With abundant opportunities for growth in the North American manufacturing market, Makino demonstrated the latest machining and automation solutions to keep businesses thriving at the 2016 International Manufacturing Technology Show. In the South Hall, attendees experienced how Makino’s latest machining centers and engineering solutions merge to create adaptive automation systems for any market or production demand, including automotive, die/mold, aerospace, medical and general production markets.

During IMTS 2016, Makino unveiled a variety of all-new machine technologies. The new versions of the a51nx and a61nx horizontal machining centers provide expanded machining capacity through several productivity-enhancing features, including vision broken tool detection, enhanced levels of inertia active control and Geometric Intelligence technologies. Expanding capability and productivity for midsize part applications, IMTS 2016 also marked the introduction of the new a71nx, a high-speed 50 taper, 500mm horizontal machining center with a standard direct-drive NC rotary table and other nx-Series next-generation technologies.

Makino demonstrated several new vertical machining platforms as well. The L2 VMC provides high-volume, small-part production capability using a minimal footprint, while the processing speeds of the new DA300 5-axis VMC reduce manufacturing time and the pallet pool system helps shrink setups and keep work flowing across the spindle quickly and efficiently.

In addition, some of Makino’s proven technologies such as the EDAF3 sinker EDM machine with Hyper-i control shows faster servo speeds in multi-axis machining and features an on-board Alicona measuring system. The U6 H.E.A.T. wire EDM machine demonstrated its on-board CAM software and easy part setup using offline part loading and a manual shuttle system. The EDBV8 EDM hole drill was also on hand to showcase fast hole-drilling for blade and vane machining.

Makino’s booth demonstrated a variety of automation systems, as detailed below:

  • The a51nx-5xu 5-axis HMC, designed with a unique work-holding magazine and large-tool magazine, can perform continuous 5-axis machining unattended for extended hours in both high-mix, low-volume and low-mix, high-volume production environments.
  • The J3 HMC with stacked axes design enables it to be easily and reliably integrated into high-volume automation concepts. Two machines are included in this cell to demonstrate serial processing of repetitive, high-volume parts.
  • A die/mold automation cell featuring an EDNC6 sinker EDM and V33i-5XB 5-axis VMC with an EROWA ERC is set up to demonstrate low-volume, high-mix production of mold components while achieving utilization rates approaching 85 percent.
  • The a40 HMC with overhead gantry system performs high-volume, parallel processing of small, nonferrous, die-cast parts.

Manufacturers are certainly using these automation tools to improve productivity, reduce costs and produce quality parts, but there is potential to deliver even better efficiency through an enterprise connected by the Internet of Things (IoT).

Published in Makino

Okuma America Corporation offers an expansive line of vertical machining centers that provide reliable machining meeting a variety of production needs. Okuma’s new MU-6300V is no exception as it delivers high efficiency and high-productivity for 5-axis, multi-sided machining.

This CNC vertical machining center has a highly rigid and accurate double column structure and low center of gravity in workpiece movement (trunnion table) that enable both heavy duty cutting and high speed finishing. Built on Okuma’s Thermo-Friendly structure, this machine performs consistently from the first part to the last, regardless of warm up time or ambient temperatures.

“The MU-6300V is a true workhorse machine that is able to take on the toughest materials with its dual-driven rotary trunnion design,” says Kyle Klaver, 5-axis Product Specialist, “and would be a great fit for any industry looking to add a high efficiency, 5-axis machining center especially the aerospace, automotive, and medical industries”.

The MU-6300V was recently honored with the Nikkan Kogyo Shimbun’s (Business and Technology Daily News) 2012 Best 10 New Product Awards. The Best 10 New Product Awards are given to selected products for their contributions to the development of manufacturing and strengthening of Japan’s international competitiveness. Winners are chosen from among all products developed and in practical use in a given year.

