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Manufacturing Expansion Program, The Next Generation of Horizontal Machining Centers

Makino
Makino

This presentation on Manufacturing Expansion Program, The Next Generation of Horizontal Machining Centers has been adapted from Makinos webinar series. To view the full webinar, visit http://www.makino.com//resources/webinars/archive/manufacturing-expansion-program-the-next-generation-of-hmcs/205/ What type of horizontal machining center technology does it take to achieve next-generation productivity and efficiency? In this presentation, we provide a technical break down of the new nx-Series horizontal machining centers, and discuss what it means to take manufacturing to the next level. Through a series of case studies and test parts, we evaluate the capabilities of the latest 40-taper spindle technology and how it can redefine expectations for capability, capacity, productivity and reliability. See how these new horizontal machining centers can expand capabilities in making lower-cost parts faster than ever.

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Manufacturing Expansion Program Makinos nx-Series Horizontal Machining Centers David Ward Horizontal Product Manager 息Copyright Makino 2011
Manufacturing Expansion Program Makinos nx-Series Horizontal Machining Centers Topics to be discussed - What are the nx machines - Moving 40-Taper Machining to the Next Level - Expanding Capacity - Expanding Productivity - Expanding Reliability - Case Study 息Copyright Makino 2011
nx Horizontal Machining Centers X: Y: Z: 息Copyright Makino 2011 560mm (22.0) 640mm (25.2) 640mm (25.2) X: Y: Z: 730mm (28.7) 650mm (25.6) 800mm (31.5)
nx Horizontal Machining Centers a51nx Pallet Size Max. Weight Max. Workzone APC Time 息Copyright Makino 2011 a61nx 400mm (15.7) 500mm (19.7) 400 kg (880 lbs.) 500/700 kg (1,100/1,540 lbs.) 630 x 900 (24.8 x 35.4) 800 x 1,000 (31.5 x 39.4) 5.3 seconds 8.5/10 seconds
The Original 1-Series Machine Launched in 2002 New design Productivity Reliability Value Global production over 2,300 680 in North America 息Copyright Makino 2011
Next Generation 40-Taper HMC Redefine the boundaries of 40-taper machining by to levels typically not associated with 40 taper machines 息Copyright Makino 2011
nx Machines: Expanding Capacity Soft Hard Harder materials Larger work pieces Small 息Copyright Makino 2011 Large
nx Machines: Expanding Capacity How did Makino accomplish this? Larger work zones Rigid construction Higher spindle power 息Copyright Makino 2011
: Expanding Capacities Expand Y-axis stroke 14% Expand Z-axis stroke 7% Expand maximum tool length a51nx X-axis 560mm Y-axis 640mm Z-axis 640mm Tool length BT/HSK 430mm a51nx:640mm (25.2) a51:560mm (22.0) Expand machining area 息Copyright Makino 2011 Expanded machining area 14%
: Expanding Capacities Expand Y-axis stroke 12% Expand Z-axis stroke 10% Expand maximum tool length a61nx X-axis 730mm Y-axis 650 / (op:730)mm Z-axis 800mm Tool length BT/HSK 510mm a61nx:730mm (28.7) a61:650mm (25.6) Expand machining area 730mm High Column Option 息Copyright Makino 2011 Expanded machining area 12%
: Expanding Capacities Expanding Machining Area Accommodate MORE parts - Reduced Piece Part Cycle Time - Multiple Operation Fixtures Accommodate LARGER parts - Increased Flexibility - Reduced Floor Space 息Copyright Makino 2011
: Expanding Capacities Financial impact of larger work zones Produce same part on a smaller machine - 400mm vs 500mm - 500mm 40T vs 500mm 50T - 13% Capital equipment reduction Reduced floor space Reduced fixture and tooling costs Reduced energy consumption 息Copyright Makino 2011
: Rigid Casting Structure 息Copyright Makino 2011
: Rigid Casting Structure One Piece Bed Casting Provides foundation for all critical components Precision machined vs. Compensated Integral chip management 息Copyright Makino 2011
: Rigid Casting Structure Three Point Support Simplifies installation Easy to move / relocate Maintains geometry 息Copyright Makino 2011
: Rigid Casting Structure Tiered Column Design Resists deflection even high in Y-axis High degree of stiffness 息Copyright Makino 2011
: Rigid Casting Structure Roller guide rigidity and performance Improved load capacity Increased stiffness Improved life 息Copyright Makino 2011
