Although much of current manufacturing practice emphasizes high-mix, low volume production, an acute need remains to efficiently produce medium to high volumes of certain parts. In those situations, the bottom line is minimizing the cost to machine a part.
Machine tool builders offer a variety of systems engineered for cost-efficient production. Maximizing output generally requires those that minimize tool change time and part load/unload time, along with reliable automation that permits minimally tended operation.
Choosing a machining system aimed at medium to high volume output basically initially depends on the size of the raw material and finished parts. Smaller parts generally can be machined from bar stock of 38 mm (1.5") diameter and smaller on Swiss-style CNC machines that use bar loaders to maintain a continuous stream of workpiece material, process workpieces with multiple tools and minimal tool change times, then cut off and drop finished parts with no interruption of machining operations.
Originally developed to produce tiny precise parts for watchmaking, Swiss machines are favored in the machining of long, complex, small diameter parts like those common in the medical equipment, automotive, aerospace and electronics industries. As compared to conventional turning, the Swiss CNC process facilitates a Multi-Tasking/DONE IN ONE type approach for medium to high volume machining.
In a conventional turning center, the workpiece bar advances from the machine's headstock into the work envelope. The tool moves along the length of the workpiece in one direction, retreating and performing more passes for greater depth of cut when necessary.
Conversely, the workpiece bar with a Swiss-style machine advances from the headstock through a guide bushing and moves past a stationery cutting tool or tools. The tools work in close proximity to the guide bushing, eliminating flexing of the workpiece bar and enhancing precision. Cutting can take place in two directions, and end-working and gang tool arrangements minimize tool change time and permit more than one tool to cut at a time. This Multi-Tasking style of machining reduces cycle time over a fixed headstock lathe.
As an example, Mazak's new SYNCREX series of Swiss-style machines feature a 10,000 RPM spindle and different versions handle bar diameters of 20 mm and 25 mm (32 mm and 38 mm). Seven, eight and nine axis designs allow shops to process a comprehensive range of part configurations, and the machines accommodate up to 35 tools as standard, including 22 static and 13 live tools in end working and gang tool arrangements.
Previously, shops may have avoided implementing Swiss-style machines because they perceived the changeover between jobs and programming as too difficult and time consuming. However, current machines have controls and programming capabilities that permit faster set-ups. SYNCREX machines, for instance, feature Mazak's new MAZATROL SmoothST CNC, with Swiss Setup Assist (MSSA) for quick set-ups and Mazak Dynamic Chip Control (MDCC) functionality.
For workpiece material over 1.5" diameter (38 mm), twin-spindle, twin-turret CNC turning centers provide a path to high output. The spindles face each other and are served by upper and lower tool turrets, enabling machining of both the front and back sides of a part and permitting DONE IN ONE part processing. The dual spindles allow two parts to be cut simultaneously, and synchronized rotation delivers fast, high-accuracy part handoffs. Simultaneous first and second operations and balanced cutting or milling are possible. The combination of multiple spindles and turrets produces parts much faster than a basic turret lathe.
Part loading methods differ depending on workpiece size. Bar-fed multispindle lathes are limited as to how fast they can spin heavier, larger diameter bars, so a gantry robot typically will be used to mount larger diameter parts in the machine chuck.
Mazak MULTIPLEX and HYPER QUADREX are examples of twin-spindle, twin turret machines that boost output into the high production range. Both turrets have 12-tool capacity, and the upper turret features 6,000 RPM live tools. MAZATROL Conversational language programming streamlines set-up.
The MULTIPLEX is best for chucker applications, while the HYPER QUADREX is well suited for bar feeder operations. When quipped with systems for loading/unloading, both machines allow for continuous production.
In the case of the MULTIPLEX with its center partition, shops can load/unload either the main or second turning spindle without interruption. With the HYPER QUADREX series machines and bar feeders, a built-in unloader over machine's second spindle provides maximum throughput as do machining strategies such as pinch turning/milling and balanced cutting operations.
In the pursuit of high production numbers, careful coolant and chip management sometimes is overlooked. Machines with a magazine bar feeder can be loaded for a full day's worth of bar stock and run unattended. Large amounts of chips accompany large production volumes, and reliable 24/7 production requires adequate coolant flush to get chips into the machine's chip pan and into a chip conveyor that is matched for the type of chips being produced.
