Game-Changing Technology on a Roll I · PDF fileprovides real-time measurement of tool load ensuring consistent and safe machining by monitoring tool damage and deteriora- ... AEROSTRUCTURE

December 2014 | ManufacturingEngineeringMedia.com 49

In the development of machining centers and cells,

we’re always looking for game changers. Most

recently, marrying 3D printing to standard machine

platforms has been all the rage. Mazak Corp. (Flor-

ence, KY) is the latest entrant into the 3D printing/

hybrid sweepstakes with the introduction of the

Integrex i-400AM (additive manufacturing) Hybrid Multi-

Tasking Machine for small-lot production from powder

metals of difficult-to-cut materials such as those used in

the aerospace, energy, and medical industries. Together

with DMG MORI’s (Hoffman Estates, IL) Lasertec 65 that

uses laser sintering and milling of powder metals and MC

Machinery Systems Inc.’s (Wood Dale, IL) Lumex Avance

25 metal laser sintering hybrid milling machine, these

machines are surely forerunners of yet-to-be-conceived

innovative additive manufacturing machine designs.

Hwacheon’s H6 HMC is designed for heavy-duty

machining of steel, titanium, and iron parts in

either short or longer runs. Integrated adaptive

software suite optimizes performance for

machining efficiency and quality.

Game-Changing Technology on a RollRobust design, data communication, advanced CNCs lead the way

Jim LorinczSenior Editor

Machining Centers & Cells

But what of traditional material-removing machining

centers like heavy-duty horizontals for automotive produc-

tion, high-speed verticals for precision mold-and-die work,

and multitasking and five-axis machines for production of

complex workpieces? At IMTS 2014, developments in each

of these technology categories were shown along with the

latest digital communication to and from the shop floor. Data

collection from machines operating in real-time on the factory

floor using the MT Connect standard

and proprietary CNC control software is

just such a game changer for manage-

ment control and analysis. It enables

manufacturers to monitor performance,

improve productivity, and boost bottom

line profitability.

“MT Connect enables manufacturers

to calculate overall equipment efficiency

[OEE], monitor all equipment from one

system, reduce production losses, and

identify lean manufacturing strategies,”

said Neil Desrosiers, software developer,

Mazak Corp. Mazak introduced its latest

evolution in CNC control called Mazatrol

SmoothX CNC technology, including

machine hardware and servosystems.

Smooth technology integrates the entire

part production from programming and

setup to actual material removal opera-

tions to automation to monitoring/data

collection and transfer. “Think of it as a

hybrid born from the marriage of a CAM

system and conversational program-

ming,” said Desrosiers.

SmoothX technology, which is said

to “essentially quadruple the new CNC’s

interpolation speed, eliminating two of

the most common CNC bottlenecks—

sluggish hardware and slow processing

speeds,” incorporates features that

were formerly supplied through third-

party software. Intelligent pocket milling

engages a high-efficiency toolpath when

milling-out part cavities by maintaining

a constant angle of tool engagement

and cutting loads to ensure optimum

machining conditions. Seamless corner

control reduces vibrations and shortens

part-machining cycle times through

cutter path adjustments made when

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machining into corners. Rather than moving the cutter directly

into a 90° corner, the function inserts a preset radial tolerance

that eliminates any dwell resulting from a rapid deceleration

in the axial movements, producing smoother corner surfaces,

reducing the risk of cutter gouging, and

cutter feed much faster.

Advanced Technology Pushes

Machine Builder’s Envelope

The focus of new technologies from

Doosan Infracore Machine Tools (Pine

Brook, NJ) is on a large-capacity travel-

ling column vertical machining center

(VCF 850LSR), a five-axis linear drive

machining center (FM 200/5AX Linear),

and a third-generation mill-turn mul-

titasking machine (SMX 3100 S) with

a more rigid 90° vertical axis. Doosan

machines have MT Connect capabil-

ity and were demonstrated streaming

off-site created machining live data from

Doosan turning centers on the factory

floor of Bobcat in North Dakota, as well

as from machines and robots inside of

Doosan’s IMTS booth.

