At General Manufacturing, we offer a wide variety of machining and assembly services. Use the Services menu to explore examples from each department.
Click the PDF file below to see our Capabilites document
Milling Capabilities: At GMC, we utilize both vertical and horizontal milling machines. With each type of machine having it's own special use.
In our horizontal milling machines, we have added numerous features that will increase quality of any item during production. The first item is a Renishaw probing system. This feature allows us to do numerous functions while in production. For instance, we are able to probe a part while in its fixture to find its exact location. This is especially important when working with casting or forgings as from part to part, the area where it is being clamped may vary just a small amount. By probing the part, this eliminates any deviation that may be caused by the casting/forging process. The second function we use the probe system for is light inspection of a part while in the machine. A custom macro is written for each part telling the probe what features to inspect and also gives them a tolerance. Where this is needed is when a critical tolerance is given on a drawing and if the part were to be removed from it's fixture, repairing the part may be very time consuming to do so. Having this macro in the program allows the machines to continuously run production without having any critical or tight tolerances become non conforming.
The second feature installed on the horizontal mills is a laser tool measuring system. This feature is also controlled by a custom macro which allows a tool to pass through the laser beam after it has been ran to ensure the tool has not broken or that the tool has not worn too much. If the tool is measured and shows enough wear and will not machine as programmed, an alarm will be posted to the operator stopping the machine. Once the alarm is sent to the operator, the operator is aware a tool is worn and needs to be changed. If the tool has broken, again an alarm is sent, and a new tool is loaded. The basic function of this feature allows production to continue without any tolerance going out of spec. When the laser tool measuring feature and probing system are combined in a program, the chances of a non conforming part being produced is slim to none.
When running items on our vertical milling machines, we are still able to run high volumes of production using minimal setups which will in turn produce a higher quality item. In the vertical mills, we are able to use a full 4th axis for any complex milling that needs to be completed on a single part. Utilizing our larger table sizes, we are able to fit numerous vises on one machine when producing a single part. Doing so allows that part to be tied to one operator and one machine during it's life through production.
Turning Capabilities: Using the technology of our multi axis lathes, we are not only able to do simple two axis turning, but have milling capabilities. These capabilities are used when a part has not only turned, grooved, threaded or drilled, but also requires any type of profile, shapes, gear teeth, milled slots. Having the extra axis allows for a high precision part to be manufactured. This eliminates the need to produce a turned part, or blank, then take that part to the milling machine to be completed. This not only saves time and money, but also allows a single part to run continuously while being bar fed. With the bar feeder integration to each of our lathes, we are able to load material, up to 3" diameter, onto the material tray. As long as material is loaded the machine will continue to run. Thus creating "lights out" capabilities. Also integrated in the lathes, we have come up with a custom macro for tool inspection. Doing a "tool check" during production, allows the machine to adjust itself for any type of tool wear or tool breakage. For example, if a turning tool has worn and a tolerance is not being made to size, the machine will compensate for this and adjust the wear in the tool offset. If, for example, a drill or tap were to break during production, the machine will send out an alarm notifying the operator that something has broken. The tool will be replaced and production will continue. The consistency of each part produced is obtained using these features.
Along with those features, the lathes are also equipped with a feature called Polygon Turning. This option allows both the live tooling and either the main or sub spindle to rotate in perfect synchronization with each other. When this happens, shapes and profiles can be machined using only one tool and in most cases in less time. The main function we use this feature for is gear hobbing. When gear hobbing with this feature, we are able to cut 24 teeth in a bevel gear in less than 30 seconds. For a video of this, visit our video page.
Inspection Capabilities: To ensure that the products we are manufacturing are meeting the highest standards possible, we employ a few different methods to verify this. Not only are in process inspections being done at the machine by the operator, but we also employ a full time QC department.
The use of a manual CMM is an essential tool that every shop employee utilizes and has been trained to use by the manufacturer. The piece of equipment is used for the inspection of dimensions that require more than just basic hand tools. The software will also allow to determine GD&T as inputted by the operator.
When the manual machine is not being used for inspection, the CNC CMM is the main tool of the shop. This CMM can be programed to inspect a part completly, no matter how complex the part may be. Featuring a fully motorized PH10 head and TP20 modules, using the PC-DMIS based software makes the inspection of an item much less complicated. With the ability to "tool change" to different types of probes, most features only require this machine to be inspected.
The VMM (Vision Measuring Machine) is also a major tool used for inspection. The VMM is a digital version of an optical comparator. With it's digital readout and easy to use software, this inspection tool is a very simple piece of equipment to operate.
As for the inspections being done by the operators during in process, we utilize basic calibrated hand measuring tools. There are also times when the operator may need to inspect a hole diameter. When inspecting this feature, the operators use a gage pin that have been coated with a black oxide coating. The reasoning behind this coating is that once the coating wears off, it is time to replace the gage pin. Thus, a diameter will also be within it's called for tolerance.
With the use of thread gages, both rings and plugs, we have developed a gage usage tracking system. With this system, we track how many times a gage has been ran over a part and also what type of material is being inspected. When the predetermined threshold has been reached, the gages are then sent to a third party to be calibrated. Upon their return, they are again tracked by usage to maintain a consistent record.
Laser Marking: General Manufacturing has decided to implement a laser marker to our list of services. Laser marking is a process of creating surface contrast using a range of physical effects, laser engraving creates surface contrast by removing certain (typically .005 to .02") depth of material. GMC specializes in marking anodized aluminum, stainless steel, steel, titanium, gold, silver, nickel. We can mark any font or custom logo required by our customer.
Max Part Size
13.75"W x 12"L x 6"H
100mm x 100mm
Assembly/Inventory Control Capabilities: We not only offer full machining capabilities, but we also offer full assembly of our products. For years, we have been assembling a lot of small arms products. For example, gun sights for the M2, M60, M249 and M240. Along with those assemblies, we also assemble all three mortar mount systems, the 60mm, 81mm and 120mm. With these assemblies, we are in a unique position where we manufacture and assemble everything in house. This allows for better quality control of every aspect of an assembly from start to finish.
To keep a better track of all of our inventory, we have purchased a fully computerized storage system. This system acts like an elevator of shelves managed by an on-board computer. A product is entered into the system, a shelf is designated, a name is given and a minimum quantity level is entered. This software allows for real time viewing of inventory from any PC connected to the GMC network. Having this type of access allows scheduling machines for production to be done with ease. It also allows the person who is assembling the product to be assured that there is enough product available for assembly. When an item reaches it's minimum inventory level, an email is sent to purchasing and production alerting them to this. At that time it is determined when this item will be put back into production or purchased from one of our vendors if needed.