QUICK CHANGEOVER
AT A GLANCE:
- Customer: Precision Manufacturer (Southeast US)
- Regional Manager: Jeremy Wright
- Application: High-Security Rail Car Latch Systems
- Machine: Doosan DVF-5000 (5-Axis VMC)
- Material: Stainless Steel
- Royal Solution: SLV™ Multi-Vise Pyramids (8 Pyramids / 24 Vises)
- Key Result: 400 parts per shift, 24/7 lights-out production
A precision manufacturer in the Southeast recently developed an innovative rail car latch system designed to stop cargo theft during the brief 5-minute windows when trains are stationary. To meet high-volume demand for these tough stainless-steel components, the shop chose a Doosan DVF-5000 5-axis machining center. However, their previous conventional workholding setup couldn’t keep pace. The traditional vises lacked the rigidity required to aggressively machine stainless steel without extensive part prep, while the restrictive flat layout limited part density, forced awkward toolpaths, and required operators to constantly flip parts for secondary operations. To hit their demanding target of 400 parts per shift, the shop needed a more rigid workholding solution that could maximize spindle utilization and run completely unattended overnight.
To eliminate these bottlenecks, the shop invested in the new Royal SLV™ (Sturdy Little Vise) line, opting for the high-density SLV™ Multi-Vise Pyramids. By installing an 8-pyramid array featuring 3 compact SLV™ vises per pyramid, they instantly tripled their part density per cycle. Presenting the workpieces on the angled faces of the Royal pyramids completely unlocked the capabilities of their Doosan 5-axis machine. Instead of the spindle maneuvering around corners or fighting for clearance on a single plane, the cutting tools approach the parts naturally. This optimized positioning allowed the programmer to use shorter, more rigid tools, drastically reducing tool chatter, improving surface finishes, and minimizing the risk of costly machine collisions.
The production payoff was immediate. Royal SLV™ vises each feature box way construction and an elevated drive spindle that combine to provide extreme grip force and rigidity. This enabled the shop to completely eliminate the extra operation of cutting dovetails into the raw stock. Operators simply drop the material in, line it up on the grid, and hit cycle start. Machining multiple faces in a single clamping also eliminated stack-up tolerance errors and slashed setup times. With 24 parts prepped across the pyramids, the Doosan DVF-5000 now runs 24/7, cutting components long after the lights go out. By pairing the exceptional holding power of the SLV™ line with a high-density pyramid configuration, the shop effortlessly maintains its 400 parts per shift target with flawless accuracy.
