Case Study | Automotive
Forged Stabilizer Bar: One-Setup Machining at 59 Seconds
A forged stabilizer bar required complex end machining on an odd-shaped long part. The customer needed all operations completed in one setup while maintaining hole location integrity despite forging variation.
Capability Tags
Visual Proof
Production Challenge
The process required compound-angle machining at both ends of a long part, with hole location controlled at each forged flat. Cycle-time target was 59 seconds per part.
Critical Constraints
Geometry
Long, odd-shaped forged component with dimensional variation.
Setup Strategy
All operations had to be completed in one setup and clamping cycle.
Quality
Maintain production quality at 1.67 CPK while hitting takt.
Solution Architecture
Midstates deployed a Kira KN40Va 1200 mm traveling-column CNC with a dual-part fixture that automatically tilts parts into the correct attitude. Touch probes locate outside surfaces on both part ends, calculate centers in real time, and guide hole location compensation. The system combined CNC logic, hydraulic servo systems, probing, and high-volume chip management.
Measured Outcome
Cycle Time
59 sec target met
Quality
1.67 CPK
Machining
Heavy straddle milling + tapered drilling/reaming
Commercial Signal
3 repeat orders
Why This Worked
The solution absorbed part-to-part forging variation at the control and probing layer instead of forcing manual compensation. One-setup strategy reduced cumulative stack-up risk and improved production repeatability.
Request Similar Application Review