How to Aggressively Tackle Full Five-Side Machining of Increasingly Complex Medical and Dental Parts

The DA300 5-axis vertical machining center from Makino Inc. (Mason, OH) perfectly blends speed, precision and flexibility needed for complex medical part applications to deliver the highest productive capabilities for multi-axis workpieces in the smallest of machine footprints. These features make the DA300 ideal for single setup, multi-side accessibility, or full-contouring capability to quickly and efficiently tackle a wide variety of complex production part applications commonly found in medical and dental products, as well as industrial hydraulic and pneumatics elements, optical, electrical and semiconductor components, die-cast parts, automotive components and aerospace parts.

“The DA300 integrates numerous features that increase productivity and efficiency by providing significant reductions in non-cut time,” said Bill Howard, the VMC product manager at Makino. “This machine provides a 50 percent reduction in spindle acceleration time, 15 percent reduction in positioning time, 40 percent reduction in tool-change chip-to-chip time, and includes a standard vision-type broken-tool sensor [Vision BTS] that optically checks tools outside the work zone to ensure tool consistency and part quality while simultaneously reducing non-cut time during tool changes by 80 percent. Individually, each element reduces part cycle time and increases productivity, but when all of these time savings are combined, the result is a dramatic advantage in reduced part-production times and increased profitability.”

The DA300 worktable is an integral 340 mm by 300 mm table that accommodates workpiece sizes up to 450 mm diameter, 400 mm tall and weighing 250 kg. The machine provides X, Y and Z-axis travels of 450 mm, 620 mm and 500 mm, respectively, at feed rates of up to 60,000 mm per minute. The direct-drive, motor-driven A-axis table offers 150 deg (+30 to -120) of tilt capability at 100 rpm. The rotary C-axis has full 360 deg rotational positioning at 150 rpm. Combined, these rotational axes have the range and speed necessary to achieve the highest productivity in complex five-face or full 5-axis machining application. Equipped with scale feedback on all axes, the DA300 also offers a rare blend of speed and precision. It comes standard with a 20,000 rpm HSK-A63 spindle, delivering the speed and flexibility to tackle high speed, highly productive machining of various workpiece materials, including aluminum, die-cast, steel and titanium. Acceleration and deceleration to and from full speed can be accomplished in a mere 1.5 seconds, reducing chip-to-chip times.

The machine’s standard configuration includes a 60-position ring-type tool magazine with capacity for a wide variety of tooling, as well as a Vision BTS to verify the integrity of the tooling prior to use. Using the proven stability of FANUC hardware and Microsoft Windows Embedded OS, the state-of-the-art Professional 6 (Pro6) control helps move operators fluidly through machine setup, empower them with easily accessible information and protect them with enhanced safety. Cycle-time saving and dynamic-control capabilities have been added to the control’s GI functions to help lower costs per part. Included is GI Drilling, a unique G-code drilling cycle that enables the spindle and tool to arc from hole-to-hole instead of following a square path. This simple change reduces non-cut time by as much as 15 percent on common hole-pattern drilling.

On complex 2D paths, testing has reduced cut time up to 35 percent. While not every tool can make use of these functions, advanced motion control GI is proven to reduce overall cycle time by three to eight percent in typical production components. This reduction saves substantial cost in both high-volume and low-volume production environments by reducing the number of spindles required and freeing up machine availability to take on more work. Other intelligent machine functions include Inertia Active Control (IAC) designed to further speed up machine motions based upon system dynamic attributes, and Collision Safe Guard (CSG), a real-time crash-avoidance feature that has a look-ahead function and takes real machining conditions into consideration to prevent collisions. To eliminate interferences in accessing the pallet, the DA300 can be configured using several approaches, including direct part handling as a stand-alone machine, manual handling using a table chuck and pallet, one of the workpiece pallet systems (WPS) or third-party automation using an EROWA chuck and pallet system.

The DA300 can be field modified to add multiple pallet magazines, starting with a seven-pallet workpiece pallet system (WPS-7) up to a 19-pallet workpiece pallet system (WPS-19). These configurations deliver the highest productive capabilities using minimal floor space. Using Makino automation integration services, manufacturers can combat fierce pricing pressures from low-labor-cost countries by providing complete automated cells and systems. Whether demands call for simple machine tending or complex, high-volume robotic cells, these automation integration services offer the equipment, skills and manpower necessary to reduce labor costs, increase throughput, ensure and enhance part quality, all while retaining the flexibility to adapt quickly to changing volumes or new parts.

