was dismissed—rather, decisions were made jointly about which approaches were viable and which were not.
For instance, the customer followed our recommendation to select a spindle with the more stable HSK-A100 interface, despite previously using machines with HSK-A63. Due to the sometimes longer tool lengths, this was a crucial factor in reducing machining time. The design for an almost unmanned machining process was also a major requirement, which we successfully realised by using a large tool changer that could also accommodate the necessary angular heads. The customer’s openness to exploring new approaches was a key factor in the project's success.
High-End Tools & Innovative Manufacturing Technology
A crucial success factor was the intelligent selection of tools. In addition to proven standard tools, specially developed custom solutions were used, which significantly contributed to reducing machining time. Furthermore, a specialised clamping fixture was designed, allowing components to be machined without complex retooling. This not only minimised set-up times but also significantly reduced the risk of collisions.
Groundbreaking Process Optimisation & Sustainable Efficiency Increase
By combining a high-performance milling machine, a component-specific clamping strategy, and innovative tool solutions, machining time was drastically reduced. The results impressively demonstrate how modern manufacturing technologies lead to maximum productivity.
Collaboration at Eye Level – A Future-Oriented Success Project
The project was characterised by open exchange and a partnership-based collaboration. Regular consultations and close contact with tool suppliers enabled the creation of a long-term stable solution.
The result: A sustainable process optimisation that not only met but exceeded the planned goals!
The Outcome: A Resounding Success!
Through this close, partnership-based collaboration and the use of cutting-edge technologies, we were able to significantly reduce machining times while providing the customer with a future-proof turnkey solution. The planned times were not only achieved but even surpassed—an absolute success for both parties.
Your Benefits with FOOKE
- Radical reduction of machining times
- Individually customised turnkey solutions
- Innovative, highly efficient manufacturing technologies
- Partnership-based collaboration for sustainable success
Let us also revolutionise your manufacturing processes—with FOOKE as your strong partner at your side!