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.

Merger provides enhanced customer support, broader geographic presence and greater product diversity to SST

Makino Inc. is pleased to announce its merger with EDM consumables supplier Global EDM Supplies. The merger is expected to expand the company’s SST Consumables business, providing customers with broader geographic reach, greater product diversity and increased accessibility to experienced technical services and support.

“We are very pleased to continue our growth in the consumables business through the merger of Global EDM Supplies,” said Don Lane, CEO of Makino Inc. “We look forward to better serving our customers through the addition of Global’s skilled and experienced personnel, geographic presence and product portfolio.”

Headquartered in Mason, Ohio, Global EDM Supplies is a leading supplier of top-quality EDM technologies and turnkey application solutions. Its EDM consumables catalogue includes more than 3,000 different EDM parts and supplies from leading manufacturers, including wire, filters, wear parts, resin, fluid and lubricants, and electrodes. Since its founding in 1995, Global EDM Supplies has built a reputation for its technical support and customer service across the United States with eight locations across the country.

“We are excited about the prospects for expanding Global’s reach afforded by our merger with Makino,” said Tom Kucharski, President of Global EDM, Inc. “Our unmatched technical and personal service will be further enhanced by the resources of Makino and SST”.

The integration of Global EDM Supplies into SST, is expected to be completed within the first quarter of 2017. With its robust network of engineers, Global and SST are committed to offering fast local support with complete machine repair and maintenance programs. SST and Global support and services are to continue to operate uninterrupted across all regions and locations.

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.

Makino is excited to announce the latest addition to its next-generation series of horizontal machining centers, the a71nx. This horizontal machine platform extends the capabilities of the original a71 with a host of brand-new features and technologies, including an expanded work envelope, improved ergonomics, increased spindle torque, innovative tool monitoring, advanced motion controls and the new Professional 6 control. The net result is a true next-generation machine platform designed with the most advanced capabilities for productivity, accuracy and reliability.

“The a71nx expands on all of the characteristics that made the original a71 an industry leader,” said David Ward, product marketing manager at Makino. “By expanding machine capacity and integrating cutting-edge technologies, like Vision B.T.S. [broken-tool sensing] and advanced motion controls, Makino has successfully leveraged proven design attributes while enhancing the productive capabilities and overall reliability.”

Designed for the production of midsized cast iron and light alloy parts, the a71nx features a 19.7-inch (500-mm) pallet and added extensions in the X, Y and Z axes, bringing full-axis travels to 31.5 inches, 29.5 inches and 32.7 inches (800 mm, 750 mm and 830 mm), respectively. The expanded axis travels increase the total machining volume 16 percent compared to the original a71. To accommodate these larger workpieces, the maximum payload was also raised, providing capacity for parts weighing up to 1,000 kg.

Larger parts frequently require larger tools. As such, the a71nx has been updated to handle longer and heavier tools. The machine’s standard 60-tool-capacity automatic tool changer (ATC) has six reinforced pockets, yielding a maximum tool length of 18.9 / 22.4 inches (Cat / HSK) and maximum weight of 30 kg.

Additionally, the original a71’s standard worm-gear-driven NC rotary table has been replaced with a direct-drive (DD) motor B-axis table for dramatically faster indexing time. The 1-second 90-degree rotation improves production processes with a substantial reduction in non-cutting motion. The DD motor table on the a71nx also reduces B-axis complexity and eliminates backlash and key component wear for improved reliability.

Enhanced Material Removal and Spindle Reliability
The a71nx takes spindle reliability and productivity to a new level with an updated high-power spindle design. With options available for CAT-50, BT 50 and HSK-A100 interfaces, the standard 10,000-rpm spindle offers 37kW of power (26kW continuous power) and 512 Nm of torque (305 Nm continuous), delivering the flexibility and speed necessary to efficiently machine a variety of ferrous, hard metal or light alloy workpieces. The large-diameter angular contact bearings and direct-inject air-oil lubrication ensure the highest level of rigidity and longevity. An optional 20,000-rpm core-cooled spindle is also available.

