ARTICLE

Display Differing Degrees of Automation For Any Sized Mold Making Operation

Makino will display and operate three different levels of automated and integrated work cells for mold making at its Main Booth # 8400 location during the 2004 International Manufacturing Technology Show (IMTS) at McCormick Place in Chicago, Illinois, September 8 through 15.

A single machine pallet changing system, a multi-station auto work changer and a full service robotically integrated cell will demonstrate three different degrees of automation for any sized operation. This versatile ensemble will highlight Makino’s moldmaking capabilities and the synergy potential of its machinery with other advanced technology.

Single Machine (Level One)

The competitively priced a61 horizontal machining center (HMC) from Makino is ideal for automated and cellular manufacturing applications that require maximum throughput and reliability. The compact and versatile workhorse has a pallet changing system as a standard feature, with safety guards and two pallets, for a fast pallet change time of 7 seconds. And, it offers a tool-to-tool change time of 0.9 seconds with a chip-to-chip time of 2.5 seconds.

This pallet-changing, horizontal machining center can concurrently run multiple setups, milling core, cavity and mold base parts all on the same machine. The a61 has an exceptional travel capacity and work zone for a machine in this class. With an X-, Y-, Z-axis travel of 28.7 x 25.6 x 28.7 inches (730 x 650 x 730 mm), the a61 has a work zone size of 32 x 36 inches (800 x 900 mm).

The pallet size is 19.7 inches (500 mm), with a maximum load capacity of up to 1,540 pounds (700 kg). The rapid traverse and the feedrate of the a61 are 1970 ipm (50 m/min.). A host of tool monitoring capabilities, all equipped as standard features, allows users to achieve extended machining hours with minimal labor costs.

The a61 will be shown with a 40-taper, 18,000-rpm spindle that has exceptional acceleration characteristics, and minimal vibration. It also has a ring-type, 40-tool magazine standard, with larger magazines from 60 to 313 tools optional.

The machine also has Makino’s proprietary, next generation Super Geometric Intelligence (SGI.3) servo controller. Other features include a chip conveyor and filtration system, through spindle coolant (300 psi), a standard three-point support system, an ergonomic swing, operator control panel and an overhead shower coolant.

Multi-Station Automatic Work Changer and Software (Level Two)

The V33 from Makino delivers superior high-performancemachining capabilities—superb accuracy, ultra-fine finishes, efficient chip removal and excellent ease of operation—in a more compact footprint. It provides machined finishes so superior, the need for EDMing and benchwork on dies and molds can be virtually eliminated.

With the 60-station Automatic Work Changer (AWC) run by the new MicroCell Expert™ management software, the V33 cell can handle a maximum workpiece  size of 3.78 x 12.40 x 5.90/5.51 inches (96 x 315 x 150/140 mm).  It can also handle a pallet load of 22 pounds (10kg) maximum, and can process a total work change in 50 seconds.

This cell configuration is designed to simplify operations and enhance capabilities by adding increased work scheduling capacity and capability to the existing machine control. It is an ideal ensemble for a small- to medium-sized die/mold operation wishing to gain the benefits of reduced setup time and unattended machining operation.

MicroCell Expert™

The key technology to this type of cell alignment is the new MicroCell Expert™ software from Makino. It includes DNC functionality, added tool data capabilities, machine monitoring functions, NC program upload/download capability, random machining schedule operation, M198 functionality from a PC and historical data recording.

All these features are available from a simple, user-friendly Windows® user interface. Makino’s MicroCell Expert also features capabilities that allow NC programs to be downloaded to CNC memory as required, immediately before machining. It also simplifies the management of NC programs by storing them on the PC using logical filenames.

MicroCell Expert allows operators to create a schedule of execution for pallets, fixtures and workpieces in the Makino AWC or pallet magazine system. It will associate NC programs to each fixture or workpiece on a pallet and execute the NC programs from CNC memory or  by using DNC operation. MicroCell Expert also provides for the ability to use subprograms stored on PC, and to use different NC program execution methods for each fixture or workpiece.

Use of the data server function allows subprograms to be called from the PC hard disk by NC programs executing in CNC memory. A high-speed communication interface provides seamless transfer of NC programs and data from the PC to the machine control.

Fully network capable, MicroCell Expert provides the flexibility to store NC programs on another PC or server, and to execute them using the DNC function. DNC operation is then started after the creation of a temporary local copy, ensuring that other network traffic does not affect the machining process.

DNC processing results are stored on the PC, and include items such as machining start and finish time, machining state and filename. All alarm history information is also stored on the PC.

Makino V33

Makino’s proprietary, next generation Super Geometric Intelligence (SGI.3) servo control delivers the lowest cycle times achievable while maintaining exceptional accuracy and producing finishes that only a machine designed specifically for a die/mold application can provide.

Designed to machine complex cavities and cores, this has a standard 20 HP, 20,000-rpm spindle, complemented by Makino’s patented core cooling and under race lubrication system that has proven essential for optimal high-performance applications.

To maximize shop floor space, the V33 measures 89.76 x 80.32 inches (2,280 x 2,040 mm) and all setup work is concentrated within the machine’s front width of 90.55 inches (2.3 m). The coolant tank slides out from the front of the machine and the front-loading chip bucket is shaped for easy and efficient chip removal.

All axes motion is guaranteed to deliver straightness and perpendicularity of 0.00012-inch (3 microns) full stroke. Machine construction is such that there are no overhangs, providing excellent rigidity and dampening characteristics, with an 787 ipm (20,000 mm/min) rapid traverse with equally fast cutting feeds boosts productivity by reducing out-of-cut time while increasing metal removal rates.

