Manufacturing Process
Die Casting
We have 81 die cast
machines ranging from 300 to 3500 ton lock-up capacity
at our various locations around the world. These machines are microprocessor
controlled
with high pressure shot ends designed to produce the
porosity free requirements demanded by today's automotive engineers.
To
assist in the effort of controlling the process parameters on each shot,
J.L. French uses advanced software designed specifically for
our machines. These parameters are closely analyzed
to ensure proper plunger position, velocity, and pressure along with
16 additional single point inputs. Visual and audible alarm signals are
activated by any out of limit condition which allows the operator to
concentrate
on making quality die castings.
Assembly & Testing
After machining, our parts are high-pressure
washed and dried in preparation for the assembly and testing processes.
Various components are assembled
into our castings such as bearings, bushings, gaskets, baffles, electronic
oil sensors, dowels, studs, and vent tubes. J.L.
French utilizes Poka Yoke devices throughout all of our operations to check
for proper assembly of components.
Since most of our parts hold oil or water under pressure, we verify pressure tightness with a final test on a mass flow leak tester. Most parts are then packaged in nestable, returnable dunnage created specifically for each part design.
Throughout our manufacturing processes,
J.L. French keeps its focus on quality. We work more efficiently and
deliver superior products that in turn save
our customers valuable time and money.
Secondary Machining
Once the casting is cooled,
it is trimmed and inspected, then transported to our secondary machining
operations. High velocity shot blasting machines are used
to remove sharp edges and residual flash in preparation for machining and
assembly.
J.L. French machines nearly all of
the parts we supply on dedicated high volume machining centers or precision
horizontal or vertical CNC machines.
In some cases where extraordinary flatness and surface finish is required for sealing, we use rotary grinding machines that actually machine the parts in an unclamped state. Since the parts are machined in an unrestrained state, the residual stresses from the casting solidification process are allowed to relieve as they are machined against precision ground platens.
Machining
J.L. French machines millions
of parts each month. Dedicated machines with indexing fixtures on an indexing
table are a low cost, high quality method to machine high volume products
such as oil pans, front covers, FEAD brackets, and bearing caps.
CNC stations are incorporated in most of our dedicated machines to allow for engineering changes and to provide the ability to do special machining as required.
Another innovative approach used by J.L. French to achieve exceptional quality on difficult tolerances is the use of a Renishaw probe, which is normally used on a coordinate measuring machine, in the machining center itself.
