Product category:
Rotary and linear transfer machines
News Release from: Mikron Machining Technology | Subject: Modular rotary transfer system - prismatic parts
Edited by the Manufacturingtalk Editorial
Team on 27 September 2005
Modular transfer machine speeds up
changeover
Modular rotary transfer prismatic machining system offer almost endless configurations and are designed to considerably speed up product change-over times.
Transfer machines achieve maximal productivity in the manufacturing of large volumes Of course there are increasing variations within component families with a production rate of several hundred thousand parts
This article was originally published on Manufacturingtalk on 9 Oct 2001 at 8.00am (UK)
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With the new Multifast modular machining system, Mikron has revolutionised the high volume rotary transfer machine.
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Claiming to being the world's fastest rotary special purpose machine tool for components up to 32mm diameter, a 24-station design is able to machine up to 500 components/min.
Until now, change-over on the transfer machines was complicated, as well costly in time and labor.
These factors can now be substantially improved with transfer machines which are designed modular with a consequent modular concept.
One of the special advantages of this concept is that it allows the customer to choose the, for him most beneficial solution, between minimal cycle time, high change-over flexibility and investment.
Further reading
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.
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.
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.
At the EMO 2005 in Hannover, Mikron Machining Tecnology introduced the Mikron NRG-50 Rotary Transfer Machine.
This machine will introduce new dimensions in the cost efficient production of large volume series.
The machines are designed for prismatic parts with an edge length of up to 50mm or alternatively 35mm diameter and 70mm length.
These machines are scalable when initially acquired or when changing over to other work pieces later in life.
Therefore, the customer has the advantage of being able to choose from a large selection of building blocks and order transfer machines from the manufacturer built to his specific requirements Modular building blocks, which are designed for optimal combination, help to design a machine from highly productive to very flexible.
The flexible combination possibilities are almost endless.
With these features, the Mikron NRG-50 is well-suited for a very wide application spectrum.
The modular components are equipped with standard interfaces connecting them to the base machine as well as to the subsequent modular building block assembly groups.
For example, in case of the machining units, the customer can choose from four different units.
The machining units available consist of vertical or horizontal with 3 NC-axis each, a unit with four axis (additional rotating axis) as well as a single axis unit, which can be optionally and freely positioned.
The later option is suitable for drilling or threading.
The units are mounted in the required angle to the workpiece and only perform the necessary feed stroke.
These, one to four, NC-axis variations are programmed to perform the feed stroke on a linear or circular slide.
Their guided C-axis also allow thread cutting without chasing head.
Through the NC system, the Machining Units can quickly be reconfigured for different workpieces.
These can be mounted on each working station from above, below or from the outside radially to the rotary table.
A maximum of three working units on each of the twelve stations affords machining of the workpieces on the rotary table from three sides simultaneously.
If interchangeable operations are necessary, up to four tools from a magazine can be changed on each working unit.
A maximum of 30 working units can be mounted on this new machine.
Due to the four interchangeable tools which can be used on each working unit, the machine can work with a total of 96 cutting tools.
The advantage for the user are the minimal change-over times - if machining a variety of workpieces there are already sufficient tools and machining options installed on the equipment.
Even very complex workpieces, for which a variety of different tools have to be used, can be machined in one single cycle ie one clamping.
Furthermore, auxiliary operations such as deburring can be integrated as a process step into the Rotary Transfer Machine.
This reduces machining costs drastically.
For instance, when machining components for Diesel Engine fuel systems, the machining costs can be reduced by up to 20%.
Also, the Mikron NRG-50 can work autonomously, without operator assistance, in a third shift or on weekends by using duplicate tooling.
Thanks to the strictly modular concept of the machine, a highly productive and cost efficient Transfer Machine can be offered.
All workstations are equipped with simple drill, mill, grind or thread cutting units.
If, on the other hand, one needs a high degree of flexibility, a few four-axis NC units are mounted next to the load- and unload stations.
With this on one hand, some complex machining operations can be executed.
On the other hand, the Transfer Machine can machine different workpieces with minimal change-over by using the corresponding NC programs.
Thus, the Transfer Machine Mikron NRG-50 has nearly the same flexibility as today's traditional Machining Centers.
With the difference, that the machine affords the high productivity typical for a Transfer Machine.
Between the described extremes of productivity and flexibility, lots of compromises and combinations are possible.
A crucial advantage of this revolutionary Transfer Machine is that the user can change it easily after many years of use to completely different tasks.
For this he merely has to exchange machining units from one position to another and buy additional ones, if needed and then integrate the new working cycle into the NC program.
The Rotary Table can be equipped selectively with workpiece holding pallets (fixtures) in an axial or outside mounted radial position.
The vertical fixtures are especially suited for workpieces with many axial machining operations.
With the outside mounted radial fixtures, material can be loaded from bar and this way of fixturing is well suited for radial machining operations.
A big advantage is that the execution with horizontal workpiece fixturing can be changed into vertical fixturing with an angular table.
Later affords a additional NC-axis if so desired.
This makes the positioning (indexing) or the OD or ID turning of workpieces possible.
This complex equipment allows the complete machining of workpieces from six sides ie from different angles.
The overall concept of the Mikron NRG-50 machine is such that all drive and control elements are outside the totally enclosed machining area.
Therefore they are optimally protected from damage through coolant, oil and chips.
Besides, the by these elements generated heat is not getting into the machining area of the equipment.
A coolant liquid circulates in the body of the machine and keeps a constant temperature.
Also, conditioned cooling air circulates through the working area of the Transfer Machine.
The hot chips and swarf is flushed quickly with the coolant through the funnel shaped work area into a receiving tank.
This specific equipment assures a constant temperature in the work area of the machine and guarantees therefore highest accuracy and repeatability.
When changing the tools manually, the automatic push button actuated toolholders assure quick tool change.
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