Among the innovative at IMTS - Produce - International Manufacturing Technology Show

Automotive Design & Production,  Nov, 2002  by Gary S. Vasilash

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Cost conscious

Cost is a concern that is an abiding one throughout the industry. Some companies have specifically focused on developing flexible machines for the auto industry that are in keeping with this overall sense of fiscal responsibility. Among them is Makino (Mason, OH), which has long been known for the horizontal machining-center based systems that are used in powertrain and brake system manufacturing operations. Heretofore it has offered machines like the A55E (400-mm pallet; 14,000-rpm spindle) and the A77E (500-mm pallet; 12,000 rpm, 50-taper spindle). However, because these machines have tended to be used by OEMs and tier-one suppliers, the company has developed a series of machines with an "a" designation. So there are machines like the a 51 horizontal machining center, with a 400-mm pallet and a 12,000-rpm spindle and the a 71, with a 500-mm pallet and a 10,000rpm, 50-taper spindle. The objective in developing this line of machines was to provide performance while reducing the price vis-a-vis not only its ow n line of machines, but also those of the competition.

Vertical Approach

Similarly, Mazak Corp. (Florence, KY) has engineered machinery that is well suited for applications in high-volume production applications--where lean manufacturing and the necessity of flexibility are taken into account--but here the spindle orientation is vertical. included is the IVS 200--with the VS designating "inverted vertical spindle," which means, in part, that the spindle is used not only to rotate the part, but to provide material handling action, as well. This two-axis CNC turning machine's spindle has an integrated motor (eliminating gears and belts); it accelerates to 5,000 rpm in just 1.8 seconds and it provides a maximum torque of 147.5-lb.-ft. The rapid traverse in X is 4,330.7 ipm; it is 2,362.2 ipm in Z. The turret rotation is quick, too: 0.17-sec/step. The machine is designed with a small footprint with easy accessibility for all maintenance points. As a result, the machines can be lined up for higher-volume operations.

Eliminating space

A horizontal spindle CNC machine that's designed to operate either as a stand alone or configured in a line in an exceedingly compact manner is the TOP J from Toyoda Machinery USA (Arlington Heights, IL). First of all, the TOP J has a compact footprint: just 39 x 106 in. But they've gone far beyond just that: the machine is available in both left-and right-hand configurations: this means that you can place two machines next to one another so that there is zero dead space between them. Expensive floor space considerations are, consequently, not as big an issue as they otherwise might be.

Going Horizontal

Fadal Machining Centers (Chatsworth, CA) has long been known for its line of vertical machining centers. Yet the company has found that when its customers started looking for horizontal spindle machines to bump up their production levels, they began to look at other vendors. So, not to lose customers, they've developed the HMC 400, a 400-mm twin pallet machine. It features 20 x 24 x 20-in, travels, a 10,000-rpm spindle, a Siemens SINUMERIK 810 0 digital control, a 40-pocket toolchanger that provides 1.2-second tool-to-tool time. And it is said to be engineered for a 24/7-duty cycle. The pricing is expected to be in the $170,000 range.