For more information, visit: www.okuma.com/mu-6300v

Makino expands its line of F-Series vertical machining centers with the new F8 and F9. Large production parts present challenges due to the size and range of the part. Big die and mold components may test the work-weight capacity of most machines, and they could pose a unique dilemma for high-speed machining techniques and the accuracy capability. Designed for power, speed, precision and versatility, the F8 and F9 are built to meet these divergent manufacturing needs in both the large part production and die and mold markets.
“The F8 and F9 offer hours of continuous, tight-tolerance machining at an outstanding value,” said William Howard, Makino vertical product line manager. “Their robust design provides a versatile cutting platform that is ideal for both mold making and production machining. Standardly equipped with core-cooled ballscrews and scale feedback, the F8 and F9 offer a rare blend of precision, speed, capacity and flexibility to meet and exceed customer demands.”
The smaller F8 features X-, Y- and Z-axis travels of 51.2 inches, 31.5 inches and 25.6 inches, respectively, a 61-inch-by-31.5-inch table and a maximum workpiece size of 61 inches long by 31.5 inches wide by 21.7 inches tall. By contrast, the larger F9 features X-, Y- and Z-axis travels of 63 inches, 31.5 inches and 25.6 inches, respectively, a 72.8-inch-by-31.5-inch table and a maximum workpiece size of 72.8 inches long by 31.5 inches wide by 21.7 inches tall. Both machines offer a payload capacity of 5,510 pounds and feature a 30-tool capacity automatic tool changer.
Changing full-size workpieces can dramatically impact large machine utilization, productivity and ultimately part costs. Therefore, the F8 and F9 incorporate a unique, dual sliding door, chip- and splash-guard design for simplified loading and unloading of large workpieces. The open-corner, open-ceiling design affords unparalleled access for setups and changeovers, improving work in progress (WIP) and overall lead-times.
Dual Capabilities

The F8 and F9 vertical machining centers offer a number of spindle configurations for tailoring the machine to specific die/mold or production applications.
The standard spindle configuration is a 49.6-hp, 10,000-rpm, CAT 50 spindle. As an option, the spindle can also be provided with an HSK-A100 spindle interface. With 315 ft-lbs of torque, this combination provides stiffness and rigidity for lower-speed roughing operations and an excellent mix of spindle speed, power and torque.
As an option, the F8 and F9 can be equipped with a 40.2-hp, 20,000-rpm, HSK-A63 spindle. This configuration provides the vibration-free, chatter-free, high-ranging spindle speeds required for efficient high-speed hardmilling of small details and fine surface finishes typical of the die/mold market.
The standard coolant system provides a combination of nozzle flood coolant, flush coolant, through-spindle air and an external air-blow nozzle. Dual internal spiral chip conveyors quickly and efficiently move chips and coolant to the rear of the machine, discharging them into a scraper-drum lift-up chip conveyor. Various, optional through-spindle coolant systems can be provided to further enhance the capability and performance of the machine.
Control Productivity

The F8 and F9 vertical machining centers employ the Makino Professional 5 Control, which affords the perfect balance of a Windows CE graphical user interface (GUI), touch-screen selection offering instant access to information at one’s fingertips, user-friendly, efficient PC-like capability for data management and editing, and the networking and storage capability of a data center.
As an option, the machine can be arranged with Makino’s proprietary, next-generation Super Geometric Intelligence (SGI.4) software developed specifically for high-feedrate, tight-tolerance machining of complex, 3-D contoured shapes involving continuous, tiny blocks of NC data that ensure production rates faster than standard CNC systems while maintaining high accuracy. SGI.4 helps provide the lowest cycle times and costs achievable by reducing machining cycle times by as much as 40 percent when compared to most other control technologies.
A world leader in advanced CNC machining centers, Makino is committed to providing high-performance, leading-edge machining technologies and innovative engineered process solutions that enable manufacturers to focus on making what matters. Makino offers a wide range of high-precision metal-cutting and EDM machinery, including horizontal machining centers, vertical machining centers, 5-axis machining centers, graphite machining centers, and wire and Ram EDMs. Makino’s flexible automation solutions provide reduced labor costs and increased throughput in a variety of production volumes and designs. Makino’s engineering services offers industry-leading expertise for even the most challenging applications across all industries.

