Turn/Mill MetalTech Report – Cutting time to save money

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Beltless design for no backlash
The Puma MX 2600ST is a mill turn machine capable of producing parts up to 29.9 in. (737 mm) diameter by 59 in. (1499 mm) long.

Powering the machine’s turning component is a 35 hp, 4,000 rpm, high torque spindle motor. The motor is mounted on the headstock casting with the armature on the spindle O.D. This beltless design eliminates backlash, feedback error and vibration, resulting in longer tool life, less maintenance, high precision, and superior finishes. Driving the milling component is a 12,000 rpm, 30 hp motor.

The lower tool turret can accommodate live or static tools at any of its 12 stations, and be oriented toward either the main or sub-spindle. A 6.7 hp motor turns the live tools at speeds up to 4,000 rpm. The turret is non-lifting to protect the coupling from chips and other contaminants, and indexes station-to-station in 0.2 seconds. Milling tools are housed in a 40-tool ATC; an 80-station ATC is optional. Tool-to-tool change is 1.8 seconds.  

The MX2600 combines a B axis (tilting) with Y axis to expand the number of geometries that can be machined without using customized rotary toolholders. It can cut, drill or tap above or below centerline, machine angular features, and provide a solid platform for heavy duty machining. A rigid, three piece curvic coupling locks at 5° increments, while the RGC provides extra rigidity in 0.001° increments.

Fine-grain Meehanite castings absorb vibrations and inhibits thermal distortion and twisting. Three linear guideways on the upper carriage Z axis provide rigidity and alignment during tough cuts without lift or torsion that might otherwise compromise accuracy. The bed’s torque-tube construction prevents twisting and distortion during heavy cuts, and provides a through-the-machine conduit for cool air.

Increased cutting capacity
Feeler FT-Series High Performance CNC Turning Centres, available in North America from Methods Machine Tools, have a new all-boxway design for increased cutting capacity. 

The series includes four models: FT-200, FT-250, FT-350 and FT-350L. For exceptional rigidity when performing heavy duty cutting, each of the models has a single-piece structure with boxways, 45 ° slant bed and robust base. For maximum integrity, FEA analysis is used to ensure a solid machine base with excellent overall structural rigidity and stability. 

Additional new design features include a more rigid Z axis and tailstock rail for maximum support and accurate tracking.  The FT-Series includes a new spindle head stock with a sleeve-type spindle, and the latest high rigidity servo turret, including clamping with curvic coupling for stable and swift tool changes. For multi-tasking capabilities, the machines are equipped with a 7 ½ hp milling motor with 51.6 ft-lb torque.

The machines are equipped with a Fanuc 0i-TD control and 12-station turret.   Customers can choose from four different gear boxes and two spindle types. Spindles range from 2,500 rpm to 4,500 rpm and offer chuck diameter sizes from 8 in. (210 mm) up to 15 in. (381 mm). Bar capacity ranges from 2.6 in. (65 mm) to 4.5 in. (115 mm). Maximum turning diameters range from 13.0 in. (330 mm) to 25.0 in. (620 mm) and maximum turning lengths are from 21 in. (530 mm) to 60.2 in. (1,530 mm). Machine weight ranges from 9,925 lb (4,500 kg) to 21,500 lb (9,750 kg), depending on the model.

A BMT-65 tool system features a solid interface for toolholding. A servo programmable tailstock is standard. 

Small frame machines
Hardinge Inc. has released four new turning centres: the GS 42MS, GS 51MS, GS 150MS and GS 200MS. These small-frame machines are suited for small to medium size workpieces and offer expanded levels of functionality to address complex parts, resulting in increased throughput and reduced cycle time in a single setup.

Both the GS 42MS and GS 51MS machines feature collet-ready main spindles, while the GS 150MS and the GS 200MS models are chuck machines supplied with three-jaw chucks. The GS 42MS and 150 MS are equipped with an A2-5 in., 6,000 rpm main spindle, while the GS 51MS and GS 200MS offer a larger A2-6 in., 5,000 rpm main spindle. Sub spindles, live tooling, C axis and Fanuc 0i-TD controls are standard on all models.

Options include parts catcher, part probe, tool probe, chip conveyor, and servo or hydraulic tailstock.

Hyundai WIA
Four machines in one
Hyundai WIA’s new series of twin spindle multi-tasking CNC turning centres, the LM1600/1800TT, feature upper and lower turrets and available Y and C axes, allowing for the processing of complex parts in volume production runs. The new series is four machines in one—two lathes and two mills. They feature high power built-in spindle motors and upper and lower turrets for high productivity. Precise synchronized facing twin spindles reduce idle time, and BMT-type turrets guarantee accuracy and power. 

The LM1600/1800TT series features a 45° slant bed design. The pretensioned and double anchored design provides outstanding positioning and repeatability with virtually no thermal growth. Rapid high speed axis movement is achieved by the use of linear motion guideways in the Z axis, complimented by box guideways in the X and Y axes, for added rigidity. Rapid traverse: X1/X2 axes, 20/20 m/min (787 ipm); Z1/Z2 axes, 40/40 m/min (1575 ipm); and Y axis, 7.5 m/min (295 ipm).

The upper turret on the TTY and TTSY configured machines use a wedge-type Y axis, which permits machining of complex parts in a single chucking. With a Y axis travel of +/- 50 mm (100 mm [3.94 in.] total), a wide range of workpieces can be machined. 

Built-in spindle motors for left and right with identical specifications allow for high speed precision machining in either direction. Each spindle features angular bearings for high speed accel/decel as well as smooth machining with minimal noise and vibration at high rpms, even at the highest rotational speeds. Spindle temperature is further controlled by the use of a spindle chiller. Left and right spindle specifications are equal 6000 rpm, 15/11 kW, A2-5 with 208/140Nm of torque on the LM1600TT and 5,000rpm, 22/11 kW,  A2-6 with 358/214 Nm of torque on the LM1800TT. 