Built for Strength and Rigidity
Similar to other Makino nx-Series horizontal machining centers, the a71nx benefits from an innovative casting design and axis construction. The tiered, or stepped, column casting and oversized roller linear guides boost rigidity, eliminate vibration and extend perishable tool life even in the most challenging materials.

Chip and coolant management has been improved with the addition of a standard hydro-cyclonic filtration system. This system cleans coolant down to a 20 μm level, extending the maintenance life of the coolant.

Reducing Non-Cut Times
One of the key advantages of the a71nx is its ability to reduce non-cut time from part processes with innovative, patent-pending hardware and control features.

A vision-type broken-tool sensor (Vision B.T.S.) comes standard, supporting unattended operation by quickly validating the condition of cutting tools after each tool change. By creating a silhouette of the cutting tools, Vision B.T.S. is also able to evaluate the size and approximate weight of the tool. This information can then be applied to automatically set the tool-change speed to the appropriate setting (fast, medium or slow). The Vision B.T.S. system has fewer moving parts and requires no physical contact with the cutting tool, resulting in enhanced, long-term reliability and no risk of chipping delicate tool materials, such as polycrystalline diamond (PCD).

The a71nx is also equipped with the latest inertia active control (IAC) technologies, providing enhanced acceleration and deceleration rates in the B-axis, Z-axis and rotational positioning of the ring-type tool magazine. By quickly evaluating the total weight placed on these axes, IAC technology is able to instantly adjust acceleration to match the total load, reducing non-value-added times from part processes.

With the addition of the new Professional 6 (Pro6) control, the a71nx is equipped with two of the latest forms of advanced motion control to minimize non-cut time:

– GI Drilling is a unique G-code drilling cycle that enables the spindle and tool to arc from hole to hole instead of following a square path. This simple change reduces non-cut time by as much as 15 percent on common hole-pattern drilling.
– GI Milling is designed to improve performance in 2-D milling. GI Milling lets the user define a corner-rounding tolerance on each milling path. Even a small tolerance enables the machine to quickly flow through the cut path, completing milling paths in less time.

Together, these functions substantially cut costs in both high-volume and low-volume production environments by reducing the number of spindles required and freeing up machine availability to take on more work.

Enhanced Operability and Automation
The exterior of the a71nx has evolved in an effort to make maintaining the machine easier for the operator. An L-shaped door, when open, allows more light to enter the machine and prevents fluid from dripping onto the operator during inspection and maintenance. The wide opening on the pallet-loading station doors lends easy access for loading of fixtures and large workpieces. This type of accessibility is crucial for part loading and unloading in robot-automated environments.

The Industrial Internet of Things (IIoT) has arrived on factory floors, and Makino’s new ProNetConneX provides the data and connectivity necessary for Intelligent Factories to rapidly respond to fluctuating market demands. ProNetConneX offers manufacturers a built-in, instant on-ramp to the IIoT, with secure connectivity to today’s leading software management systems via the MTConnect standard. With support for both secure local network and private cloud-based data resources, ProNetConneX gives users the ability to connect, collect and analyze machine data from anywhere in the world.

“Factory floors are in a state of evolution, where digital connectivity and integration are bringing manufacturing operations out from behind the curtains and into the fold of enterprise planning, scheduling and product life-cycle systems,” says James Brown, manager of controls software development at Makino. “Makino has developed ProNetConneX to provide simple and secure transmission of machine information across connected devices on the factory floor. From machine status monitoring and utilization to ERP [enterprise resource planning] system integration, ProNetConneX equips companies with holistic knowledge and control of their manufacturing operations.”

