Product category:
Machining centres - all types
News Release from: Toyoda Mitsui Europe UK | Subject: Toyoda FH80S multi-pallet, 4-axis machining centre
Edited by the Manufacturingtalk Editorial
Team on 05 May 2004
Cycle times reduced by an average of 40
per cent
Two machining centres, costing GBP 1.2 million, are reducing cycle times at a diesel engine plant by an average of 40 per cent after replacing an earlier generation of German machine tools.
Engine manufacturer, MAN B and W Diesel, invested GBP17 million last year in consolidating three manufacturing plants into its Stockport, UK, facility and streamlining production In-house machining is now restricted to five core components, these being cylinder heads, liners, con rods, valve cages and major frame units, with the remainder of engine parts subcontracted out
This article was originally published on Manufacturingtalk on 14 Jul 2000 at 8.00am (UK)
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As a key part of the restructuring, the company has installed two Toyoda FH80S multi-pallet, 4-axis machining centres of nominal one-metre-cube capacity, costing GBP1.2 million.
The first machine was running by May 2003 and took over production of heads for RK270 and the new RK280 12-, 16- and 20-cylinder, 4-stroke diesel engines, formerly the Ruston range made at Newton-le-Willows, which are of the type typically used in marine propulsion, rail traction and power generation.
The second Toyoda, originally destined for MAN B and W Diesel's Colchester factory, which now has been restructured to handle service and overhaul, was commissioned last August.
Further reading
HMC developed for mould and die work
Spindle speed options up to 40,000 rpm and cutting feed rates up to 30 m/min are notable features of the new Toyoda FH63M horizontal machining centre developed for mould and die machining.
M-C designed for mould and die machining
During a recent Open House, Toyoda Machinery and Engineering Europe demonstrated its FH63M machining centre, which is purpose-built for mould and die work.
Five axis MC optimised for mould and die work
High precision, rigidity and full five-axis interpolating capability are features of a machining centre optimised for mould and die, aerospace and complex surface machining work.
This machine produces smaller heads and con rods for the VP185 12- and 18-cylinder, 4-stroke engines.
Applications include powering super yachts and high-speed generation sets, two of which have been ordered for standby power generation at the BBC's new media centre in Broadcasting House, central London.
Commented machine shop manager, John Steele, "The new machines replaced German machining centres which were over 10 years old and slower in operation.
Cutting feed rate up to 15 m/min on the Toyodas, rapid traverse at 24 m/min and a powerful spindle motor with a gearbox drive [37kW (cont)/45kW (30min)], together with the use of more modern, indexable-insert carbide tooling that this higher specification allows, has resulted in an average cycle time reduction of 40 per cent across all parts.
Such is the rigidity of the machines that we can take up to 10 mm depth of cut when roughing with a face mill." Three types of SG iron head in several variants according to fuel type and application go through the first machine.
One head requires three set-ups and is machined in a total of 20 hours, while the other two heads are completed in two clampings in 2 to 2.5 hours.
On the second Toyoda, six variants of one head are machined together with forged steel con rods.
All parts produced on these high-throughput cells are so-called main runners.
Lower volumes of less frequently required components are machined on other equipment within the factory.
Continued Steele, "We can swap components between the machine cells, which gives us considerable production flexibility, as does having a six-station, horizontal pallet pool feeding each cell.
We are able to fixture parts on pallets ready to be transferred to the machining area very quickly, the longest of all changeover scenarios being 90 seconds [pallet 1 to pallet 4], so spindle up-time is maximised.
Moreover, work can be scheduled through the cells to suit production requirements.
One day we might have a batch of 20 identical heads going through, each needing three set-ups, so one comes off complete every two hours.
Another day could see three different types of head being produced at the same time, either for engine production or for spares." A notable feature of both cells is their 340-position, matrix-type tool magazine.
During production, up to five cutters can be transported to the ATC point by a robotic crane running the length of the magazine, rather than by indexing a chain-type magazine until the tool is adjacent to the arm.
The advantage is that there is no limit to the total weight of tools in the magazine, as it does not move.
At MAN B and W, there are seven positions for boring bars up to 550mm diameter and 27 for 270mm diameter cutters, with the remaining pockets capable of accepting cutters of 127mm tools.
Maximum length is 730mm.
Both magazines accommodate sufficient cutters to machine all heads produced on their respective machines without tool changes being necessary before a new cycle starts.
Each head type needs 60 different cutters to complete the machining operations, with extra tools needed for variants and further pockets allocated for sister tooling to keep production flowing.
When it came to deciding which machines should replace the older models, Steele and his team looked at about half a dozen different suppliers including the incumbent.
A major point in favour of Toyoda was the reliability of a smaller FH55 machining centre with vertical pallet pool that had been used at the Newton-le-Willows factory since 1999, and has since been transferred to Stockport.
The price of the FH80S machines was also favourable, especially when taking into consideration their construction with hardened and ground slideways, giving high rigidity, good surface finish and long tool life.
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