Within the past few years the number of Fastems’ CNC automation solutions utilizing automated guided vehicles (AGV) or autonomous mobile robots (AMR) has multiplied, and the demand keeps rising. Most typical AGV applications include material intralogistics, delivering tools to machines, and moving machining pallets between production process phases. The common goal of all
the AGV projects is timely, safe, and economical transfers of production items and Fastems is actively developing ways to utilize these technologies efficiently with CNC automation.

“Today, the majority of our customer industries are using AGVs or AMRs in some way. Whether in aerospace, defense, machine building, medical or subcontracting, there are automated vehicles in many production shops”, said Mika Laitinen, Solution Sales Director at Fastems. “When it comes to CNC automation and AGVs or AMRs, they can be of great help in reducing manual transfers and forklift operations, reducing buffer sizes, increasing the automation level, and making production flow more predictable and reproducible.”

Fastems’ Manufacturing Management Software (MMS) brings higher intelligence for AGV use by overseeing all production orders and resources and scheduling every piece of this complex puzzle for timely customer deliveries. In practice, MMS schedules production based on customer orders and available production resources such as machine tools, cutting tools and raw materials then prompts the AGV’s fleet management software to perform the right transfers at the right time.

“We can ensure that all the AGV transfers are done just-in-time,” says Laitinen. “The benefits include reduced buffer storage sizes between process phases, and employees being able to prepare the right production resources in advance to reduce machine waiting times. And, when the unexpected happens

such as a tool goes missing, an urgent customer order comes in, or a machine breaks, MMS adjusts the production – including the AGV movement – so that the most urgent jobs still get done in time and all the needed resources are in place when needed.”

CNC specialist NUM is helping Grupo Plasma Automation – one of Latin America’s top fabrication equipment manufacturers – to develop an innovative high speed laser cutting machine that uses real-time adaptive height control to accelerate throughput.

Grupo Plasma Automation comprises eight companies that specialise in the design and manufacture of fabrication automation. The group produces a broad range of plasma, laser and water jet cutting machines. Founded in 1991, GPA has grown steadily over the years and has built up a large and prestigious customer base; it has more than 700 cutting systems installed at companies in Mexico alone, and nowadays serves both the domestic and international markets.

GPA’s latest CNC laser cutting machine is designed to provide sheet metal fabricators with an ultra-flexible precision cutting solution. Branded SPEED CUT, the machine is capable of cutting a wide variety of metals with different densities, including galvanised iron, aluminium, brass, stainless and carbon steel. It has a work area of 1.5 x 3 metres and a maximum cutting speed of 120 metres per minute, with 40 microns positioning accuracy. The system delivers extremely smooth operation even at high speeds.

To help maximise performance and reliability, GPA’s new cutting machine is based entirely on industry-leading laser and control technology. The laser source is a 2 kW IPG Photonics’ solid state ytterbium fibre system, with a wavelength of 1.07 micrometres, while the cutting head is a Precitec LightCutter 2.0 unit. This particular cutting head is renowned for its dynamic performance – it features automated motor-driven adjustment of the axial focus position, can handle acceleration rates as high as 3 g, and covers a large focus position range of 23 mm.

All cutting head positioning functions on the machine are controlled by a NUM Flexium+ 8 CNC system. According to Omar Sandoval, Owner and CEO of GPA, “We chose to partner with NUM mainly because of its open architecture CNC platform and NUM’s willingness to actively participate in joint development projects such as this.”

All four machine axes are driven by NUM high torque BPX servomotors controlled by NUMDrive X digital servo drives; the Y1 and Y2 gantry axes are equipped with powerful 9.8 Nm motors, while the X and Z axes have smaller 2.7 Nm and 1.4 Nm motors, respectively. NUM’s Flexium Tool commissioning software allows the Y1/Y2 axes to be tuned while the synchronisation is active, which provides a very powerful means of maximising performance and precision.