ProNetConneX facilitates the free-flow of machine data for Intelligent Factories through a variety of capabilities, such as:
– Real-time data collection and accessibility
– Machine health monitoring
– Cloud data collection either locally or Internet
– Secure local network and cloud-based systems connectivity
– MTConnect v1.3 compliancy

Unlike many other IIoT machine interfaces, ProNetConneX is fully integrated into Makino’s latest machine controls, requiring no supplemental hardware. Additional machine sensors can be installed within machines and added to ProNetConneX to expand data collection capabilities based on manufacturers’ unique needs.

Compatibility with the latest MTConnect standards enables Makino’s ProNetConneX to connect with a company’s choice of software management system, including solutions from Memex, Scytec, Lemoine, Freedom eLog, Forcam and many other leading providers. For example, using ProNetConneX, machine data can be supplied to the Forcam system for part production monitoring, control and interfacing to MRP/ERP systems. Data security and cloud services are enabled in cooperation with one of today’s leading network hardware providers, making the networking platform familiar and easy to use for IT technicians.

Makino is set to display ProNetConneX during IMTS 2016 in booth S-8700. The system is planned to be connected to Makino’s MPmax software and FORCAM’s FORCAM FORCE software suite. FORCAM FORCE is an advanced shop floor management technology that enables companies to harmonize all manufacturing operations from the top to the shop floor and across the global supply chain and enterprise to create a transparent factory environment. Visit Makino at IMTS in booth S-8700 for a live demonstration.

Maximizing Productivity with MPmax
Among the ProNetConneX-compatible software solutions on the market is Makino’s MPmax real-time machine process monitoring and data management solution. Developed to support manufacturers in optimizing machine processes, MPmax includes analysis tools and capabilities that are not available in any other software platform, including spindle load, speed and vibration monitoring.

“ProNetConneX and MPmax combine to create the perfect package for manufacturers looking to optimize the efficiency of their shop floor and get the most out of their machining investments. Together, these utilities reveal near limitless opportunity to enhance productivity and utilization,” says Brown.

MPmax is compatible with all MTConnect-supported machines and acts as a central hub for monitoring critical processes across a variety of machine platforms. Its data-management capabilities track a variety of key machine performance indicators:
– Status monitoring
– Utilization monitoring
– Alarm analysis
– Spindle and axis monitoring
– Tool data management
– Probe data analysis
– Camera monitoring (option)
– Power-consumption monitoring (option)

Makino is proud to introduce the L2 vertical machining center designed for high-volume, small-part manufacturing. Combining a rigid construction, compact footprint and flexible spindle design, the L2 offers a highly stable and reliable machine platform for fully unattended, around-the-clock part processing.

“The minimal floor-space design and wide range of highly productive standard specifications make the L2 an ideal solution for any type of high-volume, small-component processing,” said William Howard, vertical product line manager at Makino. “Given the small size of the machine, it can be effectively employed in virtually any type of workpiece flow arrangement, ranging from manual part transfers to automated part movement facilitated by robotic systems. The L2 can be deployed to meet the specific needs of any manufacturing environment.”

The L2 vertical machining center features a compact footprint of 850mm wide by 2,130mm long (33.46 inches by 83.86 inches), including cooling tank. The X-, Y- and Z-axis travels on the machine are 400mm by 300mm by 300mm (15.74 inches by 11.81 inches by 11.81 inches). A standard, integrated A-axis rotary table and automatic pallet-change system can accommodate workpiece sizes up to 413mm by 267mm by 215mm (16.26 inches by 10.51 inches by 8.46 inches). The A-axis provides six integral ports for hydraulics and pneumatics to support fully automated fixtures. An optional fixed-table configuration without pallet-change system is also available, and can accommodate a maximum workpiece size of 413mm by 267mm by 215mm (16.26 inches by 10.51 inches by 8.46 inches).

