Makino knows that one of the biggest drivers of cost per piece is cycle time. Cycle time drives the number of machines required, but also has far-reaching cost implications for labour, floor space, utilities and durable tooling. In pursuit of the goal of zero downtime, the a40 SE incorporates Makino’s Intelligent R.O.I. (Reduction of Inertia) design philosophy. This collection of innovative technologies is designed to slash unproductive non-cutting times in the part production process – and take users a significant step forward on the path to zero downtime.
The a40 SE's spindle is designed to address the specific challenges of aluminium die cast parts production. Its responsive direct drive design accelerates to 20,000 rpm in just 1.5 seconds, delivering the reliability of an HSK-A63 with the performance advantages typically associated with 30 taper drill tap solutions. The a40 SE’s spindle speed represents a significant improvement on the old a40 at 12,000 rpm. As a result, the a40SE completes common tapping operations fast thanks to its 6,000-rpm rigid tapping synchronisation speed. The a40 SE’s fast spindle acceleration and deceleration reduce tapping times per hole by 0.5-0.7 sec compared to typical 400 mm HMC solutions. Tests have shown that the a40 SE can deliver a 45% reduction in total tapping time compared to competitors’ machines, which can help to significantly cut overall per piece costs.
The a40 SE’s ATC magazine features a compact steel ring design to store up to 60 tools (up from 40 in the old a40). This robust, proven design has a proven record from its deployment in Makino’s a-series machining centres. Responsive indexing ensures that the next tool is moved to the ready station fast, with tool preparation time ranging from 2.9 sec (min.) to 4.8 sec (max.). Inertia Active Control automatically accesses the total tool weight and further optimises ring acceleration to minimise tool seek times.
The a40 SE comes with all that is required for its deployment in an automated production environment. The pallet changer, continuous pressure hydraulic (CPH) upper on-line type hydraulic piping (8+8 port), robot interface and automatic doors are all standard features.
Makino machines have long been renowned for their highly effective thermal management systems. The a40 SE comes with an outstanding chip and coolant management system as well. The splash guard interior is constructed entirely of vertical and sloped panels. Dedicated interior wall wash nozzles for vertical panels and terrace washing jets on sloped surfaces ensure efficient removal of chips and a self-cleaning operation. The centre trough is designed in such a way that all the chips and coolant are directed into the trough, where high-volume base coolant moves the chips to the lift-up chip conveyor. To reduce the potential for leaks, the interior panels are single-piece construction with sheet metal bends rather than a multi-piece construction joined by welds and caulking.
Designed specifically for die cast operations, this chip and coolant system also features hydro-cyclonic filtration to ensure ultra-clean coolant. The hydro-cyclone fills an ultra-clean tank with coolant filtered to 20 μm and coolant is supplied from this tank to the through spindle and taper washing coolant pumps. Hydro-cyclonic filtration of the coolant system dramatically reduces the sludge that is so common in aluminium applications and thus extends preventive maintenance tank cleaning intervals.
2020 changed the way we all see the world. Not least for this reason, Makino decided to adopt a new motto: "Promise of Performance". And to visualise this significant change, the new corporate philosophy was accompanied by a marked change in the design of the machines.
Urko J. Ugalde
Team Leader, Marketing and Product Planning
Phone: +49 7021 503-400
E-mail: [email protected]
Website: www.makino.eu