1、1 附 录 附录 1 英文原文 Manufacturing Engineering Multitasking Machining Done-in-one setup makes parts better Hardened gear wheels (RC 62-65) are rough and finish-turned and finish-ground, drilled, threaded, and broached on an EMAG VSC 250 DS machine. Multifunction machine tools have been around long enough
2、 in various configurations for manufacturers to appreciate their potential for cost-saving, quality production of parts from miniature connectors to transmission housings for off-highway equipment. Development of true multitasking machines,however, has removed them from the category of special machi
3、nes. Manufacturers have made them one of the fastest growing categories of CNC machine tools because they improve competitiveness. They offer the flexibility to meet just-in-time delivery of a variety of parts in smaller lot sizes. They consolidate the processes of many machines, improve accuracy, a
4、nd save time formerly required for multiple setups as work was moved from machine to machine and operation to operation. Finally, they employ resources of people and capital equipment more efficiently, a definite plus that the most astute accountants can appreciate. The most familiar multitasking ma
5、chines are NC lathes with live tools in the turret, mill-turns, and Swiss turning centers. NC lathes with a Y axis that allows turrets to move from side to side have full milling or drilling capability. They can mill, drill, and machine off the spindle centerline. A B axis allows rotation around the
6、 Y axis for drilling at an angle or contour milling. sand dollars to over a million dollars. That hardly qualifies them as commodity machines； yet, increasingly, these multitasking machines form the backbone of advanced machining operations for everyone from contract manufacturers to OEMs. Trends in
7、 the design of multitasking machines include packing more punch into a limited and crowded work area with extra slides, more horsepower, even matching subspindle horsepower to that of the main spindle, putting more driven tools in the cut at the same time, and developing sophisticated software and c
8、ontrols for collision-avoidance, scheduling, and production analysis. For machine tool manufacturers with extensive experience in building CNC lathes and turning 2 centers, developing multitasking machines is a natural next step. Romi Machine Tools Ltd. (Erlanger, KY) developed its multitasking E se
9、ries turning centers to perform turning, boring, milling, and tapping in one setup in a machine with a compact footprint. The E 320 turning center can be configured with one or two spindles,C axis, live tools, and Y axis for mid to high-volume production. The left spindle features a belt-driven cart
10、ridge-style gearless headstock with a high-torque 25 or 35-hp (18.6 or 26.1-kW) GE Fanuc AC spindle motor with a variable speed drive. The right spindle can match the left spindle with a similar 25-hp spindle motor. The slant-bed style E 320 series has a swing of 27.55 (700 mm), a maximum cutting le
11、ngth of 23.62 (600 mm), distance between spindle faces of 41.26 (1048 mm) and a cutting diam of 12.6 (320 mm). The E series includes an E 280 model, which features 15-hp (11.1-kW) spindles, as well as a double-turret, double-spindle E 220 model. pressure coolant, air blast, tool touch probe, and par
12、t sensor. The Hardinge-designed and built jaw chuck/collet-ready spindle design permits faster spindle speeds for faster cycle times and maximum part rigidity as parts are gripped close to the spindle bearings, resulting in increased concentricity. When equipped with Hardinges patented HydroGlide hy
13、drostatic linear guideway system, the Quest CNC lathes have the rigidity and precision required for hard turning, as well as the improved crash protection that hydrostatic design offers. The concept of done in one rules today, especially as complex parts can be machined from bar stock or from solid,
14、 often eliminating the leadtime and expense involved to design and produce castings and forgings. Manufacturers have been quick to recognize and study their potential for maintaining critical tolerances between features by eliminating multiple setups and the time and accuracy lost moving from operat
15、ion to operation. At its Technical Center, Caterpillar Inc. (Peoria, IL) works in alliance with its machine tool suppliers to evaluate the potential of equipment and processes that can range from prototype work to production for next-generation Caterpillar equipment, according to Jim Reeb, director
16、of manufacturing research and development. Caterpillar is currently working with Cincinnati Lambs H5 Geminex series machine for machining and turning powertrain components. The H5 Geminex machine is a flexible solution for processing medium-sized and large parts requiring milling and turning in a si
17、ngle setup, combining four and five-axis machining and high-speed turning. Were doing some horizontal types of machining and turning on ductile housings, says Reeb. Well develop the process at the Tech Center and once its worked out, well release the machine to our Decatur, IL facility for installat
18、ion and production. 3 Early experience with the potential of multitasking machine cells led Sandvik Mining and Construction (Sandviken, Sweden) to move production of its DTH (down-the-hole) rock drilling bits from the low-cost manufacturing environment of Mexico to Sweden in 2001. The DTH rock drill
19、ing bits are made from alloy steel forging blanks in 200 different types, of which 15 types are most frequently produced in batches varying from eight to 48. Making the move possible was the performance of a multitasking cell featuring three Nakamura STS-40 super multitasking turning centers with ro
20、botic workpiece handling. The cell is able to perform all turning, milling, drilling, and button-hole drilling, including a hardening cycle, of the alloy steel DTH drill bits in five days with 12 operators. The previous conventional method required seven machines and 50 people. Standardizing on the
21、Sandvik Coromant Capto interface and selecting twin-edge tooling with two inserts in each toolholder enable each machine to independently perform complete machining of drill bits. The need to be competitive in its manufacturing processes is no less important to a machine tool builder than it is to i
22、ts customers. In mid-November 2005, at the unveiling of its latest investment in advanced technology at its headquarters and manufacturing facility in Florence, KY, Brian Papke, president, Mazak Corp. said: It is nae to be committed to manufacturing in the US without a plan to become cost and price
23、competitive. To support production of its Nexus family of machines, many of which have multitasking capabilities, Mazak implemented lean manufacturing practices, including building to market demand rather than forecast and developing modularly assembled systems. A Palletech automation system for don
24、e-in-one manufacturing was installed. Production capacity for Nexus machines at its Florence facility has risen to 140 machines per month. - Rotomill MPMC machines can turn, mill (both with B axis and U axis), as well as drill, tap, or hob complex workpieces. - Manufacturing cells at Mazaks Florence
25、 facility feature Integrex multitasking machines produced by parent company, Yamazaki Mazak (Oguchi, Japan). Mazak has installed two Integrex-500HS multitasking machines teamed with robots for part loading and material handling within the flex cells. A large Integrex e-1060 V/8 multitasking center i
26、s being integrated with an existing HMC FMS to allow more flexibility in processing medium-sized machine components. In its product mix, Mazak numbers 11 different Integrex multitasking models and another 20 models with some degree of multitasking capability. In recognition of the unique challenges in programming and operation of multitasking machines, Mazak has established a Center for Multi-Tasking and Manufacturing Excellence for training customers in all aspects of multitasking machining at its National Technology Center, which was doubled in size.