For one Doosan customer, Joe

Gibbs Racing, a new design of a drag

link machined as a single part on a

Puma MX2600ST nine-axis VMC and

horizontal turning center took the hand-

numbing vibration out of a race car’s

steering wheel. The drag link connects

the power steering box to the spindles

and was formerly produced by welding

three pieces together.

“The VCF 850LSR travelling column

VMC is a completely new platform from

Doosan and offers our customers the

expanded capacity required for machin-

ing large size and large mass parts, es-

pecially for applications as challenging

as those in the oil industry,” said Ron

Kilgore, product manager-machining

centers. “As many as 14 configurations

of the machine are possible, varying in

spindle type (fixed or articulating), table length, and table con-

figurations that can feature a fourth axis built into the table,

or placed on top of the table. Finally, a center divider can also

be installed to create two distinct work areas, so parts can

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be loaded and unloaded on one side,

while the spindle continues making

chips in the other.”

“With 850 mm in Y-axis travel, the

VCF is ideal for machining the top half

and bottom half of molds together.

When configured with a fourth axis table

mounted horizontally at one end and

a tailstock on the other, you have the

perfect platform for machining pipe up

to 3 meters in length. And in its stan-

dard three-axis configuration the VCF

can machine a wide range of aluminum

spars for aerospace,” said Kilgore.

“The new Puma SMX 3100S,

Doosan’s third-generation mill-turn

multitasking machine is distinguished

by a more rigid 90° vertical axis and a

forward positioned ATC for improved

milling capabilities, making it more of

a milling machine with turning, than

previous generations that featured a 45°

slant bed,” said David Barber, general

manager-marketing. “In fact, these new

characteristics in the Puma SMX as

compared to the new platform we have

in our VCF 850LSR allow manufactur-

ers to consider two different platforms

for long shafts featuring complex angles

and multiple bores.”

The Puma SMX series will initially be

made available in two sizes, the Puma

SMX2600 with a 10" (254-mm) chuck

or the Puma SMX3100 with a 12" (305-

mm) chuck. Both Puma SMX models

have the capacity to machine parts up

to 60" (1524 mm) in length and 26"

(660 mm) in diameter. Typical applica-

tions are long shafts with a lot of angle

in them that require milling features.

Heavy-Duty HMC with Integrated Software

According to Michael Huggett, presi-

dent, Hwacheon Machinery America’s

(Lincolnshire, IL) new H6 horizontal

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NFL Hall of Fame Coach and Founder of Joe Gibbs Racing, Joe Gibbs holds

a vibration-damping steering drag link that was machined as a single part

on a Puma MX2600ST. Formerly the drag link was a weldment of three pieces.

Pho

to c

ourt

esy

Doo

san

Infr

acor

e M

achi

ne T

ools

machining center is designed to meet the re-

quirements of machine shops for an afford-

able heavy-duty 630-mm pallet machine that

can produce various lots of steel, titanium,

and iron parts in either short or longer runs.

“The machine integrates the mechanical

strengths of the Hwacheon stable box-way

machine design and its adaptive software

suite for machining efficiency and quality at

a cost approximately 20% less than similar-

sized machines from other leading machine

builders,” said Huggett.

Features of the H6 HMC include a gear-

driven 29-hp (22-kW), 8000 or 15,000-rpm,

50-taper spindle for powerful high-torque

cutting, and a twin drive system for the X

and Y axes for precise and faster cutting

rates. An oil-jet cooling system ensures

heavy-duty cutting performance and preci-

sion motion even after long periods of machining. Axis strokes

are 1050 × 900 × 1000 mm with a B-axis rotation of 360°

on a table with a working surface of 630 × 630 mm and load

capacity of 1600 kg. A 41" (1041-mm) swing inside the ma-

chine allows 80-mm pallets to be used. A 40-tool magazine is

standard with options to 150 tools.