Highly Precise, Highly Productive Design
Non-cut times, including positioning and chip-to-chip times, are dramatically reduced with rapid traverse rates of 48,000mm/minute (1,890 inches/minute) and acceleration rates of 2.0G, 1.5G and 1.7G in the X-, Y- and Z-axes respectively. The standard A-axis rotary table and automatic pallet changer further enhance productive capabilities, providing 3-second pallet changeovers to maximize spindle utilization and machine productivity. Configured with 0.05-micron scale feedback and the highly rigid machine design, the L2 machine is both quick and highly accurate.

Standardly equipped with a 16,000-rpm, HSK-A50 spindle, the L2 accommodates a wide range of applications. Through-spindle, nozzle, overhead shower and even fixture wash coolant systems provide quick and efficient evacuation of chips from the machine work area. Completing the process, a strategically placed, center trough chip conveyor rapidly removes the chip from the machine. Additionally, the L2 features a 30-tool-capacity automatic tool changer that can accommodate tooling up to 80mm (3.14 inches) in diameter, 250mm (9.84 inches) in length and 5 kg (11 lbs.) in weight. An optional 8,000-rpm spindle configuration is also available.

Unattended and Automated Processing
The A-axis rotary table facilitates access to multiple sides of the workpiece in a single setup, and the automatic pallet changer delivers a fast 3-second pallet change. Outfitted with wide, front-access, automatic doors, the L2 is quick and convenient for manual loading applications, and ready for integration into a wide variety of automated load and unload arrangements.

The L2 is designed for simple and easy integration within a variety of automated transfer and loading configurations, including exterior loading arms, gantry loaders, and fixed or movable robot loaders. These automated configurations help maximize the capabilities and value of the L2, resulting in higher production rates, shorter lead-times, reduced labor costs and saving significant floor space.

With Makino automation integration services, manufacturers are able to combat fierce pricing pressures from low-labor-cost countries by providing complete automated cells and systems. Whether demands call for simple machine tending or complex, high-volume robotic cells, Makino’s automation integration services offer the equipment, skills and manpower necessary to reduce labor costs, increase throughput, ensure and enhance part quality, all while retaining the flexibility to adapt quickly to changing volumes or new parts.

Makino announces its latest full 5-axis machine solution, the DA300 vertical machining center, providing the ideal blend of speed, precision and flexibility for complex part applications. Inspired by the best design characteristics from both vertical and horizontal machine platforms, the DA300 delivers the highest productive capabilities for multi-axis workpieces in the smallest of machine footprints. These features make the DA300 ideal for single setup, multi-side accessibility, or full-contouring capability to quickly and efficiently tackle a wide variety of complex production part applications commonly found in industrial hydraulic and pneumatics elements, optical, electrical and semiconductor components, medical and dental products, die-cast parts, automotive components and aerospace parts.

“The DA300 integrates numerous features that increase productivity and efficiency by providing significant reductions in non-cut time,” said Bill Howard, VMC product manager at Makino. “The machine provides a 50 percent reduction in spindle acceleration time, 15 percent reduction in positioning time, 40 percent reduction in tool-change chip-to-chip time and includes a standard vision-type broken-tool sensor [Vision B.T.S.] that optically checks tools outside the work zone to ensure tool consistency and part quality while simultaneously reducing non-cut time during tool changes by 80 percent. Individually, each element reduces part cycle time and increases productivity; however, when all of these time savings are combined, the result is a dramatic advantage in reduced part-production times and increased profitability.”

The DA300 worktable is an integral, 340mm by 300mm table, accommodating workpiece sizes up to 450mm in diameter, 400mm tall and weighing 250 kg. The machine provides X-, Y- and Z-axis travels of 450mm, 620mm and 500mm, respectively, at feed rates of up to 60,000mm per minute. The direct-drive, motor-driven A-axis table offers 150 degrees (+30 to -120) of tilt capability at 100 rpm. The rotary C-axis has full 360-degree rotational positioning at 150 rpm. Combined, these rotational axes have the range and speed necessary to achieve the highest productivity in complex five-face or full 5-axis machining application. Equipped with scale feedback on all axes, the DA300 also offers a rare blend of speed and precision.

