Thursday, September 7, 2023

New Machine Tools - Productivity Engineering Applications

New.

Popular E-Book on IE,

Introduction to Modern Industrial Engineering.  #FREE #Download.

In 0.1% on Academia.edu. 3600+ Downloads so far.

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0




The New GENOS M560V-5AX


The new GENOS M560V-5AX is an impressive next-generation product evolved from two of the company’s best-selling vertical machining centers – the GENOS M560V which has become a standard-bearer in the industry, and the GENOS M460V-5AX which launched in 2017 as an answer to a market need for an affordable, compact 5-axis vertical machine,


Machine Design


The GENOS M560V-5AX is built with a double-column machine design, affording it maximum structural integrity. The machine offers an impressive working envelope with a 500mm table and wide axis travels (X: 1,050 mm, Y: 560 mm, Z: 460 mm), while still maintaining a compact footprint of 2,515 mm x 3,750 mm. Further optimizing the machine’s design, the GENOS M560V-5AX includes a trunnion table positioned parallel to the front of the machine which allows for easier access to the table and good visibility during machining. This, and other user-friendly features on the machine, reduce physical burden on the operator. Additionally, the machine comes standard with a 60 ATC (automatic tool changer) magazine and can also accommodate tools measuring up to 400mm in length.


Built-In Energy Savings Features


The GENOS M560V-5AX comes standard with Okuma’s Thermo-Friendly Concept, an on-board thermal and energy management technology to support both stable, high-accuracy machining and reduce energy consumption.


Key Specs of the GENOS M560V-5AX Vertical Machining Center:


Table Size: 500 mm

Max Workpiece Dimensions: 700 x 500 mm

Spindle Maximum Speed: 15,000 min⁻¹

Spindle Motor Power: 22/18.5 kW

Axes Travel: 1,050 mm (X-axis), 560 mm (Y-axis), 460 mm (Z-axis)

Floor Space: 2,515 x 3,750 mm (w x d)

Weight: 10,000 kg

With its versatility and 5-axis cutting capabilities, the GENOS M560V-5AX provides shops with the ability to expand their operational possibilities.


https://www.okuma.com/press/okuma-america-corporation-debuts-the-genos-m560v-5ax-machining-center-at-imts-2022


https://www.okuma.com/products/genos-m560v-5ax


High machining capacity and high-rigidity machine construction

that makes highly efficient production possible


Capable of heavy machining of a wide variety of materials and has a powerful standard spindle that reduces machining time.


Maximum spindle speed 15,000 min-1, maximum output 22 kW

Maximum cutting capacity 672 cm3/min

(Material to be cut: S45C steel, end mill machining)

https://www.okuma.co.jp/english/product/5avmc/genos_m560v-5ax.html



Machining a Latch Bracket with Okuma Genos M560v 5AX and PowerMill (Full Video)

Autodesk Advanced Manufacturing

4 Feb 2019

Here's the complete 5-axis machining cycle of a latch bracket. This video shows Okuma's latest CNC machine, the GENOS M460V-5AX, designed to deliver 5-axis milling at a lower price point. Machining cycles created and simulated using Autodesk PowerMill and the live cutting was showcased at IMTS2018.


A Linkedin Post

https://www.linkedin.com/feed/update/urn:li:activity:7044654017292980225 


Unfolding Swiss Style Machines Advances

July 12, 2023

Bill Koenig

By Bill Koenig

Senior Editor,

SME Media

https://www.sme.org/technologies/articles/2023/july/unfolding-swiss-style-machines-advances/


Lesson 102 of Industrial Engineering ONLINE Course.

Refer to Industrial Engineering Case Studies Collection for case studies and productivity engineering applications

Lesson 102. New Machining Processes - Productivity Engineering Applications

Increasing productivity of each and every input is to be attempted by industrial engineers.

Process Improvement - Productivity Analysis and Productivity Engineering.

Industrial engineer analyzes each process into its ultimate, simple elements, and compares each of these simplest steps or processes with an ideal or perfect condition and modifies the element appropriately. - F.W. Taylor - Hugo Diemer.

Prof. Hugo Diemer  - Taylor's Industrial Engineering

https://nraoiekc.blogspot.com/2020/05/prof-hugo-diemer-taylors-industrial.html

Industrial Engineering

Industrial engineering redesigns and installs engineering systems primarily. It also examines and redesigns managerial processes that impact productivity in engineering systems. Machine tools and other machines are important components of engineering systems. Industrial engineers have to analyze the currently available machine tools in the market and the existing machine tools being used in the factory, plant and processes to identify more productive and profitable replacement of new machine acquisition opportunities.