: High Torque, High Power Spindles Standard Spindle a51nx and a61nx Horsepower 29.5 cont / 40 duty HP Torque 240 Nm (177 ft-lbs) Speed 14,000 Acc/Dec 19% increase in torque and HP compared to previous model 息Copyright Makino 2011 1.7 / 1.9 sec
: Standard 240 Nm Spindle Increased continuous HP expands MRR capacity in non ferrous applications 息Copyright Makino 2011
: High Torque, High Power Spindles High Torque Spindle a51nx and a61nx Horsepower 29.5 cont / 40 duty HP Torque 302 Nm (233 ft-lbs) Speed 14,000 Acc/Dec Ideal for ferrous applications Iron metal removal rates of 36.4 in3/min 息Copyright Makino 2011 1.7 / 1.9 sec
: Expanding Productivity In-Cut Time Cycle Time Non-Cut Time Traditional 息Copyright Makino 2011 Cycle Time In-Cut Time Non-Cut Time a51nx / a61nx
: Expanding Productivity How do the nx machines achieve this? In-Cut Time Cycle Time Non-Cut Time Direct Drive Rotary Table Improved Axis Acceleration Cycle Time In-Cut Time Non-Cut Time Traditional 息Copyright Makino 2011 a51nx / a61nx
: Direct Drive Motor Table Standard DD motor - NC rotary table Rotation speed鐚max.125min-1 High-speed positioning a51nx = 1.05 seconds (90 degree) a61nx = 0.98 seconds (90 degree) Reduce cycle time No backlash Increase accuracy Simple design structure Increase reliability 息Copyright Makino 2011
: Direct Drive Motor Table IAC (Inertia Adaptive Control) Acc/Dec control function based on work piece inertia With IAC Conventional Default Acc/Dec Heavy workpiece (large inertia) Light workpiece (small inertia) 息Copyright Makino 2011 Same Acc/Dec for Maximum Workpiece Heavy workpiece (large inertia) High Acc/Dec Light workpiece (small inertia)
: 1G Axis Acceleration Linear Axis Acc / Dec a51nx: 1G X / Y / Z a61nx: 1G X / Y 0.8G Z Rapid: 60 M/min (2,360 ipm) Capitalize on machine rigidity and high performance servo motors to: Reduce distance to full rapid Reduce time to full rapid 息Copyright Makino 2011
Expanding Productivity: Case Study Steering Gear Housing - 55,000 pcs / year - Customer defined operation parameters - 250 days / year - 20.5 hrs / day - 85% utilization - Machining process - 2 Operations - 2 Unique fixtures - 2 Parts / fixture - 26 Unique Tools 息Copyright Makino 2011
Expanding Productivity: Case Study Steering Gear Housing 15% Lower Cycle Time Reduced Machine Count Lower Per Piece Cost 息Copyright Makino 2011
: Expanding Reliability Life Cycle Cost (LCC) Acquisition Cost Operating Cost Maintenance Cost Decommission Cost Installation Direct Labor PM Schedule Redeploy Purchase Price Consumables Cost of Repair Sell Training Lost Production Unscheduled Downtime Spare Parts Typically more than the acquisition cost 息Copyright Makino 2011
: Expanding Reliability Case Study - Midwest manufacturer - (16) 1-Series Machines - Power-on hours: 231,000 - Tool changes: 14,656,152 No tool change component replacement parts No way cover replacements No spindle replacements Leverage existing systems 息Copyright Makino 2011
Proven Reliability: Way Covers Have you ever lost a way cover? - Single piece X-axis (a51nx) Single piece Z-axis covers Fewer moving parts Eliminates telescoping cover maintenance issues With nearly 700 a51s in the field a51 Way cover sales (2005 2010) (0) X-axis (2) Y-axis (0) Z-axis 息Copyright Makino 2011
Proven Reliability: ATC & Magazine Dual Support Tool Change Arm Axis with bearing on each side provides strength and rigidity Documented case studies of 14 million tool changes without failure 息Copyright Makino 2011 Ring Style ATC Magazine Fast highly reliable solution for production environments Simple design with fewer parts Compact design with small foot print
: Expanding Reliability How do you improve on industry leading HMC reliability? Look for opportunities to improve 息Copyright Makino 2011
Expanding Reliability: ATC Shutter ATC Shutter Mechanism New servo driven design Simplifies setup Highly reliable Capable of variable open distance Reduce ATC magazine contamination ATC Shutter 息Copyright Makino 2011 Ball Screw Servo Motor
Expanding Reliability: Drum Filter Coolant Filtration Standard system utilizes rotating drum filter to provide coolant to clean tank side Nylon filter media susceptible to damage Drum filter failures lead to Coolant contamination Coolant nozzle plugging nx uses a stainless steel filter media 息Copyright Makino 2011