For more information, visit: www.makino.com/vertical-machining-centers

Published in Makino

Forkardt, a leading manufacturer of workholding solutions including both standard and applications-specific chucks, has announced the purchase of a Mazak Variaxis 730 vertical machining center. The acquisition represents a significant investment by Forkardt to utilize the latest machining technology available.

According to Bill Sepanik, group general manager of Forkardt, “The new system expands our capacity to meet growing application needs.  “With this new machine we’ve positioned ourselves to better handle larger parts, hold tighter accuracies and greatly improve cycle times.”

Sepanik added, “We’re also able to reduce the number of setups due to the machine’s five axis capability, while saving time due to the ease of programming with the Variaxis.”

The Mazak Variaxis 730 has a highly-rigid, built-in tilting rotary table that allows workpieces with complex contours and features to be finished in just a single machine setup. The 5-axis vertical machining center allows for table tilts up to 150° in the A-axis and rotation to 380° C-axis.  The machine boasts an X, Y, Z travel of 28.7" x 33.4" x 22", with spindle speed at 10,000rpm. The machine, equipped with a 120-tool magazine, allows for machining on heavy parts with a maximum part load of 1100 lb as well as a Big Plus Cat 50 Spindle. The tool holding system improves automatic tool change repeatability and has excellent rigidity, reduces chatter and eliminates axial movement at high speeds.

Forkardt’s brand names of products include N.A. Woodworth, Sheffer, Logansport, SP Cylinders and Buck in addition to the Forkardt name. Utilizing its worldwide research and development resources, Forkardt focuses on machining process efficiencies and creating meaningful workholding solutions. It is one of the world’s premier builders of workholding technologies for standard applications, for high-precision applications, and for specialized, engineered solutions.

The company’s products include chucks for general machining and application-specific chucks, cylinders and indexing chucks, expanding mandrels, chucks for hard part turning, collet chucks, steady rests, and grip force meters.

For more information, visit: www.forkardt.us

Published in Forkardt

Mitsui Seiki USA, Inc. has developed a specially-designed, 5-axis CNC vertical machining center for the production of turbine blades from forgings, castings, bar stock, or solid billets of titanium and stainless steel.  It will be officially introduced to the metalworking industry at the International Manufacturing Technology Show, September 10 – 15 in Chicago. According to the company, several customers provided design criteria, including a reasonable capital cost per part, small machine footprint, the ability to rough and finish parts in competitive cycle times, and improved part accuracy and surface finish. “In other words,” says Tom Dolan, VP of Mitsui Seiki, “the total machining center package had to be smaller, faster, more accurate than what they had been using – all at an affordable price.” After about 18 months in development, the new Vertex 550-5XB machine is the result.

Key specifications include a footprint of approximately 65 sq. ft., an X, Y, Z working envelope of 550mm x 600mm x 500mm, and rapid traverse rates in all linear axes of 48m/min.  A and B axes are represented in a rotating/tilting table. A-axis tilts from +45 to – 90 degree angles, and the B-axis features infinite positioning points. The engineering of the rotary axes offers a new, non-traditional approach, which Dolan says enhances manual and automatic load/unload operations, such as the integration of a robot and cellular manufacturing capability. Further, Mitsui Seiki has incorporated its proven spindle configuration in the new Vertex 550-5XB, ideally suited to cut hard titanium and stainless steel grades. It also is directed by the latest and most advanced Fanuc control system.

