The combination of speed and power on the MA-12500HW is well suited for large part aerospace machining.

The hallmark of the MA-12500HW is its ability to provide a good balance of speed and cutting power for machining difficult-to-machine materials, cast iron and aluminum alloys. This makes it well suited for large part aerospace machining. The W-axis allows for a longer tool stroke to machine complex, difficult to reach part features. It has a maximum tool length of 1,100 mm. At IMTS 2016 the MA-12500HW will be shown with the new W-axis option and in skeleton form. It will feature a cutting simulation of a steel construction frame.

Key Features of Okuma’s MA-12500HW Horizontal Machining Center Built on an integral bed and base, and designed with reinforcing ribs for increased stability and load carrying capacity, the MA-12500H incorporates Okuma’s exclusive Thermo-Friendly Concept to achieve maximum thermal stability and accuracy. Standardly-equipped with a 50 taper 6,000 rpm, 60/50 horsepower spindle, it is also available with either a 12,000 rpm wide range spindle or 4,500 rpm heavy duty spindle.

• Maximum load capacity of 11,000 pounds
• Rapid traverse (X, Y, Z) of 1,653 ipm
• Maximum part size: 78.72” diameter x 58.07” high
• Axis travels: X-86.61”, Y-58.07”, Z-64.96”
• .001 degree B-axis rotary table
•  49.21” square pallet
• • Parallel-type 2 pallet APC
• • 81 tool matrix ATC standard, up to 171 tool matrix optional

Based in Dettingen, not far from Stuttgart, Germany, DIETZ-motoren is a privately owned business that has spent almost 100 years perfecting electric motors and radial fans used in niche industry sectors, such as food production, textiles, specialist machinery, etc.

None of the company’s products are made in great volume; some of the manufacturing processes, such as winding, are in fact still done by hand. However, DIETZ manages to produce around 150,000 motors and fans of various sizes and power outputs every year, most of which are shipped to customers overseas.

The company’s finishing and assembly buildings are busy, but light and relatively quiet, and are dotted with small tress and plants, which give a peaceful, natural feel. The adjacent machine shop, on the other hand, is noisy and, by comparison, frenetic. On most days, it’s open and running round the clock.

This is just one of the company’s two factory sites. The other is in the Swabian Jura, the low, snowy mountain range of the state of Baden-Württemberg.

The Dettingen site, with the bigger of the two machine shops, is home to six of the company’s eight Haas CNC machine tools. As well as Haas SL-30 and ST-30 turning centres and a Haas Mini Mill, there’s a Haas VF-5 and two Haas VM-3s, which do most of the higher-volume machining.

“The VM-3 was our first Haas machine,” says Chief Engineer, Dieter Irsiegler. “We needed a flexible vertical machining centre with good power and high spindle speed.

“We have a large and varied product range, so we also needed the optional 40-station tool changer. The table on the VM-3 – which has T-slots in X and Y, allows us very quickly and easily to create fixtures for our parts.”

Between them, the VF-5 and the VM-3 can be called upon to machine any part from a database of 400 different programmes, to tolerances of 0.02 mm. All the Haas machines work between 16 and 24 hours a day, depending upon demand, and each of them is equipped with a Haas HRT310 CNC rotary table.

“They’re very reliable machines,” adds Chief Engineer Irsiegler. “It doesn’t matter how many hours they work, they always keep tolerance. The VF-5 is actually ten years old, so it has made a lot of parts in its life so far.”

After the company had bought its two Haas vertical machining centres, it also invested in a Haas SL-30 turning centre, which, like the other Haas workhorses, runs 24-hour shifts. It’s used to machine high-tolerance surfaces on flanges.

“The Haas CNC is another feature of all the Haas machines that gives us greater flexibility. The control is very easy to use, and it’s essentially the same on all Haas machines, so we’re able to move operators between machines – whether vertical mill or lathe – when we need to.”

Again, according to Eng. Irsiegler, the Haas SL-30 has proven to be 100-percent reliable.

“Reliability and service are very important,” he reiterates. “We have no back-up, so if a machine were to break down, we’d need it fixed and up-and-running straight away. The local Haas Factory Outlet is very efficient, and they give us good and prompt support.”