Manufacturing Expansion Program: Summary Introduction to nx machines: - a51nx - a61nx Expanding Capacity: - Larger Axis Travels - Rigid Casting Structure - Increased Spindle Power Expanding Productivity: - Direct Drive B-axis Table - 1G Axis Acceleration Expanding Reliability: - Servo ATC Shutter - Stainless Steel Drum Filter 息Copyright Makino 2011
Manufacturing Expansion Program Makinos nx-Series Horizontal Machining Centers David Ward Horizontal Product Manager 息Copyright Makino 2011

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Manufacturing Expansion Program, The Next Generation of Horizontal Machining Centers

  • 1. Manufacturing Expansion Program Makinos nx-Series Horizontal Machining Centers David Ward Horizontal Product Manager 息Copyright Makino 2011
  • 2. Manufacturing Expansion Program Makinos nx-Series Horizontal Machining Centers Topics to be discussed - What are the nx machines - Moving 40-Taper Machining to the Next Level - Expanding Capacity - Expanding Productivity - Expanding Reliability - Case Study 息Copyright Makino 2011
  • 3. nx Horizontal Machining Centers X: Y: Z: 息Copyright Makino 2011 560mm (22.0) 640mm (25.2) 640mm (25.2) X: Y: Z: 730mm (28.7) 650mm (25.6) 800mm (31.5)
  • 4. nx Horizontal Machining Centers a51nx Pallet Size Max. Weight Max. Workzone APC Time 息Copyright Makino 2011 a61nx 400mm (15.7) 500mm (19.7) 400 kg (880 lbs.) 500/700 kg (1,100/1,540 lbs.) 630 x 900 (24.8 x 35.4) 800 x 1,000 (31.5 x 39.4) 5.3 seconds 8.5/10 seconds
  • 5. The Original 1-Series Machine Launched in 2002 New design Productivity Reliability Value Global production over 2,300 680 in North America 息Copyright Makino 2011
  • 6. Next Generation 40-Taper HMC Redefine the boundaries of 40-taper machining by to levels typically not associated with 40 taper machines 息Copyright Makino 2011
  • 7. nx Machines: Expanding Capacity Soft Hard Harder materials Larger work pieces Small 息Copyright Makino 2011 Large
  • 8. nx Machines: Expanding Capacity How did Makino accomplish this? Larger work zones Rigid construction Higher spindle power 息Copyright Makino 2011
  • 9. : Expanding Capacities Expand Y-axis stroke 14% Expand Z-axis stroke 7% Expand maximum tool length a51nx X-axis 560mm Y-axis 640mm Z-axis 640mm Tool length BT/HSK 430mm a51nx:640mm (25.2) a51:560mm (22.0) Expand machining area 息Copyright Makino 2011 Expanded machining area 14%
  • 10. : Expanding Capacities Expand Y-axis stroke 12% Expand Z-axis stroke 10% Expand maximum tool length a61nx X-axis 730mm Y-axis 650 / (op:730)mm Z-axis 800mm Tool length BT/HSK 510mm a61nx:730mm (28.7) a61:650mm (25.6) Expand machining area 730mm High Column Option 息Copyright Makino 2011 Expanded machining area 12%
  • 11. : Expanding Capacities Expanding Machining Area Accommodate MORE parts - Reduced Piece Part Cycle Time - Multiple Operation Fixtures Accommodate LARGER parts - Increased Flexibility - Reduced Floor Space 息Copyright Makino 2011
  • 12. : Expanding Capacities Financial impact of larger work zones Produce same part on a smaller machine - 400mm vs 500mm - 500mm 40T vs 500mm 50T - 13% Capital equipment reduction Reduced floor space Reduced fixture and tooling costs Reduced energy consumption 息Copyright Makino 2011
  • 13. : Rigid Casting Structure 息Copyright Makino 2011
  • 14. : Rigid Casting Structure One Piece Bed Casting Provides foundation for all critical components Precision machined vs. Compensated Integral chip management 息Copyright Makino 2011
  • 15. : Rigid Casting Structure Three Point Support Simplifies installation Easy to move / relocate Maintains geometry 息Copyright Makino 2011
  • 16. : Rigid Casting Structure Tiered Column Design Resists deflection even high in Y-axis High degree of stiffness 息Copyright Makino 2011
  • 17. : Rigid Casting Structure Roller guide rigidity and performance Improved load capacity Increased stiffness Improved life 息Copyright Makino 2011
  • 18. : High Torque, High Power Spindles Standard Spindle a51nx and a61nx Horsepower 29.5 cont / 40 duty HP Torque 240 Nm (177 ft-lbs) Speed 14,000 Acc/Dec 19% increase in torque and HP compared to previous model 息Copyright Makino 2011 1.7 / 1.9 sec
  • 19. : Standard 240 Nm Spindle Increased continuous HP expands MRR capacity in non ferrous applications 息Copyright Makino 2011
  • 20. : High Torque, High Power Spindles High Torque Spindle a51nx and a61nx Horsepower 29.5 cont / 40 duty HP Torque 302 Nm (233 ft-lbs) Speed 14,000 Acc/Dec Ideal for ferrous applications Iron metal removal rates of 36.4 in3/min 息Copyright Makino 2011 1.7 / 1.9 sec