Live tooling features a 5.5/1.1 kW motor with a maximum milling speed of 5,000 rpm and torque of 47 Nm. An ER25 collet system allows for the use of up to 16 mm diameter tools. The machines feature the latest generation Fanuc 31iA CNC control. 

Five axis tool tip positioning
Integrex j-300 is a multi-tasking machine from Mazak Corp. that specializes in four axis simultaneous machining with five axis tool tip positioning. It performs turning, milling and drilling operations for simple and complex workpieces in fewer setups.

The machine increases spindle utilization with its standard 20-tool magazine (optional 36 or 72-tool magazine), increasing versatility in part production. The machine’s main turning spindle with C axis control and 10 in. chuck capability delivers 25 hp, 4,000 rpm for handling even the most demanding metal removal applications

The machine’s 30 hp, 12,000 rpm milling spindle allows for four axis simultaneous machining plus five axis tool tip positioning indexed in 5º (or optional 1º) increments from –30º to 190º (B axis control). This capability makes it possible to perform O.D. machining, as well as turning, facing, grooving and threading with the same flash tool. Because of its Y axis stroke of 9.84 in., the Integrex j-300 has a larger machining envelope and extended tool reach with minimum interference, and chip evacuation is much more efficient as compared with conventional turn/mill slant bed lathes.  

The milling spindle can be radially indexed and clamped, enabling the same tool to be used for turning in both forward and reverse directions. Mazak’s MX Hybrid Roller Guide System dampens vibration to extend tool life, handles higher load capacities, and accelerates and decelerates quicker to shorten cycle times.

Mazak’s Matric Nexus CNC control allows for both conversational and EIA/ISO programming, and ensures easy programming for C axis, Y axis and angle machining. The control also provides realistic 3D machining simulations, time study analysis and the Mazak Voice Advisor, which assists operators during setup to make initial operations smoother and safer.

As part of Mazak’s “Five Levels of Multi-Tasking,” the Integrex j-300 is a level three machine: independent milling spindle headstocks with B axis indexing, as well as full Y axis travels and tool storage magazines. Machine features and functionalities within the other four levels range from level one with single spindle and rotating tool capabilities and level two with Y axis off-centre machining to l      evel four machines providing full simultaneous five axis capability and level five Ultra-tasking machines with additional specialized machining functions.

Mori Seiki
Machining small parts
The NTX 2000S is a compact high precision, high efficiency integrated mill-turn centre designed for machining complex small precision parts for medical equipment and measuring instruments. The machine is designed with a 40 per cent smaller footprint than previous models.

The NTX machines offer extensive features including advanced thermal displacement compensation, a 40 per cent smaller footprint than previous models, and Mori Seiki’s original DDM (Direct Drive Motor), ORC (Octagonal Ram Construction) and BMT (Built-in Motor Turret) technologies.

It features speeds of up to 5,000 rpm and is designed with X, Y and Z axis travels of 19.5 in. (194 mm), 9.8 in. (250 mm) and 61.4 in. (1,560 mm) respectively. Tool storage capacity is 38 tools.

The machine features a maximum turning length of 60.6 in. (1540 mm), part diameter of 24 in. (610 mm) and a bar capacity of 2 in. (52 mm). Rapid traverse rates in X, Y and Z axes is 1,574.8 ipm (40,000 mm/min).

Mori Seiki’s MAPPS IV operating system combined with ESPRIT CAM software (standard) allows the machine to handle complex machining programming and to flexibly meet customer needs. In addition, the 3D interference checking function (standard) checks collisions between spindles, workpieces, soft jaws, tools, holders, and turrets in 3D. If an interference is detected, it stops the machine in both automatic and manual modes. 

High rigidity machining

The Nakamura-Tome WT-300 is a high speed multi-tasking machine that provides simultaneous machining of turning and milling to XZC/XYC axes, as well as complex drilling to edge face/OD, outlining and pocketing machining processes.  

It offers up to 30 kW of cutting power for turning shaft work with synchronized spindles. Motor power is 15/11 kW per spindle. Key features include a driven-tool motor power of 5.5/3.7 kW for heavy cutting with small tools. The flexible machine features upper and lower turret construction and four axis machining; other machining combinations are also possible on either spindle. The two spindle/upper and lower turret design allows for complex multi-axis machining.

It has a 12-station turret with half-index capability (48 tool positions in total) and up to 24 tools per turret. The 24-station bi-directional turret features high speed indexing (0.2 sec to the adjacent tool). 

Shorter idle time is achieved with faster rapid traverse rates of 16 m/min (630 ipm) for the X axis and 27 m/min (1063 ipm) for the Z axis. The Y axis, with a stroke of +/-60 mm (+/-2.36 in.), allows machining of accurate keyways, drilling off-centre holes, face milling, chamfering and circular threading.

Collision avoidance software
Okuma’s Multus B200II CNC machine is a general purpose, multi-function lathe designed to reduce setup by virtually eliminating repetitive fixturing, improving accuracy and keeping non-cutting time to a minimum.  

The machine is designed to complete milling and turning operations in one setup. The machine features Machining-Navi L-g, full five axis capability with high accuracy C axis, Super NURBS, TCPC (tool centre point control), inverse time feed, and Blum gauging. The machine is equipped with the industry’s first Collision Avoidance System software powered by Okuma’s THINC-OSP P300 control, allowing the machining process to be simulated and prevent potential collisions before they damage the machine. Built on Okuma’s exclusive Thermo-Friendly Concept, the Multus B200II ensures high accuracy, even in the most complex applications.

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