The Z axis controls the vertical height of the laser cutting head above the sheet of metal that is being cut. By capitalising on the unique ‘Dynamic Operator’ (DO) function in NUM’s Flexium software – which enables event-driven machine cycles to be integrated into the real-time CNC kernel – the user of the speed cut machine benefits from an automated dynamic height control system that accommodates extremely fast cutting speeds. The system interprets data from the machine’s cutting head height sensor and uses it to very quickly adjust proportional-integral-derivative (PID) loop parameters in the Z axis servo. The height sensor is also employed to facilitate an automatic sheet detection routine: this determines the workpiece’s dimensions, zero, and angular offset, further simplifying the machine’s operation.

Steven Schilling, Managing Director of NUM Corporation in Naperville, Illinois, points out, “We are delighted to be collaborating with GPA in the development of this new machine. In addition to the real-time adaptive height control and sheet detection systems, the customised version of NUMcut software that we are providing features a user library of material cutting conditions. It is preloaded by GPA with the optimal laser power levels, cutting speeds, etc., as a function of material type and thickness. The provision of this library will further add to the machine’s productivity and cutting accuracy.”

CNC Machines, like everything else in life, begin to wear down as they age. Whether your issues are performance or maintenance related, an aging piece of equipment can leave you wondering whether or not it is time to replace your CNC machine. On the surface, it may seem like a simple decision, but there are many facets that can have lasting impacts on your business’ profitability. While the simple dollars and cents will weigh heavily in your decision making process, it is also important to consider several key alternatives before pulling the trigger on a machine replacement.

Here are some signs that it’s time to replace your CNC machine.

A Dip in Production
One indicator that it may be time to replace your machine is that it takes longer to produce parts than it did in the past. A wide range of wear and tear could force you to break down for maintenance or adjust your speeds and feeds to yield acceptable parts (leaking fluid, timing circuits, busted belts, etc.) and these malfunctions can significantly hinder your rate of production. For machines that are running ‘round the clock’, it won’t take long to notice these delays eating into your shop’s bottom line.

Often times, these issues aren’t readily apparent.. Delays can occur by the second, (as opposed to hours of down time), but when these instances are combined, we begin to see a bigger picture. This is why it is important for diligent operators to track production times and delays, so they can begin to notice trends as soon as possible.

Replacement parts are harder to find
When it comes to machine maintenance, the million-dollar question is always “should I repair the machine or replace it?” A good signal that it’s time to replace your machine is that replacement parts are harder and harder to find. With skilled operators and a routine maintenance schedule, some CNC machines will outlive their maker. This is great when it comes to machine longevity, but not so much when the primary source of replacement part ceases to exist.

Secondary part providers are always an option, but as replacements stop being produced, it will become harder (and more expensive) to get your machine the components it needs to function at a high level. Taking time to search for new parts while your machine sits idle is another source of lost revenue. If you’re already struggling to find replacement parts, it may be time to replace your machine.

Poor Maintenance
There is generally a clear correlation between the life of a CNC machine, and the routine/preventative maintenance it receives. Has your machine been maintained regularly? Do you have detailed maintenance logs and perform routine audits? If you have a used machine and don’t know the entire maintenance history, consider the frequency that the machine needs repairs. Without a proper log, on-going maintenance issues can go unnoticed.

The Cost of Repairs
Time to do some math. Replacement parts get spendy. Service technicians even more so. Depending on the rate at which your machine needs repairs, when factoring in parts, labor, down time, etc. you can quickly get to a point where it no longer make sense to stick with a piece of aging equipment. Before long, you could be spending more than it costs to purchase a new machine, just to keep your used CNC limping along.

This, of course, depends on what sort of machines you’re looking to acquire. While technology is becoming more affordable, new CNCs can vary widely in price. Some will cost hundreds of thousands of dollars or more. It may not make sense in every scenario to purchase a brand new replacement, but there are “new used” or factory refurbished options that would be significant improvements on an old piece of machinery. This is why it is so important to understand the true costs of your used machines, and how those relate to other options on the market.

Safety First!
Finally, and perhaps one of the most important factors, is whether the machine is still safe to run. It’s easy to get caught up in doing the math and finding the most cost-effective solution to keep your business running, but the safety of your employees should always come first. If there’s a reason to believe the machine isn’t safe to operate, or could malfunction during production, it is time to replace your equipment.