Wide-Ranging Spindle and Tooling Selection
The DA300 comes standardly equipped with a 20,000-rpm HSK-A63 spindle, delivering the speed and flexibility to tackle high-speed, highly productive machining of various workpiece materials, including aluminum, die-cast, steel and titanium. Acceleration and deceleration to and from full speed can be accomplished in a mere 1.5 seconds, reducing chip-to-chip times. Additionally, the machine’s standard configuration includes a 60-position ring-type tool magazine with capacity for a wide variety of tooling as well as a Vision B.T.S. to verify the integrity of the tooling prior to use.

Intelligent Functionality
With a perfect blend of the proven stability of the FANUC hardware and Microsoft Windows Embedded Standard 7 OS, the state-of-the-art Professional 6 (Pro6) control helps move operators fluidly through machine setup, empower them with easily accessible information and protect them with enhanced safety. Cycle-time saving and dynamic-control capabilities have been added to the control’s GI functions to help lower costs per part.

Included is GI Drilling, a unique G-code drilling cycle that enables the spindle and tool to arc from hole to hole instead of following a square path. This simple change reduces non-cut time by as much as 15 percent on common hole-pattern drilling.

On complex 2-D paths, testing has reduced cut time up to 35 percent. While not every tool can make use of these functions, advanced motion control GI is proven to reduce overall cycle time by 3 to 8 percent in typical production components. This reduction saves substantial cost in both high-volume and low-volume production environments by reducing the number of spindles required and freeing up machine availability to take on more work.

Other intelligent machine functions include Inertia Active Control (IAC) designed to further speed up machine motions based upon system dynamic attributes and Collision Safe Guard (CSG), a real-time crash-avoidance feature that has a look-ahead function and takes real machining conditions into consideration to prevent collisions.

Automation for Greater Efficiency and Productivity
Designed to eliminate interferences in accessing the pallet, the DA300 can be configured using several approaches, including direct part handling as a stand-alone machine, manual handling using a table chuck and pallet, one of the workpiece pallet systems (WPS) or third-party automation using an EROWA chuck and pallet system. The DA300 can be field modified to add multiple pallet magazines, starting with a seven-pallet workpiece pallet system (WPS-7), and up to a 19-pallet workpiece pallet system (WPS-19). These configurations deliver the highest productive capabilities using minimal floor space.

With Makino automation integration services, manufacturers are able to combat fierce pricing pressures from low-labor-cost countries by providing complete automated cells and systems. Whether demands call for simple machine tending or complex, high-volume robotic cells, Makino’s automation integration services offer the equipment, skills and manpower necessary to reduce labor costs, increase throughput, ensure and enhance part quality, all while retaining the flexibility to adapt quickly to changing volumes or new parts.

Building on the industry-leading success of its top-performing horizontal machine platforms, Makino proudly introduces the newly updated a51nx and a61nx horizontal machining centers. With the same highly acclaimed rigid casting and axis designs of the original platforms, the updated a51nx and a61nx feature an expanded list of technology advancements, including increased spindle torque, innovative tool monitoring, advanced motion controls and the new Professional 6 control.

“When it comes to uptime, reliability and productivity, manufacturers won’t find a more robust pair of horizontal machining centers,” said David Ward, horizontal product line manager at Makino. “The updated set of features on these machines unleashes a whole new level of productive capability that will greatly reduce cycle times and improve overall throughput, enabling companies to gain a competitive edge with the lowest possible cost per part.”

The a51nx and a61nx models boast expansive axis travels to accommodate a wide range of parts and more parts per fixture. The a51nx has a 560-mm (22-inch) X-axis and extended Y- and Z-axes of 640 mm (25.2 inches) for an industry-leading total axis volume of 8.1 cubic feet.

