MACH 2018: Intelligent machining

The configuration at the show will include a Cellro robotic system from Holland (https://cellro.com/en) for automatically loading and unloading components.

The compact machine is ideal for five-sided and fully interpolative 5-axis production of complex components in one clamping. A rigid structure combines with high dynamic motion control to reduce cycle times significantly while maintaining accurate performance.

Equipped with integral, direct-drive motors for the swivelling +30 to -120° A-axis trunnion and also for C-axis rotation of the 340mm by 300mm table, the machine deploys a 20,000rpm, 22kW, HSK-A63 spindle capable of rigorous milling, drilling and tapping. A 60-tool magazine ensures availability of an extensive selection of cutters to tackle the most complex of parts or component families.

The table is prepared with pneumatic ports for easy integration of an automated pallet change system to provide quick, efficient component exchange, maximising machine utilisation. Makino offers two standard workpiece pallet systems that can be factory fitted or retrofitted: a seven-pallet arrangement, expandable in the field, or a 19-pallet configuration. An Erowa chuck-type pallet system for automated component handling may alternatively be attached in a similar fashion to the Cellro equipment on display.

The Fanuc-based Professional 6 CNC system with optional Super Geometric Intelligence 5 (SGI.5) provides streamlined screen layouts, operator assistance and new macros to accelerate productivity. For example, a G-code drilling cycle enables the tool to arc from hole to hole instead of following a square path, reducing non-cutting time by as much as 15% when drilling a typical hole pattern. A vision sensor outside the machine's work zone detects broken tools to ensure cutter integrity without impacting cycle times.

Workpieces up to 450mm in diameter and 400mm high with a maximum weight of 250kg can be machined within a 450mm x 620mm x 500mm working volume at feed rates up to 60m/minute. Even the rotary A- and C-axes are fast at 100 and 150rpm respectively. Acceleration and deceleration to and from full speed takes just 1.5 seconds, minimising chip-to-chip times. Accuracy is ensured by scale feedback in all axes.

Other intelligent machine functions include Inertia Active Control designed to speed machine motions further based on dynamic attributes and Collision Safe Guard, a real-time crash-avoidance feature that has a look-ahead function and takes real machining conditions into consideration.

Other standard features include temperature control by cooling of the machine structure, spindle, ballscrews, bearings and drives. A video is available at:

NCMT www.ncmt.co.uk