As you can see, there are many factors in play. There is rarely a definitive moment when you’ll know it is time to part ways with an aging CNC machine, and the question or “repair or replace” will likely be ongoing. But taking into account the variables discussed in the article will help you better understand the true cost of operation, and will better prepare you when it comes time to make this decision for your business.

About Author

“Bryan Rosenberger, a lifelong Oregonian, helps run R&R Manufacturing, a family-owned machine shop that specializes in waterjet cutting and CNC machining. Outside of manufacturing, Bryan enjoys hiking in the Pacific Northwest and spending time with his wife and two young daughters.”

Sources

https://asimachinetool.com/replace-cnc-machine/
https://www.tramarindustries.com/3-Signs-You-Should-Replace-Your-CNC-Machine_AE17.html
http://www.thermwood.com/header/upgrades_retrofits_general_info.htm
https://blog.gesrepair.com/2018/08/14/repairs-versus-replacements-objective-look-industrial-machinery-costs/
https://blog.gesrepair.com/2018/08/14/repairs-versus-replacements-objective-look-industrial-machinery-costs/
http://www.cnc.com/how-much-do-cnc-machines-cost/

 As well as being pleasing to the eye, highly polished flutes and gash surfaces improve chip evacuation and significantly improve tool performance and life. The smoother surface enables swarf (or chips) to exit more freely, preventing chip packing and material build up during machining.

ANCA is well known in the industry for its rigid grinding machines and has combined this with its sister company, ANCA Motion’s, LinX linear motor technology. Tools ground on our machines have a consistently high-quality cutting edge and surface finish. Since the product was launched customers have reported dramatically better results using the duel technologies.

Simon Richardson, ANCA Product Manager explained: “When machining softer or ductile materials, chips can stick to the carbide. If the chips created are not removed faster than they are being produced – the tool may not perform effectively. However, a better surface finish on the flute prevents the swarf from sticking onto the flute face of the tool while reducing the amount of heat that is generated when machining.”

“We realised that having a highly rigid machine with a cylindrical linear motor that boasts a smooth axis movement, would greatly improve the final surface finish on the tool. The research and development team conducted many hours of test grinding to rigorously test our assumption of what surface finish quality we thought was possible.”

An Alicona infinite focus XL metrology machine in ANCA’s Grinding Centre of Excellence was used to verify the results to Nano metre accuracy finding that a surface finish roughness average as low as 164.7nm (which translates to 0.16 Ra) was achieved.

Paul Bocchi, General Manager of ANCA Motion said: “An advantage of knowing ANCA’s customers so intimately is that we could immediately see how our technology would work seamlessly to improve performance.”

“The LinX cylindrical linear motors ensure there is no loss of preload or rigidity when grinding tools. As well as that, reversal errors are eliminated and higher contouring accuracy can be maintained due to a control algorithm we use which is unique to ANCA.”

Simon concluded: “Tools with highly polished surfaces means better cutting edges which will ensure extended tool life and improve the finish on the machined part. We have seen the demand for tools with a superior surface finish continue to increase and cutting tool manufacturers are producing more highly polished tools in larger quantities.”

Tips on achieving a superior tooling surface finish

• The quality of the grinding wheel is critical in achieving a high-quality surface finish. A fine-grit wheel can form small chips during grinding which could impart fine marks on the flute face and gash.
• Using a fine-grit also poses a challenge as the wheel must be fine enough to produce the required surface finish while maintaining a good toroid radius over a batch of tools.
• Ensure the wheel is properly trued and dressed so that it performs as expected.
• Ensure efficient coolant delivery and fine filtration systems are in place.
• Ensure the grinding wheels are balanced correctly using iBalance

SORALUCE presents the new TA-M turning-milling centre, a multi-tasking solution aimed at maximising productivity, with the ability to carry out milling and turning operations on a single machine, offering great machining capabilities and functions.

The machine responds to multi-tasking and versatility requirements, maximising productivity and minimising the time to prepare a part. In this regard, the new SORALUCE TA-M multifunctional fixed bed reduces the number of clamps required, minimising both cycle times and potential errors. This model was designed to respond to the machining needs of various high demand components.