The standard a61nx has a 730-mm (28.7-inch) X-axis, 650-mm (25.6-inch) Y-axis and extended Z-axis of 800 mm (31.5 inches). An optional tall column on the a61nx expands the Y-axis to 730 mm (28.7 inches), allowing customers to process larger parts that may have previously required 50 taper machines. Thanks to the expanded Z-axis stroke, maximum tool length on the a51nx and a61nx models is increased to 430 mm (16.9 inches) and 510 mm (20.1 inches), respectively.

Makino is set to debut the updated a51nx and a61nx machines in booth S-8700 of the South Hall during the 2016 International Manufacturing Technology Show (IMTS), Sept. 12-17, at McCormick Place in Chicago.

High-Torque, High-Power Spindles
Industry-leading spindle reliability continues with the updated a51nx and a61nx models, featuring a standard 14,000-rpm (30-kW) spindle that has been upgraded to deliver 303 Nm of duty-rated torque. This design enables the machines to accelerate and decelerate from full rpm in 17 percent less time. When compared to previous models, the additional torque reduces rigid tapping time by 20 to 25 percent per hole. Large-diameter angular contact bearings ensure the highest level of rigidity for a variety of applications and processes.

An optional 24,000-rpm (80/60-kW) spindle is available on the a61nx model for extremely high metal-removal rates in aluminum part applications. A new 20,000-rpm (30/18-kW) spindle with direct-inject air-oil lubrication is also available, delivering improved reliability and greater power for enhanced productivity.

Reducing Non-Productive Time
Several enhancements have been made to reduce non-cut time on the updated a51nx and a61nx machines. A vision-type broken-tool sensor (Vision B.T.S.) comes standard, supporting unattended operation by quickly validating the condition of cutting tools after each tool change. By creating a silhouette of the cutting tools, Vision B.T.S. is also able to detect the length, size and approximate weight of the tool. This information can then be applied to automatically set the tool-change speed to the appropriate setting (fast, medium or slow). The Vision B.T.S. system has fewer moving parts and requires no physical contact with the cutting tool, allowing for enhanced, long-term reliability and less risk of chipping delicate tool materials, such as polycrystalline diamond (PCD).

Inertia active control (IAC) technology has also been expanded for greater efficiency on the updated a51nx and a61nx machines. In addition to optimizing positioning motion of the rotational B-axis, IAC technology is now able to improve acceleration and deceleration rates along the Z-axis—the most frequently moved axis during cutting processes. IAC has also been added to the rotation of the ring-type tool magazine. Each time tools are loaded into the magazine, IAC quickly evaluates the total weight held in the ring and adjusts acceleration to match the total load for reducing the time the tool magazine seeks tools.

Professional 6 Control
With a perfect blend of the proven stability of the FANUC hardware and Microsoft Windows Embedded Standard 7 OS, the state-of-the-art Professional 6 (Pro6) control helps move operators fluidly through machine setup, empower them with easily accessible information and protect them with enhanced safety. Cycle-time saving and dynamic-control capabilities have been added to the control’s GI functions to help lower costs per part.

Two forms of advanced motion-control GI are included with the Pro6 control:

– GI Drilling is a unique G-code drilling cycle that enables the spindle and tool to arc from hole to hole instead of following a square path. This simple change reduces non-cut time by as much as 15 percent on common hole-pattern drilling.
– GI Milling is designed to improve performance in 2-D milling. GI Milling lets the user define a corner-rounding tolerance on each milling path. Even a small tolerance enables the machine to quickly flow through the cut path, completing milling paths in less time.

On complex 2-D paths, testing has reduced cut time up to 35 percent. While not every tool can make use of these functions, advanced motion control GI is proven to reduce overall cycle time by 3 to 8 percent in typical production components. This reduction saves substantial cost in both high-volume and low-volume production environments by reducing the number of spindles required and freeing up machine availability to take on more work.

