Top Japanese innovation comes to the NEC – MACH 2022

From a machining and turning perspective, visitors to NCMT’s dual stands will be able to see a raft of new technology from its principals Okuma and Makino. 

MACH 2022 will mark the UK launch of the D200Z 5-axis, vertical-spindle machining centre from Japanese machine tool builder, Makino. The machine will cycle through a reflector mould program. Also being demonstrated will be Makino’s iSetup, an on-the-fly probing solution.

From roughing to high-speed finishing of multi-faceted and 3D contoured geometries, the D200Z boosts productivity of complex dies and moulds typically found in the automotive, injection moulding, packaging, medical and optics markets. The machine's speed and precision provide a solid foundation for responsive, high-speed metalcutting and for the production of outstanding surface finishes that reduce or eliminate hand polishing.

The 30,000rpm spindle and integral, direct-drive table provide quick, precise, full 5-axis machining. This capability combines with high-speed SGI.5 motion control software in the Makino Professional 6 CNC to maintain the tightest tolerances and quality requirements and ensure accurate blending of 3D surfaces, even during simultaneous 5-axis motions.

Designed to maximise working volume and load capacity, the compact D200Z accommodates workpiece sizes up to 300mm in diameter, 210mm tall and weighing up to 75kg. The X-, Y-, Z-axis travels of 350mm, 300mm and 250mm respectively feature rapid traverse and cutting feed rates of 60m/minute. The machine utilises a lightweight B-axis structure with 0 to 180° of tilt at 100rpm. Both the B-axis and 150rpm, 360° C-axis table feature direct-drive motors for accurate, high-speed operation.

New HMC matches 30-taper productivity

The speed and agility normally associated with a 30-taper production centre has been built into Makino's new HSK-A63 HMC, the a40 SE. The 4-axis machine will also be launched in the UK at MACH 2022.

A high rate of change of axis acceleration, or jerk, delivers high-speed in the HSK-A63 machine sector. Additionally, the inertia of the 22kW/91Nm spindle is two-thirds that of the spindle in the similarly sized model in Makino’s standard HMC range. Side-by-side comparative tests against a couple of competitive, high-speed HMCs showed cycle time savings from 10% up to one-third, depending on the type of component as well as the number of operations and tools involved and the frequency of table indexing.

The a40 SE is designed for taking light cuts from near-net-shape, non-ferrous components, it is aimed at high-volume producers and users of aluminium and zinc die castings. Axis travels are 560 x 640 x 640mm, the rotary table has 0.001° indexing and maximum table load is 400kg.

The machine features a collection of innovative technologies, known as Makino’s Intelligent R.O.I. design, for slashing unproductive non-cutting times. Various automation options are available to reduce cost per part still further.

Machining performance at the right price from Okuma 

Highly rigid, thermally-stable construction protects the Okuma Genos M560-V vertical machining centre from thermal deformation, resulting in high machining performance for an entry-level machine, as will be demonstrated at MACH 2022.

The 3-axis machine is able to process a variety of materials, from titanium to aluminium, and does so without sacrificing dimensional accuracy, finish quality or productivity.

The model on the stand will be equipped for the first time at a MACH show with Okuma's Standroid floor-mounted, robotic automation solution, developed by the manufacturer for its prismatic machining platforms with the requirements of small and medium size enterprises in mind. The compact unit can be placed next to, and integrated with, various different Okuma machines.

Standroid is easy to operate by simply defining start and end points of the robot arm, while the system automatically calculates movements and avoids collisions. This greatly reduces set-up and prove-out times. For maximum flexibility, it is possible to switch between automated and manual workpiece loading and unloading.

The M560-V has a 1,050 x 560 x 460mm working envelope and a maximum table load of 900kg. The CAT40 BIG Plus, 15,000rpm spindle moves in the X- and Z-axes, with the table moving in Y. A 32-position tool magazine is provided.

To emphasise the build quality and thermal stability of the Genos vertical machining centre range, an identical static machine will be on the stand with all guarding removed so that the machine construction may be inspected.

Genos M460V-5AX

Next up from Okuma, the Genos M460V-5AX vertical machining centre with a working volume of 762 x 460 x 460mm will be in evidence again. It was the original 5-axis machine in Okuma's economical, series-built Genos range. The trunnion with rotary table and 5-axis simultaneous control give the machine the ability to produce highly complex components. The BT40 spindle is rated at 15,000rpm/22kW, which is served from a 48-position tool magazine. Control is via the proprietary, user-friendly OSP-P300MA CNC.

The theme of NCMT's Okuma stand at MACH will feature Okuma Smart Factory. It will exemplify how Industry 4.0 applications can improve manufacturing processes by linking every machine tool throughout an entire manufacturing environment to Connect Plan. The solution allows complete visualisation of the factory and provides analytics for improved machine tool utilisation.

Okuma integrates machine tool and robot in world first

The Okuma Spaceturn LB3000 EX II turn-milling centre will make its first appearance in the UK equipped with the Japanese manufacturer's Armroid robotic arm, the first in the world to be integrated inside a CNC machine tool.

Three different end-of-arm effector options are available for the robot, capable of performing different tasks. One is for blasting the cutting zone with a mixture of air and coolant to improve chip management. Another provides additional support during the cutting process to prevent chatter. In combination with a workpiece stocker, the third effector is a two-finger gripper for holding shaft-type workpieces weighing up to 5kg and then automatically loading and unloading them. 

While most conventional robotic systems require complex integration and special training for staff, Armroid needs neither. As the robot is part of the machine tool, separate system integration is unnecessary. 

Cost-effective lathe now with higher specification

The competitively priced Genos L3000 lathe will make another appearance at MACH, but this time with a higher specification including a sub spindle and a 12-station turret with Y-axis and live tooling. Maximum turning diameter is 300mm and rotational speed of the 22kW spindle is up to 3,800rpm, all in a compact footprint of 2.5 x 1.9m.

The six-tonne Genos L3000-MYW turning centre is rigidly constructed and features an integral spindle motor and rigid guideways for powerful, high precision machining of a wide range of materials including exotic alloys. The Japanese manufacturer's Thermo Friendly Concept has been applied to the machine construction to enable tight tolerances to be maintained on the shopfloor.

The final turning machine on the stand will be a Genos L2000 equipped with an Okuma Gantry Loader workpiece handling system.

NCMT
www.ncmt.co.uk
Hall 19, Stands 120 and 130