For engineers like Dieter Irsiegler, who run CNC machines round the clock, and who want to sleep soundly at night, reliability and dependable support are essential. Unlike finishing and assembly areas, machine shops are very noisy places. They need to stay that way.

Makino introduces the a40, the first and only horizontal machining center purpose-built for non-ferrous die-cast parts machining. Until now, machine tool selection for the die cast market has been limited to general-purpose horizontals that possess unnecessary capabilities and result in extended cycle times in the machining of near net shape die cast parts. The a40 addresses the unique needs of the die cast market by enhancing machine attributes most critical to improving productivity and per-piece costs in the machining of near net shape die-cast aluminum parts.

“Die cast manufacturers are under intense pricing pressure with mandatory cost reductions from OEMs and increasing global competition. The keys to overcoming these challenges lies in the reduction of machining cycle time and elimination of unplanned down time,” said David Ward, horizontal product line manager for Makino. “To address the cycle time issue, Makino has re-evaluated each of the major castings using a Intelligent R.O.I [Reduction of Inertia] design philosophy. The new design provides superior linear and radial agility and acceleration.”

With the introduction of the a40, die cast manufacturers now have a machine that is designed specifically with their production goals in mind. The machine’s ability to reduce part machining cycle time not only cuts down on per-piece cost, but also has far-reaching savings affecting capital investment, labor, floor space, utility consumption and durable tooling.

The a40 offers a 400-mm pallet with a workpiece capacity of 630 mm (24.8 inches) in diameter by 900 mm (35.4 inches) tall, making it an ideal platform for die cast parts commonly machined in the automotive and consumer product industries. Axis travels of the machine are 560 mm (22.0 inches), 640 mm (25.2 inches) and 640 mm (25.2 inches) in the X, Y and Z planes, respectively. Maximum payload is 400 kg (880 lbs). The a40 also offers numerous features and capabilities for improved utilization and reductions in non-cut time, including a 40-position automatic tool changer and an automatic pallet change system ensure uninterrupted operation

Makino’s Intelligent R.O.I. Design

Makino’s Intelligent R.O.I. (Reduction of Inertia) design is a collection of innovative technologies designed to slash un-productive non-cut times from part processes. Through this unique design strategy the a40 is able to provide:

• Responsive CAT40 spindle acceleration to 12,000 rpm in 0.5 seconds.
• Quick completion of common tapping operations with 6,000-rpm rigid tapping synchronization speed.
• An average of 29% faster time to full rapid traverse rate, minimizing common feature to feature positioning time.
• Optimal acceleration performance of multiple machine systems with evaluation of fixture and tool weights through Inertia Active Control (IAC) technology.

Proven Reliability

Unplanned down time is devastating to high-volume die cast production machining. As such, the reliability of the machining system is paramount. The a40 utilizes several of the robust, proven systems from Makino’s 1-Series horizontal machining centers. Systems like single-piece X- and Z-axis covers, center trough chip and coolant management and dual supported ATC mechanisms provide exceptional reliability throughout the life of the machine. The a40 leverages these proven technologies, but then advances reliability with a host of new systems:

• Standard Vision type broken tool detection supports unattended operation by quickly validating the condition of the cutting tools after each tool change.
• Dedicated tool taper cleaning nozzles wash the tool taper with 20μ filtered coolant with each tool change, ensuring contamination free tool clamping.
• Three stage coolant filtration with 20μ hydro-cyclone, eliminates coolant tank sludge common with aluminum machining, extending time between coolant system PM or cleaning.

Makino Engineering Services and Automation Solutions

For many die cast part manufacturing facilities, machining is a secondary capability that demands specialized labor skillsets and expertise. Machine shops seeking to maximize the productive benefits of the a40 can turn to Makino for engineering support that maximizes the productive capabilities of their machine investment.

Makino Engineering Services have an unmatched history of creating robust production-ready processes—including machinery, fixtures, tools, programs and documentation—for parts with complex geometries, demanding deadlines, challenging budget constraints and Six Sigma standards. While many North American manufacturers face difficulty finding skilled labor, Makino Engineering Services has experienced engineers and project managers that can manage every step of a project with single-point contact, project engineering, on-site supervision and post-installation training and support. Hundreds of manufacturers in need of integrated flexible manufacturing solutions have taken advantage of these services, each benefiting from guaranteed cycle times, Cpk and cost per part that meet or exceed their production goals.

