SEMINAR/WEBINAR ARCHIVE

Makino's vision is to perform as many operations as possible on the machine with the ideal situation of loading a raw part in the machine and taking a finished part out of the machine. There are many advantages to a process like this. You can fixture the part and perform as many operations as possible.  Combining operations will lead to better part quality and consistency, a reduction in total part cycle time and scrap, a reduction in material handling, and the cost savings associated with not having to purchase dedicated equipment or maintain and staff that dedicated equipment. And, with a single flexible machine there's more opportunity to introduce new parts in the future.

First we will discuss the reasons why grinding is needed. Then we will talk about why you should grind on a Makino horizontal machine center, which will include some discussions about the options added to the machine to allow grinding. Following that we will go over different types of grinding which will include a patented grinding process called, “Viper Grinding, which Makino uses to achieve extreme high metal removal rates. Finally, we will look at some examples of where we've applied grinding to customer's parts.

There are other questions we'll share answers to. Such as, why grind? What feature on the part requires a grinding operation? Is there a very tight tolerance that requires grinding or a complex form?  Is the material such that grinding is the only method to remove the stock? For example, some parts are finished ground after a heat treat operation and, due to the hardness of the part, now milling may not be practical or even possible so grinding is a good alternative. Or, in some cases, grinding is required to bruise a finish that is needed for the part.

When comparing the Makino horizontal machining center to a typical creep feed grinding machine, there are obvious advantages with the horizontal machining center. A creep feed grinding machine has a single wheel set up and you must use the same wheel specification for all the required cuts. With the Makino solution and our ability to change tools, we can use any combination of grit size, grit type, and bond, allowing for optimum performance.

The typical grinding machine has a single purpose, and that is to grind. A dedicated grinding machine is not flexible and may require considerably more time for a change over. Grinding machines are also relatively slow when compared to a Makino horizontal machine center.

What makes the Makino solution different?

The automatic tool changer on the Makino machine increases the machine's flexibility by allowing different types of machining tools to be quickly presented to the part. Automatic work change also gives us more through-put by reducing part load unload time and reducing set up.

The dedicated grinding machine is most compromised when choosing grinding wheels. The Makino solution allows for many different specification grinding wheels in the same machine; each form can have its own wheel (or even multiple wheels) allowing for savings in wheel life and better roll life when compared to a dedicated grinding solution.

Axis movements at 50 meters per minute and more can provide for fast movement between cuts to quickly ready itself for the next operation. A horizontal machining center also has the ability to quick change diamond roles.

Why choose Makino? Features.

Next, I'll go a little more in depth on why you should grind on a Makino horizontal machining center. All of the features that make the Makino horizontal machine center a word-class milling machine are some of the same features that also make it ideal for grinding.

Obviously, it may sound like I have a bias towards Makino machines, which I do because the company signs my paycheck; but I'm going to tell you now why Makino machines are ideal for grinding. Some of the features that make the Makino horizontal machining center a robust and accurate machine tool, include three-point leveling. The three-point leveling allows for quick, easy, accurate, and reliable set up with a one-piece bed casting.

The linear motion guides are oil lubricated to protect against contamination, and supply smooth movement at high speeds and accurate positioning. Makino's patented spindle technology uses temperature control lubrication that enters from the center of the spindle under the rays. This eliminates spindle growth associated with heat. Reducing this growth allows for a much higher preload which, in turn, allows for increased rigidity. This is an ideal grinding spindle.

Temperature controlled oil is also circulated through the ball screw and motor brackets to evacuate the heat generators from the motor and ball screw. This allows for more accurate and repeatable positioning.  The ball screws are also supported at both ends and pre-tensioned to reduce any effects of growth over time.