Process Description : BRACKET MILLING AND DRILLING

Cast Bracket Materials :

Cast Iron ASTM A159 G2500 – Up to 3.3% C, 2.2% Si, 0.7% Mn, 0.15% P, 0.15% S

Major Equipment: ACE micromatic’s High-Speed Vertical Milling Centre with 8

different Tool holders and automatic tool control ( ATC ).

Process description:
In this machine, 4 process occurs with 4 different tools, which will be explained
sequentially below.
The bracket is loaded into the fixture and the cycle start button is pressed. The
hydraulic clamps activate, tighten the bracket’s resting area, and close the machine’s
safety door. The splash coolant flows over the bracket. A ‘disc mill cutter’ with a
diameter of 142.50 mm makes vertical movement ( +Z direction ) and removes the
material from the bracket. This is the area where the brake disc gets assembled. After
this, the ‘side milling cutter’ of diameter 38.75 mm moves horizontally ( +X direction )
and removes material. This is where the Anti-Rattle clip will be assembled. Following
this, the drill tool of diameter 14.85 mm makes rough drilling on 2 areas up to 78 mm (-
X direction) length. This is followed by a fine boring process where a tool with a
diameter of 14.90 mm drills existing 2 holes up to the length of 78.50 mm ( -X direction
). This is the area where Sliding Pins are assembled. The process is completed in this
machine. Coolant flow stops. Tools go back to the holder. The safety door opens.
 Process Name: Bracket Milling
Process : Disc clearance milling, clip seat milling, Sliding Pinhole drilling

Suppliers Inputs Process Output(s) Customers

• Disc clearance
TVS Foundry Cast Iron A159 Bracket - milled Internal:
milling
Kennametal DF shank Ø14.85
Coolant – Goes to • Plating
DF shank Ø14.90 • Clip seat milling
Recycling reservoir shop
ACE micromatic
Mill Cutter Ø142.50 • Pinhole Rough
• In-situ
ARK tooling Inc Mill Cutter Ø38.75 drilling Chips – Debris quality
Collected at the inspection
DermX Coolant Inc Kut-Sol 1GP coolant • Pinhole finish bottom
drilling

Input Metrics Process Metrics Output Metrics

• Bracket – Visual inspection ‘OK’ card Tool speed, coolant Disc milling Length
• Tool cutter compensation temperature, clamp USL: 110.05 mm Quality
pressure, tool feed rate, LSL: 109.85 mm
CONFIRMATION sticker
no. of passes, , cutter Shear Strength : 340 MPa
• Coolant Temperature = <15 deg height compensation,
Celsius Retraction: Clip – 6 N max
depth of cut
Pad – 8 N max
Tools speed for Disc and
Cycle time and Throughput rate of
Clip seat Milling, rough
changeover time the machine Speed
drilling, finish drilling

1. Tooling cost 1. Utilities 1. Chips wastage

2. Labour cost 2. Cost/component 2. Tool life degradation
of this machine 3. Coolant top-up Cost
 High-Level Process Map (BFD)
Disc Clearance Milling Chip Waste
Load component
Cycle Start button ON Clamp Pressure = 95-100 Bar Coolant Waste
Coolant temperature < 20 Deg C
Cutter Speed: 500 rpm, Feed: 10mm/s

Next operation
Clip Seat Milling
Chip Waste
Clamp Pressure = 90-95 Bar
Coolant Waste
Coolant temperature < 20 Deg C
Cutter Speed: 400 rpm, Feed: 15mm/s
Next operation

Rough Drilling
Chip Waste
Clamp Pressure = 100-110 Bar
Coolant temperature < 20 Deg C Coolant Waste
Cutter Speed: 1000 rpm, Feed: 15mm/s
Next operation
Finish Drilling
Clamp Pressure = 89-95 Bar Chip Waste
Coolant temperature < 20 Deg C Coolant Waste
Cutter Speed: 1200 rpm, Feed: 7 mm/s

GO-NOGO Gauge Inspection