Mitsui Seiki’s tradition is to build rigid and ultra precise metal cutting and grinding machines. The Vertex 550-5XB’s geometric accuracy is carefully monitored in the tightest temperature-controlled factory environment in the world.  The machine features a cast bed which provides an ultra rigid machine structure. A unique “box in a box” design provides superior rigidity and stiffness that typically is not available in a machine of this size.  All guide way mounting surfaces are hand-scraped, achieving very high volumetric accuracies, which would be impossible to achieve on surfaces that are simply machined and /or ground. This engineering and construction concept, coupled with a newly designed machine, provides users with competitive advantages over traditional, similar purpose machines.

For more information, visit: www.mitsuiseiki.com

Published in Mitsui Seiki

Makino’s PS-Series machines are the new standard in vertical machining centers for production machining, offering a reduction in cycle time, increased productivity, improved quality and minimization of capital investment. The PS-Series features a field-proven design with key technologies from several of Makino’s most reliable production machines. Its rigid construction, thermal stability and versatile spindle are ideal for a variety of applications, including automotive, aerospace, medical and other small-component manufacturing applications.

“Makino’s PS-Series comes standard with a high power 33.5 HP, high speed 14,000-rpm CAT40 spindle delivering 130 ft-lbs peak torque. No other vertical comes standard with these features,” says William Howard, Makino’s vertical machining product manager. “The PS-Series is fully equipped and ready to run all of a manufacturer’s production parts. It brings the productivity of a Makino horizontal machining center to a vertical platform at a great value.”

The PS-Series is available in two models: the PS65 and PS95. The smaller PS65 features X-, Y- and Z-axis travels of 26", 20" and 18.1", respectively; a 36.2"-by-20" table; and a maximum workload of 1,323 lbs. The larger PS95 features X-, Y- and Z-axis travels of 36.2", 20" and 18.1", respectively; a 46"-by-20" table; and a maximum workload of 1,763 lbs. Both models are standardly equipped with an easy-to-access, highly reliable, 30-tool-capacity automatic tool changer (optional 50-tool capacity available).

Based upon a traditional C frame, the PS-Series design utilizes Finite Element Analysis (FEA) techniques to perfect the massive cast iron components that offer optimal rigidity and torsional stiffness. The construction ensures the quick, efficient transfer of the cutting forces through the structure of the machine—from spindle into the column and ultimately the bed of the machine. In addition, the symmetrical nature of the casting, incorporation of core-cooled ball screws and support bearings and a closed-loop temperature compensation system secure the tightest tolerance and minimal variations during long production part runs.

Flexible Job-Shop Production Capabilities
Designed for flexibility and high productivity, the PS-Series’ standard 14,000-rpm CAT40 spindle (HSK-A63 optional) offers the ideal blend of speed, torque and horsepower for today’s competitive job shop environment. Duty rated at 33.5 HP (24.2 HP continuous) and 130 ft-lbs peak torque (70.5 ft-lbs continuous), these spindle characteristics offer efficient, highly productive machining over a wide range of materials. Large-diameter bearings, air-oil lubrication and jacket-spindle temperature control deliver long-term thermal stability and stiff, rigid, chatter-free cutting.

Created with the production environment in mind, the PS-Series chip and coolant systems enhance the productivity of the machine. Configured with flood, overhead shower, flush and through-spindle coolant as standard features, chips are efficiently and effectively removed from the cutting zone. Spiral chip augers located in the front and rear of the worktable quickly and efficiently evacuate chips and coolant from the machining zone and into a standard lift-up chip conveyor (LUCC).

The PS-Series also features Makino’s new Professional P control software configured to support a wide variety of applications in the job-shop and production environment. With a large color LCD, menu-driven, touch-sensitive screen, information is at one’s fingertips.  Configured with generous program storage (4,200-foot), 400 registerable programs, 400 tool-offset pairs and 48 pairs of work coordinate systems, the Professional P provides ample standard capabilities for production shops of all sizes.

For more information, visit: www.makino.com/machines/VMC

Published in Makino

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