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.

The HTM-H series machining centers from Hision are designed with rigidity while offering state-of-the-art accuracy. The interior of each machine tool features triangular strengthening tendons to increase the thickness of the body and provide unparalleled durability. This machining centre is suitable for the heavy duty cutting and high precision machining with high rigidity and high accuracy.

The Horizontal Machining Center Series products:

• Are equipped with FANUC control system
• Feature adopt T type casting bed
• Include gang type columns
• Feature positive hanging spindle box
• Feature positive hanging spindle box

Its unique design T-shaped bed and headstock hung frontal with symmetrical configuration.

All major component such as bed, column, pallet saddle and spindle headstock are high grade meehanite casting to provide superior stability and vibration damping characteristics. Structural strength of each part has been optimised by thik walled casting together with extensive use of ribs, preventing from bending or distortion.

The cross section of the rectangular guideways is thick and wide for maximum machine rigidity. Guideways are hardened and ground to assure accuracy and long life cycle. The sliding surface is sticked with the Turcite B-HP from Shampan, super vibration absorbing ability.

Equipment, parts and engineering services will be available to all tiers of aerospace manufacturing for test cuts and productivity trials

Okuma announces that they have opened an Aerospace Center of Excellence at their facility in Charlotte, North Carolina. The Aerospace Center of Excellence is open to aerospace manufacturers for use as a testing and proving ground for advanced CNC machining technology to enhance productivity while solving the unique challenges faced by the industry. The nearly 10,000 square foot space currently houses nine CNC machines designed for the aerospace market, totaling more than $6.5 million in value. The space also includes a fully-operational metrology room including CMM equipment and other quality measurement devices, and a conference room. Additionally, visitors have access to the Partners in THINC facility, which currently houses an additional 16 machines, valued at $4.5 million and ranging from entry-level CNC lathes to machining centers and grinders.

In addition to Okuma equipment and dedicated engineering personnel, facility activities will incorporate resources from members of Partners in THINC, enabling access to an additional 50 suppliers of peripheral equipment and accessories. Tooling, workholding, gauging, software and other products necessary to optimize manufacturing processes will be easily available, as will the corresponding engineering experts.

“We envision that the facility will be used by various levels of aerospace suppliers, from Tier 3 to OEMs, to help them test new equipment, processes and materials. We have been working with our Partners to improve exotic metal cutting through the use of tool management software, cutting tool selection and other productivity enhancements, and now we want to help the actual manufacturers with these same challenges,” notes Jim Kosmala, Vice President of Technology.

The debut of the center will be December 9 and 10, 2014 when Okuma America Corporation hosts its annual open house. The theme of this year’s event is “Make the Leap” and will be showcasing technology and machines that enable manufacturers to move up the technology spectrum. Aerospace demonstrations taking place at this year’s event include:

• Titanium cutting on the new MA-12500H horizontal machining center
• A stator segment being cut on the MU-10000H 5-axis vertical machining center
• Gear cutting on the new MULTUS U4000 multitasking horizontal lathe
• Blade cutting on the new MULTUS U3000 multitasking horizontal lathe

Jim King, President and COO states, “While the Aerospace Center of Excellence is physically located in Charlotte, we are using our worldwide resources to support this effort. Okuma has a global team made up of people from Okuma Japan, Europe and America, who are working closely to identify new processes and technologies specifically to help this industry address their challenges. It’s an existing and ongoing mission and the Center establishes a centralized point of collaborative expertise for delivering innovation and productivity enhancements to aerospace manufacturers.”

The Okuma aerospace initiative has already resulted in a collaboration with The Boeing Company on the new ISO STEP-NC standard, originally presented at the recent International Manufacturing Technology Show (IMTS) 2014. Additional technologies will be on display at the Paris Air Show in June, 2015 where Okuma Europe and America will be jointly exhibiting.

“Everything adds up to accuracy. It’s our purpose as a company,” says Stephen Flynn, president of Optical Gaging Products (OGP), a division of Quality Vision International (QVI). “Manufacturers of high-accuracy, leading-edge products require precision-engineered measurement and inspection equipment that can guarantee definitive accuracy. In order for our equipment to meet this demand, we require a high degree of precision machining from our machine shop.”

