Building cars is a complex process in which the role of machine tooling is central. Let’s take a closer look at how and why that’s the case. Broadly, automotive manufacturing involves seven steps. These are:
- Obtaining and then working/reworking the raw materials from which the car is made
- The design (body and engineering) of the car
- The stamping or press process (or shop)
- The welding or body process (or shop)
- Painting, as a component of the assembly line
- Engine building and fitment
- Final testing and inspection
The three key types of machining
Within these steps, different kinds of machining are required but three are absolutely central. They are:
- Turning: The turning process involves a workpiece being rotated while the cutting tool is moved parallel to the axis of rotation to shave material from its outer surface. Generally, turning is used where cylindrical shapes like shafts, rods, and tubes are the required end-product. Turning machines, better known as lathes, are deployed here.
- Milling: In milling, a rotating multi-toothed cutting tool is used for a similar outcome as turning; to remove material from a workpiece’s surface but this time by making multiple passes over it. Milling machines are most often used to make complex shapes, slots, holes, etc. in various raw materials. Depending on the set up of the tool and surface, milling can be further broken down into vertical milling, horizontal milling, or universal milling.
- Drilling: Drilling again involves a rotating cutting tool (most often the familiar drill bit) and this is exclusively used to create holes in a workpiece. Self-evidently, the drill bit is pressed against the workpiece’s surface and by rotation removes material and creates a hole with specific dimensions.
Between them, turning, milling, and drilling account for the most common applications of machine tooling in the automotive industry.
The manufacturing processes to which machine tooling is applied
Therefore, all three processes are used in and are integral to the manufacturing process of automobiles. They appear throughout the seven steps described earlier. In combination, they are responsible for shaping, cutting, forming, and helping to assemble the various components that make up the finished product. How? We see the machine tools specifically in the following aspects of the car manufacturing process:
- Computer Numerical Control machines: CNC machines, which are now commonplace in the industry, include lathes, milling machines, and routers. They’re responsible for cutting and shaping numerous components of cars including engine parts, chassis components, and body panels.
- Stamping Presses: These presses cut, shape, and form metal sheets into specific parts such as body panels, doors, bonnets, and other mainly structural components.
- Welding Machines: There are different types of welding machines (for instance, Metal Inert Gas welders, Tungsten Inert Gas welders, and resistance spot welders). These join metal components together. Welding is crucial to the car’s structural integrity.
- Die Casting Machines: These build the complex metal parts within a car with high precision. They are mainly responsible for making engine components, transmission parts, and more intricate pieces.
- Injection Moulding Machines: These are responsible for plastic components like interior panels, dashboards, and the like.
- Laser Cutting Machines: High-powered lasers are used to cut often intricate shapes out of various raw materials. They are used where precision cutting is required.
- Water Jet Cutting Machines: These, rather than lasers, use high-pressure water jets mixed with abrasives to perform cutting. They are mainly used for precision cutting where complex shapes are required.
- Robotic Assembly Systems: Robot arms are used to assemble different components, handling tasks including placing bolts, screws, and other fasteners, as well as welding and adhesive application.
- Machining Centers: Sometime, various machining processes are combined in one machine, such as milling, drilling, and tapping. These “centers” produce complex-shaped parts with a high degree of precision.
- Grinding Machines: Grinding delivers precise dimensions and finishes for various different components, in particular engine crankshafts and camshafts.
- Assembly Line Equipment: There’s a range of machines and tools for different stages of car assembly including conveyor systems, robotic arms, automated guided vehicles (AGVs), and various inspection and testing equipment.
Even at a cursory glance, it’s clear that all the systems, tools, and processes above rely on accuracy to perform to expectations.
Machine tools and measurement systems
In the automotive industry, then, accuracy is critical to assuring performance. There really isn’t any margin for error but achieving accurate outcomes is challenging. For one thing, the environment works against it; cars are built in harsh surroundings where the presence of oil and coolant are common, often coating everything in sight, metal chips fly about, and the machine tools required are exposed to a high degree of continuous stress. All this can work against their performance, meaning accuracy isn’t easy to sustain.
As a result, the deployment of measurement systems is a key facet of successful automotive manufacturing processes. Let’s look at just one practical example of such a solution that backs up that assertion; in this case a camera-based machine tool measurement system, designed for use in turning and milling machines specifically.
Made for measuring tools in a demanding environment, effective deployment of such a system will improve manufacturing outcomes. While any measurement system can make a difference, camera-based systems are particularly effective in turning and milling machines in the automotive industry because unlike others, camera-based technology can be highly effective even when the tools are dirty – provided that you can create a reference measurement of the tools themselves. You can read a detailed explanation of why this is the case in our blog on the subject here.
Of course, there are multiple use cases applying to various tool measurement scenarios but generally, car manufacturing involves repetitive processes. Therefore, deploying and continuously using measurement tools such as a camera-based system will be an investment that helps the manufacturer maximise its return. There are no shortcuts to accuracy, and a lot of parameters to consider if you want to achieve it. If you’d like to discuss these with us directly, please get in touch.
About Conoptica
Conoptica has been providing high tech camera-based measurement solutions for the metal working industry since the 1993. We make sure that the metal working industry has access to key quantitative data about their products and tools. Conoptica is the market leader for measurement equipment in the wire & cable industry.