The trend toward smaller batch sizes is affecting all machine tool development programmes, including those for multi-spindle automatic lathes. Whereas machines used to produce many millions of parts throughout the year without re-tooling, it is now common for subcontract lathe operators to re-tool their multi-spindle machines every two to three days. Set-up times therefore have a significant impact on unit costs.

Karl-Heinz Schumacher, head of development and design of multi-spindle machines at Index (represented in the UK by Kingsbury), says an optimised set-up concept is therefore essential when looking to the future: “Batch sizes are going to get even smaller. This means we need to devise solutions that accelerate tooling and set-up and – no less important – simplify these processes while maintaining a high-precision result.”

The development teams at Index have included a range of effective solutions on the new MS24-6 multi-spindle automatic lathe, as they did previously in the MS32-6 launched last year. One special feature is the Index quick-clamping system with integrated W-serration on the cross slide. Instead of the previously common dovetail system, each cross slide now features a W-serration to simplify micron-precise alignment of the tool holder. The W-serration eliminates the degree of freedom in X, meaning that operators can simply attach the tool holder, which is already pre-set in the X and Y directions. It is attached using a quick-clamping system developed by Index that fixes the holder in position using a tie rod and a pre-tensioned wedge rod. Just a quick turn with the wrench ensures the firm contact required for use.

“This makes the operator 50% faster than when changing holders the conventional way, and practically eliminates the risk of errors,” says Schumacher.

For further information
https://kingsburyuk.com/

The first fixed-head lathe in Citizen Machinery UK’s Miyano range to feature the company’s patented LFV (low frequency vibration) chip-breaking software in a FANUC control system is the new, 42 mm bar capacity ANX-42SYY. It features 10 CNC axes including a ±35 mm Y axis on both the upper and lower turrets in addition to X- and Z-axis movements, enabling the production of complex components to tight geometrical tolerances.

LFV involves synchronising the rotation of the spindles with high-frequency oscillating motions of the tools in the X and Z axes to break what would normally be stringy swarf into manageable chips that can be disposed of easily. During turning and drilling, swarf is prevented from entangling around the component and tool, which would otherwise risk damage to both, and prove time-consuming to remove. Machine stoppage for swarf clearance is unrequired, even when machining materials such as stainless steel and plastics.

In addition to LFV software, which is programmable via G-codes in the part program, the 15” (380 mm) XGA touch panel FANUC 31i control features a new Citizen HMI and incorporates the company’s multi-axis technology. This configuration allows three-axis simultaneous cycles, double Y-axis cutting and superimposed machining whereby three tools can be in cut at the same time thanks to X-axis movement of the sub spindle. The technology also helps to share operations between the two spindles more evenly, which helps increase production efficiency and throughput.

The 6.2-tonne machine occupies only 2650 x 1630 mm of floor space. Both main and sub spindle have a bar capacity of 42 mm diameter and are powered by 11 kW/6000 rpm built-in motors.

For further information
www.citizenmachinery.co.uk

For many production planners, IoT in manufacturing is still a visionary principle: machines form a fully integrated system that production planners monitor, control and evaluate from a central location. However, this approach is no longer a vision of the future, as demonstrated by an impressive production solution at MAT Machining Europe GmbH, headquartered in Immenhausen. The automotive supplier manufactures differential gear housings on Emag production lines where full automation includes extensive data monitoring and evaluation of machine data. MAT’s aim is to increase line output and process reliability significantly.

The production process for the differential gear housing is impressive: the company has a total of five production lines, each with seven Emag vertical turning lathes, linked via TrackMotion from Emag. A so-called TransLift unit travels “through” the machines on a rail system and transports the component from one pick-up station to the next. Various preliminary processes are carried out on the housings: turning of the first side, including machining of fits and bores; turning of the second side and the outer contour; and – in the final set-up – internal machining of the spherical shape and fitting bores. Finally, washing, measuring and marking follow. In total, MAT produces almost 2 million differential gear housings every year at its Immenhausen location alone.

“Digitisation is naturally an important topic here,” says Axel Dräger, head of engineering at MAT Machining Europe. “At the same time, we knew that Emag has made great efforts around IoT in recent years and is quite interested in testing new IoT solutions with users and getting qualified feedback. So for both companies, the whole thing is a win-win situation.”

For further information
www.emag.com

Terry Benfield, owner of TPB Precision Engineering in Abingdon, has more than 25 years’ experience working in subcontract machining for a broad range of customers in sectors such as medical, scientific and motorsport. Once an applications engineer at Hurco, he chose two of the company’s machines, a TM8i lathe and a VM20i three-axis machining centre, when he started his own company in 2018.

Thanks to a recent redesign, the TM8Mi turning centre now encompasses functions that are widely appreciated on the company’s proprietary WinMax conversational CNC software driving Hurco’s machining centres. Concurrent programming, error checking and estimated run time now feature, while processing speeds are faster and the graphics enhanced.

“The programming of milling operations on the lathe is the same as rotary programming for the mill,” says Benfield. “Due to space being limited within our workshop, we use a bar puller rather than a bar-feed. It’s perfect for us because a lot of our batches are quite small, often in the order of 50-off or less.”

For a business such as TPB, continuous, consistent accuracy of machining to within microns is essential. The TM8Mi processes tough materials such as D2 tool steel without difficulty or vibration, and Benfield describes the surface finish achieved as “always excellent”.
He adds that owning the new TM8Mi is like having two machines. The ability to carry out off-centre drilling and milling operations on a shaft mean that complete components can often be finished in one hit, allowing him to offer more competitive prices.

For further information
www.hurco.co.uk

EMAG has developed a compact manufacturing solution based on its VL8 vertical turning lathes that expedites the machining of large brake drums for a leading manufacturer in the commercial vehicle segment.

The vertical structure of EMAG pick-up machines is among the factors that helped to compress the entire machining process into just three operations. EMAG provides all components of the solution, including the machines, robotic handling, peripherals, clamping devices and tools. The customer therefore receives a co-ordinated system, designed for maximum productivity. EMAG also takes care of service and maintenance.

In terms of the process, raw parts arrive on pallets, from where the robotic rail automation system takes over all component handling tasks. In Op 10, which takes place on two machines due to the cycle time, all turning work on the first side of the brake drum is performed, both inside and outside. The part is turned over between Op 10 and Op 20, allowing the bolt ring on the brake drum to be machined, including drilling the holes for the bolts. This is possible via a turret on which driven tools can be used. Op 30 follows with the final balancing work, which is also performed on a system developed by EMAG.

The flexible system is capable of adding another station, such as a measuring station, before the finished part is stacked on its pallet. Also, the VL8 machines from EMAG can be optionally equipped with measuring probes that can carry out pre- and post-process measurements.
EMAG’s VL8 offers a chuck diameter of 500 mm, while the pick-up spindle picks up workpieces with diameters as large as 400 mm.

For further information
www.emag.com