Click here to watch Tutorial Videos >

Two Sides of the High-Volume Output Equation

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

< back