Founded in Rochester, N.Y., in 1945, QVI is a global leader of metrology solution. Its brands include OGP, VIEW Micro-Metrology, Quality Vision Services, RAM Optical Instrumentation and Certified Comparator Products.

The shop at the Rochester headquarters is key to the company’s highest quality metrology devices, producing precision parts that can make or break the equipment’s accuracy and reliability. Machining these precision parts in-house gives QVI complete control over their products and enables them to use their own metrology expertise to verify the accuracy of parts they make.

“You always want your measurement gauges and equipment to be more accurate than the specs you need to measure,” says QVI Shop Floor Manager David Wolf. “Likewise, our products must be more accurate than what our customers are measuring. We’re fighting the same battle as our customers—always improving accuracy and precision machining capabilities so we can deliver superior products.”

Visionaries in Precision Metrology
“To stay current with customer demand, we provide a diverse product range covering a wide spectrum of industries,” says Flynn. Starting with a selection of 50 standard-model machines, QVI is also capable of engineering a metrology solution ideal for specific customer applications.

“The final product we deliver represents measurement devices and services we use internally,” says Flynn. “We work at the shop-floor level with our customers, helping drive our products ahead of most manufacturing trends. A good example of this is OGP’s emphasis on multisensor systems.”

OGP’s multisensor measurement systems contain a variety of sensor types, often including lasers, touch probes, microprobes and other sensors working in conjunction with their video measurement technology to measure the most critical components and difficult-to-measure features. QVI’s engineering department designs these metrology systems with broad customer applications in mind.

“A multisensor measurement system can provide extremely detailed measurements, doing precise measurements of more dimensions in a single part setup,” explains Wolf. “Since the sensors work throughout the system’s usable volume, overall accuracy relies on the base-model construction, which is why we focus on producing the base-model precision parts here in Rochester.”

QVI’s manufacturing partners produce the components of some of their products, but they keep the precision machining of critical components in-house to control final quality and accuracy. OGP’s SmartScope® Flash 302 contains several critical components machined by QVI at its Rochester location.

Smartscope Presents Manufacturing Challenges
QVI began development of the SmartScope Flash 302 for OGP in 2007, a CNC benchtop multisensor system that can accurately measure parts within its 300-mm-by-300-mm-by-250-mm volume. “A key to manufacturing the 302 was a high strength-to-weight ratio,” says Wolf. QVI had to meet tolerances typically machined in hardened ground tool-steel but did it in aluminum to reduce weight.

The Flash 302 is the largest benchtop machine in the OGP inventory. Aluminum comprises 90 percent of its weight. These tight tolerances as well as high production goals and critical precision parts, such as the base plate and X-axis yoke, made it clear to QVI that their current lineup of machine tools was unable to meet the 302’s manufacturing requirements.

“Most machine tools require a sacrifice in accuracy for a larger work envelope, which we couldn’t afford,” says Wolf. “And while profitable machining for us once meant utilizing machine tools long after they were paid for, the 302 required capabilities that could only be found in modern, precision machining centers.”

QVI evaluated horizontal machining centers from several manufacturers, based on the specific design and engineering requirements of the 302 yoke, which moves in one axis and carries the sensors that move on it in a perpendicular axis. (The third axis moves across the base.) Two of the yoke’s most critical features, a pair of identical bores located on opposite ends of the part, required bore accuracies of ±5 micron, while holding location tolerances to ±2.5 micron. In assembly the yoke must hold better than 1 arc second per inch of travel.

“Most horizontal machining centers use a vertical machining center spindle on a horizontal plane. Makino’s a61 was designed with a slant column structure for a stronger Y-axis that resists Z-direction cutting forces,” explains Wolf. “We told Makino Y-axis straightness travel of less than 10 arc seconds was required, and they were the only builder that immediately responded that wasn’t a problem. In fact, when we measured the a61, we found it exceeded all the tolerances Makino listed, including Y-axis straightness, which we measured at 4 arc seconds.”