Hwacheon casts its own bases and columns, hand scrapes

boxways, and designs frame structures with 3D CAD and FEM

analysis to support workpiece quality. According to Robert

Nedler, vice president-sales, Hwacheon integrates its own

unique software developed in conjunction with the latest Fanuc

CNC to measure thermal displacement control and compensa-

tion. In this way, Hwacheon can control the kinematics of the

machines for contour machining, optimizing machine perfor-

mance for roughing, semifinish, and finish machining.

Included in the software suite are tool load detection software

(HTLD), high-efficiency contour control (HECC), and a cutting

feed optimization routine (Optima). Tool load detection software

provides real-time measurement of tool load ensuring consistent

and safe machining by monitoring tool damage and deteriora-

tion for prevention of complete tool failure to prevent tool failure

causing workpiece damage and ensuring accuracy and perfor-

mance. Tool load is measured as frequently as every 8 msecs.

Hwacheon's high-efficiency contour control (HECC)

software offers an easy-to-use programming interface system

that provides a precise, custom contour control for the Software. Education. Training. Parts. Service. Support. Leasing. Rebuild.

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Port of an engine is being machined by the B-axis spindle head of the

Doosan VCF 850LSR.

workpiece while supporting longer machine life and reduced

process time. HECC offers different options for cutting

speed and accuracy, and for surface finish and geometry.

The customizable display provides real-time monitoring and

easy access, and the software may be used with existing NC

systems and is compatible with G-Code programming.

To sustain a consistent cutting load while machining, the H6

features a cutting feed optimization routine (Optima) that uses an

adaptive control method to regulate the

feed rate in real time. The result is that

cutting tools are less prone to damage and

machining time is reduced. The system

controls the feed velocity to maintain

consistent cutting load. Sensors at various

locations in the machine castings where

thermal displacement is possible permit

software monitoring and correction of de-

tected thermal displacement. Hwacheon

spindle displacement control (HSDC)

software monitors temperature at a num-

ber of points within the spindle assembly

and then makes necessary adjustments to

prevent Z-axis error due to taper expan-

sion as the spindle rotates at high speed.

“This axis accuracy is vital to precision

mating of die components in mold-and-

die machining applications,” said Nedler.

Maximum Flexibility for

Varying Volumes/Mixes of Parts

OEMs and job shops that are

manufacturing precision components

from difficult-to-machine materials need

a highly accurate machining solution,

one that will make their operations

more productive and cost effective.

“Many precision manufacturers today

are taking on a variety of jobs—some

high-volume, low-mix and others a low-

volume, high-mix of part with differing

part geometries and materials,” said

Steve Previti, YASDA product manager,

Methods Machine Tools Inc. (Sudbury,

MA). “Because part requirements are so

broad, machine tool providers must an-

swer with solutions that provide flexibility

as well as the required accuracy.”

At IMTS 2014, Methods Machine

Tools and YASDA unveiled a high-preci-

AZ_USA_2014_Manufacturing_Enineering_Automotive_115,89x190,5+3mm.indd 1 06.02.14 14:5656 ManufacturingEngineeringMedia.com | December 2014


sion, automated five-axis vertical machining center, the PX-30i engineered to meet

challenging OEM and job-shop requirements. The Methods-YASDA PX-30i fea-

tures extensive design and engineering by Methods in a five-axis machining center

manufactured by YASDA, a Japanese builder of high-precision machining centers

and jig borers. Previti said that combining five-axis machining with automation offers

manufacturers many advantages for the efficient manufacture of high-precision,

complex components.

The PX-30i offers an automated turnkey machining center solution that features

a full complement of 32 storage pallet positions plus one in the work zone provid-

ing the capability to do lights-out or untended manufacturing, The automatic tool

changer (ATC) and automatic pallet changer (APC) feature a Methods-developed

software program for efficient tool/pallet management and advanced scheduling

functions. The ATC has a standard capacity of 300 tools and can be retrofitted for

additional tool capacities of up to 500.

