More Ways to Increase Spindle Utilization
To minimize costs while achieving required production volumes in shorter periods of time, shops are finding new ways to increase their spindle utilization by doing more processes between changeovers on their machine tools.
Posted: March 5, 2014
5-AXIS CD GRINDING CENTER FEATURES AUTOMATIC GRINDING WHEEL AND TOOL CHANGER
United Grinding Technologies (Miamisburg, OH) offers their new Mägerle MFP 50 5-axis CD Grinding Center that features automatic grinding wheel and tool changer and represents one of the most flexible, multi-tasking CD grinders in the Mägerle family. The MFP 50 is the smallest in the Mägerle machine line and offers a great number of various configurations, depending on the application. The compact and symmetrical traversing sliding column design, together with precision pre-loaded ball screws and wide hydrostatic guideway bearings, ensures high static, dynamic and thermal stability.
Grind, Mill and Drill in One Setup
The MFP 50 includes an integrated automatic tool changer which can switch wheels in eight seconds using a swing arm configuration. Maximum tool dimensions are 300 mm x 60 mm x 76.2 mm, and wheel/tool changer capacity, depending on the diameter, is 10 to 30 conventional grinding wheels, plated or ceramic bonded CBN wheels as well as drilling and milling tools. A reliable HSK-80 wheel flange system offers rigidity and precision needed for close tolerance parts with high surface finish requirements. Tool options include vitrified CBN, plated CBN, conventional grinding wheels and various other metal cutting options.
The machine is equipped with a proven overhead mounted two axes CD diamond dresser with horizontal and vertical NC axis for the accommodation of several diamond rolls with various profiles for CD or non-CD, as well as for CNC dressing with a disc. The grinding wheels with different profiles are always on the same spindle position.
Wrap-Around Hydrostatic Guideways for Stiffness, Reliability
An important feature of the MFP 50 are its guideways. Mägerle developed hydrostatic wrap-around guideways utilized in the Y-axis. These are 100 percent wear-free and offer high rigidity and load capacity, optimum smoothness and vibration dampening and maximum precision and process reliability. All main axes of the MFP 50 can rapid traverse at 20,000 mm/min (790 ipm). X-axis travel is 500 mm, Y-axis spindle travel is 660 mm and Z-axis travel is 660 mm.
http://youtu.be/ToaeuKCW1Sg
The Mägerle 6-Axis Creep Feed Grinding Machine is configured for efficient and cost-effective machining of compressor blades for jet engines.
Control
The MFP 50 features state-of-the-art Siemens Sinumerik 840D digital controls. Machine operation, setup, changeover, dressing and programming of even complex parts are easily accomplished through the operator-friendly control.
United Grinding Technologies, Inc., 510 Earl Boulevard, Miamisburg, OH 45342, 937-847-1253, Fax: 937-859-1115, www.grinding.com.
7-AXIS TWIN SPINDLE MULTITASKING CENTER WITH B-AXIS
Machine tool importer Absolute Machine Tools, Inc. (Lorain, OH) offers their Quicktech XTS-42 7-axis twin spindle multitasking turning center. This high precision, high production CNC bar processing center enables complete part machining, including milling of complex features.
Available in both 42 mm and 60 mm (1.65 in or 2.36 in) bar capacities as the XTS-42 or XTS-60, the machines feature 7 axes, 2 turning spindles, 1 milling spindle, and a capacity of 27 tools. A 3-axis (X,Y, Z) gang type vertical tool post serves each spindle, with the tool post featuring a full B axis for the live tools. Maximum turning length for the main spindle is 226 mm (9.05 in), and maximum turning diameter for the sub-spindle is 98.5 mm (3.94 in).
The main spindle has a 15 hp high torque spindle motor, and the sub-spindle is equipped with a 5 hp high torque spindle motor for backworking. Both spindles feature a full continuous C-axis with braking system and standard 42 mm DIN-173-42B collet chucks. The main spindle has either 42 mm or 60 mm bar capacity, the sub-spindle has 30 mm (1.18 in) bar capacity, and the spindles are synchronized for fast and accurate part transfer. The cartridge-type spindles employ P4 high precision bearings for stability and heavy cutting ability.
