MJC Engineering is a US based technology leader in hi-tech flow forming. Grind Master, a leader in robotics/automation and finishing technology represents MJC (engineering products) in India. Considering the strength and focus of both the companies, this collaboration is quite natural to bring in value to the industry.

In automotive industries, steel is being replaced by materials such as aluminum, plastics and composites.
New metals and materials are being used in defense and aerospace industries as well. As they march towards achieving higher standards, they need light weight, heat resistant as well as corrosion resistant components that offer solid strength. This is where flow forming of metals plays a crucial role. Flow forming is a process where a deformation (i.e. lengthening and thinning) of the metal is achieved by putting tremendous pressure on the metal work piece with one or multiple rollers.

MJC Engineering has a global recognition in metal-spinning machines for applications such as sheet spinning, flow forming, wheels pinning and rotary forging. Spin forming, like no other metal-forming process, has the ability to form very large and thick plates quickly and accurately. MJC machine solutions feature an advanced control system and an interface which monitors and displays multiple KPI’s and vital metrics such as flow, temperature, and power consumption during the spinning process. These machines are fully Industry 4.0 ready and Internet of Things compatible, ensuring that they will integrate seamlessly with existing or future factory floor networks and protocols. MJC’s spin-forming and machining techniques have been found to reduce overall manufacturing time and tooling costs while improving part consistency.
MJC provides the solutions that would spin form production-run components out-of-round by 8½ to 9 inches in various aluminum alloy blanks measuring up to 270 inches in diameter and 5/8 inch in thickness, while holding tight tolerances.

Supramatic: Robust, Smooth, and super-fine Superfinishing of powertrain componentsCombining old and new technologies
MJC has combined the traditional metal-forming process with modern CNC and robotics to create the state-of-the-art manufacturing process used to produce laminar-flow lip skins for the engine housings on latest-generation passenger aircrafts.

MJC also incorporated their state-of-the-art hydraulic power unit with Variable Speed Drive Technology, named Green Hydraulic Power (GHP). GHP units are fully Industry 4.0 ready and Internet of Things compatible, ensuring that they will integrate seamlessly with existing or future factory floor networks and protocols.

Supramatic: Robust, Smooth, and super-fine Superfinishing of powertrain components1Adapting to the challenges
The lip skin is the highly engineered aerodynamic structure that makes up the leading edge of jet engine nacelles. Until recently, manufacturers of these lip skin components relied upon human intervention to control the direct application of heat throughout the spin-forming cycle. While this method could certainly produce a functional part, the associated variations in part consistency created downstream difficulties and challenges in subsequent fabrication and assembly operations. In the past, lipskins were produced by other methods, including draw forming, bulge forming and drop hammering. The spin-forming and machining techniques now have been found to reduce overall manufacturing time and tooling costs while improving part consistency. When inconsistencies are detected, the heat is appropriately adjusted in real time by the controllers.

Continuous innovation
Each MJC machine involved in this project also incorporates Sinamics drives and Simatic motors.
There are seven axes of motion controlled by the CNC. Custom screens are created for teach – in and playback on the machine to facilitate faster commissioning and troubleshooting on-site for the machine operators

Credits: MJC Engineering

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