QVI’s a61 has a 14,000-rpm spindle, allowing the use of high-speed tools and advanced tool holders that let them achieve surface finishes of 0.8 RMS and 2- to 3-micron roundness tolerances. The a61 exceeds all tolerance requirements and is even used to machine prismatic components with tolerances that require single setup machining to eliminate stack-up error. While the company originally anticipated the need to purchase a $50,000 trunnion fixture to accomplish this task, the a61’s rotary table provided the positioning accuracy to machine the parts without extra equipment.

In addition to providing the necessary precision machining accuracy, with the a61, QVI experienced increased machine tool reliability, essential to the fast production of precision parts for the 302.

Maintenance requirements were another pleasant surprise. “We had come to expect way cover replacements every two to three years, which often entailed long periods of machine downtime,” says Wolf. “The a61’s way covers show no signs of degradation after two years of heavy use.”

Increasing Throughput
Wolf continues, “The a61’s capabilities are exceptional, exceeding our expectations and impressing even the most skeptical in our shop. In addition to meeting the yoke’s accuracy demands, the machine’s rapid acceleration/deceleration rates and 0.9-second tool changes have reduced part cycle times by 50 percent.”

Nearly two years after purchasing the a61, QVI approached Makino again for a machine with a larger work zone and high metal-removal rates. They chose a Makino a81 horizontal machining center.

“The 302 base plate requires serious metal removal that our previous machines could not complete fast enough, causing large backlogs,” says Wolf. “Since we got the a81, base plate roughing times have reduced by almost 70 percent while still achieving the required 5-micron tolerances.”

To further reduce cycle times and retain the highest accuracy, QVI purchased a multisided fixturing vise that enables the a81 to machine all six sides of the base plate in one setup. Operators use the a81’s two-pallet system to fixture additional base plates, reducing out-of-cut time and increasing throughput.

“The slowest operation of the base plate was the final finishing procedure due to the straightness and perpendicularity requirements of the 302’s structural supports,” says Wolf. “Increased roughing accuracies reduced finishing times and sped 302 production, allowing us to achieve a much faster than expected ROI on the a81.”

Verification
QVI’s knowledge and experience in precision metrology provide them with unique inspection and machine verification resources unavailable to most machine shops. One such resource is QVI’s Chief Metrologist Eric Gesner, who uses the unique Etalon LaserTRACER® volumetric accuracy test equipment to measure geometric errors in the working volume of a machine tool. The device’s core component is a laser interferometer with nanometer resolution that automatically follows a reflector to measure distance and calculate accuracy.

“Our products don’t just measure accuracy. They define it,” says Gesner. “To accomplish this, we calibrate and compensate machine tools using volumetric error mapping and compensation technology.”

After a year of service, QVI performed machine calibration tests on the a61 to qualify and verify the machine’s accuracy. The results showed an average of less than a 3-micron error in straightness accuracy for all axes. Gesner attributes that good performance to the machine’s design elements, which include rigid construction and features such as glass scales. Using the LaserTRACER, QVI was able to tweak the a61 even further, resulting in submicron positioning accuracies. The Etalon software outputs a volumetric error map that is downloaded to the machine’s Fanuc controller’s 3D Error Compensation option. Verification of the straightness errors after volumetric compensation showed a threefold improvement with an average of less than 1-micron error in straightness accuracy for all axes.

“We found the dynamic accuracy of the a61 to be excellent, even after an extended period of service,” says Gesner. “The machine’s design has ensured superior performance in terms of geometric, thermal and cutting-force characteristics. These tests don’t lie, which is why we use these same inspection techniques on our products.”

Measuring Future Growth
“Our precision machining processes must be superior in order to provide our customers with equipment that provides definitive accuracy and constant reliability,” says Flynn. “No matter how complex parts become, we have to provide measurement capabilities that are ahead of the trends. To accomplish this, we turn to high-performance machining technologies that provide the same performance we expect from our own machines.”

“Being a market leader in measurement equipment requires the ability to produce parts with accuracies beyond our customers’ required specs,” adds Wolf. “This shop isn’t afraid of new technology and with the results we’re seeing out of our a61 and a81, we’re more excited than ever to push the envelope of measurement standards. When your purpose as a company is accuracy, you can’t settle for anything less.”