This collection offers you information on new machine tools and application of new machine tools to increase productivity to help you in giving ideas and directions in developing alternatives for your current machine tools in operations productivity improvement exercises/studies.

Reasons for buying a  new machine tool: Increase productivity, increase capacity, reduce costs, new machines for new products,  tighter quality standards, process flexibility,  and make more parts instead of buy. 

Analysis of of the appropriateness of existing machine tools and the scope to utilize new machine tools that are being offered by various companies is also part of facilities industrial engineering. Industrial engineers need to evaluate the existing facilities every year to find opportunities for replacing them for productivity.

The machine tools and other production equipment are also examined during process improvement studies using process charts. Each time an operation is being examined, the opportunity of using equipment that is available with outside vendor is to be compared with using the equipment available within the company. This is the comparison of the element of work being currently done with the best alternative available.


Top Machine tool companies: DMG Mori, Germany/Japan - Yamazaki Mazak - TRUMPF, Germany

SMTCL, China - Amada, Japan - Dalian, China - Komatsu NTC Ltd. - Schuler, Germany

Toyoda, Jtekt, Japan - Okuma, Japan


A DECISION SUPPORT SYSTEM FOR MACHINE TOOL SELECTION

Continuous introduction of new technologies force companies to use new machine tools. 

Appropriate selection of a machine tool for a production system is an important task.

https://pdfs.semanticscholar.org/bf55/aa817da37d73faacd6db6a3fc6d1f75f43ef.pdf



New Machine Tools and Their Applications to Improve Productivity

2020

North American debut of the all-new VARIAXIS C-600, a full simultaneous 5-axis Multi-Tasking machining center featuring a flexible, automation-ready design and the new MAZATROL SmoothAi CNC.

25/2/2020

https://www.mazakusa.com/news-events/news-releases/new-machines-and-technology-to-debut-at-mazak-midwest-discover-event/

The Best of both Worlds - Schütte  ECX series,   single-spindle automatic 

With the new ECX series, Schütte presents a single-spindle automatic for the first time. The ECX represents the optimal solution for decreasing lot sizes in mass production. It combines the flexibility and simple handling of single-spindle automatics with the productivity of multi-spindle automatics and thus closes the gap between the two worlds.

http://my.page2flip.de/15433595/17758102/17758154/html5.html#/8


Double Column type Machining Centers - shibaura-machine.co.jp

https://www.shibaura-machine.co.jp/en/product/machinetool/lineup/m/


Compact with huge potential - compact 105 linear grinding machine

The innovative, compact 105 linear grinding machine impresses with its high productivity, short cycle times and lasting precision. This is made possible by special kinematics, which ensure maximum accuracy with an innovative axis arrangement. With scalable automation solutions and intelligent expansion options, the machine adapts exactly to the production requirements.

http://my.page2flip.de/15433595/18693150/18693151/html5.html#/1

New Entry Level 5-Axis Universal Machine Technology Increases Job Shops looking for machining solutions that increase productivity.

https://www.automation.com/en-us/articles/august-2020/universal-machine-increases-job-shop-productivity


Machine Tool Components That Help Improve Process Efficiency, Productivity

July 29, 2020, Article From: July 2020 Manufacturing Engineering, Kip Hanson, Contributing Editor

Stuff a shop needs to utilize machine tools effectively and efficiently to make parts efficiently, accurately, and cost-effectively.

https://www.practicalmachinist.com/manufacturing-engineering/machine-components-help-improve-process-efficiency-productivity/

2019

Trends In CNC Automation: Efficient, Connective, Simple

by Industrial Automation Asia | May 23, 2019 | Issues & Insights

https://www.iaasiaonline.com/trends-in-cnc-automation-efficient-connective-simple/

New DUO Machine for Series Production: The VL 5 DUO from EMAG delivers a boost to the Production of Powertrain Components up to 250 mm

08/07/2019

https://www.emag.com/press/news/single-view/article/new-duo-machine-for-series-production-the-vl-5-duo-from-emag-delivers-a-boost-to-the-production-of.html


A new CNC sliding-head lathe: the 12 mm bar capacity Cincom L12 Type X. 

