Problem
product was produced to the required specifications and heat treated. post heat threat product was tempered and bead blasted to clean up; product was found to thread only two to three turns; threads were found to be under size and partially oblong from post processing. turning machines were found to be too fast and hard to retime and a custom tap would be at least $3,000 and take 2 weeks. possible solution was to remake the items and toss them.
Production cost and time loss - $20,000
Solution
The part had been thread milled and had been done as the last operation. I brought up that fact and that we could probably reindex the tool to the part and the start of the thread is unused.
used a phone camera and bore scope to check the threads
indexed the start of the thread to the start of the tool path and started the program and sent to the starting location
used cutter compensation and WCS-Z to slowly adjust the cutter into the groove
Result
Re-ran 20 parts within 4 hours without scrap. product was sent out on time and per specifications.
