Case Study: Rapid Response to a Field Failure with Redesigned Part
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- Source:Cynergy
In the demanding world of precision manufacturing, a field failure is not just an inconvenience; it's a critical test of a supplier's capability and commitment. This case study details how our CNC machining factory successfully managed such a scenario, turning a potential client loss into a longterm partnership through rapid response and expert redesign.
A client in the semiconductor equipment industry approached us with an urgent problem. A critical aluminum actuator bracket in their new system was failing prematurely under cyclic loading. Cracks were developing at a sharp internal corner, leading to unexpected downtime and costly service calls. Their previous supplier was slow to react, prompting them to seek a new manufacturing partner who could offer a solution, not just a replacement.
Our engagement began with a Root Cause Analysis (RCA). Our engineering team immediately examined the failed part and the original CAD model. The issue was identified as a classic stress concentration problem. The initial design featured a 90degree internal corner, a known weak point under dynamic loads. Furthermore, the specified aluminum 6061, while costeffective, was operating at the very limit of its fatigue strength for this specific application.
We did not simply reproduce the faulty component. Within 48 hours, we presented the client with a comprehensive report and a proposed redesign. The solution was multifaceted:
1. Design for Manufacturability (DFM) and Durability: We redesigned the bracket to incorporate generous fillets at all internal corners, effectively distributing stress over a larger area. We also added slight ribbing to increase stiffness without significantly adding weight.
CNC machining 2. Material Upgrade: We recommended a switch to aluminum 7075T6, which offers significantly higher tensile and fatigue strength, making it ideal for highstress dynamic applications.
3. Precision Manufacturing: The complex geometry of the new design was executed using our advanced 5axis CNC machines, ensuring perfect conformity to the new 3D model and superior surface integrity.
A prototype batch was machined, heattreated, and shipped within one week. The client tested the redesigned brackets rigorously, and the results were conclusive: the failure was completely eliminated. The part's lifespan exceeded expectations.
The outcome was transformative. The client was not only able to resolve their field failure crisis but also improve their product's reliability. We demonstrated that we are more than a parts supplier; we are a solutions partner. This incident solidified our role as their primary vendor for critical components, leading to a 30% increase in their order volume with us.
This case underscores a core value of our business: Proactive Engineering. We leverage our deep expertise in materials science, DFM, and highprecision, batch CNC machining to not only manufacture parts but to enhance them. For global clients who cannot afford delays or compromises, we provide the reliable, engineered solutions that keep their operations and their products running smoothly.