Product category:
CNC turning centres, mill/turning, multi-tasking centres, horizontal and VTLs.
News Release from: Yamazaki Mazak UK | Subject: Mazak Integrex 'e' 1060V multi tasking machine
Edited by the Manufacturingtalk Editorial
Team on 24 September 2003
Multi-tasking mill turning centre
attracts work
Having placed the first UK order for a multi tasking mill-turning centre a subcontractor is now experiencing a very positive customer reaction to the shorter lead times made possible.
Having placed the first UK order for a Mazak Integrex 'e' 1060V multi tasking machine tool at the MACH 2002 exhibition, Tyne and Wear based MKW Engineering is now experiencing a very positive customer reaction to its improved response times and to the turning and milling capabilities offered by the machine Specialising in a wide spectrum of engineering design and manufacturing, MKW has the capacity to handle projects as large as components for satellite communications systems and wind turbines to highly specialist, complex components used in micro-surgery
This article was originally published on Manufacturingtalk on 22 Apr 2004 at 8.00am (UK)
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However, given the highly competitive nature of sub-contract engineering, MKW is always looking to improve its services to customers and its engineering team has for some time recognised the benefits of multi function machining in terms of speed of turn around, reduced fixturing and maintaining higher precision.
Within its operations, MKW successfully operates a two chuck Mazak Integrex 400-SY for the manufacture of smaller components with the 'done-in-one' benefits offered by a multi function machine with 5 axes.
Since commissioning the 'e' 1060V in early spring of this year, the machine has had a major impact of MKW's commercial and manufacturing activities.
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Having recently introduced one of the world's most innovative ranges of new generation machine tools Yamazaki Mazak will be featuring two of its 'e' models at the MACH 2002 exhibition.
"In many respects the machine has been like a magnet in attracting work," explains Dave Graham, who with fellow machine shop manager Phil Little, has responsibility for both manufacturing activity and maintaining strong customer relations.
"We were increasingly aware of the abilities of multi function/multi axis machines to complete a finished component in a single set up.
That said, while we have a long standing relationship with Mazak, we approached the purchase of the new machine with an open mind." As Phil Little explains, "in our factory we have a very considerable capacity, both in terms of accommodating high volumes of work as well as for machining very large components.
"The purchase of a 5 axis machine with turning capabilities was approached in a strategic way because it had to not only complement our existing machines but offer substantial commercial improvements in terms of reduced WIP, improving the cash flow and significantly reducing both lead times and actual machining cycles.
Already, we are seeing benefits.
In fact, when new work comes in, our first reaction is 'can we machine it on the 1060V'?" With its purchase of the lntegrex 'e' 1060V, MKW has added further to its capacity while ensuring it has the versatility to meet the widest scope of machining requirements.
The concept of the new machine is to bring the benefits of multi-tasking to large diameter workpieces that are normally processed by a vertical turning lathe and machining centre.
By completing these large workpieces in a single machine set-up, substantial improvements are made to in-process and lead times and machining accuracy with fixturing requirements also reduced.
A typical example is the machining of adapter chamber components used in power generation switch gear.
Previously the target machining time was 26 hours - with a scheduling lead time sometimes in weeks - and involving 8 operations on 5 different machine tools.
Now, on the new Mazak machine, the reduced lead time and single set-up cycle - involving milling, vertical turning, drilling and thread milling - has been reduced to 12 hours.
Bores are machined to a 40 micron tolerance as is the flatness across the milled surface.
MKW believes that both of these tolerances, on a component of this size, would prove very exacting if machined 'conventionally' whereas on the 'e' 1060V they are comfortably met and maintained.
Such an example highlights how the multi-function machine is meeting both MKW's machining and commercial criteria.
The vertical turning operations on the 800mm diameter circular machine table have a maximum speed of 600 rev/min.
The combination of the B-axis, which has a 150deg range, and the tilting driven tool spindle allows multiple faces to be machined in the same set up at any angle and with complex profiles.
The model nomenclature '1060' indicates that the Y-axis stroke is 1060mm, the same as found on larger machining centres and in contrast to the relatively small Y axis capability on most turning centres.
In conclusion, Ian Young, managing director of MKW Engineering comments; "In evaluating the merits of investing further in multi-function machine tools, we were anxious that we were investing in a machine that offered the best fit.
Sub contract work has a high element of the unknown and we need to be quick on our feet across the operation. Request a free brochure from Yamazaki Mazak UK ...
"After only a few months it is evident that this latest investment has impacted very positively on our organisation and we feel it gives us a competitive edge in our fields of operation.".
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