Faster speeds and feeds aren't the only ways to slash cycle times
Conquest TwinTurn 65
Loaded with many standard features, including two 2 1 /2-in. spindles, each with maximum speeds of 4,000 rpm, and twin 10 or 12-station turrets for VDI 30-mm tooling, this machine features live tooling capacity on both turrets and a Hardinge/GE Fanuc 18i-T dual-path CNC.
The 25-hp main spindle and 15-hp secondary spindle provide C-axis movement. Both spindles are capable of using B65 Dead-Length collets that provide increased bar capacity and exacting part length control, S-22 master collets and pads, or jaw chucks.
The twin-turret configuration permits simultaneous machining for reducing cycle times and simplifying processing of part families. One or both turrets can machine on either spindle for simultaneous operations. Y-axis is available on the upper turret for precise off-center milling and drilling operations. The machine features separate, heavy duty linear guides for the upper turret, carriage, and secondary spindle.
Unlike other turning centers where the upper turret and secondary spindles share the same set of rails, an independent rail design provides static and dynamic stiffness for improved accuracy and super finishes. Hardinge Inc., Elmira, N.Y.; (607)734-2281; www.hardinge.com
This six-spindle automatic lathe uses virtual cams to calculate and coordinate its stroke and synchronization. It is equipped with a three-part Hirth coupling mechanism that locates and locks. Two axis slides provide up to 30 programmable axes. The machine can perform on-the-fly stops, and options include parallel and numerical processing. Schütte, Jackson, Mich.; (517) 782-3600; [email protected]
This graphite machining center, equipped with twin SC 50102 high speed electric spindles, provides fast cutting speeds and high feed rates for carbide tooling. It can be used to produce identical EDM electrodes simultaneously. Spindle speeds go from 5,000 to 25,000 rpm. Users can also run the machine with only one spindle when they need to make a single electrode or a large item. The average size of the graphite blocks for dual-spindle operation is about 6 in. 2 , but the machines will handle sizes up to 16 in. 2 . Runout at the spindle taper is only 0.00008 in. maximum T.I.R. The machines are also equipped with automatic tool changers and magazines that can hold up to 20 tools each. Boston Digital/The Precise Corp., Racine, Wis.; (414)632-6173.
This twin-turret, twin-spindle, turn/mill center uses multitasking capabilities to machine workpieces complete in a single setup. The Y-axis drive is integrated in the turret's movement to offer increased productivity, rapid feedrates (an X of 1,300 ipm; Z of 1,300 ipm; Y of 394 ipm; C of 400 rpm), and a 2.5-sec spindle accelleration/deceleration response time. The twin opposed spindles can work independently or continuously on the same workpiece to complete first and second operations. With the addition of the integral Y axis, the machine can cut perpendicularly to the spindle, giving it full machining capabilities such as drilling, milling, and tapping on or off the centerline.
The unit is equipped with an 8-in chuck and can machine workpieces with a maximum diameter of 10.24 in. and length of 7 in. It can cut up to 2-in.-diameter barstock. A 30-hp, 5,000-rpm main spindle motor makes high speed turning possible. In addition, a 5-hp rotary-tool spindle motor with speeds up to 4,500 rpm (6,000 rpm optional) offers performance comparable to a machining center for secondary operations performed while a part remains chucked. With a C axis, the spindle can be indexed in 0.001° increments.
A 12-position drum turret indexes in just 0.2 sec., and a gearless, beltless, low-vibration headstock with thermal displacement improves surface finishes. High accuracy is also achieved by using high-response, linear guides and backlashless direct drives for the X and Z axes. Mazak Corp., Florence, Ky.; (606) 342-1700.
This multispindle machine offers 20-mm capacity with six spindles. The MultiDeco series machines combine the flexibility of CNC with the speed of cam operation. They are capable of managing 18 axes at once through parallel numerical controls(PNC). With the control, each machine axis is governed by its own microprocessor chip that carries the executable program for one part at a time. Each electronic cam executes the preprogrammed moves at specific times, eliminating the need for path calculations. Parallel execution of axis and machine function minimizes unproductive machine time. Tornos Technologies U.S. Corp., Brookfield, Conn.; (203) 775-4319.
Independent motor spindles and programmable C and Y axes are two standard features on this 1 1 /4-in.-diameter capacity CNC multispindle machine. It also has a quick-change tooling system and precise spindle drum locking via a Hirth coupling system. Designed with a modular build, the machines integrate ballscrew axis drives and Index C200-4D CNCs.
The machines of the MS 32 series are available in three versions, the MS 32 B (basic, single carrier version, the MS 32 P (quill version), and the MS 32 G (opposed drum version). The MS 32 B can be equipped with up to 10 tool carriers, eight of which can have 2-axis contour control. Both the MS 32 G and MS 32 P accommodate up to 17 tool carriers with X and Z axes CNC controlled. Additionally, four of these tool carriers have the optional Y axis. On the MS 32 G version, a drum is mounted opposite to the spindle drum with the six main spindles. This second drum has an additional six spindles for backworking operations. The two spindle drums can be operated independently of each other or synchronously. All motor spindles are individually driven and have a drive power of 4 kW. Their maximum speed is 6,300 rpm. The parts are machined simultaneously on the main and counterspindle, making it possible to produce complex parts. Using mainly standard tools, the system can perform extensive machining on the cutoff side in one operation. Index Corp., Shelton, Conn.; (203) 926-0323.
PM-6A gantry profiler
Designed to machine aluminum, steel, and titanium, this powerful, gantry-type, profiling machine features three independent 30-hp spindle motors. In addition, its three-spindle vertical design permits the simultaneous 5-axis machining of multiple workpieces. A 120 720 in. table offers a maximum load capacity of 500 lb/ft 2 . The unit offers a swivel/tilt of 30° and spindle speeds of 20 to 4,000 rpm. SNK America Inc., Elk Grove, Ill.; (847) 364-0801.
DZ 18 W Magnum
This twin-spindle machine offers twice the output of a single-spindle system. It features an integrated workpiece changer for large scale production.
Two tool capacities are available: 2 12 or 2 24. Chip-to-chip times are 2.4 and 2.9 sec, while tool change times are approximately 0.9 and 1.5 sec. Spindles reach speeds up to 10,500 rpm.
Maximum diameter is 2.5 for the 12-tool version and 3 in. for the 24-tool. The DZ 18 W Magnum has an optional laser control system for tool breakage control, tool measurement, and temperature compensation as well as an optional two-axis rotary table. Chiron America Inc., Charlotte; (704)587-9526.
MVC-10T twin-spindle vertical chucker
Designed for high-speed, low-cost production of workpieces up to 10 in. in diameter, this twin-spindle vertical chucker features a large work envelope with two independent high-speed, eight-station turrets. The eight-station turrets (0.23 sec index time) reduce cycle times. Precision coupling ensures accurate positioning ( 6 arc sec) for high repeatability from tool to tool (62 arc sec).
The 12-hp high-torque spindle motor quickly reaches and maintains its maximum torque of 155 ft-lb and maximum spindle speed of 4,000 rpm. Four-axis control lets operators make two identical parts, perform both primary and secondary operations, or machine two different parts.
Rigid, cartridge-type spindles use three large angular-contact ball bearings at the top and two opposed angular contact bearings at the bottom for maximum rigidity and speed. Other standard features include two 10-in. three-jaw power chucks and actuators, two sets of hard and soft jaws, a through-the-tool coolant system, and more. Motch Corp., Cleveland; (216) 486-3600.
Multispindle (screw) machines have always had a reputation for high volume production, but setup was often a problem. Single spindle machines, on the other hand, were easier to set up, but didn't turn parts out as quickly. However, with the emergence of such technologies as electronic cams and twin-spindle machining centers, a whole new group of machines, easily set up, are offering a versatile means of elevating productivity and improving quality. Built to stand up to the rugged demands of high-speed production, these multispindle and multiple spindle machines tackle the complex machining of various materials in a variety of applications.
Independent motor speeds, variable spindle speeds, and quick-change tooling systems make the machining of different parts simultaneously on one machine as easy as producing single workpieces. And by eliminating the need for multiple setups on more than one machine, users boost throughput, slash setup time, and reduce inventory.
Another advantage is that many of these machines generally take up less floor space than even two compact single-spindle machines. Likewise, most feature heavy duty linear guides that promise accurate positioning for high repeatability from tool to tool. The result is consistent high-speed accuracy, minimal downtime, reduced operator fatigue, and less operator intervention—a solution that affords both ultimate flexibility and maximum productivity.