 If several spindles are required for the output volume in question, the economical approach is sequential production with the processes spread over a number of machines. In the past, this usually meant using the same types of machines. But now Makino can offer its customers a broader choice of machines for sequential production: a1 Series horizontal machining centres (HMC), J Series agile manufacturing modules and the Slim3 vertical machining centre (VMC). The type of machine chosen depends on the complexity of the parts geometry and the machining. The Makino portfolio allows machine profiles to be specifically selected to suit the task in question and idle functions reduced to a minimum. This new manufacturing package is rounded off by technological solutions based on Makino’s worldwide market experience – Smart Tools™ and devices as well as suitable automation concepts.
Choosing a machine
The Makino a1 Series is ideal for applications where highly precise pitch tolerances, linear drilling or complex contours apply. These HMCs are designed for outstanding accuracy, thermal stability and high capability requirements. The J Series agile manufacturing modules can be easily configured to suit the workpiece in question, e.g. four or five axes in a variety of positions. The fixed table design simplifies the fixture interface in automated operations. Smart Tools™ can be deployed via additional axes, e.g. a U- or W-axis, and heavy tools and long drill rods via an optional rack tool magazine. The Slim3 is a recently launched vertical machining centre for milling, drilling and tapping operations and is also suitable for precise thread cutting. All the linear axes are in line with the workpiece
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movement and the table is detached so that, like the J Series, all the requirements for integration into automated operations are met.
Slim3: technical highlights
This machine is built for speed, accuracy and reliability. Speed in this case means a 15,000RPM spindle system, 1.3 sec acceleration and a fast axis speed of 48 m/min. The dynamic acceleration/deceleration is even more impressive: X = 1G, X = 1G, Z = 1.5G. A chip-to-chip time of just 3 sec counteracts the problem of non-machining periods, which can account for 60-70% of the time with preformed aluminium workpieces. The positioning accuracy is <5µm, roundness the same (NAS part). The machine’s reliability is based on the simplicity and robustness of its construction: a simple design of the axis parts, no telescopic cover, an armless ATC and no cylinder for the ATC door – mechatronics pure. However, numerous optional extras are available, e.g. a pallet changer, auto work and tool length measurement, a broken tool sensor, 3+2 or 4+1 axis concepts, a hydraulic fixture control interface and various monitoring systems.
Automated production
The simplest automation solution is the lean part conveyor concept, which in this case can truly be described as ideal since this Makino machine is so slim with an X stroke/width ratio of 1:2.5. A 6-axis robot can be added for highly autonomous, changeable systems and a gantry robot for compact, highly dynamic production cells involving peripherals. Makino can point to several decades of experience in the automation field so that Makino’s specialist team of system integrators can implement either standard or customised systems.
Customised turnkey projects
Makino has the technology, application and automation know-how for turnkey solutions. For example, seven Slim3
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machines and an a61 HMC were deployed in a project to manufacture clutch housings and transmission casings. The parts were produced in a total of eight operations on more than ten fixtures. Two of the machines were equipped with pallet changers and three had additional rotational axes. The machining time was between 11 and 15 minutes, and the number of tools per workpiece varied between 49 and 54. 100,000 parts were produced per year and the Cmk capability factor was 1.33.
Lean manufacturing
These machines are tailor-made for lean manufacturing concept in that different technologies can be intelligently combined to suit the complexity of the parts geometry and the machining. The automation interface enables a lean, agile and changeable production cell to be set up. In other words, this lean manufacturing concept is just the right for the turbulent times the market is going through.
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