Irvine, CA -- (MARKET WIRE) -- Jan 3, 2011 For over 40 years,MetalMoro in Rio Grande do Sul, Brazil, hasbeen producing competitive automotive ra cing cars and parts. Asa manufacturerof high-performance race cars, go-karts and aftermarket parts,they are a wellknown brand in key categories of motor racing: CampeonatoGaúcho, Brasileiro deEndurance, Troféu Linea & Championship and Brazilian Kart.In the lastdecade, MetalMoro’s Sport Protótipo MCR model race car hasamassed animpressive list of victories in major championships, evenwinning theprestigious 12 Hours of Tarumã an impressive seven times.
Their newest model, the Sport Protótipo MRX model is positionedto continue thesuccessful heritage that has made MetalMoro so successful. TheMRX is offeredin both turbo and aspirated versions, is characterized by highperformance, offersexcellent aerodynamics and easy body adjustments.
One of the biggerchallenges in the development of the MRXwas deciding which engine and transmission combination to use toaccomplish thecars high performance goals. They decided on a Ford Cosworth, 4cylinder, 2.0liter engine with 410 horsepower, along with a Hewland FTR 6speed sequential transmission.The engineers at MetalMoro were confident this combinationoffered the bestpower to weight ratio. As typically happens however when being amarketinnovator, MetalMoro’s engineering team quickly came up againsta manufacturingchallenge.
“The flange, which is themain housing that connects theengine to the transmission, needed to be longer than normal,”stated ClaudioFerretti Jr., Supervisor of Engineering at MetalMoro. “Thisrequired us to comeup with a new design in SolidWorks (mechanical CAD software).”
Once the part wasdesigned, the real challenge was finding away to accurately and efficiently manufacture the flange on aCNC. “The flangeis an extremely complex part and requires many set-ups,” saidFerretti.“Programming the part manually was nearly impossible andrequired way too muchtime. In addition to the high manufacturing costs, we had someconcerns aboutaccuracy.”
To help clear thismanufacturing hurdle, MetalMoro contactedMAX3D in São Leopold, their CAD software vendor and a specialistin CAM(computer aided-manufacturing) software. “After evaluating theirunique CAM needswith our sales team: ease of use, fast programming time andefficient toolpaths, I quickly recommended VisualMILL,” stated Márcio Ribeiro,CAM Technical Specialistat MAX3D. “MetalMoro’s engineering team had standardized onSolidWorks fortheir product design so I also suggested they use the VisualMILLadd-in forSolidWorks.” This solution allowed MetalMoro to create an NCprogram (to drivethe CNC) directly inside SolidWorks, which was a very familiardesignenvironment. And, because VisualMILL directly references theSolidWorks CADmodel, it helped ensure the NC program was very accurate.
Within 24 hours ofreceiving approval from MetalMoro tostart the proof of concept process, MAX3D was at MetalMoro’slocation testingtheir flange part on their CNC with VisualMILL. “The proof ofconcept createdsome interesting challenges and required several steps:adjusting thepost-processor, graphical simulation and machining the testpiece to name afew,” said Ribeiro. “This was the first time the part had beenproduced on aCNC so we were all curious and excited to see the results.”
The final results: Inless than 63 hours from the time MetalMorofirst contacted MAX3D, they had an accurate finished partproduced on theirCNC. The entire process, from programming to output, wascompleted in a veryshort period of time and to the complete satisfaction ofMetalMoro. “WithVisualMILL and MAX3D’s help, we realized our goal of accuratelyand quickly producingour new flange,” said Ferretti.