But engines are not the only drivetrain components processed – the company also handles transmissions and precision machined components such as cylinder heads and blocks, plus sub-assembly of automotive parts.
In common with similar engineering concerns, Autocraft depends on fast and accurate production machinery backed by an efficient inspection resource to grow its business. This reality was highlighted recently when the company was presented with a commercial prospect involving inspection of various complex components, all manufactured to a high level of accuracy with quite specific reporting requirements.
The production team felt their metrology supplier would be unable to provide the level of support needed for this new business opportunity, particularly as they had been let down in terms of machine reliability and support in the past.
The team realised that what was needed was a total metrology package covering 3D coordinate measuring, roundness testing and surface finish assessment capability, all supplied as a turnkey package by a company that could offer them not just the equipment, but also the level of expertise and support that was deemed necessary for a successful outcome.
After the usual evaluation of vendors, Mitutoyo was chosen as the preferred partner, but not without some initial apprehension, as Autocraft Quality Manager, Alan Doughty explains:
“It was a big gamble for us to go with Mitutoyo because we had only a little experience with them; our customer was also nervous. But it felt right at the time and we are now convinced we made the right decision.”
The right tools for the job
The equipment brought in included two coordinate measuring machines (models Crysta-Apex S9168 and S9208) to inspect precision components such as cylinder heads and blocks; an RA-H5200AH Roundtest, which is a dedicated roundform measuring machine for components such as crankshafts and camshafts; and an SJ500 Surftest, a surface roughness tester acquired mainly to ensure that the ground finish of critical bearing surfaces is maintained at the correct material-ratio-parameter value (Abbott-Firestone analysis).
The new investment quickly paid off: the operators quickly took to the coordinate measuring machines, which they appraised as being capable, quality machines that provided fast, accurate measurements while being easy to use and hassle-free. Similar sentiments were expressed for the Surftest, especially appreciated for its level of functionality.
However, the star acquisition was the RA-H5200AH Roundtest, a highly accurate machine, capable not only of precision roundness measurement but also of characterising many roundform parameters such as concentricity, coaxiality, cylindricity, straightness, perpendicularity to axis and plane, flatness, axial and radial runout, among others. In particular, an automatic centering and levelling feature makes the essential pre-measurement procedure of component axis alignment with the turntable axis a straightforward task for any operator.
A particularly successful application of the Roundtest was measuring roundness, straightness, parallelism and coaxiality of the main journals and crankpins of crankshafts. The challenge with this component was getting the crankpins in position ready for measurement, as the eccentric throw of the pins and the variety of crank angles make the task difficult to accomplish on a general purpose measuring machine.
However, the solution lay in a dedicated fixture that was designed and built by Mitutoyo’s Gauging Technology division to mount on the machine’s turntable. This fixture clamps the crankshaft at one end in a chuck mounted on a linear slide so that it is held vertically. This arrangement allows it to be moved on the slide by the amount of crank throw, so enabling the positioning of any crankpin axis within the adjustment range of the automatic centering and levelling mechanism.
This was quite a departure from the measuring method traditionally employed for this problematic component and, initially, did not find universal favour, as Autocraft co-owner and engineering director, Michael Hague-Morgan explains:
“After some initial scepticism from our customer about using the RA-H5200AH for this component, they have since been blown away by its capabilities, and the investment has been appreciated by our entire inspection team. We now have data from the Mitutoyo equipment that enables us to converse with a customer in a way that we had not previously been able to do. As a result, this has improved our customer relationships significantly.”
In fact, the possibilities opened up by their newly acquired machines mean that Autocraft is now looking at developing new streams of business on the sub-contract side.
But then there is that all-important support element that Autocraft were so keen to establish at the outset. Mr Hague-Morgan again:
“Naturally, with a large project such as this, difficulties were expected, but what small problems did arise were resolved quickly and handled on the spot by the relevant Mitutoyo engineer. Nothing was too much trouble. Mitutoyo delivered what we asked for and more – fast, accurate and reliable machines with excellent support and a total commitment to us as their customer. Mitutoyo’s drive, commitment and enthusiasm to work with and support Autocraft is evident all the way from the MD through to technical support, service support and training.”