Coolant supply considerations include providing sufficient through spindle coolant, through tool coolant and high-pressure coolant, if needed. An appropriate system of filters must be designed to prevent chips from clogging filters and entering turret coolant lines. High-production scenarios, especially with long continuous cuts, also can produce chip breaking issues.
In response, Mazak developed its Dynamic Chip control for the SYNCREX machines that oscillates a tool axis to help break the chips into smaller, more manageable pieces and avoid formation of long chips and obstructive birds nests.
Choosing a machine tool for high-volume production really boils down to determining the part size, specific application, part volume and what will best suit a user's specific needs. Always, at the top of the list is the cost per part: how fast can a shop deliver parts to a customer, and what is the lowest cost per part. Achieving both is possible with the right machine built for cost-effective high-volume production.
Authored by Mazak Corporation
For more information contact:
Mazak Corporation
P.O. Box 970
Florence, KY 41022-0970
859-342-1700
www.mazakusa.com
Southwest
Chris Papke
Mazak SW Technology Center
10950 Greenbend Blvd.
Houston, TX 77667
281-931-7770
cpapke@mazakcorp.com
www.mazakusa.com
LA
Richard Cahn
Dixie Mill Machine Tools Co.
901 Tchoupitoulass Street
New Orleans, LA 70152
504-525-6101 / 888-462-9519
rcahn@dixiemill.com
www.dixiemill.com
OK, AR
Butch Cumminsky
David James
Machinery Resources Inc.
5550 South 94th East Avenue
Tulsa, OK 74145
918-622-6495 / 800-448-1878
butch@mritul.com
www.mritul.com
N. TX
Chris Papke
Mazak Corporation
935 S. Kimball St., Ste. 151
Southlake, TX 76092
800-642-6110 / 817-329-6290
cpapke@mazakcorp.com
www.mazakcorp.com
W. TX
Chris Edgar
Magnum Precision Machines, Inc.
12025 Rojas Drive, Suite A
El Paso, TX 79936
915-856-7900
cedgar@magnumabq.com
www.magnumprecisionmachines.com
NM
Chris Edgar
Magnum Precision Machines, Inc.
8448 Washington Place NE
Albuquerque, NM 87113
505-345-8389
cedgar@magnumabq.com
www.magnumprecisionmachines.com
Southeast
Dave Kennedy
Mazak Southeast Technology Center
1075 Northbrook Pkwy
Suwanee, GA 30024
678-985-4800
dkennedy@mazakcorp.com
www.mazakusa.com
NC, SC, VA
Crotts & Saunders, LLC
2709 Boulder Park Ct.
Winston-Salem, NC 27101
336-765-7250
www.crottsandsaunders.com
TN
Dennis McCurry
Pinnacle Machine Tools, Inc.
5912 Toole Drive
Knoxville, TN 37919
865-951-0260
mccurry@pinnaclemachine.net
AL, FL Panhandle
Jerry Edwards
Pinnacle Machine Tool Inc.
141 Nick Fitcheard Road
Huntsville, AL 35806
256-852-0900
edwards@pinnaclemachine.net
GA
Tim Kramer
Premier Engineering Co.
1635 Lakes Pkwy. Ste. U
Lawrenceville, GA 30043-5858
678-442-8382
tim@premierengineering.com
www.premierengineering.com
MS
Richard Cahn
Dixie Mill Machine Tools Co.
901 Tchoupitoulass Street
New Orleans, LA 70152
504-525-6101
rcahn@dixiemill.com
www.dixiemill.com
FL
Perry Leonor
Mazak Florida Technology Center
6895 McCoy Drive, Suite 100
Orlando, FL 60504
689-205-5626
pleonor@mazakcorp.com
www.mazakusa.com
Northeast
New England, E. NY, NJ, E. PA, MD, DE
Greg Kaufman
Mazak Northeast Technology Center
700 Old County Cir.
Windsor Locks, CT 06096
800-436-8900 / 860-292-4400
gkaufman@mazakcorp.com
www.mazakusa.com
W. NY
Bill Miller
A.W. Miller Technical Sales
7661 Seneca St. / PO Box 69
East Aurora, NY 14052
716-652-8282
bmiller@awmiller.com
www.awmiller.com
W. PA, N. WV
Bill Miller
A.W. Miller Technical Sales
3 Tara Drive / PO Box 220
Harmony, PA 16037
724-453-1690
bmiller@awmiller.com
www.awmiller.com
S. WV
Crotts & Saunders, LLC
2709 Boulder Park Ct.
Winston-Salem, NC 27101
336-765-7250
www.crottsandsaunders.com
Midwest
Kevin Bates
Mazak Midwest Technology Center
300 East Commerce Drive
Schaumburg, IL 60173
847-885-8311
kbates@mazakcorp.com
www.mazakusa.com
ND, SD, MN, W. WI
Joel Lundin
Tony Bailey
Northwest Machine Technologies, Inc.
