CNC machining Complete machining of complex chassis structural parts

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The automotive supplier Tuopu manufactures suspension systems, exterior and interior systems as well as intelligent driving systems. Licon supports not only with machines, but also with fixtures and process know-how.

Jianing Wu is the General Manager China at Licon mt Machine Tools.

To develop products such as swing bearings and subframes with its customers within a very short period of time, Tuopu decided to invest in reliable CNC machining centers and the latest technologies. Licon was the first choice. After a close examination and visiting reference customers, Tuopu ordered the first ten machines from Licon in 2018. After the successful launch of swing bearing production in the greater Shanghai area, another 19 Licon machines for various subframe lines were purchased in the last three years. The benefits of the Licon machines have had such a great impact that they have become widely used in the Chinese e-mobility industry.

Complete processing in just one set-up

Licon is known to Chinese customers as one of the best German manufacturers of 5-axis machining centers. The complete machining of complex chassis structural parts not only requires the corresponding machines, but also the fixtures and process know-how. These are precisely the core competencies of Licon. In 2018, the Tuopu team was a new player in the area of lightweight chassis structural parts and already trusted Licon's expertise at this stage. For swing bearings made of an aluminum alloy, Licon supplied a dual spindle solution with pallet changer, which allows parallel loading and unloading during machining and complete machining of LH/RH parts on each individual machine. All fixtures and tools are designed to fit into a clamping concept.

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For die-cast subframes, Licon provided a single-spindle solution with a working space diameter of 1,600 millimeters in the A- and B- axis with direct loading. This design allows the parts to be clamped vertically on the custom-made, narrower bridge. This combination enabled six-sided machining of the complex subframe in just one set-up. The digitally developed fixtures were designed and manufactured at Licon's headquarters in Germany. They worked perfectly in terms of light weight, rigidity, dynamic balancing, easy access, and hidden fluid lines.

The overall package, where everything is bundled in one interface with Licon, was most crucial for the great success of this project with sub-frames for electric vehicles. Based on what we learned from Licon, we can now develop a clamping concept for the other structural components.

Jun Zhao, Operation Director, R&D Power Chassis System

"Our goal is to provide safer, more comfortable and environmentally friendly technologies and products for cars. That's why we are always looking for green manufacturing technologies. Licon is the perfect strategic partner for us when it comes to this topic," says XinXin Li, GM Business Unit Subframe. All 29 machines are equipped with the MMS (Minimal Quantity) lubrication system and the Licon ECO mode, which help Tuopu reduce energy consumption by about 40 percent. Unlike conventional lubrication with emulsion, the dry metal chips in MMS lubrication can be easily recycled without further cleaning and drying process.

Also, the filtration and disposal of emulsion residues is saved. In addition, the workshops are kept very clean and dry despite the three-shift production seven days a week and have thus become the showrooms of Tuopu. "Our EHS management team is particularly pleased with the Licon technologies," confirms XinXin Li.

For more than 60 years, Licon has been known for technical development and production from Germany for the world. Tuopu believes in Licon's philosophy of "Made in Germany." The machining quality and process stability were excellent from the start. Meanwhile, more and more different CNC machines and automation lines for the production of chassis parts are in operation in the greater Shanghai area. Tuopu found that Licon's machines are the best among all international and national providers in terms of machining quality, overall equipment efficiency and mean time between failures. In addition, the Licon machines are very easy to operate both in manual mode and in the automation line. This is very important for Tuopu, as the supplier is not only involved in series production, but also in small series machining, where the operators must work manually on the machine. Due to the performance of the Licon machines, Tuopu was able to increase production capacity by almost 50%. "The Licon machines operate with greater precision and reduce scrap during the manufacturing process. This results in higher-quality products, shorter lead times, and ultimately higher profits. Even though the price of the Licon machine is the highest among all suppliers, we are willing to invest in this top quality," explains the Tuopu Management Team at the Key Suppliers Conference in August 2022.

Licon is aware of how important excellent service is for Chinese customers. For this reason, Licon has established local branches in Shanghai, Beijing and Changchun to provide customers with quick and effective support.

For Tuopu, Licon takes care of customer needs in Shanghai. The local team of engineers is available for technical support, maintenance, and repairs of the Licon machines. Licon also offers training programs for Tuopu employees to ensure they know how to operate the machines optimally. This way, Tuopu can maximize its productivity and get the most out of its investment in Licon CNC machines.

"In addition to these services, Licon also takes our feedback seriously. The Licon staff often communicate with us to understand our needs and feedback on the CNC machines and take it into account," says Kent Ke, Operation Director Business Unit Subframe.

This work ethic helps Licon to further renew and improve its products in order to better serve customers worldwide. Licon is committed to providing its customers with exceptional service - and Tuopu is a great example of how Licon goes above and beyond to ensure customer satisfaction.