High Precision Machining, Lower Cost Metal 3D Hybrid Machining of Large Parts

In Booth S-338420, Takumi USA (Indianapolis, IN) will debut their new line of 5-axis machining centers, including the U600 (XYZ/AC travels: 24.4 in x 39.4 in x 19.7 in / +30 deg to 110 deg x 360 deg) and U800 (XYZ/AC travels: 31.5 in x 39.3 in x 29.5 in / ±120 deg x 360 deg). Both machines utilize a trunnion style, two-axis table and a Heidenhain TNC 640 control. The U800 is a high speed gantry machining center over the high torque table (800 mm platter) that features an 80 rpm twin-torque motor A-axis and a 100 rpm single-torque motor C-axis. The U series was developed to achieve world-class performance for die and mold, aerospace and other high speed applications that require tighter tolerances.

The U800 will be featured with a 5-axis simultaneous cutting demonstration of a 20 in tall replica of the famous Venus De Milo sculpture. The reproduction will be produced in 4140 steel to showcase the rigid machine construction, speed and superior part surface finish. Programming of the Venus De Milo will be provided in partnership with Cimquest Inc. (Branchburg, NJ) using Mastercam 5-axis toolpaths. “We decided on this sculpture for the demo because the Takumi tagline is The Art of Productivity, which is a rough translation of the word “Takumi,” and 5-axis illustrates the art of productivity perfectly,” said Maggie Smith, their marketing manager. U800 specifications include:

• Table Size 800 mm
• Table Load 2,204 lb
• XYZ Travels 31.5 in x 39.4 in x 29.5 in
• A/C Travels ±120 deg / 360 deg
• XYZ Rapids 1,890 ipm
• A/C Rapids 80 rpm / 100 rpm (Direct Drive Ballscrews)
• Spindle Taper HSK-63A
• Spindle 20,000 rpm, 33.5 hp, 88 ft-lb torque
• ATC Stations 32
• Machine Weight 39,683 lb

Also on display will be a Takumi H12 double-column machining center, the perfect platform to accept the integration of the additive manufacturing process with its large work envelope and high speed machining capabilities. H12 specifications include:

• Table Size 59.1 in x 37.8 in
• Table Load 5,512 lb
• XYZ Travels 53.2 in x 37.4 in x 23.6 in
• XYZ Rapids 1,181 ipm (Direct Drive Ballscrews)
• Spindle Taper BIG PLUS® 40
• Spindle 15,000 rpm (Direct Drive), 20.1/24.8 hp, 105.5 ft-lb torque
• ATC Stations 30
• Machine Weight 28,600 lbs

Integrated with the H12 will be the Metal 3D Printing Tool from 3D-Hybrid Solutions (Seal Beach, CA), one of the largest and fastest metal 3D printers with full in-process machining capability, according to company founder Karl F. Hranka. “With this large double column machining center and our economical Wire-Arc Additive tool, we will be breaking new ground in the market for a high precision, lower cost metal 3D hybrid machining center,” said Hranka. “Large scale metal additive manufacturing applications will be realized with the technology on this machine.” A demonstration will be focused on matching with the machine’s strengths for producing very large high precision parts found in the tooling, mold and die industries. Why hybrid? Consolidating this AM tool with a CNC machine is filled with value propositions:

• Single setup and in-process machining.
• Simplified management structure and reduced learning curve.
• Greatly reduced barrier to entry for metal AM.
• Repair and salvage applications.
• Just-in-time manufacturing, feeding wire to near-net-shape production.
• Reduced material costs on large parts.
• Multi-material parts.

Production metal 3D printed parts require post machining to be joined to mating parts. “We embrace this and focus on evolving and advancing directed energy deposition technologies like 3D-Tools for the CNC environment,” added Hranka. “We offer three metal AM technologies for CNC machines: Wire-Arc Additive Manufacturing, Laser Metal Deposition and Cold Spray. Together, these technologies can handle almost any metal AM application and alloy.” Visitors will also learn how to “make more chips” with a FANUC H control on a heavy duty, high torque Takumi V11 machining center, in a partnership with Greenleaf Corporation (Saegertown, PA). V11 specifications include:

• Table Size 45.28 in x 25.59 in
• Table Load 2,420 lb
• XYZ Travels 43.31 in x 26 in x 24.01 in
• XYZ Rapids 787 ipm (Direct Drive Ballscrews)
• Spindle Taper CAT 50
• Spindle 6,000 rpm (Geared), 14.8/20.1 hp, 397 ft-lb torque
• ATC Stations 24
• Machine Weight 14,960 lb

Takumi USA, 7220 Winton Drive, Indianapolis, IN 46268, 844-302-3792, Fax: 952-314-0119, www.takumiusa.com.