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Ford Motor Co, Dearborn, MI, recognized the need for a "prototype-only" facility nearly two decades ago, and Ford EMDO (Engine Manufacturing Development Operations, Allen Park, MI) has been instrumental in testing design and manufacturing feasibility ever since. EMDO produces engine prototypes for Ford, Jaguar, and Mazda.
To test a process offline, a Ford engine plant can request EMDO to simulate it first. EMDO manufactures the prototype parts on site, without interrupting production at the engine facility. EMDO typically produces volumes of about 3 to 300 parts per run, vs production plants that yield 7 to 800 parts per hour.
In a prototype facility, the focus is on quality. The process, tolerances, fixturing, and procedures need to be evaulated in order to optimize production facilities.
Parts, processes, and tooling are tested. EMDO employed a Gardner G-Series double disc grinder from Landis Gardner for roughing and finishing stepped connecting rods, which have different thicknesses at at the crank and pin ends, as opposed to uniform thickness co-planar rods.
EMDO used the Gardner 6750 horizontal double disc grinder with a reciprocating fixture because of its exceptional performance in achieving close tolerances-50 millionths of an inch. The machines used at Ford EMDO are similar, if not identical, to machines on a production floor, but they're fitted with custom, reciprocating-type fixturing to accomodate EMDO's prototype parts. With a reciprocating fixture, the workpiece is supported in a servo motor-driven paddle-type fixture that reciprocates between disc faces.
For the prototype operations at EMDO, Ford selected 30" dia disc wheels. In addition, the Gardner grinder incorporates a reciprocating fixture with a built-in...