Machining Cylinder Heads, Cylinder Blocks, Gearbox Housings

When it comes to making high-quality, high-performance automobiles, high productivity is a non-negotiable prerequisite. Yet what manufacturers are really looking for is long-term reliability in their machining processes. This is why some of the top automakers in the world use horizontal machining centers to help manufacture the cars of the future. The Urane 25 horizontal machining center from Comau LLC (Royal Oak, MI) is designed to meet the specific needs of the automotive industry. With over 20 years of experience and more than 2,000 machines installed worldwide, Comau has now evolved the new Urane 25 to handle more complex machining processes that are suitable for managing lightweight materials including aluminum prismatic parts such as the cylinder head, cylinder block, and gearbox housing. At the same time, the Urane 25 can also handle steel and cast-iron components within the limits of the machine specifications.

Before looking at how the Urane 25 horizontal machining center is being used on the factory floor, it’s important to understand that today’s market requires high-volume, cost-effective production of consistently high-quality parts that meet even the most demanding requirements in terms of the size, dimension, weight and material surface. Additional drivers are the need for long-term durability in a low maintenance solution. Urane 25 uses state-of-the-art technology and premium, proven components, to handle different levels of process complexity within an autonomous structure. Thanks to linear motors that offer faster performance over a longer period than alternative solutions based on ball screws, Minimum Quantity Lubrication (MQL) technology, and the improved lifespan of primary components such as the electric spindle, automakers can count on the Urane 25 to confidently hit their production volumes while cutting costs at the same time.

Currently deployed all over the world, this machining center has the dual advantage of being able to machine multiple variants of parts, while easily adapting to the introduction of new products and delivering full scalability in terms of volume changes. In addition to its inherent modularity, new configurations, such as the 5-axis option that have been specifically designed to answer the needs of the Top Tier automakers, guarantee the ability to meet higher, more complex production targets without missing a step, year after year, with the same accuracy and efficiency as when it was first installed. Its compact design and optimized “box-in-the box” structure is ideal for high-volume production environments where floor space is a premium. Now featuring a 40 percent reduction in size compared to previous models, its footprint, modular configuration and various loading concepts allow the machining center to easily and efficiently adapt to almost any factory setting.

Not only does this HMC deliver outstanding dynamic functioning for virtually any process, from drilling tapping, rough and finishing milling, boring and reaming, to rough and finishing circular interpolation. The innovative tool management design increases throughput while protecting the longevity of the machine. Tools are directly picked up by the spindle without an ATM arm, thereby increasing system reliability and protecting tools themselves from chips. In addition, the patent-pending tools attachment cleaning device cleans tools inside the tool magazine, during the hidden time when the spindle is working, via a maintenance and contact-free coolant flushing process. And the fast and simple tool breakage detection system utilizes a smooth-motion electric drive while the spindle is operating, to identify breakage of tools by touch inside the magazine.

Energy savings solutions are a priority, and the Urane 25 optimizes work flows while minimizing lubricants, coolants and overall energy consumption. With an energy reduction system based upon eComau Energy Management System principles and optional MQL technology, this horizontal machining center can guarantee automotive manufacturers continued, tangible savings year after year. The system includes three management modes – warm-up, stand-by and sleep mode – in the latest generation, low energy componentry and an energy recovery module. Together with other energy-efficiency and reduced fluids consumption technologies, these can help produce an annual savings of up to one MWh/year based on a typical scenario of 225 days, 24-hour days/year.

Downtime and production losses are also minimized thanks to the operator-friendly HMI with its clear and intuitive interface, and advanced management functions such as Secure Withdrawal, which allow the operator to safely remove the tool from the workpiece in a manner that is conducive to the type of machining that was taking place. The machining cycle can then be restarted under the optimum safety conditions without specifying where the program was abandoned or where it must be restarted. In this way, the control system helps facilitate program and parts changes, while the advanced troubleshooting and on-board support systems reduce diagnostic times as well as production losses. Such functionality helps protect both the machine and the tools, while decreasing the issue of scrapped parts.

Comau LLC, 2800 West 14 Mile Road, Royal Oak, MI 48073, 248-353-8888, www.comau.com.