  • 21. : Expanding Productivity In-Cut Time Cycle Time Non-Cut Time Traditional 息Copyright Makino 2011 Cycle Time In-Cut Time Non-Cut Time a51nx / a61nx
  • 22. : Expanding Productivity How do the nx machines achieve this? In-Cut Time Cycle Time Non-Cut Time Direct Drive Rotary Table Improved Axis Acceleration Cycle Time In-Cut Time Non-Cut Time Traditional 息Copyright Makino 2011 a51nx / a61nx
  • 23. : Direct Drive Motor Table Standard DD motor - NC rotary table Rotation speed鐚max.125min-1 High-speed positioning a51nx = 1.05 seconds (90 degree) a61nx = 0.98 seconds (90 degree) Reduce cycle time No backlash Increase accuracy Simple design structure Increase reliability 息Copyright Makino 2011
  • 24. : Direct Drive Motor Table IAC (Inertia Adaptive Control) Acc/Dec control function based on work piece inertia With IAC Conventional Default Acc/Dec Heavy workpiece (large inertia) Light workpiece (small inertia) 息Copyright Makino 2011 Same Acc/Dec for Maximum Workpiece Heavy workpiece (large inertia) High Acc/Dec Light workpiece (small inertia)
  • 25. : 1G Axis Acceleration Linear Axis Acc / Dec a51nx: 1G X / Y / Z a61nx: 1G X / Y 0.8G Z Rapid: 60 M/min (2,360 ipm) Capitalize on machine rigidity and high performance servo motors to: Reduce distance to full rapid Reduce time to full rapid 息Copyright Makino 2011
  • 26. Expanding Productivity: Case Study Steering Gear Housing - 55,000 pcs / year - Customer defined operation parameters - 250 days / year - 20.5 hrs / day - 85% utilization - Machining process - 2 Operations - 2 Unique fixtures - 2 Parts / fixture - 26 Unique Tools 息Copyright Makino 2011
  • 27. Expanding Productivity: Case Study Steering Gear Housing 15% Lower Cycle Time Reduced Machine Count Lower Per Piece Cost 息Copyright Makino 2011
  • 28. : Expanding Reliability Life Cycle Cost (LCC) Acquisition Cost Operating Cost Maintenance Cost Decommission Cost Installation Direct Labor PM Schedule Redeploy Purchase Price Consumables Cost of Repair Sell Training Lost Production Unscheduled Downtime Spare Parts Typically more than the acquisition cost 息Copyright Makino 2011
  • 29. : Expanding Reliability Case Study - Midwest manufacturer - (16) 1-Series Machines - Power-on hours: 231,000 - Tool changes: 14,656,152 No tool change component replacement parts No way cover replacements No spindle replacements Leverage existing systems 息Copyright Makino 2011
  • 30. Proven Reliability: Way Covers Have you ever lost a way cover? - Single piece X-axis (a51nx) Single piece Z-axis covers Fewer moving parts Eliminates telescoping cover maintenance issues With nearly 700 a51s in the field a51 Way cover sales (2005 2010) (0) X-axis (2) Y-axis (0) Z-axis 息Copyright Makino 2011
  • 31. Proven Reliability: ATC & Magazine Dual Support Tool Change Arm Axis with bearing on each side provides strength and rigidity Documented case studies of 14 million tool changes without failure 息Copyright Makino 2011 Ring Style ATC Magazine Fast highly reliable solution for production environments Simple design with fewer parts Compact design with small foot print
  • 32. : Expanding Reliability How do you improve on industry leading HMC reliability? Look for opportunities to improve 息Copyright Makino 2011
  • 33. Expanding Reliability: ATC Shutter ATC Shutter Mechanism New servo driven design Simplifies setup Highly reliable Capable of variable open distance Reduce ATC magazine contamination ATC Shutter 息Copyright Makino 2011 Ball Screw Servo Motor
  • 34. Expanding Reliability: Drum Filter Coolant Filtration Standard system utilizes rotating drum filter to provide coolant to clean tank side Nylon filter media susceptible to damage Drum filter failures lead to Coolant contamination Coolant nozzle plugging nx uses a stainless steel filter media 息Copyright Makino 2011
  • 35. Manufacturing Expansion Program: Summary Introduction to nx machines: - a51nx - a61nx Expanding Capacity: - Larger Axis Travels - Rigid Casting Structure - Increased Spindle Power Expanding Productivity: - Direct Drive B-axis Table - 1G Axis Acceleration Expanding Reliability: - Servo ATC Shutter - Stainless Steel Drum Filter 息Copyright Makino 2011
  • 36. Manufacturing Expansion Program Makinos nx-Series Horizontal Machining Centers David Ward Horizontal Product Manager 息Copyright Makino 2011