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The
five-axis machining capability of Chiron FZ 12S Magnum vertical machining
centres is enabling a major automotive first-tier supplier to produce
finished parts in a single set-up and satisfy its annual output requirement
of 300,000 components with minimal manual involvement.
Configured
as a Flexline high-volume manufacturing system, four Chiron Magnums are
located side-by-side and fed by linear component carrying robot to machine
camshaft adjusters required at the rate of 75/hour.
Each
Chiron's 20-tool magazine is equipped with the appropriate tooling to
accommodate variations in the family of parts, and each machine performs
both fourth- and fifth-axis machining without workpiece reclamping. One
operator maintains all four machines by, for example, ensuring that sufficient
parts are provided at the load station, then unloading finished-machined
workpieces.
The
camshaft adjuster forgings are manually clamped onto a fixture plate that
has an HSK toolholder at its rear, for location into the carrier robot
and subsequently into one of the individual VMCs. The workpiece is manipulated
under NC in a single clamping to machine four faces in a simple fourth
axis rotary indexer, and all compound angles using a fifth axis tilt and
rotary device.
Each
Chiron Magnum performs a variety of machining routines in sequence - including
drilling piston apertures to a tolerance of +/-0.01 mm.
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Flexline
has been configured by Chiron to gain all the benefits of a flexible transfer
line and flexible manufacturing system or cell - but without the drawbacks.
Because
each unit is essentially a standard VMC, the resulting system is not only
easy to program and operate but it is also one of the most cost-effective,
fastest and efficient manufacturing systems available - thanks to the
machines' characteristic fast speed of operation and attractive price
tags.
Each
FZ 12S Magnum has X, Y and Z axes travels of 550 mm by 300 mm by 425 mm,
rapid traverse rates of 40 m/min and boasts a tool change time of only
0.9 sec with chip-to-chip being 2.4 secs. Spindle speed is 15,000 revs/min.
The complementary robot workpiece carrying system operates at 250 m/min.
In
addition to fast throughput times, other benefits of such high-speed machining
are clearly appreciated on the camshaft adjuster line where the high spindle
speeds combine with through-tool high-pressure coolant to consistently
maintain an SPC requirement of 1.67 CmK.
The
Magnum's impressive specification – and the fact that all machining programs
and tools are housed in the machines – makes Flexline the ideal choice
for producing complete families of parts in small or large batches either
simultaneously or consecutively.
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