Welcome to Imago Manufacturing
At Imago Manufacturing, we are an ISO 9001:2015 certified, solar-powered precision CNC machining company in Northern Illinois. We specialize in precision CNC milling and CNC turning services, serving businesses across Chicagoland, Northern Illinois, Southern Wisconsin, and North America. Our expertise lies in short to mid-range production machining of turned parts with milled features in a wide range of materials.
Today, let’s dive into the world of CNC broaching with live tooling and how it compares to traditional broaching methods.
What Is a Keyway?
A keyway is a small slot in a part that helps keep it from spinning on a shaft. It is commonly used in fan motors and other rotating equipment. Traditionally, a keyway is cut using a push broach and a hydraulic or arbor press, making it a good option for small production runs. However, for high-volume manufacturing, this method can be slow and inefficient.
Traditional Broaching vs. CNC Broaching with Live Tooling
Traditional broaching is great for low-volume production (1-25 parts). However, for higher volumes, CNC broaching is the best solution. At Imago Manufacturing, we run 50,000+ parts per year on our CNC lathe, which means efficiency is critical.
How CNC Broaching Works
With CNC broaching, a special cutting tool mimics the teeth of a traditional broach. Instead of manually pressing through the material, the CNC machine moves back and forth, shaving off tiny amounts until the slot is complete. This method is more efficient but can cause wear and tear on the machine.
The Power of Live Tooling
To avoid excessive wear, we use live tooling. This method features a motorized turret that spins the broaching tool, cutting much like a woodpecker pecking at wood. The benefits of live tooling include:
- Faster cycle times (reducing broaching time from 45 seconds to just 8 seconds!)
- Increased efficiency (saving time and money on high-volume production)
- Less wear on CNC machines
- Ability to create multiple keyways or splines quickly
While a live tooling broaching head costs $13,000 to $15,000, the time savings and long-term machine protection make it a great investment for high-volume production.
The Benefits of Sub Spindle CNC Machining
Another way we improve efficiency at Imago Manufacturing is with sub spindle CNC machining. A sub spindle allows us to machine both sides of a part without moving it to another machine. This reduces:
- Setup time
- Cycle time
- Human intervention
With sub spindle machining, parts come off the machine fully finished, allowing us to run parts unattended for even greater productivity.
Working with Exotic and High-Temperature Materials
At Imago Manufacturing, we are experts in machining difficult materials that many other shops avoid. Our experience includes:
- Nickel 200 (a challenging material that work-hardens quickly)
- Copper (soft but difficult to break chips)
- Stainless Steel (304, 316, 17-4)
- Manganese Steel (considered “impossible” to machine, but we do it every day!)
- High-temperature alloys (we specialize in machining materials ending in “alloy”)
Because of our advanced machine tools, specialized tooling, and expert machinists, we can handle even the toughest materials with precision and efficiency.
Laser Marking and Engraving for Part Identification
To further improve efficiency, we recently invested in a high-quality American-made laser engraving system. This allows us to:
- Engrave part numbers and serial numbers quickly and accurately
- Reduce engraving cycle time from 45 seconds to just 5 seconds
- Increase throughput by offloading marking tasks from expensive CNC machines
- Ensure traceability for high-precision parts
By removing engraving from the CNC process, we free up valuable spindle time, helping us manufacture parts faster and more cost-effectively.
Why Choose Imago Manufacturing?
At Imago Manufacturing, our team is committed to precision, efficiency, and quality. With our CNC broaching with live tooling, sub spindle machining, and laser marking capabilities, we can deliver high-quality parts at competitive prices. Whether you need high-volume production or specialized machining of exotic materials, we have the experience and technology to get the job done right.
Get in Touch!
If you need precision CNC machining, contact us today to learn how we can improve your production process, reduce cycle times, and increase profitability!