“Methods and YASDA engineers worked closely together during the design and

manufacture of the five-axis PX-30i. We focused on precision, reliability and versatil-

ity, all at a cost-effective price,” said Previti. The PX-30i features a newly designed

direct-drive spindle with self-adjusting preload, which is designed to improve per-

formance and increase spindle life. The YASDA in-house built spindle delivers the

rigidity, torque, speed and horsepower to facilitate the efficient machining of a wide

range of materials from aluminum to high-temperature alloys, including Inconel,

titanium and steels with high-hardness ratings. A two-axis rotary table offers flexibility

and speed with a wide range of movement.

Penetrating Customer Shops with Even More Machining Capability

“Our main strategy at MC Machinery is to offer our valuable customers a single-

source supply chain of quality manufacturing solutions. By adding more technol-

ogy, we can build upon our core businesses where we have over 13,000 machines

installed, across EDM, laser, press brake, Roku Roku and waterjet equipment in North

America. This represents a total of more than 8000 customers,” said Alan Hallmann,

North American sales manager, MC Machinery Systems Inc. (Wood Dale, IL).

Twelve years ago, MC Machinery introduced its Roku Roku line of high-speed

graphite and hard milling machines to complement its EDM technology in mold-

and-die shops. “Three years ago, we introduced five new lines of milling machines

to complement not only our EDM customers, but also our fabrication customers. We

have since expanded by adding five-axis milling and a line of small-to-medium-size

CNC lathes in our product mix,” said Hallmann.

IMTS was an eye opener that brought on a whole resurgence of interest and

orders for MC Machinery, according to Hallmann. “Our focus now is on penetration

into the mold industry, with production machines aimed at the aerospace, oil tool, and

medical applications, and milling and turning for the Tier Two automotive suppliers.

With current forecasts of a 17-million car market, we’ll be setting up a supply chain

and products to participate fully in that market by the end of 2015,” said Hallmann.

To achieve these goals, MC Machinery is upgrading existing products with more

productive features while they also expand and develop new product lines. For

Protect High Value Parts

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example, thermal compensation option for moldmakers in an

affordable package DM (die mold) series of milling machines

is on track for early 2015 release. This is expected to further

penetrate the mold-and-die market where the company has

a strong EDM presence. “Linear technology for the high-end

Roku Roku line is being introduced as well,” said Hallmann.

“Our strong market areas continue to be in the oil tool

and related energy industry, electronic goods, and mold

and die. General-purpose machine

platforms account for our greatest

number of orders. Our MCV line is

our number one platform for good

reasons. It’s a heavy-duty VMC with

Mitsubishi CNC control, drive and

motor package for faster processing,

faster cycle time, and longer longevity

than products that are typically more

expensive,” said Hallmann.

“Our goal is to place ourselves at

the top of the quality platform with

other leading high-precision, multiaxis

machining center suppliers while main-

taining great value in terms of pricing.

Our advantage is in performance where

the Mitsubishi control can mean a

difference of up to 30% faster cycle

times than many other value priced

machines and with higher reliability,”

said Hallmann. ME

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DMG MORIPh: 847-593-5400

Web site: www.dmgmori.com

Doosan Infracore Machine ToolsPh: 973-618-2500

Web site: www.doosanmachinetoolsusa.com

Hwacheon Machinery America Inc.Ph: 847-573-0100

Web site: www.hwacheon.com

Mazak Corp.Ph: 859-342-1700

Web site: www.mazakusa.com

MC Machinery Systems Inc.Ph: 630-616-5920

Web site: www.mcmachinery.com

Methods Machine Tools Inc.Ph: 978-443-5388

Web site: www.methodsmachine.com

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Game-Changing Technology on a Roll I · PDF fileprovides real-time measurement of tool load ensuring consistent and safe machining by monitoring tool damage and deteriora- ... AEROSTRUCTURE