Product category:
5-axis (3+2 axes and continuous path) machining centres
News Release from: Agie Charmilles | Subject: Mikron HPM 1000U machining centre
Edited by the Manufacturingtalk Editorial
Team on 22 January 2008
Five-axis machining ups instruments
output
To machine complex parts out of stainless steel and aluminium, an instruments manufacturer reports that a 5-axis machining centre has improved productivity, performance and profitability.
High-precision instrumentation manufacturer, MKS Telvac (part of MKS Instruments Group, USA), recently invested in a high-performance 5-axis Mikron HPM 1000U machining centre supplied by GF AgieCharmilles Installed at MKS Telvac's modern and impressive 25,000ft2 facility in Telford, UK, the HPM 1000U is being used to machine (3 + 2 positional) high-precision complex parts and components
This article was originally published on Manufacturingtalk on 17 May 2001 at 8.00am (UK)
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These are assembled to produce a range of high-value scientific instruments that include mass spectrometers, chemical testing equipment and so on, used by the manufacturers of thin-film, semi-conductor, medical and analytical instruments.
Parts manufactured on the HPM 1000U are made from either stainless stel or aluminium, and are usually machined from solid billets.
Batch runs are short - with 10 parts off being a typical requirement at any one time.
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The decision by MKS Telvac to invest in a 5-axis machine was made back in 2005.
Machine shop manager, Matthew Ensor, at MKS Telvac said: "We knew about all the benefits of 5-axis machining in terms of fewer setup times and reduced fixturing and workholding costs, etc - and we recognised that there was a 'natural fit' between this technology and the type of manufacturing we were involved in.
All we had to do was decide which machine was best suited to our needs".
MKS Telvac's needs included the following.
* To ensure high volumetric accuracies when machining large parts.
* To achieve excellent surface finishes.
* To increase productivity and manufacturing flexibility via automation.
Ensor explained: "Many of the parts we manufacture - such as instrument housings and casings - are large, have an awkward-shape and require high-precision features to be machined on them.
The 5-axis machine solution we were looking for had to be able to deliver high volumetric accuracy and fast material removal".
The accuracies required by the MKS Telvac differ from job to job - but, for example, achieving 20 micron accuracy over/across large parts is common and includes precise bore alignments over 750mm.
Another requirement was the machine's ability to achieve excellent surface finishes of Ra 0.8 micron down to Ra 0.4 micron on precision parts (thereby eliminating secondary hand polishing operations).
Talking about accuracy, Ensor said: "In terms of accuracy, repeatability and surface finish the Mikron machine was a clear winner".
* Automation - another important consideration in the machine tool selection process concerned automation - and the way in which the machine's automation could improve MKS Telvac's productivity.
Ensor explained: "The HPM 1000U machine is equipped with a 5-station APC (automatic pallet changer) and generous 210-tool position ATC (automatic tool changer) that have helped us increase work throughput and to benefit from unattended operation.
These in turn have helped us cut lead times and reduce the cost per part".
Other HPM 1000U machining centre features that impressed MKS Telvac included the following.
* Rigid construction.
* Powerful spindle technology.
* Ergonomic design, which enables easy workpiece loading and unloading.
* Excellent visibility of the working area.
Following a series of trials and test cuts undertaken during 2005-6 with GF AgieCharmilles and other 5-axis machine tool manufacturers, the decision to invest in the Mikron HPM 1000U was made.
And since the machine's installation other productivity benefits have also been exploited.
Ensor explained that the Mikron machine is equipped with SMART technology software.
Modules such as APS (Advanced Process System) help MKS Telvac optimise the 5-axis process by alerting the machine shop to real time issues affecting the machining operations.
* Roughing - an example occurred during a roughing operation where deep pockets were being milled.
During the machining operation the APS system alerted the operator to excessive vibration that was being generated, which, in turn, enabled the operator to take immediate action by reducing the depth of cut but increasing the feeds.
Without APS it is likely that the excessive vibrations would have affected part quality, tool and spindle life and so on, said Ensor.
Ensor concluded: "We are delighted not only with the Mikron machine but also the speed and reliability of technical and applications support we get from GF AgieCharmilles.
The introduction of 5-axis technology into our company has helped us make things different - quite literally".
* About MKS Telvac - MKS Telvac employs around 60 people at it Telford facility.
In addition to its recent 5-axis acquisition the company also has CNC turning; 3- and 4-axis milling, and wire EDM machines - as well as advanced welding (including orbital welding) capabilities.
The company also has an automated aqueous cleaning plant, clean assembly area (6,000ft2), and a 2700ft2 of Class 10,000 clean room facility.
* About the Mikron HPM 1000U machining centre - the HPM 1000U has been designed to machine large and heavy workpieces.
The machine has impressive machining capabilities: X-axis (1000mm); Y-axis (800mm); Z-axis (600mm) and 140 deg tilt and 360 deg rotation on its two rotary axes.
The machine's rigid design and construction ensures good absorption and dissipation of vibration and heat.
The HPM 1000U has 60m/min rapid feeds (on X-, Y- and Z-axis) and a number of spindle speed options that range from 10,000 rev/min up to a faster and more powerful 66kW 24,000 rev/min (75Nm torque) spindle.
For high productivity and manufacturing flexibility the machine has an ATC (HSK - A63 tooling) with 40/115/165 or 210 tool position capability that can be specified at the point of purchase.
An integrated APC can have either five, six or seven pallets each handling workpieces of up to 800kg.
The machine has a Heidenhain iTNC 530 CNC and comes equipped with SMART technology software modules that optimise the 5-axis machining process.
These modules include: APS; APS extended; ITC; ITC-5X and RNS.
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