Operator Enhancements
The exterior of the machines have evolved in an effort to make maintaining the machine easier for the operator. An L-shaped door, when open, allows more light to enter the machine and prevents fluid from dripping onto the operator during inspection and maintenance. The wide opening on the pallet-loading station doors lends easy access for loading of fixtures and large workpieces. This type of accessibility is crucial for part loading and unloading in robot-automated environments.

Chip and coolant management has been improved with the addition of a standard hydro-cyclonic filtration system. This system cleans coolant down to a 20 μm level, extending the maintenance life of the coolant.

With abundant opportunities for growth in the North American manufacturing market, Makino is set to demonstrate the latest machining and automation solutions to keep businesses thriving at the 2016 International Manufacturing Technology Show (IMTS), Sept. 12-17, at McCormick Place in Chicago. In booth S-8700 of the South Hall, attendees can experience 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.

“The demand to reduce costs in today’s hypercompetitive manufacturing climate is relentless and requires North American manufacturers to invest in the highest degree of engineering and advanced technologies,” said Don Lane, president and CEO of Makino Inc. “At IMTS 2016, Makino will demonstrate how the application of human ingenuity within automation can alleviate these downward cost pressures and unlock new potential for companies to gain a competitive edge and thrive. We encourage all visitors to the Makino booth to meet with our industry-leading application and system engineers to see how Makino’s adaptive automation solutions can enable companies to prosper through the ups and downs that we continue to face in the global economy.”

All-New Products and Proven Technologies
During IMTS 2016, Makino plans to unveil 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 will also mark 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 is prepared to demonstrate several new vertical machining platforms as well. The L2 vertical machining center provides high-volume, small-part production capability using a minimal footprint, while the processing speeds of the new DA300 5-axis vertical machining center 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 is set to demonstrate its on-board CAM software and easy part setup using offline part loading and a manual shuttle system. The EDBV8 EDM hole drill is going to be on hand to showcase fast hole-drilling for blade and vane machining.

Finally, the aerospace theater is streaming video of the T-series 5-axis horizontal machining centers built for titanium aerospace machining.

Human Ingenuity Meets Automation
There’s no doubt that automation helps companies reduce costs and increase throughput to remain globally competitive. Makino’s booth is designed to demonstrate a variety of automation systems, as detailed below:

– A Makino Machining Complex (MMC2) pallet-handling system with an a61nx-5E 5-axis horizontal machining center showcases high-mix, low-volume production with improved machine utilization and exceptionally high material-removal rates.

– The a51nx-5xu 5-axis horizontal machining center, 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.

– A custom, automated system includes the newly updated a51nx horizontal machine with 60-tool magazine and EROWA robot multi-ERM system.

– The J3 horizontal machining center 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 vertical machining center 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 high-performance horizontal machining center 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). Learn how this technology is changing the factory floor and is expected to serve up disruption as well as opportunity over the next few years.

Lunch & Learn Sessions
In addition to the demonstrations and displays at IMTS, Makino plans to host Lunch & Learn events throughout the week. Each session includes presentations from Makino customers discussing real-world manufacturing challenges, and how they applied technology to their operations to become more competitive and more profitable. Lunch & Learn presentations offer relevant information to attendees from a wide array of industries and manufacturing environments, including automotive, aerospace, medical, die and mold, and more. This year’s guest presentations currently include Tennessee Tool & Engineering (Oak Ridge, Tenn.), Turbine Technologies (Farmington, Conn.) and Dynamic NC (Rose Hill, Kan.).

Makino introduces its EDNC21 sinker electrical discharge machine (EDM) with dual heads that provide an industry-changing advantage by improving productivity and lowering the tool build time for large molds. The EDNC21 also includes Makino’s latest EDM innovations and developments including the Hyper-i control, HyperCut technology, and new HS-Rib high speed Z-Axis.