It is intended primarily for production of dental abutments and implants, but is also well suited to manufacturing parts for the medical industry in general.

https://www.citizenmachinery.co.uk/new-sliding-head-lathe-tailored-to-medical-component-production/

Toward Intelligent Machine Tool, Engineering

Volume 5, Issue 4, August 2019, Pages 679-690

https://www.sciencedirect.com/science/article/pii/S2095809919307635


EMO 2019 Fair - Machine Tools on Display from Leading Manufacturers

3 SEPTEMBER 2019

https://www.aero-mag.com/emo-hannover-2019-machining-technology/

MHI Machine Tool Launches the New MAF-E II Series of Table-type Horizontal Boring Mills.

Thermal Deformation Control Provides Stability in  High Processing Accuracy and Productivity --

2019-07-24

https://www.mhi.com/news/190724.html

Retrofitting an aging CNC machine with a new CNC can improve its productivity, cut soaring maintenance costs - Siemens retrofit services

https://assets.new.siemens.com/siemens/assets/api/uuid:0223e6fc-c93e-4d8d-846c-97626e9c824f/siemens-machine-tool-retrofit-article.pdf



A Low-Cost Vision-Based Monitoring of Computer Numerical Control (CNC) Machine Tools for Small and Medium-Sized Enterprises (SMEs) 

Sensors (Basel). 2019 Oct; 19(20): 4506.

https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6832709/

2016

New Machines for  Productivity, Flexibility, & Connectivity


New-generation automatic lathe
INDEX Corporation  ABC machine 

for turning out simple to moderately complex parts in cycle times up to 15% faster than the series’ previous standard, with rapid spindle acceleration (8 g), shorter spindle ramp-up times, higher rapid traverse rates, and quick chip-to-chip times. 

Suitable for runs of 5,000 to 50,000 parts in the 42-60 mm range. Provides low cost per piece targets, even for complex parts.

Up to 19 tools  with live tools for both turrets. Very short cycle times are achievable due to simultaneous machining with up to three tools. The ABC is equipped with up to five driven back-working tools and offers driven tools in all turret positions.

The machine is available in two-, three-, or four-axis versions. The motorized 27-kW, 6000-rpm spindle, can generate up to 95 Nm of torque.

Within the easy-to-access work area, mounted above the main spindle is the upper turret used mainly for I.D. work. The lower turret is typically for O.D. work. A synchronized spindle operates in the upper turret. Both turrets feature a rapid traverse of 36m/min. The ABC can handle heavy-duty polygon turning and thread milling with a counterspindle or drive attachment.

Also, the ABC can can be fitted with a quiet-running Index bar loader, which may save 4-30 seconds per cycle, and automatic part unloader automation.

www.indextraub.com

"Ultra narrow" machines for high speed, high volume
MAZAK recently introduced the new UN Series of high-speed horizontal (left) and vertical (right) machining centers, the UN-600/30H and UN-600/30V, respectively, to address requirements for high productivity, reliability, maintenance and automation in automotive manufacturing.

Designed for the mass production of automotive components, these #30 taper machines feature an extremely small footprint (as indicated by their UN designation, for "ultra-narrow") and are up to three times more productive per unit of floor space than normal-sized machines, according to the developer.

UN Series machines are automation-friendly, allowing multiple machines to be placed together and tended by one robot.

The width of the UN-600/30V vertical machining center is 27.4 in.; it can accommodate a maximum workpiece diameter of approximately 23.6 in. This is possible because of the interpolated machine C- and Y- axes for the X-axis, which is programmed in the same way as a conventional machine X-axis.

The UN-600/30V offers 20-tool storage capability.

The UN-600/30H horizontal machining center has the same, 23.6 in. maximum workpiece diameter and is substantially smaller than other horizontal machining centers in its class. This is due to a compound X-axis, whereby half of the axis stroke is on the machine table and the other half is on the machine column.

The UN-600/30H features 30-tool storage capability.

New integral spindle/motors are used for faster acceleration/deceleration to provide unsurpassed high productivity. The UN Series machines feature high-speed 20,000 rpm machine spindles that accelerate to top speeds in just 0.55 seconds, and perform synchronized tapping at 8,000 rpm.

www.MazakUSA.com

Five-axis vertical machining for faster production

MAKINO’s latest full five-axis machine solution is the DA300 vertical machining center, combining speed, precision and flexibility for complex part applications. The DA300 “delivers the highest productive capabilities for multi-axis workpieces in the smallest of machine footprints.” 