For tighter tolerances and flawless blends and matches in increasingly complex 3D contoured medical parts, the D200Z 5-axis VMC combines the quickness of machine movements and accuracies with the latest software developments for high precision, high speed motion control. From roughing to high-speed finishing of multifaceted, contoured 3D geometries, it boosts productivity with the most competitive processing capabilities for complex dies and molds typically found in the medical and optical markets, as well as automotive, injection molding and packaging applications. “With mold manufacturers strained for capacity and challenged to keep pace with new design changes, all while minimizing costs, the need for high-performance 5-axis machining has never been more critical,” noted Howard. “The speed and precision of the D200Z supply a unique foundation for responsive high-speed cutting and outstanding surface finishes that reduce or eliminate handwork. Its 30,000 rpm spindle and integral direct-drive table provide quick, precise, full 5-axis machining.”

All of this capability is tied together with proprietary SGI.5 motion control software for the highest degree of accuracy and quality in the blends and matches of intricate surfaces and 3D accuracy requirements typical of today’s die, mold, medical and intricate-geometry components. Designed with an integral chuck to maximize work-zone volume and load capacity, the D200Z accommodates workpiece sizes up to 300 mm diameter and 210 mm tall with weight up to 75 kg. The X, Y and Z axes (350 mm, 300 mm and 250 mm travels, respectively) provide swift movement with rapid traverse and cutting feedrates of 60 m/min. The D200Z has also adopted a unique, lightweight B-axis tilting structure with 180 deg (0 to +180) of tilt capability at 100 rpm. Both the B-axis and rotational C-axis (360 deg continuous at 150 rpm) feature direct-drive motors for agile, accurate, high-speed, responsive angular and rotational operation.

The D200Z packs industry-leading speed and precision into a compact unit (1,500 mm wide by 2,220 mm deep) for efficient use of floor space. All machine elements and peripheral equipment are strategically located within the main body of the machine to limit the overall machine footprint. Both the standard 20-tool capacity automatic tool changer (ATC) and the optional 40-tool ATC fit within the same machine floor space, enabling companies to expand capability without loss of floor space. The machine tool magazine capacity can also be optionally expanded to 100 tools and 300 tools. Wide base castings and core-cooled ballscrews serve as a base platform for all other machine components, enhancing overall process stability. The machine’s 30,000 rpm, HSK-E50 spindle is designed with a high-tech spindle core and jacket cooling system to tightly control thermal growth, deflection and vibration during high-speed machining operations. As a result, the D200Z extends tool life and has exceptional surface finishes even in applications requiring fine tool blends and matches.

An integrated pallet chuck reinforces the stiffness and rigidity of the machine tool, all while ensuring efficient workpiece changeover speed and full usage of work zone and workload capacities. Additionally, a common pallet interface can be readily integrated into a variety of automated cells and systems that are prevalent in today’s tool, die and mold shop environments. The D200Z can also be configured with a graphite machining package to provide high speed, exceptionally accurate, and very productive 5-axis production of graphite electrodes. The D200Z is equipped with the powerful yet intuitive Pro6 control. With streamlined screen layouts, operator assistance features and new machine functions, Pro6 boasts a seamless interface for operators to maximize productivity.

Included within the Pro6 control is proprietary, next-generation Super Geometric Intelligence (SGI.5) software developed specifically for high-feed rate, tight-tolerance machining of complex 3D contoured shapes involving continuous tiny blocks of NC data. Using a combination of highly refined AC digital servos and proprietary software, SGI.5 enables the machine to feed at rates faster than standard CNC systems while maintaining high accuracy. Its high resolution, 3 million pulses per revolution (PPR) feedback system ensures that the servo system operates at optimum performance during execution of the toolpath. Depending upon the specific geometry of the application, SGI.5 yields 20 percent to 60 percent faster cycle times while maintaining accuracy and surface finishes. A Makino proprietary data center offers easy, flexible program and data management, and enhanced networking capability. The data center is the single source for all files on the machine and network, able to run directly from memory, internal/external card, full direct numerical control (DNC) or from a network.

The D200Z also features proprietary Collision Safe Guard technology, a function that runs real-time interference checks to avoid spindle crashes. By combining on-board machine geometry models with workpiece, fixture and tooling data input by the user, Collision Safe Guard is able to predict and stop the machine prior to collision, protecting investments in the machines, fixture, tooling and workpiece.

Makino Inc., 7680 Innovation Way, Mason, OH 45040, 513-573-7200, Fax: 513-573-7360, www.makino.com.