Designing the next groundbreaking technology innovation requires a vendor base that doesn’t know how to say “no” when presented a challenge. The tighter tolerances and more demanding parts of today’s High-Tech Industries only give us more opportunity to shine.
Sub-Micron accuracy requirements in diameter, roundness and cylindricity are becoming more commonplace as engineers push the technology envelope in their respective fields. From Computer Hard Drives to Mass Spectrometry…from NASCAR engines to Solar Energy – we are ready to
"provide you the answers you need"!
Case Studies
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Motor Shaft
Motor Rotor
Solar Energy Components
Project: Motor Shaft
Problem: A manufacturer of High-Tech components for computers could not find a source within the US to prototype extremely high-end motor shafts. The company was forced to use its production partners overseas that were engaged in manufacturing high volume runs of similar parts. Long delays and high costs in the prototypes resulted as production partners could not efficiently break into the 100,000/day production runs to respond adequately to prototyping needs.
Material: 420 SST HT 50+RC.
Critical Dimensions:
Diameter: 4mm +/- .0005mm (20 millionths inch)
Roundness to .0005mm (20 millionths inch)
Finish .06µm Ra (2.3 MIF)
Resolution: M&S was approved as a vendor after careful inspection of the facility and capabilities. Three hundred (300) prototype parts were produced within four (4) weeks (lead time from production partner was 12 weeks) to the specifications listed above. Customer now off-loads prototyping to M&S confidently while production of high volume daily needs can continue uninterrupted.
Grinding discipline(s) that contributed to resolution:
Project: Motor Rotor
Problem: Very thin wall and tight tolerances on OD & ID make the part very difficult to manufacture. The ultimate customer, a defense contractor, could not find source to keep up w/ production.
Material: HT Cobalt
Critical Dimensions:
OD – approximately .7000” with a total tolerance of .0004” (.01mm)
ID – approximately .6640” with a total tolerance of .0003” (.0076mm)
Wall thickness = .018” (.46mm)
Finish 16 Ra
Concentricity .0003” TIR (.0076mm)
Resolution: A grinding process was developed that yielded < 1 % scrap with a production rate that could easily keep up with part demand. The ability to meet quality and delivery requirements resulted in an ongoing, long term contract for the part.
Grinding discipline(s) that contributed to resolution:
Project: Solar Energy Components
Problem: The tolerances for diameter size and roundness on the ID of a special tube made manufacturing costly and vendors difficult to find. Product acceptance was going through the roof, but the lack an adequate supply of this key component caused delivery delays and increasing order backlog which jeopardized the entire project.
Material: 304 SST tubing
Critical Dimensions:
OD – approximately .2500 +/- .0002
ID – approximately .2100 with a .0002” (.005mm) total tolerance
Grind length on ID approximately .375” (9.5mm)
Roundness .0001” max (.0025mm)
Finish 16 Ra (.4)
Resolution: A manufacturing process was developed to provide parts complete to the customer. The process is extremely repeatable and reliable, resulting in no part rejections by end user. Production requirements have continued to increase with virtually no lag in shipments. The customer has been awarded long-term, multi-year commitments for the project.
Grinding discipline(s) that contributed to resolution:
