Manufacturing Expansion Program, The Next Generation of Horizontal Machining Centers

Manufacturing Expansion Program
Makino’s nx-Series Horizontal Machining Centers

David Ward
Horizontal Product Manager

©Copyright Makino 2011

Manufacturing Expansion Program
Makino’s nx-Series Horizontal Machining Centers

 Topics to be discussed
- What are the “nx” machines
- Moving 40-Taper Machining to the Next Level
- Expanding Capacity
- Expanding Productivity
- Expanding Reliability

- Case Study


nx Horizontal Machining Centers

X:
Y:
Z:


560mm (22.0”)
640mm (25.2”)
640mm (25.2”)

X:
Y:
Z:

730mm (28.7”)
650mm (25.6”)
800mm (31.5”)

nx Horizontal Machining Centers
a51nx
Pallet Size
Max. Weight

Max. Workzone
APC Time


a61nx

400mm (15.7”)

500mm (19.7”)

400 kg (880 lbs.)

500/700 kg (1,100/1,540 lbs.)

630 x 900 (24.8” x 35.4”)

800 x 1,000 (31.5” x 39.4”)

5.3 seconds

8.5/10 seconds

The Original 1-Series Machine
 Launched in 2002
 New design
– Productivity
– Reliability
– Value
 Global production over 2,300
 680 in North America


Next Generation 40-Taper HMC
Redefine the boundaries of 40-taper machining by

to levels typically not associated
with 40 taper machines


nx Machines: Expanding Capacity

Soft

Hard

Harder materials
Larger work pieces

Small


Large

nx Machines: Expanding Capacity
How did Makino accomplish this?
 Larger work zones
 Rigid construction
 Higher spindle power


: Expanding Capacities
– Expand Y-axis stroke 14%
– Expand Z-axis stroke 7%
– Expand maximum tool length
a51nx
X-axis

560mm

Y-axis

640mm

Z-axis

640mm

Tool length BT/HSK

430mm

a51nx:640mm (25.2”)
a51:560mm (22.0”)

Expand machining area


Expanded machining area

14%

– Expand Y-axis stroke 12%
– Expand Z-axis stroke 10%
– Expand maximum tool length
a61nx
X-axis

730mm

Y-axis

650 / (op:730)mm

Z-axis

800mm

Tool length BT/HSK

510mm

a61nx:730mm (28.7”)
a61:650mm (25.6”)

Expand machining area

730mm High Column Option


Expanded machining area

12%

Expanding Machining Area
 Accommodate MORE parts
- Reduced Piece Part Cycle Time
- Multiple Operation Fixtures

 Accommodate LARGER parts
- Increased Flexibility
- Reduced Floor Space


Financial impact of larger work zones
 Produce same part on a smaller machine
- 400mm vs 500mm
- 500mm 40T vs 500mm 50T
- 13% Capital equipment reduction

 Reduced floor space
 Reduced fixture and tooling costs
 Reduced energy consumption


: Rigid Casting Structure


One Piece Bed Casting
– Provides foundation for all critical
components
– Precision machined
vs.
Compensated
– Integral chip management



Three Point Support
– Simplifies installation
– Easy to move / relocate
– Maintains geometry


Tiered Column Design
– Resists deflection even high in Y-axis
– High degree of stiffness


Roller guide rigidity and performance
– Improved load capacity
– Increased stiffness
– Improved life


: High Torque, High Power
Spindles
Standard Spindle
a51nx and a61nx
Horsepower

29.5 cont / 40 duty HP

Torque

240 Nm (177 ft-lbs)

Speed

14,000

Acc/Dec
19% increase in torque and HP
compared to previous model


1.7 / 1.9 sec

: Standard 240 Nm Spindle
Increased continuous HP expands MRR
capacity in non ferrous applications


: High Torque, High Power
Spindles
High Torque Spindle
a51nx and a61nx
Horsepower

29.5 cont / 40 duty HP

Torque

302 Nm (233 ft-lbs)

Speed

14,000

Acc/Dec

Ideal for ferrous applications…
Iron metal removal rates of 36.4 in3/min


1.7 / 1.9 sec

: Expanding Productivity

In-Cut
Time
Cycle
Time

Non-Cut
Time

Traditional


Cycle
Time

In-Cut
Time
Non-Cut
Time
a51nx / a61nx

: Expanding Productivity
How do the nx machines achieve this?
In-Cut
Time
Cycle
Time

Non-Cut
Time

– Direct Drive Rotary Table
– Improved Axis Acceleration

Cycle
Time

In-Cut
Time
Non-Cut
Time

Traditional


a51nx / a61nx

: Direct Drive Motor Table
Standard DD motor - NC rotary table
– Rotation speed：max.125min-1
– High-speed positioning
a51nx = 1.05 seconds (90 degree)

a61nx = 0.98 seconds (90 degree)

• Reduce cycle time

– No backlash
• Increase accuracy

– Simple design structure
• Increase reliability


: Direct Drive Motor Table
IAC (Inertia Adaptive Control)
– Acc/Dec control function based on work piece inertia
With IAC

Conventional

Default
Acc/Dec

Heavy workpiece (large inertia)

Light workpiece (small inertia)


Same
Acc/Dec
for
Maximum
Workpiece

Heavy workpiece (large inertia)

High
Acc/Dec
Light workpiece (small inertia)

: 1G Axis Acceleration
Linear Axis Acc / Dec
– a51nx: 1G X / Y / Z
– a61nx: 1G X / Y 0.8G Z
– Rapid: 60 M/min (2,360 ipm)

Capitalize on machine rigidity
and high performance servo
motors to:
⇒ Reduce distance to full rapid
⇒ Reduce time to full rapid


Expanding Productivity: Case Study
 Steering Gear Housing
- 55,000 pcs / year
- Customer defined operation parameters
- 250 days / year
- 20.5 hrs / day
- 85% utilization

- Machining process
- 2 Operations
- 2 Unique fixtures - 2 Parts / fixture
- 26 Unique Tools


Expanding Productivity: Case Study
Steering Gear Housing

15% Lower Cycle Time
Reduced Machine Count
Lower Per Piece Cost


: Expanding Reliability
Life Cycle Cost (LCC)
Acquisition
Cost

Operating
Cost

Maintenance
Cost

Decommission
Cost

Installation

Direct Labor

PM Schedule

Redeploy

Purchase Price

Consumables

Cost of Repair

Sell

Training

Lost Production

Unscheduled
Downtime

Spare Parts

Typically more than the acquisition cost


Case Study
- Midwest manufacturer
- (16) 1-Series Machines
- Power-on hours: 231,000
- Tool changes: 14,656,152

 No tool change component
replacement parts
 No way cover replacements
 No spindle replacements

Leverage existing systems


Proven Reliability: Way Covers
 Have you ever lost a way cover?
-

Single piece X-axis (a51nx)
Single piece Z-axis covers
Fewer moving parts
Eliminates telescoping cover
maintenance issues

With nearly 700 a51s in the field
a51 Way cover sales (2005 – 2010)
(0) X-axis
(2) Y-axis
(0) Z-axis


Proven Reliability: ATC & Magazine

Dual Support Tool Change Arm
 Axis with bearing on each side
provides strength and rigidity
 Documented case studies of 14
million tool changes without failure


Ring Style ATC Magazine
 Fast highly reliable solution for
production environments
 Simple design with fewer parts
 Compact design with small foot print

How do you improve on industry leading HMC reliability?

Look for opportunities to improve


Expanding Reliability: ATC Shutter
ATC Shutter Mechanism
– New servo driven design
•
•
•
•

Simplifies setup
Highly reliable
Capable of variable open distance
Reduce ATC magazine
contamination

ATC Shutter


Ball
Screw

Servo
Motor

Expanding Reliability: Drum Filter
Coolant Filtration
– Standard system utilizes rotating drum
filter to provide coolant to clean tank side
– Nylon filter media susceptible to damage
– Drum filter failures lead to
• Coolant contamination
• Coolant nozzle plugging

– nx uses a stainless steel filter media


Manufacturing Expansion
Program: Summary
 Introduction to nx machines:
- a51nx
- a61nx

 Expanding Capacity:
- Larger Axis Travels
- Rigid Casting Structure
- Increased Spindle Power

 Expanding Productivity:
- Direct Drive B-axis Table
- 1G Axis Acceleration

 Expanding Reliability:
- Servo ATC Shutter
- Stainless Steel Drum Filter


Manufacturing Expansion Program, The Next Generation of Horizontal Machining Centers

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