Cutting it: an array of equipment that can help undertake even your most-demanding machining tasks

Automotive Design & Production, August, 2004

01 WHAT: Twin spindle machining centers

NAME & SOURCE: MCT Series from Heller Machine Tools (Troy, MI; www.heller-machinetools.com).

FEATURES & FUNCTIONS: There are two models, the MCT 160 (working envelope: 450 X 450 X 450 mm; maximum part diameter and height, respectively: 450 mm, 600 mm) and the MCT 250 (working envelope: 690 X 690 X 520 mm; maximum part diameter and height, respectively: 700 mm, 750 mm). The twin-spindle machines (38 kW each) have a dedicated servo-driven B-axis for each spindle, which means that there can be simultaneous machining of four sides of two different parts (e.g., left- and right-hand parts). The machine is designed so that it can operate as a stand-alone machine or integrated into a system (the shared X-axis is integrated into the column; the shared Y-axis is a vertical slide; the independent ram-style Z-axes are integrated into the Y-slide; the speed and feed of each Z-axis can be independently set). It has a compact footprint (2,450 mm wide; 3,400 mm high). The machine is quick: speed in each axis is 60m/min, acceleration is 10m/sec/sec in X and Y and 14 m/sec/sec in Z. There is a standard tool magazine of 40 tools (HSK 63) each for each spindle.

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02 WHAT: Multifunctional turning center

NAME & SOURCE: E 280 from Romi Machine Tools (Erlanger, KY; www.romiusa.com).

FEATURES & FUNCTIONS: The machine can perform turning (swing: 25.6 in.; maximum cutting length and diameter, respectively: 15.75 in., 11.02 in.), as well as boring, milling, and tapping in a single setup. Each of the machine's left- and right-side spindles can be equipped with 15 or 25-hp motors. There are three turret options: one for standard turning tools; a motor-driven turret for live tools; and a motor-driven turret with an additional Y-axis assembly (both motor-driven types have a 5-hp motor). The toolholder disc for the turrets can handle 12 tools.

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03 WHAT: Multifunctional horizontal machining center

NAME & SOURCE: H5-1000MT from Cincinnati Lamb (Hebron, KY; www.cincinnatilamb.com).

FEATURES & FUNCTIONS: This five-axis machine is designed to handle parts 50-in. in diameter and larger. The machine is not only capable of performing milling operations, but it can also perform turning, as well. The machine is featured with a direct-drive motor-driven rotary table that is available either in high-torque (300 rpm) or high-speed (700 rpm) types. It also has an A-axis tilt spindle with an 180[degrees] tilt for five-sided machining. As in the case of the spindle, selections are high torque or high speed; the speed range is from 6,000 to 24,000 rpm.

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04 WHAT: High-speed machining center

NAME & SOURCE: VCP 1000 Duro from Mikron (Holliston, MA;) www.micron-us.com).

FEATURES & FUNCTIONS: This vertical machining center can be configured as a three- or four-axis machine. The machine features vector-controlled spindles with ceramic bearings that provide a speed range from 12,000 to 42,000 rpm. The machine provides X, Y, Z feeds of 20 m/min with a rapid traverse of 30 m/min and an acceleration of 4.2 m/[sec.sup.2]. The machine has a polymer concrete base to ensure rigidity, stability, and thermal dampening. The machine's 1,300 X 600-mm worktable can handle workpieces weighting up to 1,600 kg.

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05 WHAT: Twin-spindle production module

NAME & SOURCE: SPECHT 550 duo from Cross Huller North America (Sterling Heights, MI; www.crosshuelier.com).

FEATURES & FUNCTIONS: The machine is designed for part volumes of about 500,000 per year. Each of the 16,000-rpm spindles has an output of 25 hp. The X, Y, Z travels are 710, 710, and 610 mm, respectively. Each of the Z-axes has its own independent drive so there can be different tool offsets and other spindle-specific settings. Rotary tables are available that permit A- or B-axis work presentation. There is a single chain-type tool magazine (72-tools, including single setup tool) that serves both spindles with tools up to 400 mm long (HSK 63). The machine can setup for either wet or minimum quantity lubrication (MQL) cutting.

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06 WHAT: Vertical spindle machining center

NAME & SOURCE: V22 from Makino (Mason, OH; www.makino.com).

FEATURES & FUNCTIONS: With an 11.3-hp (continuous) motor that drives the spindle to 40,000 rpm, this machine is designed for small-parts machining. The travels are 12.6-in. X, 11-in. Y, and 11.8-in. Z. Moves are made quickly, with a rapid traverse of 787 ipm. The work zone measures 17.7 X 13.8 in. Maximum part weight is 220 lb. It is equipped with an HSK-E32 spindle interface. The standard automatic tool changer handles 30 tools. The machine has a compact footprint: 4.9 X 6.5 ft.

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07 WHAT: Face mills

NAME & SOURCE: F45MN from Iscar Metals (Arlington, TX; www.iscarmetals.com).

FEATURES & FUNCTIONS: This family of cutters is designed for medium and rough face milling operations. They are available in diameters from 3 to 8 in. The cutters use double-sided octagonal inserts (ONMU 080608 insert geometry, each of which provides 16 cutting edges with positive rake angles (when used in [less than or equal to]0.216-in. depth of cut)). Up to 0.020-in./tooth feed can be achieved. There is a central screw for clamping the inserts in place.