Casing penetrator machined from blank – Case study

A screenshot of a CAD design for a CNC machined flange on a custom work holding for the final stage of CNC machining

Machining a casing penetrator from a blank – Case study

We had an enquiry for the sub-contract manufacturing of a 30˚ flange to flange connection casing penetrator. The item could not be sourced as a casting so was required to be manufactured from a solid piece. We worked with the customer to repair the component CAD model to ensure it was suitable for the finish part required. Our Manufacturing Engineer reconfigured the model for customer approval so we could commence with manufacture.

A screenshot of a CAD design for a completed CNC machined flange

We had to design a work holding method and carefully plan the machining operations in order to successfully produce the component, which required full 5 axis machining. The component was machined in 3 operations:

  1. The first operation did not require any specialist fixtures and was held in the four-jaw chuck on the machine.A screenshot of a CAD design for a CNC machined flange showing the first stage of machining
  2. The reverse side of the component was machined with a custom jig so that we could securely hold the machined face from the first operation.A screenshot of a CAD design for a CNC machined flange at the start of the second 5 axis CNC operationA screenshot of a CAD design for a CNC machined flange showing the flange after the second stage of 5 axis machining has been completed
  3. The final operation involved turning the component back over to complete the machining processes. This required another custom jig that could ensure correct alignment by bolting into place.A custom system for holding a component during CNC machiningA screenshot of a CAD design for a CNC machined flange on a custom work holding for the final stage of CNC machining

Thanks to this careful planning and work holding design we were able to machine a finished component to specification with a quick turnaround time.A cnc machined flange on an inspection bench ready for approval