Courtesy: Makino

In addition to the presentations of a newly-developed motor spindle with a cross-feed device and the innovative swivel axis calibration for universal machines, GROB-WERKE will be exhibiting its latest technologies in the fields of energy efficiency and production control systems at the AMB. Der GROB-WERKE trade fair stand is in Hall 5, stand C38.

Since the construction of the new exhibition center, the International Metalworking Trade Fair (AMB) in Stuttgart has been an excellent platform for GROB-WERKE to present its latest developments in the universal machine sector. Six years ago when GROB first demonstrated a universal machine at the AMB, trade fair visitors were able to gain an impression of what it means for the GROB engineers to incorporate and implement concentrated know-how from systems business in the universal machine business. Another example of such a “development” can be seen at the AMB in the newly-developed motor spindle with an integrated cross-feed device for contour turning of complex work pieces. This can be used in the future, for example, to produce the contour of a high-temperature resistant turbocharger housing directly in the GROB universal machine in one clamping operation and therefore much more economically.

GROB will be demonstrating such a process with the universal machine G550 NEW at its trade fair stand C38 in Hall 5. It is equipped with the new motor spindle with an integrated cross-feed device as well as HSK-A100 and a Siemens control unit. It is used at the fair to demonstrate contour turning of a turbocharger made of high-temperature resistant steel and a demonstration work piece made of aluminum. The second GROB machine on display will be the G350 NEW universal machine with the 28,000 motor spindle and Heidenhain control unit. The machine will be processing an aerospace aluminum structural component live in operation with a high cutting rate and tremendous 5-axis dynamics. Finishing is possible with the large swivel range of the axis (225°) in one clamping operation.

Chip-in-spindle detection system (SiS) for universal machines.
GROB will also be demonstrating another technology that can be used for system and universal machine business with its SiS detection system. This system permits peak time neutral detection of tool clamping errors caused by chip inlays between the face of the hollow shank taper and the spindle nose. The special feature of the GROB SiS system is safe and independent detection of very small chips between the tool taper and the spindle taper as well as between the faces of the spindle and the tool holder of 10µm and more. As the detection of tool clamping errors caused by chip inlays is not only a topic in large-scale automotive production, but especially for safety-relevant components, GROB also supplies its motor spindles with chip-in-spindle detection system for its universal machines. This is a system that is integrated into the motor spindle and that inspects the tool interface for possible errors after automatic tool changes. Sensors in the spindle nose detect and evaluate the asymmetric deformation of the tool clamping point caused by chips. Energy and signal communication between the stator and rotor is wireless. The chip-in-spindle detection system is not tied to cycle times and does not require any preparation in the working area of the machine. It is therefore an ideal supplement for enhancing process reliability during automatic tool changes in the machining centers.

New GROB production control system G-Net
The fourth industrial revolution “Industry 4.0” is currently a frequently discussed topic. The “G-Net” Manufacturing Execution System creates cross-work transparency throughout the entire production process by means of web technology. The “G-Net” permits machine feedback for the CIP process and lets the machine “talk” to its environment. Visitors to the fair will be able to see for themselves how G-Net can be used practically by users at the GROB trade fair stand. GROB customers can in future be supported in production with GROB software solutions from CAD models through to the finished component. Customized solutions can be shown with modular applications for topics such as production data acquisition (PDA) and machine data acquisition (MDA) or web-based, mobile reporting. With the G-Net app it is possible to exchange all production-specific data from the ERP und PLM systems directly from the machine. The new G-Net interface permits real-time access to the ERP system from the machine or from the ERP systems to the machine. The perfect interaction between the robust and high-precision G-module range and the intelligent G-Net generates tremendous productivity advantages. GROB has been thoroughly testing G-Net at its own production works for more than a year. G-Net is currently generating more than 60,000 messages per week in the GROB production works – without stress. Machine operators quickly become accustomed to using the intuitive and easy-to-use G-Net user interface with minimal training. The practical findings are directly incorporated into the development cycle. GROB customers therefore benefit from practical solutions for practical applications.