The ability to carry out different machining processes efficiently and accurately, including turning, milling, boring, drilling and threading, are part of its identifying features. To do this, the machine is equipped with a table for milling and turning in two variants of Ø 1000 or Ø 1250 mm and a new SORALUCE H200T multifunctional head for turning and milling operations. The H200T head is equipped with an innovative rotational locking system for the chuck, making it possible to use both milling and turning tools directly without the need for intermediate elements.

The machine has 1250 mm of travel vertically and 1200 mm across and has a capacity for parts of up to 8000 kg for milling and 2000 kg for turning in a range of speeds of 6 ÷ 400 rpm.

Designed to provide maximum stability, its high level of torque power (28 kW / 479 Nm) makes it possible to carry out roughing operations with a great depth of cut. The structural elements are made entirely of cast iron, a material appreciated for its good intrinsic qualities in terms of stability and internal damping capacity.

Being compact and ergonomic, it stands out for its accessibility to the work area, with access from the front and rear to facilitate the set-up of parts and measuring operations, as well as monitoring the operation of the machine.

The SORALUCE TA-M multifunctional centre offers the user all of the technology developed by SORALUCE aimed at improving precision and productivity, such as Accura Heads, Adaptive Control and SSV, the latter being a development which makes it possible to prevent the regenerative effect of certain chatter conditions during the destabilisation process.

The new SORALUCE TA-M completes the wide range of SORALUCE multifunctional machines: FMT milling and turning centre with a 4000 x 1250 mm fixed table and a Ø 1600 mm integrated milling and turning table, highly configurable mobile column multifunctional centres (F range) with milling and turning tables and multifunctional gantry milling machines (P range).

SORALUCE has extensive experience in vertical milling, boring and turning, being acknowledged by its customers for the quality of its service and the high reliability, high performance, flexibility and advanced technology of its solutions, always aimed at improving efficiency and productivity.

Automation is essential in helping manufacturers achieve maximum return on investment (ROI) from their machine tools. Today, Makino is pleased to share the availability of a new design configuration for its popular MMC2 automated pallet-handling system, which enables full compatibility with the company’s uniquely designed a61nx-5E 5-axis horizontal machining center. Together, these technologies offer a powerhouse combination of processing speed and flexibility, giving aerospace manufacturers more control over their workflow and the ability to adapt quickly to customers’ just-in-time needs for complex, multi-dimension part applications.

The updated MMC2 retains the same modular design and capabilities of its predecessors, but with a new pallet-transfer interface on the system’s rail-guided vehicle (RGV). This interface can handle the unique pallet designs used on the a61nx-5E. As a result, manufacturers are able to achieve spindle utilization rates upwards of 95 percent to further maximize the value of their a61nx-5E investment.

“Based on feedback from current a61nx-5E owners, we’d come to realize that the machine’s productive capabilities were so high that most operators were struggling to keep their machines fed with raw materials,” said David Ward, product marketing manager at Makino. “While we see this as a good problem to have, it is still an issue that we wanted to address. By providing this optional pallet interface on the MMC2, we’re able to help manufacturers keep up with the productivity rates of the a61nx-5E to get the most value out of their investments.”
 
Capacity for Future Business Development
The MMC2 is designed to accommodate up to 15 machining centers and four work-setting stations into a single system. Each system can hold up to 200 pallet stockers—stacked either one, two or three layers high—with a virtually unlimited variety of parts and fixtures.

The system’s RGV is supported by a floor rail and upper-guide rail for enhanced stability and simultaneous, high-speed movement. The system’s work-setting stations (WSS) provide easy access for operators to load and unload parts either by hand or crane. Each WSS has 180-degree pivoting doors to save space and prevent a cluttered work area. The MMC2 can be equipped with optional workpiece washing guns.

Users of the MMC2 frequently report spindle utilization rate improvements of up to 95 percent, leading to dramatic increases in production without adding staff or equipment. The MMC2 system permits users to virtually eliminate part setup time, reducing non-value-added time in their machining operations. By providing a continual flow of parts to the a61nx-5E, the system can run for extended periods unattended, including over nights and weekends.

