Linear transfer machines short batches quicker

Linear transfer machining system performs 5.1/2-face machining and combines simultaneous 5-axis machining with a productivity rate some 47% higher than normal machining centres.

Developed around the capability to perform 5.1/2-face machining of components without reclamping and combining simultaneous 5-axis cutting technology with a productivity rate some 47% higher than conventional CNC machining centres, the Mikron MultistepTM XS linear transfer machining system provides the perfect solution for short batch or middle volume production demands.

The machine can combine all the functions typically performed on a conventional machining centre and is also able to perform full 5-axis interpolation as well as high speed cutting at up to 32,000 rev/min with production of compound angle holes or features within the cycle.

Available from Mikron Machining Technology of Lugano, in Switzerland, the Multistep is totally modular in construction and can be combined with manual or automatic loading systems to provide a highly flexible unmanned production cell for parts such as housings, pumps, valves and pneumatic controllers in a single cycle.

It comprises a series of high performance machining modules with rapid transfer units that can be expanded at any time to meet changing demand and in particular, the tailoring of capital investment to increase or decrease output requirements.

Central to the production technology is the ability to cater for fast changeover, most often completed within 30 min for a new component within the workplace envelope of 150mm by 150mm by 100mm and weighing up to 6kg.

Each module comprises two horizontal spindles able to move independently in the vertical Z-axis and serviced by their own 11-position tool magazines.

The component is carried on a 600mm by 400mm pallet that is fed through the module located by a high accuracy Erowa interface on a direct driven 2-axis (B and C) rotary and inclined table unit that is able to rotate to combine turning and milling cycles at up to 400 rev/min.

A further two axes of movement are created by the slide that carries the pallet location.

Each axis has a rapid traverse rate of 40m/min with an acceleration of 8m/sec2.

Operating between the modules, to effect transfer of the workpiece and pallet, is a twin-arm rotary mechanism that moves the pallets between adjacent spindle positions providing a continuous linear work flow from, and back to, a common loading/unloading station.

The spindles in each module operate alternatively allowing a simultaneous toolchange to be performed within just one second while the other spindle is cutting.

Altogether, up to 22 tools can be applied to a component at each module.

Two types of HSK-40 taper high precision spindles are available.

As standard a 12,000 rev/min high torque drive or 15,000 rev/min unit can be supplied however, a high speed 35,000 rev/min vector controlled high frequency unit can also be specified.

High pressure 120 bar coolant system is available in addition to the standard 80 bar system.

Multistep XS is controlled via the latest Bosch Rexroth IndraMotion MTX system and drives package with 1,000 block look-ahead and Mikron developed software able to supervise up to 64 axes.

The control is fully integrated with Profibus communications that enables a dynamic and very precise means of tracing complicated machining paths and simplifies diagnostics.

Programming can be initiated either at the control or off-line directly on a solid model via Pathrace;s well-proven EdgeCAM software.

A range of bowl feeders and robot-loaded systems can be specified with further options such as Renishaw probing, tool breakage control, heavy duty milling, NC-facing and multi-spindle drilling units as well as onboard deburring.

Processes such as pressing and joining and inspection routines can also be incorporated within the production cycle.

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