A new dimension of 5-axis accuracy with GROB Swivel Axis Calibration (GSC)
The rotational axes of all machine tools have slight systematic geometric deviations that add up to a total volumetric deviation in the working area. Measuring methods to detect these errors have been developed to cope with this phenomenon. These include the “CYCLE996” and the “CYCLE800” measuring cycles that take the measured values during swiveling into account. With the GROB Swivel Axis Calibration (GSC) GROB engineers have revolutionized this measuring process – another GROB trade fair innovation. With the GSC technology it is possible to almost double the accuracy of the work processes in comparison with existing technologies. This is a tremendous advantage over classic technologies, especially for customers who have to produce very precise parts (individual components), for example in the aviation industry.

This high accuracy is achieved by a more exact description of the kinematics. While conventional methods describe the kinematics with four figures, the GSC typically uses 30. The GSC technology practically replaces the “CYCLE996” or quick-check, as GSC works considerably more accurately and is always active – not only when the “CYCLE800” swivel cycle is programmed. As a result GSC can also be used in automotive applications in which no “CYCLE800” but predetermined zero values are used. In addition measurement is simpler and more flexible. GSC not only enables high-precision work piece machining, but also minimizes the number of necessary run-in parts.

GROB energy efficiency – complex and comprehensive
GROB development engineers have been focusing intensively on the topic of energy efficiency for many years. With their holistic approach they are able to enhance energy efficiency and therefore increase output. The entire complexity of this key issue will be shown at the GROB trade fair stand and an entire range of measures for improving energy efficiency in complex production systems and universal machining centers will be explained. GROB specialists will be explaining the effects on energy efficiency when a system can look into the future with the MES (Manufacturing Execution System) and knows exactly which job is coming next and when the system can “sleep” because there is nothing to do or when it has to “wake up” so that it can prepare “just-in-time” for production of the next part. There is hardly a field of research that is so complex and comprehensive, as it has to deal with the technology, i.e. the product, the optimum production of the components and also the entire manufacturing strategy.

Manufacturers of medical, aerospace, prototype and complex multi-face parts have long understood the positive impact that 5-axis machining can have on productivity and quality, simply by consolidating operations. Makino’s a51nx-5XU 5-axis horizontal machining center raises these capabilities to a new level, building on the quality, durability and reliability of the nx-series next-generation horizontal machining platform. With a newly designed 5th-axis table and work-pallet magazine, this new machining center enables manufacturers of complex parts to obtain the highest levels of utilization and efficiency.

“When looking for a small 5-axis machining solution, companies are typically limited to single-pallet-load vertical machining centers,” said Dave Ward, horizontal product line manager at Makino. “The a51nx-5XU stands apart with its horizontal orientation, integral cast 5th-axis table and integrated workpiece automation. Together, these features provide for a highly productive, highly reliable multi-axis machining solution that eliminates recutting of chips, stack-up errors and challenges of 5-axis part loading. It’s the perfect blend of capabilities for the manufacturing of rotating cutting tools, aerospace, medical and prototype components.”

The linear X, Y and Z axes of the a51nx-5XU are built from the same proven structure as Makino’s industry-leading a51nx horizontal machining center. Its rigid bed casting with three-point leveling system provides a solid foundation for all critical machine components. A tiered-column design redirects machining forces and resists deflection even high in the Y-axis. These features are further complemented by high-performance linear guides, for long-term reliability. Altogether, the a51nx-5XU design offers dynamic stiffness and exceptional vibration management for the highest degree of cutting stability.

A 5th-Axis Table Built to Last
With increasing demand for small-part 5-axis machining, many companies are adding aftermarket 5th-axis rotary tables to 4-axis machining centers. However, these 5-axis retrofits frequently offer less rigidity and pose several challenges in cable interface management. The a51nx-5XU avoids these issues with a single casting design that houses and integrates the B- and C-axis’ twin direct-drive motors. This single-piece casting provides ideal rigidity and a minimized profile that reduces interference between the spindle and worktable. All cables are concealed to the roofline of the machine’s splashguard and can be easily accessed and managed outside of the machining area. The a51nx-5XU rotary table design eliminates the stack-up errors, loss of rigidity and cable management challenges common to many table-on-table designs.