It is developed as a single setup, multi-side accessible, or full-contouring operation for processing complex parts comming in industrial hydraulic and pneumatics elements, optical, electrical and semiconductor components, medical and dental products, diecastings, automotive components, and aerospace parts.

“The DA300 integrates numerous features that increase productivity and efficiency by providing significant reductions in non-cut time.  “The machine provides a 50% reduction in spindle acceleration time, 15% reduction in positioning time, 40% reduction in tool-change chip-to-chip time, and (it) 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%.

When all of these time savings are combined,  dramatic advantage in reduced part-production times and increased profitability can be obtained.

The DA300 worktable is an integral, 340X300-mm table, accommodating workpiece sizes up to 450 mm in diameter, 400 mm tall and weighing 250 kg. The machine provides X-, Y- and Z-axis travels of 450, 620, and 500 mm, respectively, at feed rates of up to 60,000 mm 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 for high productivity in complex five-face or full five-axis machining.

www.makino.com

New high-productivity HMC
MATSUURA MACHINERY USA INC.’s new H.Plus-504 horizontal machining center achieves high productivity thanks to high speed, rigidity, precision, reliability, and low cost of ownership. The series delivers long periods of reliable, unmanned operation, high accuracy, and exceptionally efficient production. Since the H.Plus series’ debut in 2000, over 1,700 of the machining centers have been installed worldwide in various industries, including: aerospace, aircraft, automobile, medical and precision subcontractors.

The H.Plus-504 is equipped with 500x500-mm pallet and #40-taper spindle. In response to customer and market demand for accommodating larger workpieces, the H.Plus-504 possesses the largest working envelope in its class and will handle a maximum workpiece size of 800x1,000 mm (DxH), weighing 750 kg on each pallet.

In addition to the standard 12,000 min-1 spindle, a 20,000 min-1 (108.4 Nm) for high-speed machining and 15,000 min-1 (350.0 Nm) for high-torque, heavy-duty machining are available.

A rotary indexing table (B axis) is provided as a standard feature, which is driven with a direct drive motor with a maximum feed rate of 100 min-1. In addition, Matsuura's DCS (Dynamic Clamp System) and ADC (Automatic Acceleration and Deceleration Control) contribute to shorter cycle and indexing times.

www.matsuurausa.com


1999

Case Study 64 of Industrial Engineering ONLINE Course  


High Speed Machining of  Bulkhead at Raytheon Aircraft Makino (Mason, Ohio) MC1516 high-speed horizontal machining center


Raytheon Aircraft Company (Wichita, Kansas) does industrial engineering, that is continuous improvement in engineering. Attention is given to  maximize throughput and efficiency. 

Raytheon engineers came to know about high speed machining and  decided to use a Makino (Mason, Ohio) MC1516 high-speed horizontal machining center with a seven-pallet modular machining center (MMC) to machine  bulkhead.   MC1516's Jet 50 spindle provides up to  15,000 rpm. The 50 taper spindle provides horsepower at various ranges and brings a high level of rigidity.  

To machine the bulk heads,  end mills reach 12,500 rpm and achieve metal removal rates as high as 320 cubic inches per minute.  In two setups, the MC1516 machines thin wall tolerances under 0.00010 inch to near net shape. Roughing and finishing are conducted simultaneously using carbide end mills.

The seven-pallet MMC allows the spindle engagement for more than 90 percent of the time. The MMC allows setups offline and keeps the MC1516 constantly fed.

The new technology adoption had challenge of learning quickly. The team consisting  of people in every discipline involved in the process, from manufacturing engineers, programmers to the operator  worked with Makino to learn and optimize the new process. The planned learning paid off with production parts being machined immediately after installation. Raytheon quickly realized the efficiencies, such as reduction in machine and labor hours per part. The machine uses  universal vacuum fixturing also. While the larger bulkhead is machined on a dedicated fixture, vacuum fixtures allowed operators to set up smaller parts in one operation.

The successful process improvement using high speed machining  will be extended to more parts.

https://www.mmsonline.com/articles/high-speed-machining-helps-modernize-bulkhead-manufacturing

Machine tools - Production machining case studies

5 axis machine
https://www.productionmachining.com/search?q=case+study+five+axis&page=2

7/2/2020 
Meet Production Machining’s 2020 Emerging Leaders
https://www.productionmachining.com/blog/post/meet-production-machinings-2020-emerging-leaders

ud.7.9.2023,  9.10.2022
pub. 7.9.2021

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