Flexible Scheduling and Cell Management
The updated MMC2 retains the same Microsoft Windows-based MAS-A5 control software, which helps maximize production output while monitoring multi-machine production requirements. The MAS-A5 main PC hard drive stores and manages all NC programs for optimum machine utilization, including NC programs that exceed CNC memory. With these storage capabilities, there is practically no limit to the number of fixtures and associated process sequences and offsets that can be logically assigned to an individual pallet.

Tool data, both in and out of the a61nx-5E machines, can be accessed and modified from the MAS-A5 user interface. A variety of file formats for tooling and part information are supported and can be displayed to assist with part loading/unloading and tool-setting operations. The Tool-Life Predict function enables the MAS-A5 to gather tool-life data per NC program. When a request is opened, this function informs the operator of how long a tool is used in each NC program execution, as well as how many spare tools per machine are required to finish any work that is currently loaded or awaiting processing at the time that the request was placed. The MAS-A5 then schedules work only for the machines that meet tool-life and availability requirements for the desired process sequence. Interfacing with a tool presetter also reduces errors by automatically capturing tool-offset data, which can be transferred from the presetter to the MAS-A5 system control.

Standard control features include in-cell production scheduling, equipment status monitoring, NC program management and on-board reporting. These capabilities enable the MMC2 to assign work and initiate operations automatically, based on machine and material availability, using maximum spindle capabilities and monitoring all automated procedures.

Fanar is one of the top five manufacturers of tools in Europe and is known in the market for its uncompromising quality. The Polish based company supplies a wide range of cutting tools for threading, drilling, milling and turning and specialises in shank tools for machining holes. Fanar’s global network of customers operate in the automotive, aerospace, medical and home appliances industries among others.

From the beginning Fanar has invested in the newest technology and machine tools to ensure they have the capability to offer the latest products. However, in 2016 Fanar realised that if it was going to remain ahead in the market they needed to improve the production time for manufacturing complex cutting tools.

Dariusz Ptaszkiewicz, Technical Director at Fanar said “In the era of e-bay people are accustomed to the convivence of online shopping where products are delivered within two to three days. This mindset can be challenging when customers expect this same type of service especially when purchasing specialist cutting tools. We needed to find a way to meet our customers’ expectations without compromising on quality.”

“The more complex the tool, the longer it takes to produce and may require several machines and different set ups as part of the grinding process. Essentially, this process can be quite lengthy. However, at FANAR we are not afraid of a challenge and we set ourselves the ambitious goal of delivery to our customers within seventy-two hours from receipt of the order.”

“We looked for a supplier who could provide a solution that enabled fast changeovers, precision and repeatability. Another important requirement was that the grinding machine had a software package that was intuitive to use and didn’t require highly skilled programmers.

 “After reviewing what was available on the market, we were confident that ANCA’s MX7 Linear was right for our businesses because of its numerous innovative features. The polymer concrete base, linear motors, ability to prepare tools (wheels) on the machine and integrated measuring system meant that we could achieve our goal of seventy-two-hour delivery with a grinding machine of the highest standard.”

First impressions and opening new markets
Dariusz Ptaszkiewicz, continued “When investing in a new product, there is always some concern that the machine may not deliver what was promised. ANCA’s MX7 Linear exceeded our expectations and I am yet to find a product that offers so many innovations and features that are unique to the market.”

“Once we had the latest technology, combined with our years of experience in grinding and metalworking, we could quickly begin production of the most complex geometry and high dimensional precision tools.”

 “I am excited that Fanar is now in a position where we can consider orders that in the past we avoided. The technology means we have the capacity to produce complex tools, even for individual orders, at the highest quality with minimal risk. With the investment, we have achieved our goal of significantly reducing lead times and production costs, while opening new potential markets for our business.”

Special features such as RoboMate have enabled simple but accurate automation and ANCA’s in process measuring system, Laser Plus, has meant that for the first time our company has implemented unmanned production without any concern that the products may be defective.