The design of the large direct-drive motors within the B and C axes enhance the productive capabilities of the a51nx-5XU, providing rapid traverse rates of 75 rpm and 150 rpm to minimize non-cut times. Jacket cooling of the direct-drive motor stators and bearing perimeters eliminate all risk of thermal deformation to help maintain repeatable, high-accuracy performance with exceptional quality. The C-axis also benefits from a BT-style 50-taper Big Plus (BBT50) interface and clamping mechanism, which provides location and clamping of the workpiece within the 5-axis machine envelope.

Integral Automation Efficiency
Traditionally, one of the biggest challenges associated with 5-axis part production has been automated capabilities. This is why Makino designed the a51nx-5XU with a unique work-pallet magazine (WPM) that simplifies pallet changes in horizontally oriented 5-axis applications, and facilitates unattended operation for more value-added labor demands.

The WPM takes the place of a traditional horizontal pallet changer, providing manufacturers with automated load/unload capabilities for maximum machine utilization. This technology follows a similar design to that of Makino’s proven matrix tool magazine, ensuring quick and reliable transfer of workpieces between magazine and machine worktable. The standard WPM offers storage capacity of 22 different workpieces with sizes up to 300 mm in diameter by 300 mm tall. An optional, larger capacity WPM provides storage of up to 58 workpieces with diameters up to 200 mm. Parts are mounted directly to the 50-taper dual-contact tool holders (BBT50) and stored in the WPM matrix. This capability makes the a51nx-5XU an ideal solution for continuous, unattended manufacturing in both high-mix, low-volume and low-mix, high-volume production environments.

The WPM system includes a dedicated work-setting station (WSS) for loading and setup operations, providing convenient and ergonomic operator access. A nearby work data management panel allows operators to process data defined per pallet and manage work schedules. Priorities can be set and changed for each pallet, helping to accommodate for engineering changes or urgent one-off part orders. For advanced levels of scheduling control and machine networking, the a51nx-5XU can also be equipped with Makino’s MAS-A5 control system.

Makino has been honored by FANUC Robotics America with its 2013 Outstanding Sales Growth Award. The award was presented at the company’s Integrator Conference in March, and demonstrates the record volume of new robotic automation cell installations that Makino Engineering Services performed.

“We are incredibly appreciative of the award and our relationship with FANUC Robotics,” said Dave Walton, integration services manager at Makino. “The Makino Engineering Services group is constantly working to build stronger relationships with automation partners in order to provide customers with the highest degree of technology, service and support. This award is an affirmation that we are meeting these goals and raising the bar for automation integration and engineering support.”

These automated systems are supporting companies across North American in driving business growth, improving quality standards and achieving greater profitability and global competitiveness.

Makino Engineering Services
Makino Engineering Services has an unmatched history of creating robust production-ready processes—including machinery, fixtures, tools, programs and documentation—for parts with complex geometries, demanding deadlines, challenging budget constraints and Six Sigma standards. Hundreds of manufacturers in need of integrated manufacturing systems have taken advantage of these services—each benefiting from guaranteed cycle times, Cpk and cost per part that meet or exceed their production goals.

Doosan Infracore (President and CEO Yongsung Kim) recently announced that the company will support its partner companies with high potential to grow into global parts suppliers, called ‘Leading Suppliers’. Doosan Infracore selects six companies this year to start with and plans to support a total of 44 companies by 2018.

The six companies were selected as Doosan’s ‘Leading Suppliers’ among the 295 partner companies: IMB Hydraulics, S-TEEL, Woojin, Wookwang Industrial, Samwoo Tech, and Topmetal Works.

Doosan Infracore will diagnose partner companies’ capabilities in the areas of manufacturing technologies, plant operations and quality assurance, and use the result to offer each of them customized solutions. Once their strength and weaknesses are defined, Doosan will dispatch the internal experts in purchasing, engineering, manufacturing and quality management to the work sites of the partner companies to raise their competitiveness and to keep improvement efforts on-going.

The company also plans to develop a manual for systematic supports for ‘Leading Suppliers’ with the assistance of external consultants.

The partner companies grown as ‘Leading Suppliers’ will share their know-how with other partner companies in their respective business categories offering benchmarking cases.

“We will select our partner companies showing great potentials and give them a full support in order for them to grow as globally recognized ‘Leading Suppliers’ through our specially designed programs,” said Yongjin Lee, Director of Heavy Sourcing, Doosan Infracore.