Product category:
Rotary and linear transfer machines
News Release from: Mikron Machining Technology | Subject: Rotary transfer machine
Edited by the Manufacturingtalk Editorial
Team on 19 July 2005
Rotary transfer machine accuracies
raised
Rotary transfer machine enables higher levels of accuracy to be met by combining production sequences into a 'single-hit' cycle for large batch, medium batches of families of components.
A totally new concept in rotary transfer machine technology is to be launched at EMO 2005 by Mikron Machining Technology a division of the Swiss Mikron Group, developed to meet the future demands of automotive, medical, high pressure systems, and mechanical and electronic sectors of industry The machine, designated Mikron NRG 50 will enable higher levels of accuracy to be met with the combination of a multitude of production sequences into a 'single-hit' cycle for large batch, medium batches of family type components or volume production needs due to its highly flexible and modular construction
This article was originally published on Manufacturingtalk on 9 Oct 2001 at 8.00am (UK)
Related stories
Modules and CCD speed rotary transfer design
With the new Multifast modular machining system, Mikron has revolutionised the high volume rotary transfer machine.
World's fastest trotary transfer machine claimed
Producing the world's fastest rotary transfer machine able to produce parts at a rate up to 500/minute, Mikron has on offer a wide range of modular rotary and linear transfer systems.
A pre-requisite of the design of the new machine was the establishment of high orders of mechanical accuracy and performance in preference to relying on software correction in particular, to overcome the influence of any thermal changes on the structure.
As a result Mikron Machining Technology applied its Advanced Thermal Stabilisation (ATS) techniques where coolant controlled within +/-5 deg is continuously pumped inside and around the machine frame and spindle units and the machining area, enclosed by the futuristic guard design, is totally air conditioned through a heat exchanger to provide a stabilised production platform.
The Mikron NRG 50, 12 station rotary transfer machine can be specified with up to 140 CNC axes, carry up to 30 NC controlled unit heads providing up to four axes of movement.
Further reading
Rotary transfer replaces conventional machining
Three of the latest high production, single operation rotary transfer machines for the female contacts have been so effective that the user is planning to extend its newly gained production advantage.
Rotary transfer machines large volumes or batches
A flexible changeover, rotary transfer machine enables higher levels of accuracy to be met and combines production sequences into a 'single-hit' cycle for large volume or batcgh production.
Rotary transfer machine has more tools
A machining spindle unit that can change up to four tools automatically within a production cycle has expanded the number of tools carried on a 12 station rotary transfer machine.
It is capable of five-axis interpolation for milling cycles and is able to carry up to 96 cutting tools with automatic toolchanging if required.
Due to the construction and incorporation of thermal stabilisation techniques, it has an accuracy capability of +/-4 microns and a deviation tolerance of +/-2 microns at a measuring diameter on the rotary table of 1400mm.
Indeed, with the support of Mikron Machining Technology's sister operation Mikron Tool Agno to provide high productivity cutting tool technology, not only did this influence the design of the machine but extends Mikron's capability of being a production orientated solutions provider with a true turnkey engineering capability.
Bringing the flexibility of a machining centre into the volume or large batch production arena, the Mikron NRG 50 is able to produce up to 30 parts a minute depending on the application and have up to three NC heads operating simultaneously at each machining station.
The machine is able to turn, drill, mill, thread cut, deburr and even carry out measurement, subassembly and testing sequences under its 'one-hit' production strategy while meeting high levels of process security.
Already, production operations such as machining families of gas valves, normally requiring three or more distinct operations, are able to be combined into one on the machine.
Mechanical watch plates, that typically require four operations including a grinding sequence, can be completed in a single cycle which can be applied across the likes of fuel injection, air conditioning, braking, steering, high pressure systems, connectors and hard disc drives.
Indeed, any similar component area facing a growing requirement for higher productivity, ever tightening size and surface finish tolerances as well as ever-stricter geometrical positioning between a multitude of features, to meet challenging functional, performance and legislation changes.
The machine will accept cubic parts with an edge length of 50mm or be fed from bar up to 35mm diameter with a part length of 70mm.
Developed around a 12 station 1400mm rotary indexing table, it can be fitted with either vertical fixtures or pallets for machining mostly axial related features or horizontal fixtures for radial related features.
These can even include concentric internal or external programmable turning cycles achieved by rotating the workholding collets at up to 6,000 rev/min.
Indexing accuracy of the table and relationship between the tool spindle units and table is guaranteed in the machine design which is based on these key elements forming an homogenous unit.
These elements are contained in a cast iron body frame that supports a torque motor on the top of the machine directly linked via a 938mm diameter triple Hirth Ring location, having some 5,500Nm of clamping force, to accurately position and secure the rotary table which is suspended from the locating ring to enable swarf to fall clear of the working area.
The cast iron body frame also provides the location for all the NC unit heads in order to maintain high orders of geometric relationship to the workholding elements fitted to the rotary table.
These unit heads are located on a common 100mm diameter datum ring in the body frame and are mounted within 250mm of the central bearing giving higher rigidity and accuracy being one quarter the distance of normal rotary transfer machine design.
Further criteria contributing to the accuracy of the machine is the ability to accommodate the 80% or so of heat generated during the cutting process that is held in the swarf.
This is evacuated directly from the machining zone after falling under gravity into the fabricated base where it is immediately extracted.
Altogether, up to 30 NC heads can be fitted to the machine with up to three mounted on each station.
Up to 22 heads can be vertically mounted with 11 each available for down or up machining tasks and with the ability to be positioned to produce compound angle holes and features.
Up to eight units can be mounted horizontally and by taking advantage of the modular design, unit heads can be quickly changed or added for family part production, component redesign or, for instance, if production requirements change.
Unit heads can be selected from high speed 40,000 rev/min to high torque 12Nm, 16,000 revs/min as well as for deep hole type applications up to 15:1 diameter/length ratio where 20,000 rev/min spindle speed and 200 bar coolant pressure is available.
There is also a U-axis head for internal grooving with up to 7mm travel and a multi-head able to carry up to four tools with automatic tool change from a four tool magazine with 2.5s chip-to-chip time - a first in rotary transfer machine technology.
Fourth and fifth axis machining can also be carried out and tool changing is a simple push-button operation eliminating the need for hand tools.
Control is through Bosch MTX with an option of Fanuc 30i.
Software includes 3D simulation and CAM technology with unlimited program size.
The software developed by Mikron Machining Technology has been structured for fast change-over and the machine can be interfaced with a wide range of automation systems for component loading and unloading.
• Mikron Machining Technology: contact details and other news
• Email this article to a colleague
• Register for the free Manufacturingtalk email newsletter
• Manufacturingtalk Home Page
Search the Pro-Talk network of sites
