Related: Automotive Production
What: Twin spindle machining centers
Name & Source: MCT Series from Heller Machine Tools (Troy, MI; www.heller-machinetools.com).
Features & Functions: There are two models, the MCT 160 (working envelope: 450 x 450 x 450 mm; maximum part diameter and height, respectively: 450 mm, 600 mm) and the MCT 250 (working envelope: 690 x 690 x 520 mm; maximum part diameter and height, respectively: 700 mm, 750 mm). The twin-spindle machines (38 kW each) have a dedicated servo-driven B-axis for each spindle, which means that there can be simultaneous machining of four sides of two different parts (e.g., left- and right-hand parts). The machine is designed so that it can operate as a stand-alone machine or integrated into a system (the shared X-axis is integrated into the column; the shared Y-axis is a vertical slide; the independent ram-style Z-axes are integrated into the Y-slide; the speed and feed of each Z-axis can be independently set). It has a compact footprint (2,450 mm wide; 3,400 mm high). The machine is quick: speed in each axis is 60m/min, acceleration is 10m/sec/sec in X and Y and 14 m/sec/sec in Z. There is a standard tool magazine of 40 tools (HSK 63) each for each spindle.
What: Multifunctional turning center
Name & Source: E 280 from Romi Machine Tools (Erlanger, KY; www.romiusa.com).
Features & Functions: The machine can perform turning (swing: 25.6 in.; maximum cutting length and diameter, respectively: 15.75 in., 11.02 in.), as well as boring, milling, and tapping in a single setup. Each of the machine's left- and right-side spindles can be equipped with 15 or 25-hp motors. There are three turret options: one for standard turning tools; a motor-driven turret for live tools; and a motor-driven turret with an additional Y-axis assembly (both motor-driven types have a 5-hp motor). The toolholder disc for the turrets can handle 12 tools.
What: Multifunctional horizontal machining center
Name & Source: H5-1000MT from Cincinnati Lamb (Hebron, KY; www.cincinnatilamb.com).
Features & Functions: This five-axis machine is designed to handle parts 50-in. in diameter and larger. The machine is not only capable of performing milling operations, but it can also perform turning, as well. The machine is featured with a direct-drive motor-driven rotary table that is available either in high-torque (300 rpm) or high-speed (700 rpm) types. It also has an A-axis tilt spindle with an 180º tilt for five-sided machining. As in the case of the spindle, selections are high torque or high speed; the speed range is from 6,000 to 24,000 rpm.
What: High-speed machining center
Name & Source: VCP 1000 Duro from Mikron (Holliston, MA;) www.micron-us.com).
Features & Functions: This vertical machining center can be configured as a three- or four-axis machine. The machine features vector-controlled spindles with ceramic bearings that provide a speed range from 12,000 to 42,000 rpm. The machine provides X, Y, Z feeds of 20 m/min with a rapid traverse of 30 m/min and an acceleration of 4.2 m/sec2. The machine has a polymer concrete base to ensure rigidity, stability, and thermal dampening. The machine's 1,300 x 600-mm worktable can handle workpieces weighing up to 1,600 kg.
What: Twin-spindle production module
Name & Source: specht 550 duo from Cross Hüller North America (Sterling Heights, MI; www.crosshueller.com).
Features & Functions: The machine is designed for part volumes of about 500,000 per year. Each of the 16,000-rpm spindles has an output of 25 hp. The X, Y, Z travels are 710, 710, and 610 mm, respectively. Each of the Z-axes has its own independent drive so there can be different tool offsets and other spindle-specific settings. Rotary tables are available that permit A- or B-axis work presentation. There is a single chain-type tool magazine (72-tools, including single setup tool) that serves both spindles with tools up to 400 mm long (HSK 63). The machine can setup for either wet or minimum quantity lubrication (MQL) cutting.
What: Vertical spindle machining center
Name & Source: V22 from Makino (Mason, OH; www.makino.com).
Features & Functions: With an 11.3-hp (continuous) motor that drives the spindle to 40,000 rpm, this machine is designed for small-parts machining. The travels are 12.6-in. X, 11-in. Y, and 11.8-in. Z. Moves are made quickly, with a rapid traverse of 787 ipm. The work zone measures 17.7 x 13.8 in. Maximum part weight is 220 lb. It is equipped with an HSK-E32 spindle interface. The standard automatic tool changer handles 30 tools. The machine has a compact footprint: 4.9 x 6.5 ft.
What: Face mills
Name & Source: F45MN from Iscar Metals (Arlington, TX; www.iscarmetals.com).
Features & Functions: This family of cutters is designed for medium and rough face milling operations. They are available in diameters from 3 to 8 in. The cutters use double-sided octagonal inserts (ONMU 080608 insert geometry, each of which provides 16 cutting edges with positive rake angles (when used in <0.216-in. depth of cut)). Up to 0.020-in./tooth feed can be achieved. There is a central screw for clamping the inserts in place.
What: Vertical spindle machining center
Name & Source: Variaxis 730-5X from Mazak (Florence, KY; www.mazakusa.com).
Features & Functions: Think of a high-precision rotary table with 150º tilting range fixed to a five-axis vertical machining center and the control coming from a conversationally programmed CNC controller (the Mazatrol Fusion 640M). That's this machine, which can perform simultaneous five-axis machining. The 40-hp spindle motor drives the 50-taper spindle up to 10,000 rpm and with maximum torque of 387 ft-lb. The rapid traverse in X, Y and Z is 1,575 ipm. When equipped with a single pallet, the table size is 248 x 19.7 in.
What: Horizontal machining center
Name & Source: sRM80H-40 from Horkos Corp. (Canton, MI; www.horkos.com).
Features & Functions: Machine uses Horkos's patented MQL (Minimum Quantity Lubrication) system that reduces cutting fluid flow so that the amount of fluid is measured in milliliters per hour (1 milliliter = 0.0002642 gallon [US, liquid]). The system mixes air with the fluid in the spindle so that there are droplets applied through the tool to the cutting face. Parts are gripped from above so there is no chip accumulation on the fixture. The machine has a sloping, gap-bed design for chip disposal. A Dept. of Defense study on machining high-volume aluminum automotive parts indicate a cost savings of 8.5% with MQL compared with wet machining.
What: Small internal turning tools
Name & Source: CoroTurn XS turning tools from Sandvik Coromant (Fair Lawn, NJ; www.coromant.sandvik.com/us).
Features & Functions: These are small tools for sliding headstock CNC machines. The tools can perform internal turning, grooving and threading in holes as small as 1-mm diameter. The tools come in four sizes—from 4 to 7 mm. There are inserts for various hole diameters. The boring bars that are fitted with the inserts are from 10 to 25.4-mm diameter. The boring bars have an internal coolant supply and two nozzles that both cool the cut and help evacuate the chips.
What: Cutting insert material
Name & Source: CBN200 from Seco-Carboloy (Warren, MI; www.carboloy.com).
Features & Functions: The material is for rough and finish turning on hardened steel (45-65 HRC), sintered iron, and powdered metal. It can be used to produce inserts—either brazed-tip multi corner or full-face sintered-layer types—that combine impact strength and edge quality. In testing against another CBN material where pearlitic cast iron brake discs were finished, the CBN200 machined 12,000 parts per edge vs. 1,000 for the competitive material.