Lincolnshire, Illinois – Toyota Racing Development (TRD) U.S.A. has named GF Machining Solutions as an official technical partner. TRD uses GF’s high-performance manufacturing and automation technology to accelerate production of key aluminum and cast-iron components for its 800hp racing car engines – including the engines used in the #78 Furniture Row Racing Toyota Camry of Monster Energy NASCAR Cup Series driver and 2017 series champion Martin Truex Jr.
Approximately 200 TRD employees in Costa Mesa, California, design and build race engines for NASCAR teams that field Toyota Camrys in the Monster Energy NASCAR Cup series. To keep pace with a grueling 38 race annual schedule, strict series regulations, and a highly-competitive racing environment, TRD designs, develops, manufactures, and builds more than 300 engines in-house, annually.
TRD began working with GF Machining Solutions in 2014 when it added an automated production cell comprised of seven 5-axis machining centers (six Mikron HPM 800 U HD machines and one Mikron HPM 1350 U) connected to a shared pallet pool system. The system uses a rail-guided robot to load the machines from more than 80 open pallets along a 32m track.
Machining an individual part at TRD can take only a few minutes or in some cases up to 15 hours; with part sizes ranging between 1″ and nearly 20″ in a single dimension, and tolerances as precise as 5µm. Complex contoured surfaces require full simultaneous 5-axis production, which also provides better accessibility and fixturing for other parts. By using the automated cell, TRD can reduce component lead times, boost machining capacity, and achieve a 22% increase in productivity.
GF Machining Solutions North America President Scott Fosdick says, “We look forward to developing alongside TRD to improve processes and efficiencies for both companies while advancing newer technologies for the future of manufacturing and racing.”
Greg Ozmai, group vice president of operations at TRD, says. “The results of our collaboration with GF Machining Solutions were immediate and have exceeded our expectations. The Mikron cell’s flexibility allows TRD to put over 100 different parts through the cell and the added precision has improved the overall engine performance, which propelled TRD to the winner’s circle in 2017.”
GF Machining Solutions will display the Monster Energy NASCAR Cup Series Champion #78 Furniture Row Racing Toyota Camry at IMTS 2018 Booth #338754, alongside a cutaway powertrain demonstrating TRD’s engine and design for the car.