20851 Commerce Blvd.
Rogers, MN 55374
763-493-3660
tbailey@nwmtec.com
www.nwmtec.com
NE, W. IA
Duane Ohlrich
Industrial Systems & Supply Inc.
2760 E. 29th Avenue
Columbus, NE 68601
402-564-4445
ohlrich@industrial-systems-supply.com
www.industrial-systems-supply.com
E. IA
Jeff Everett
Mazak Iowa Technology Center
609 Myatt Drive, Ste. 1
Maquoketa, IA 52060
563-652-6065
jeverett@mazakcorp.com
www.mazakusa.com
E. MO, S. IL
Bill Summers
Municipal Tool & Machinery Co.
2465 Rock Island Blvd.
Maryland Heights, MO 63043
314-994-9905
bsummers@municipaltool.com
www.municipaltool.com
KS, W. MO
Nick Shelton
Concept Machinery -
A Shelton Machinery Company
9900 North by Northeast Blvd.
Fishers, IN 46037
317-845-5588
nshelton@conceptmachinery.com
www.conceptmachinery.com
E. WI
Mike Cekanor
Machinery Systems North
3280 Gateway Rd.
Brookfield, WI 53045
262-781-4850
mikec@machsys.com
www.machsys.com
N. IL, N.W. IN
Eric Hilliard
Machinery Systems Inc.
614 East State Parkway
Schaumburg, IL 60173
847-882-8085
erich@machysys.com
www.machsys.com
E. MI
Steve Addy
Addy Machinery Co.
36055 Groesbeck Highway
Clinton Township, MI 48035
586-741-3000 / 800-ADDY-NOW
steve@addymachinery.com
www.addymachinery.com
W. MI
Peter Addy
Addy Machinery Co.
3757 Broadmoor Ave. SE, Ste. A & B
Grand Rapids, MI 49512
800-AddyNOW
peter@addymachinery.com
www.addymachinery.com
S. OH
Greg Knox
Knox Machinery, Inc.
375 Industrial Drive
Franklin, OH 45005
937-743-2641
www.knoxmachinery.com
S. IN, KY
Nick Shelton
Shelton Machinery, Inc.
9900 North by Northeast Blvd.
Fisher, IN 46037
317-845-5588
nshelton@sheltonmachinery.com
www.sheltonmachinery.com
N. OH
Motch & Eichele
318 Remington Road
Cuyahoga Falls, OH 44224
800-833-9730
www.mande.com
West
CO, E. WY
Randy Breitenbach
Action Machinery International
7790 S. Wheeling Ct. Unit A
Englewood, CO 80112
303-532-2900
randy@action-machinery.com
www.action-machinery.com
WA, OR
Mark Harris
CNC Machine Services, Inc.
7808 184th St. SE
Snohomish, WA 98296
425-788-4500
sales@cncmachineservice.com
www.cncmachineservice.com
N. ID
Dave Fisher
Dependable Machine
88 W Orchard Ave
Hayden, ID 83835
866-967-0146 / 208-714-4652
sales@dependablemachineryrepair.com
www.dmi-cnc.com
AZ, S. NV
Chris Edgar
Magnum Precision Machines
4848 S. 35th St.
Phoenix, AZ 85040
602-431-8300
cedgar@magnumabq.com
www.magnumprecisionmachines.com
UT, S. ID, MT, W. WY
Tom Weaver, General Manager
Smith Machinery Company
41 W Guest Avenue
Salt Lake City, UT 84115
80l-263-6403
tweaver@smithmachinetools.com
www.smithmachinetools.com
S. CA
Richard McCauley
Mazak Western Technology Center
Aerospace Technology Center
1333 West 190th Street
Gardena, CA 90248
310-327-7172
rmccauley@mazakcorp.com
www.mazakusa.com
N. CA
Richard McCauley
Mazak Northern California
Technical Center
47273 Fremont Blvd.
Fremont, CA 94538
rmccauley@mazakcorp.com
www.mazakusa.com