“As the design complexity of extra-large workpieces, such as automotive bumper and fascia molds, continues to grow, manufacturers must identify new means for processing a wider variety and volume of small intricate features with maximum throughput,” explained Brian Pfluger, Makino’s EDM product line manager. “The dual-head configuration of the EDNC21 enables shops to process multiple fine details in a workpiece at the same time, significantly reducing total processing time. Due to its rigid and precise construction, the EDNC21 is capable of achieving the same level of accuracy and surface finish as sinker EDM machines one-tenth its size.”

The EDNC21 offers a sizable work envelope of 122.0 inches by 70.9 inches by 39.4 inches (3,100 mm by 1,800 mm by 1,000 mm) to accommodate extra-large workpieces, such as automotive bumper and fascia molds. The X-, Y- and Z-axes of the machine provide cumulative travels of 78.7 inches, 59.1 inches and 23.6 inches (2,000 mm, 1,500 mm and 600 mm), respectively. Each of the EDNC21’s gantry-style heads is capable of traveling up to 78.7 inches (2,000 mm) and is independently controlled and programmed using a dedicated Hyper-i control system for each head. The EDNC21 provides a total workpiece payload of 22,047 lbs. (10,000 kg) and accommodates electrode weights up to 662 lbs. (300 kg) per head.

The design of the EDNC21 includes a programmable rise-and-fall front door for easy operator access during setup and operation. Door height, which controls dielectric fluid level, can be set to match the height of the workpiece while providing optimum viewing of the machining operation.

Every Makino EDNC-Series machine also includes these features:

– High-mass castings to ensure mechanical and thermal stability
– Stationary table for accurate positioning regardless of workpiece size or weight
– Space-saving integrated reservoir in the base casting to reduce machine size and to achieve greater thermal stability
– Dual-anchored, direct-drive ballscrews that maintain precision long term

Revolutionary Hyper Technologies
Similar to other EDNC-Series sinker EDM machines, the EDNC21 is designed with Makino’s proprietary Hyper technologies, which ensure an ideal mix of speed, finish, and reduced electrode wear.

HyperCut technology is a new generator function that increases power levels without requiring additional reduction on the electrode, and it improves roughing speeds by up to 30 percent without affecting workpiece accuracy or surface quality. The technology minimizes electrode wear while providing the fastest possible machining speed.

Each EDNC-Series machine is equipped with the new Hyper-i control system, which is the same system used on Makino’s wire EDM products, signifying a standardization of Makino’s EDM machine controls. Hyper-i improves productivity by streamlining and simplifying the machine interface so that operators of all skill levels can achieve the most efficient results. Its 24-inch high-definition monitor provides touch-screen technology similar to that of smartphones and tablets, enabling the use of pinch, swipe and spread movements to select machining conditions for workpiece and electrode material type, and the desired feature shape and surface finish. The user friendliness of the Hyper-i control is further enhanced with the integration of on-board digital manuals, intelligent E-Tech Doctor help functions, and an e-Learning training system.

Additional Performance Enhancing Technologies
SuperSpark IV: SuperSpark IV is an advanced adaptive control technology that optimizes the machining discharge power and electrode jump motions during roughing and finishing operations. This technology is especially effective on rib or drafted electrodes; and, when combined with HyperCut settings, it can reduce total machining time by up to 50 percent.

High-Quality Surface Finish Option: All EDNC-Series sinker EDMs can be equipped with Makino’s proprietary High-Quality Surface Finish (HQSF) technology that yields achievable surface finish capabilities 50 percent better than conventional surface finishes, regardless of discharge surface area. The HQSF technology can extend tool life through improved surface integrity, and can also reduce cycle time even when fine surface finishes are not required.

High-Speed Z-Axis Option: The HS-Rib Z-axis configuration reduces rough machining speeds of small electrodes, such as plastic injection tooling ribs or pin gate details, and provides enhanced jump speeds of up to 20 m/min that can reduce machining times by up to 60 percent.