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Turning Centers

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					Turning Centers
               Summary

• Background Information

• Economics

• Advantages and Disadvantages

• Equipment and Technology

• Case Study
Background Information
• “Turning” – Process by which a cylindrical or
  conical surface is machined
     • Traditionally done on a lathe


• “Turning Centers” – More sophisticated
  capabilities
     • Secondary Spindles
     • Rotating tools for Milling, Drilling and Grinding
     • “Turn-Mill Machines”
Background Information
• Stop workpiece from spinning
     • Carry out non-turning operations
     • Process is done in same machining cycle


• Horizontal or Vertical spindles
  – Vertical Turret Lathe
     • Workpiece rests on table driven by spindle
  – Inverted Vertical Lathe
     • Workpiece held from above by vertical spindle
Background Information
• Live Tooling
     • Rotary cutting tools
     • Powered independently of the spindle motors
     • Drill hole perpendicular to main axis


• Automation Technology
     • CNC
     • Increases speed, precision and consistency
             Economics
• More processes in single machining cycle is
  very economical
     • Value added to materials


• Secondary operation after machining is
  uneconomical
     • Requires material to be secured in a different machine
Advantages / Disadvantages

• Advantages
     •   Speed
     •   Precision
     •   Consistency
     •   Less skilled workers
     •   Machines can be updated by improving software
     •   Reduces amount of non-value added processes
     •   Advantages passed to customers

• Disadvantages
     • High cost
           – Research must be conducted to see if benefits outweigh costs
     • Complicated Machines
     • Leads to unemployment
Equipment and Technology:
  Swiss Turning Centers
• Swiss Style / Swiss Turning Centers
     • Used for workpiece requiring extreme accuracy
     • Able to hold very precise tolerances
     • Polymer concrete base eliminates vibration
• Workpiece is held with a collet and guide
  bushing
     • Guide bushing provides additional support
     • Ideal for work on narrow products
     • Tool moves inward while material moves back and forth
Equipment and Technology:
  Swiss Turning Centers
• Polygim CSL Swiss Turning Center:




                              http://www.machinetools.net.tw/lathe/tai
                                      wan-cnc-swiss-turning.htm
Equipment and Technology:
    Turn Mill Centers

• Capable of turning, milling, and
  drilling
• Typically based on lathes
• Some able to pass part between
  spindles during machining
• Round part not required despite
  lathe-like qualities
   Equipment and Technology:
       Turn Mill Centers

• R200: milling and turning in a new
  dimension
   – Two independent sub-systems

   – 5-axis machining for both milling spindles

• G200/300: compact, for complete
  machining/powerful, in two dimensions
   – Identical main and counter spindle
Equipment and Technology:
    Turn Mill Centers

• G160/400: for demanding parts/unique mil
  power
   – Short setup time and tool change

   – G400 comes with 2 motor milling spindles

• G250: productive, high performance
   – High performance milling spindle

   – Building block system for individual applications
   Equipment and Technology:
       Turn Mill Centers
• Pinch Milling
  – Machining long, slender workpieces
  – Two opposing, single-point turning tools impinge on
    opposite sides, “pinching” the part, allowing for:
     • Reduced tendency of part
       deflecting from tool
     • Heavier cuts
     • More accurate cut
Equipment and Technology:
  Vertical Turn Centers
• Less prone to process variation than horizontal
  models
• Less force required in part positioning
• Gravity works with vertical turn centers and
  against horizontal turn centers
• Lower chucking pressure reduces
  imperfections
• Smaller floor space requirements
Equipment and Technology:
  Vertical Turn Centers
• V100
  – 3-dimensional movement of
    headstock
  – Easy integration of turning,
    milling, laser hardening,
    laser welding, grinding, and
    assembling
  – Short idle times
Equipment and Technology:
  Vertical Turn Centers
• V160C
  – Building block system
    creates flexible tooling
    area
  – Up to 3 turrets
  – Y/B axis for off-center
    milling/drilling
Equipment and Technology:
  Vertical Turn Centers
• V160G
  – Building block system
  – Space-saving 90 degree
    positioning of the x-axis
    of both spindles
  – Up to 4 turrets
  – Y/B axis
  – Powerful motor spindles
 Equipment and Technology:
Multi Spindle Turning Machines

• Short Setup Times
• Low Cost/Part
• Precision Parts




                      Image Source: http://www.index-werke.de/ic/englisch/556_ENU_HTML.htm
 Equipment and Technology:
Multi Spindle Turning Machines

• MS22C Series
  – Medium Complexity Bar Parts
  – 6 spindles
• MS32 Series
  – Medium-to-High Complexity Chuck Parts
  – 6 spindles, ability to configure as synchronous spindle
    machine
• MS52 Series
  – Part Families
  – Up to 12 spindles in two blocks
 Equipment and Technology:
Multi Spindle Turning Machines

• Multi-Axis Machining
  – Allow the production of
    complex parts in a single
    setup




                            Image Source: http://www.index-werke.de/ic/englisch/559_ENU_HTML.htm
Equipment and Technology:
   Turn Grind Centers
•   Turning centers modified as modular systems
•   All actions add value
•   Can produce complex parts in a single setup
•   Very low tolerances (~0.5ɥm)




     Image Source: http://www.index-werke.de/mediadata/c200-0044e.pdf
Equipment and Technology:
   Turn Grind Centers
• Horizontal Turn-Grind Centers
  – Fully automated systems for dynamic part
    measurement
  – Full function of turning center as well as grinding
  – Simultaneous work on both ends of parts
• Vertical Turn-Grind Centers
  – Complex chuck parts
  – Inner and Outer diameter grinding tools
Equipment and Technology:
   Turn Grind Centers
• CNC Software for Turn-Grind
  Centers
• P200 programming system




       Image Source: http://www.index-werke.de/mediadata/c200-0044e.pdf
          Case Study
• Leupold & Stevens – produce rifle scopes
• Complex items requiring over 60 parts each
• Each machine must produce about 20
  different parts
• Low tolerances (0.0005 inch)



                  “Optics Maker Focuses On Flexible Production”, Production Machining, Lori Beckman, 5/15/2008
           Case Study
• Solution: INDEX Turn-Mill and Multi-Spindle
  Machine Centers
• Low setup time (about 4 hours), No trial cuts
• INDEX P200 CNC programming system
  – Offline programming
  – Single program hub can control all machines



                    “Optics Maker Focuses On Flexible Production”, Production Machining, Lori Beckman, 5/15/2008
              Resources
• http://www.index-werke.de/ic/englisch/559_ENU_HTML.htm
• http://www.index-werke.de/mediadata/c200-0044e.pdf
• “Optics Maker Focuses On Flexible Production”, Production
  Machining, Lori Beckman, 5/15/2008
Questions
                  Video
• Swiss Turning
• http://www.machinetools.net.tw/lathe/taiwa
  n-cnc-swiss-turning.htm

				
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