“Furthermore, the machine was ordered with the Statistical Process Control (SPC) software package for quality control purposes. This enables Fanar (as a trusted supplier of cutting tools) to continue to meet ISO 9001, ISO / TS 16949 standards.”

Maschinenfabrik Berthold Hermle AG traditionally welcomes visitors to its annual Open House event in Gosheim with the local speciality Swabian ‘Maultaschen’ (Swabian ravioli). From 26 – 29 April 2017, well over 1000 companies and numerous visitors from across the globe are once again expected at Gosheim.

The company will be showcasing eight machine models from the Performance-Line and High-Performance-Line, which illustrate the output spectrum of Hermle AG in a wide range of configurations. Some models are of course equipped with cutting-edge automation tools, including the new HS flex handling system, various pallet changers and robot systems.

A complete production hall will be converted into a small trade fair, accommodating over 50 exhibitors from the sectors clamping technology, CAD/CAM, software and control technology.

With a different program of specialist lectures each day, visitors will also be offered concise information on all aspects of economical machining.

“Phillips Machine Tools India represents Hermle in India. Hermle enjoys a leading position today as a partner to numerous key industries. From large complex components to the smallest components in the high-tech area. From medicine to auto racing. Hermle leads the way” says Swapnil Patil – Product Manager for Hermle.

Highlights of the Open House

• More than 15 machine models of the High-Performance-Line – a benchmark in 5-axis technology
• Several machine models of the Performance-Line, which only rank below the high end machining centres of the High-Performance-Line on dynamics and equipment
• Over 20 machines, some automated, in our Technology and Training Centre
• Special show on clamping device technology, CAD/CAM and software, with over 50 well-known exhibitors
• Hermle expert forum – with a wide range of specialist lectures on state-of-the-art machining
• Hermle user training with tips and tricks for optimum milling and turning
• Hermle Maschinenbau GmbH with the latest generatively manufactured components
• Service expertise live – presentation and demonstration of our services
• The Hermle Apprentice Department with its own stand and presentation of Hermle’s training strategy
• Guided tours of the company

Kentucky-built machine opens doors for shops to take on long, heavy parts production

The new Mazak VTC-805E Vertical Traveling Column Machining Center brings high versatility and productivity to those shops that need to tackle long and/or heavy parts. The machine combines an increased Y-axis stroke, long bed/table size, high spindle speed and torque and Mazak’s new SmoothG CNC control for efficient, powerful machining.

For manufacturers that need as much Y-axis travel as possible, the VTC-805E provides an extended Y-axis travel of 32″ as a cost-effective alternative to a bridge-style machine. The machine’s fixed table measures 82.7″ x 32.3″ (2100mm x 820mm), while its moving column design provides a 69.3″ X axis and 28.3″ Z axis.

With an optional center partition, it is possible to transform the VTC-805E’s table into two separate work areas to process parts on one side, while operators load/unload parts on the other for an overall reduction in cycle times. A special turret-style magazine accommodates 40 tools for longer periods of uninterrupted production as well as for more part-processing versatility.

Mazak equipped the VTC-805E with a powerful 30-hp, CAT 50-taper, 6,000-rpm spindle that easily tackles a wide variety of materials including titanium, aluminum, steel and cast iron. And for even more power and speed, Mazak offers an optional 40-hp, CAT 50-taper, 10,000-rpm spindle.

The VTC-805E features the new MAZATROL SmoothG CNC that makes it easy to generate programs for off-centerline machining as well as angled drilling, milling and tapping operations. Several innovative programming, performance and monitoring functions bring optimum speed and accuracy to complex part production. Advanced hardware including a tilting CNC panel and intuitive, multi-touch control screen allows for complete ease of use, while an SD card stores up to 32GB of program data.

Makino announces its newest addition to the nx-series, the a120nx horizontal machining center. As the largest machining platform within the nx-series to date, this machine is built to take on oversized structural components for industrial equipment, diesel engines and semiconductor manufacturing, while delivering high levels of speed and accuracy.

