Complex parts for industrial applications often feature intricate geometries, tight tolerances, and demanding machining requirements. Not all CNC shops are equipped to tackle that kind of complexity nor have a skilled workforce capable of bringing a product engineer’s design to production manufacturing.
Original equipment manufacturers (OEMs) often reach out to Stecker Machine after other CNC shops have turned them down for a complex project. The truth is, many CNC shops simply don’t want to take on highly complex parts – because they know the chances of them achieving the required specifications are slim.
At Stecker Machine, we embrace complex projects and pride ourselves in providing solutions to manufacturing challenges. By leveraging advanced technology and relying on highly skilled engineers and operators, our team has been able to achieve unparalleled accuracy, consistency, and efficiency in machining even the most challenging parts.
Here, we’ll highlight just a few, including our featured industrial air compressor housing project.
Diesel Engine Venturi for Agriculture Application
This project included a specialized part of a diesel engine's exhaust gas recirculation (EGR) system. Stecker overcame significant challenges in casting, machining, and welding this complex diesel engine part. Collaborating with a trusted foundry, we developed a prototype tool to test alternate alloy materials and coatings. Working with the customer, numerous rounds of testing for strength, durability, and salt corrosion were conducted.
Upon approval of the PPAP (Production Part Approval Process), we used a machining cell that included a 400mm horizontal CNC machining center, a CNC lathe, pressure tests, and a skilled CNC operator. The customer was so impressed with the results that they implemented the updated design across all their diesel engine models, earning multiple awards for innovation.
Truck Transmission Components
The channel plates of a transmission system can be highly complex, appearing like a maze of grooves, elevations, and bores. When other CNC machining shops failed, one manufacturer reached out to Stecker.
Our team conducted a design review and proposed updating the material from A356 permanent mold aluminum to lost foam casting. While the manufacturer considered it an unconventional alternate casting method, it proved to be a remarkable solution. By improving machining and fixturing, our team achieved critical flatness tolerances and followed geometric dimensioning and tolerancing (GD&T) best practices.
Some CNC shops turn down projects that are too complex or because they lack the technology and know-how to successfully deliver on their promises. In this instance, Stecker not only took on the challenge, but we went a step further by investing in an advanced robotic cell to complete the project.
CNC Part Showcase: Industrial Air Compressor Housing
Industrial air compressors are used in multiple industries, from manufacturing and construction to agriculture and oil and gas. For many of these critical-use applications, an air compressor failure could result in contamination or injuries.
There are many potential causes of air compressor failure, from poor maintenance to improper lubrication. However, maintaining tight tolerances during the machining production process is the foundation of preventing system failures.
The air compressor housing in particular protects the inner workings in addition to helping direct airflow and regulate the output pressure. Improper machining tolerances of the housing can cause vibrations and premature wear, leading to leaks in the compression chamber, scoring, and increased wear on rotors and other components.
Boring perfectly cylindrical holes is relatively straightforward, which can be repeatedly achieved by skilled CNC operators. A challenge with one industrial air compressor housing design, however, was the large intersecting tight-tolerance cylindrical bores, requiring specialty tooling. Not only is it critical to maintain perfectly smooth interior walls with zero burring, but the two bores also have to be perfectly aligned. Any deviation from the specifications would result in a system failure.
Stecker collaborated with the manufacturer to understand their needs, then designed and developed the tooling. Our team produced the initial PPAP samples within a tight timeframe, which were approved for production. To achieve tight tolerances, machining was performed on a 630mm Horizontal CNC Machining Center where operators followed LEAN production processes to ensure consistency and repeatability at scale.
RELATED EBOOK: The Benefits of Lean Manufacturing in Machine Shops
CNC machining of air compressor housing units is just one example of the thousands of high-precision parts that Stecker has produced for major OEM brands. Our made-in-America production facility thrives on delivering results, whether for highly complex parts or those with simpler designs.
Have a challenge you need solved? Contact the Stecker team today to talk through potential solutions.
