Wilmic Precision Engineering was approached by a client who required a hand pump. We were given a basic design concept that would need to be developed.
We were tasked with creating detailed designs which would be feasible to manufacture accurately and efficiently. In addition, it would be necessary to ensure that the component parts of the hand pump could be easily operated by a user. Finally, an effective assembly process would need to be devised.
Research and Development
The nature of the hand pump was such that it needed to be manufactured by a precision engineering company. R&D was necessary to fully develop the designs, to create custom fixturing, and to optimise the performance of the CNC programmes used to manufacture the hand pump. Technological uncertainties were encountered and these had to be resolved before the project objectives could be completed.
The work we carried out was both the creation of a new device and the development of a manufacturing process. Given the bespoke nature of the project, off-the-shelf solutions were not available, meaning our precision engineers would have to use their ingenuity in order to overcome the various design and manufacturing challenges and improve the performance of the hand pump device. Due to the difficulty of designing and manufacturing the tooling, as well as making it possible to machine the component within the required tolerances, the results could not be guaranteed.
Toolmaking
The design and manufacture of tools is often essential in order to machine precision components to the required standard. Toolmaking is a rapidly evolving industry, driven by the increase in trades that require tools. Tools are used by precision engineers to enable them to machine components which require work to be carried out within close tolerances.
Engineering fixtures are typically precision-engineered mechanical devices used predominantly in the manufacturing industry. Their primary purpose is to hold products during a production process, including finishing operations. Engineering fixtures, also known as assembly fixtures, hold components in place to ensure that each and every product is produced (or finished) to the same standard and specification every time; promoting consistency and efficiency during each individual process.
Fixtures
Two classifications of fixture typically used are CNC Milling fixtures and CNC Turning fixtures. These refer to the type of machine with which the fixture is used. Milling operations tend to involve large, straight cuts that produce lots of chips and involve varying force. Due to the vibration of the machine, positive stops are preferred over friction for securing the workpiece. For high-volume automated processes, milling fixtures usually involve hydraulic or pneumatic clamps.
A turning fixture will be used with a lathe or turning machine. These fixtures consist of a base, location and clamping devices. A lathe fixture can be fixed to the lathe either by holding in the chuck jaws or fixing to a face plate. Such tooling and fixtures often have to be created to entirely bespoke specifications when producing precision machined components. For this reason, the level of baseline capability is necessarily low and is built on for each project.
CNC machining was utilised during the development of the project. Both these technologies make it possible to create highly precise components. However, human input is essential to the programming of the software used to operate both CNC machines and CAD analysis technology.
Wilmic's precision engineers had to scrutinise every aspect of the design of the hand pump, the fixturing, and the CNC programming. The bespoke nature of the project meant that the baseline level of relevant knowledge was low and would need to be built upon in order to successfully complete the project objectives.
Testing
We carried out numerous tests throughout the development of the project. Such testing demonstrated a number of key areas in which their creation of the designs and manufacturing process could be improved. Once testing was carried out, these modifications were made, and further tests conducted. Such was the nature of the project; it was only once the project was entirely complete that testing was concluded and a finished and working system was able to be delivered to our client.
Our client was exceedingly pleased with the final device.
The image at the top of this project is of the final prototype being operated.