Absolute Machine Tools, Inc., 7420 Industrial Parkway, Lorain, OH 44053, 800-852-7825, Fax: 440-960-6918, cortner@absolutemachine.com, www.absolutemachine.com.
DUAL-PALLET VERTICAL MACHINING CENTERS
Hyundai WIA America Corporation (Carlstadt, NJ) offers their FD Series of CNC vertical machining centers, developed for high production environments with an integrated dual pallet configuration. The FD Series range includes the F410D (travels: 22.4 in X-axis, 16 in Y-axis, 23 in Z-axis), F500D (travels: 23.6 in X-axis, 18 in Y-axis, 22.4 in Z-axis) and the F600D (travels: 31.5 in X-axis, 23.6 in Y-axis, 23.6 in Z-axis).
Moving Column/Indexing Table
The FD Series machines benefit from the superior rigidity delivered through its unique traveling column design. The table and work piece remain stationary during machining, providing uniform loads to the guideways, ballscrews and the spindle motor. Further, the machine’s accuracy is increased by enlarging the width of the column, thereby minimizing heat distortion within the casting.
The dual, automatic 180 deg indexing dual pallet is incorporated into the standard design of the machine and is accessible from the front. Because the table remains stationary during cutting, productivity is increased and set-up time reduced due to the fact that the operator is free to safely set up on the pallet not in use. Pallet change time is a mere 6 seconds.
Bed Structure
The bed, column and saddle of the FD Series are designed using finite element analysis (FEA) to ensure powerful cutting and agility and are composed of Meehanite cast iron to minimize deformation when performing heavy-duty cuts. The rigid bed is designed to absorb vibration for stable machining. In order to eliminate thermal growth during machining, all axes are driven by high precision double-nut ballscrews. The double pretension design provides outstanding positioning and repeatability with virtually no thermal growth.
All ballscrews are connected directly to the servo drive motors without gears or belts, eliminating backlash. Rapid high speed axis movement is achieved by the use of linear motion guide ways in all three axes. This reduces non-cutting time and decreases machining time for greater productivity. Rapid traverse: 36m/min in X- and Y-axis and 30 m/min in Z-axis for the F410D.
Main Spindle
The FD Series can be configured with a 10,000 rpm spindle or with a 12,000 rpm spindle for high-speed precision applications. Ultra precision class angular bearings provide high speed accel/decel for smooth machining at high rpm. The main spindle delivers minimal noise and vibration even at the highest cutting speeds, guaranteeing extremely stable machining and minimizing thermal transmission to the main spindle, and with the use of a hydraulic tool lock system machining stability has been increased. Spindle motor is 20 to 25 hp with spindle torque rated at 287/143 Nm on the F600D.
Standard Thru Spindle Coolant
Thru spindle coolant is standard on the FD Series. This feature is particularly useful for deep hole drilling where it’s necessary to keep chip flow clear of the cutting surface. Thru spindle coolant also helps to increase tool life and decrease cycle time.
ATC and Magazine
FD Series machining centers are outfitted with 24 tool (30 tool optional), side mount swing arm type tool changers. This technology offers optimal performance with impressive tool change times of 1.6 sec tool-to-tool on the F410D and a 2.4 sec tool-to-tool on the F600D. With a capacity up to 30 tools (plus one in the spindle) setup time is reduced and run times can be made longer, especially if loaded with redundant tools.
The 24 (30 optional) tool swing arm automatic tool changer and magazine are separated by a shutter system which closes during machining, thus keeping chips and fluids clear of the ATC and magazine. When a tool change is required, machining stops, the shutter opens, the ATC exchanges old tool for new, the shutter door then closes and machining begins again. Maximum tool diameter — OD: 90/150 mm. Tool selection method: Random. Tool weight: 8 kg. Tool length: 300 mm.
Control
FD Series machining centers are easy to program and operate with its start-of-the-art Fanuc i-Series CNC control featuring a 10.4 in color LCD with Manual Guide i. As the industry’s most popular control, Fanuc offers compatibility and unchallenged reliability. A Siemens 825D control is also available.
Hyundai WIA America Corporation, 450 Commerce Boulevard, Carlstadt, NJ 07072, 201-636-5640, Fax: 201-636-5678, www.hyundai-wiamachine.com.
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