Fully Integrated Robot Cell System (Level Three)

This cell will consist of Makino’s new V22 vertical machining center, which is specifically designed for high-speed hard milling production. It will be demonstrating copper electrode machining for the Makino EDGE3 Ram EDM machine, which is also integrated into the system. This combination will be producing plastic mold cavity details.

Makino’s EDCAM Professional™ offline programming solutions software will provide real time operation to the EDGE3 machine. PS Electrode™ program management software from Delcam will automatically extract the required electrode geometry and prepare NC toolpath for the V22. It will also prepare the necessary 3D model of the electrode, which will be directly imported into EDCAM for final EDM program preparation.

A 3R Workmaster™ robot, as well as 3R Workshop Manager™ software, will integrate and manage the cell. The cell will additionally include a Mitutoyo coordinate measurement machine for automatic process verification of both Makino machines and electrode specification verification.

Makino EDGE3

Makino’s EDGE3 sinker EDM machine is ideal for the plastic injection mold and forging die job shop marketplace. The EDGE3 is well suited for both the entry-level shop as well as the advanced high-level shop looking to automate EDM and to achieve high accuracy with superior surface finishes.

The relatively compact EDGE3 is 78 x 84 x 92.8 inches (1950 x 2100 x 2320 mm) and weighs in at a solid 10,340 pounds (4700 kg), which can benefit the smallest or the largest metal production shop. It is value designed to provide exceptional service that any shop can afford, without compromising on the latest technology or quality of finish provided on similar and larger Makino machines.

The EDGE3 machine is specifically intended to facilitate safe and simple unattended operation.  Makino’s Intelligent Expert System™ (IES) and MGH CNC Power Supply include the new Super Spark™ technology. This allows the EDGE3 to achieve faster overall machining rates, with superior surface finishes to 2 µinch.

The EDGE 3 has an X-, Y-, Z-axis of 18 x 12 x 12.8 inches (450 x 300 x 320 mm), with a Z-axis jump speed of 400 IPM (10,000 mm/min). The rapid traverse speed of the unit is 400 IPM (10,000 mm/min). The 24 x 18 (600 x 450 mm) worktable allows for workpieces as large as 1,760 pounds (800 kg) in weight, with a tabletop height of 35.6 inches (890 mm). This size of operation allows for electrodes that are 2 x 5 inches (50 x 125 mm) and up to 110 pounds (50 kg).

Optional features to enhance the flexibility of the EDGE3 include the EROWA ITS and 3R Macro installation sets and a wire attachment for intricate detail work. It also has an optional C-axis with an MA rotary head capable of enhancing deep, fine-hole machining applications—another key advantage to the EDGE3.

Makino V22

Makino’s V22 vertical machining center is the newest VMC from Makino designed for small part, high-accuracy machining. This ultimate machining center offers a 40,000-RPM spindle with superior finishing abilities, ideal for intricate work.

The V22 delivers superior performancein a footprint that is only two-thirds that of the popular Makino V33. It is ideal for precision parts manufacturing, such as medical equipment and small and intricate molds for plastic injection-molding operations. It provides precision, accuracy and excellent stability.

Precision and Superior Surfaces

Designed to machine complex materials, including ceramics as well as intricate cores and cavities, this newest addition to Makino’s line of die/mold machining centers offers a standard 11.3 HP continuous, 40,000-RPM spindle. It is complemented by Makino’s patented core cooling and under-race lubrication system that has proven essential for optimal high-performance applications.

The X-axis of 12.6 inches (320 mm), Y-axis of 11 inches (280 mm) and Z-axis of 11.8 inches (300 mm) operate in a work zone and table size of 17.7 inches x 13.8 inches (450 mm x 350 mm). The slideway design provides for a 787 IPM (20,000 mm/min) rapid traverse and cutting feedrates.

The V22 can handle a 220-pound (100 kg) load and maximum 17.7-inch (450 mm) x 18.7-inch (475 mm) x 7-inch (200 mm) workpiece. The machine features an HSK-E32 spindle interface with a standard 30-tool automatic tool changer with a larger 60-tool changer option. A hybrid, automatic tool length measuring device (ATLM) is also optional.

To maximize shop floor space, the V22 measures 4.9 ft x 6.5 feet (1,500 mm x 2,000 mm), and all setup work is concentrated within the machine’s front width of 4.9 ft (1500 mm). With a fully enclosed splashguard, the coolant tank slides out from the front of the machine. The front-loading chip bucket is shaped for easy and efficient chip emptying, even during machine operation.

EDCAM Professional™

The EDCAM™ software assembles and relays critical data between CAD-CAM systems and the NC program for the controller running the sinker EDM machines, bypassing the need for manual input that often leads to operator errors and mistakes. This will help reduce human error in burn programs, which in turn will reduce scrapped mold components and increase machine shop efficiency while dramatically reducing overall programming time by 70 percent.

This software enhances sinker or Ram EDM capabilities through the direct electronic reception of electrode information and necessary workpiece data as a critical relay between the machines and CAD-CAM systems. It receives all necessary peripheral information from the CAM systems, such as electrode positioning, and adds the necessary burning technology and tool change data to output a final numerical controlled (NC) program for the EDM machine to utilize.

With EDCAM Professional™ software, the information is taken directly from the part drawing or CAD-CAM system and then basic EDM technology information is applied via a simple "Electrode Advisor" prompt which then applies the necessary EDM strategies to create the final NC burn program without virtually any manual numerical inputs. This essentially provides machine shops full offline programming capabilities, making CAD-CAM departments more versatile and operators more efficient. lso visit Makino at their EDM Pavilion Booth #4110 in Hall D to see additional technological advancements in machine tool manufacturing and performance.