“You can’t approach big parts the same way you would any other part, and that’s why everything about the a120nx is sized for heavy-duty manufacturing,” said John Einberger, product line manager at Makino. “We wanted to employ the proven designs of our other nx-series machines, such as three-point leveling and tiered column design, while ensuring that the machine could mechanically handle the unique challenges of large workpiece machining processes.”

The a120nx features vast X-, Y- and Z-axis travels of 74.8 inches, 63 inches and 66.9 inches (1,900 mm, 1,600 mm and 1,700 mm, respectively), and the machine’s standard large pallet size of 39.4 inches by 39.4 inches provides capacity for parts weighing up to 11,000 pounds. The machine’s automatic pallet changer switches from one pallet to the next in 38 seconds, minimizing non-cut times for the highest levels of productivity. Capable of storing up to 204 tools of wide-ranging sizes and designs, the a120nx accommodates tools up to 35.4 inches long, 14.0 inches in diameter, and weighing up to 77 pounds. Tools are loaded into the automatic tool changer (ATC) from an easily accessible, ergonomically friendly exterior loading station to prevent operator fatigue.

Built for Rigidity During Continuous Production
At the foundation of the machine is a three-point supported bed casting to ensure all points are stable and contacting the floor. Developed to maintain the machine geometry and alignments, this design characteristic of the nx-series machines simplifies installation and enables easy relocation of the machine. Building on the rigidity of the bed casting, the a120nx uses a unique tiered column design that delivers greater resistance to Z-axis cutting forces throughout the work envelope. Robust cross roller-style B-axis table bearings work in concert with a high force rotary clamping system to ensure stable cutting throughout the machine’s expansive work zone.

The a120nx is equipped with Makino’s four cone pallet location and clamping system that delivers a secure 46,500 pounds of force on the pallet. This superior clamping capability, combined with all pallets built to a master pallet, eliminates deflection. An engineered precision air-blow system provides locating surfaces cleaning, as well as pallet clamp confirmation as standard features.

Larger parts typically mean larger features, too. Tool length, diameter and weight capacities of the a120nx support processes that feature the use of large face mills, boring bars and line-bar tooling.

To further ensure ideal geometry and accuracy, the a120nx has a number of systems in place to manage the heat generated by rapid traverse of 2,126 inches per minute. For one, the ballscrews are core-cooled in all axes to give consistent accuracy during continuous production.  Moreover, the ballscrews are all dual supported and pre-tensioned to ensure unparalleled dynamic positioning repeatability.  Feature-to-feature movement distances on large parts are typically much greater, so rapid traverse rates were increased for the a120nx in order to cover these expansive distances quickly.

Powerful Spindle, Pallet Clamping for Speed and Accuracy
Beyond its proven speed and accuracy, the a120nx also improves productivity in cutting and non-cutting performance.  The standard high torque 8,000-rpm spindle boosts continuous power levels by 19 percent over levels typical to machines of this class. With 50 continuous (74 peak) horsepower available, this spindle is ideally suited for heavy roughing of iron castings and hard-metal applications. In addition, the spindle features significant improvements in acceleration and deceleration due to its high duty rated performance characteristics that reduce rigid tapping times by up to 30 percent.  Also available is an optional 18,000-rpm high power spindle, ideally suited to high metal removal rate machining of light alloy structural components.

Chip and coolant management features are often overlooked and result in interrupted operations, increased labor costs, machine damage, part-quality issues and reduced tool life. The a120nx enables shop owners to avoid these challenges with supplementary management features, including a sloped surface to remove obstacles between the workpiece and an external chip conveyor, letting chips fall freely. The trough design facilitates rapid chip and coolant evacuation and reduces maintenance needs with a solid panel Z-axis cover design.  A standard cyclonic filter provides ultra clean coolant to the through spindle coolant pump and acts as a secondary coolant filter, polishing coolant in the main tank.

The a120nx comes to the market ‘automation ready’, being fully compatible with Makino’s versitile multi-machine, multi-pallet MMC2 flexible manufacturing system, complete with Makino’s highly capable MAS-A5 cell controller.

Machining massive parts poses multiple challenges. However, speed, accuracy and durability remain crucial when working with large parts and meeting customers’ delivery demands.