Multitasking Mania
Multitasking and hybrid machines allow you to do more with less.
Posted: July 8, 2021
Multitasking and hybrid machines (metal additives and conventional subtractive technology) have been transformational for machine shops. These innovative machines offer not only high accuracy and quality parts, but they also reduce lead times and increase production capacity. Job shops can do more with less: fewer fixturing and tools, for example. Machine companies continue to develop even more flexible and accurate machines.
AN ULTIMATE MULTITASKING MACHINE
Fuji Machine America Corp.’s (Vernon Hills, IL) Gyroflex ultimate multitasking machine is an exceptionally rigid and productive machine, featuring the latest industry-leading technology.
The Gyroflex offers the flexibility to meet a variety of production demands, from low production volume and parts prototyping to high-volume and high-mixed production. A single Gyroflex requires reduced setup and changeover times and completes complex parts efficiently and accurately.
The machine’s integrated Fuji-built LX-40 3-axis gantry robot enables unattended operation and fast parts handling. The hydraulic robot chuck provides stable clamping and workpiece handling using minimum space thanks to the innovative thin-type double hand design. Easy programming for complex parts and process combination are made possible with an Esprit 3D CAD/CAM system. In addition, the perfect chip disposal design enables non-stop production.
The Gyroflex’s opposed twin spindles are positioned on Z-axis slideways with 960 mm of stroke. Equal in size and capability, each spindle can perform the same operations (OP-10A/10B). The Z-axis slide moves at high speeds to reduce loading time to the second spindle.
A milling tool spindle, mounted on rigid X and Y axes box way slides, allows for various types of machining by accessing both Z-axis spindles and swinging up to 190 degrees. Milling tool spindle speeds reach 12,000 rpm with a 15 HP spindle motor. A 15-station live tool turret, also positioned on highly rigid X and Y axes box way slides, offers indexing times of 0.4 sec. and spindle speeds of 4,000 rpm max. with a 6 HP spindle motor.
The Gyroflex ATC rapid tool change time is 4 sec., maximum tool diameter is 130 mm, tool length is 300 mm and tool weight is 8 kg. The multitasking machine features a 40-tool ATC and a FANUC 31i-B Plus controller. The machine footprint is 5000-by-3000 mm (16’5″ × 9’10”) and height is 3530 mm (11’7″).
PUMA SMX SERIES ADDS ITS LARGEST MACHINE
Doosan Machine Tools America (Pine Brook, NJ) has added the PUMA SMX5100L, the latest addition to the company’s twin-spindle, multi-tasking turn-mill centers. The PUMA SMX Series is designed to complete complex parts in a single setup, and this new model joins the PUMA SMX2600ST (10-inch chuck) and PUMA SMX3100ST (12-inch chuck) models in the lineup.
The new addition is the largest machine in the series, with a maximum turning diameter of 32.7 inches and maximum turn length of 120.1 inches. Chuck sizes of 15, 18 and 21 inches are available for the standard main turning spindle, which features a 49.6 horsepower built-in motor that spins at 2,400 r/min. Also available is an optional gear box spindle that rotates at 1,500 r/min and outputs an impressive 4,198 Nm (3,096 ft-lb) of torque for heavy-duty applications.
The B-axis milling head features a Capto C8, powered by a 49.6 horsepower motor that rotates at 10,000 r/min. The roller gear cam mechanism that drives the B-axis is backlash-free and highly rigid, outputting B-axis torque of 2700 Nm (1,991 ft-lb).
“With its built-in size and strength, the PUMA SMX5100L is ideal for aerospace applications such as landing gear components as well as housings for large shafts like those found in the agriculture or oil field industries,” said Jim Shiner, director of sales and marketing at Doosan Machine Tools America.
All PUMA SMX models have highly rigid machine construction. Minimized thermal deformation is achieved via strategically placed sensors throughout the machine, which offer real time measurement and adjustment of the axes. For added stability and speed, the Z-axis, in which the carriage moves, is supported by three rows of cross roller linear guideways.
INTEGRATED INDUSTRIAL METAL 3D PRINTING AND CNC MACHINING
Sugino Corp. USA’s (Chicago, IL) XtenDED features a twin-head setup that combines the AMBIT laser processing head with the tool magazine of a CNC machine. AMBIT heads, developed by Hybrid Manufacturing Technologies, add metal using powder-fed laser metal deposition (LMD), which is a form of directed energy deposition (DED) — where a laser melts feedstock powder as it arrives to the surface of a workpiece. This is an ideal match for applications that benefit from higher metal deposition rates and do not require the internal complexity of powder bed fusion.
The XtenDED hybridized AM/CNC enables increased in-process finishing of AM parts with greater accuracy, higher deposition rates (thicker layers), better surface finish and improved productivity. XtenDED is less wasteful than machining alone and more productive and precise than 3D printing alone. LMD uses less energy and is more controllable layer-to-layer and gives a significantly smaller heat-affected zone versus plasma/wire AM systems.
NEW DESIGN TO MULTITASKING MACHINE ALLOWS SHOPS TO BOOST OUTPUT OF EXISTING WORKFORCES
Much like its other INTEGREX i-H Series machines, Mazak Corp.’s (Florence, KY) INTEGREX i-200H ST Multi-Tasking Machine features a new design that increases flexibility and enhances machine performance for significantly easier automation integration, allowing shops to boost the output of their existing workforces with the utmost in cost efficiency. Mazak designed its new INTEGREX i-H Series machines with the flexibility necessary to process a practically endless variety of part types without additional capital expenses. The new machines allow shops to add a multitude of automation options – some of which are retrofittable in the field – as production levels dictate long after the initial purchase of the machine, ensuring easy access to continuous improvement. The machines take up less floor space and come with faster and more powerful turning spindles, space saving milling spindles, and a new parallel-type lower turret with optional live tooling capabilities.
Changes to the INTEGREX i-200H ST include front and rear tool setup, a flat-front design to accommodate robots, tool magazine placement at the machine’s rear side and an easily retrofittable automatic machine door. Other additions include an integrated automatic jaw changer (AJC) and the parallel-type lower turrets.
Requiring no additional robot system and without interrupting machine operation, the AJC quickly exchanges jaws from turning spindle chucks with others in jaw stocker systems located above both of the machine’s turning spindles. These stocker systems have room for up to 10 jaw sets that can be loaded/unloaded while the machine continues to work uninterrupted.
Along with a parallel-type turret, the INTEGREX i-200H ST sports both a main and second turning spindle and a milling spindle headstock for DONE IN ONE part production. The new turret design works with a greater range of tool lengths, and it eliminates interference when workpieces are held between the machine’s two turning spindles and reduces chip accumulation on the machine’s X-axis covers.
The INTEGREX i-200H ST accommodates a chuck size of 8 inches and boasts a new extended Y-axis stroke of 8.27 inches and X-axis stroke of 21.06 inches for maximum part diameters of 23.62 inches. The main and second turning spindles operate at 5,000 rpm, while the milling spindle comes standard as 12,000 rpm (24/22 kW), with a 20,000 rpm (24/22 kW) version offered as an option.
The INTEGREX i-200H ST also uses the MAZATROL SmoothAi CNC. For fully optimized machining operations, the AI-powered technologies within the new control make for fast and easy programming, controlled spindle speed for reduced vibration and greater machine thermal stability.
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