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Machining Pg. 5 VMC for Large Molds Makino offers the F8 and F9 machines with its line of F-Series vertical machining centers. Big mold and die components may test the work-weight capacity of most machines, and they could pose a unique dilemma for high-speed machining techniques and the accuracy capability; and, large production parts present challenges due to the size and range of the part. Designed for power, speed, precision and versatility, the F8 and F9 are built to meet these divergent manufacturing needs in both the die and mold and large part production markets. The smaller F8 features X-, Y- and Z-axis travels of 51.2 inches, 31.5 inches and 25.6 inches, respectively, a 61-inch-by-31.5-inch table and a maximum workpiece size of 61 inches long by 31.5 inches wide by 21.7 inches tall. By contrast, the larger F9 features X-, Y- and Z-axis travels of 63 inches, 31.5 inches and 25.6 inches, respectively, a 72.8-inch-by-31.5-inch table and a maximum workpiece size of 72.8 inches long by 31.5 inches wide by 21.7 inches tall. Both machines offer a payload capacity of 5,510 pounds and feature a 30-tool capacity automatic tool changer. Changing full-size workpieces can dramatically impact large machine utilization, productivity and ultimately part costs. Therefore, the F8 and F9 incorporate a unique, dual sliding door, chip- and splash-guard design for simplified loading and unloading of large workpieces. The open-corner, open-ceiling design affords unparalleled access for setups and changeovers, improving work in progress (WIP) and overall lead-times. The F8 and F9 vertical machining centers offer a number of spindle configurations for tailoring the machine to specific die/mold or production applications. The standard spindle configuration is a 49.6-hp, 10,000-rpm, CAT 50 spindle. As an option, the spindle can also be provided with an HSK-A100 spindle interface. With 315 ft-lbs of torque, this combination provides stiffness and rigidity for lower-speed roughing operations and an excellent mix of spindle speed, power and torque. As an option, the F8 and F9 can be equipped with a 40.2-hp, 20,000-rpm, HSK-A63 spindle. This configuration provides the vibration-free, chatter-free, high-ranging spindle speeds required for efficient high-speed hardmilling of small details and fine surface finishes typical of the die/mold market. The standard coolant system provides a combination of nozzle flood coolant, flush coolant, through-spindle air and an external air-blow nozzle. Dual internal spiral chip conveyors quickly and efficiently move chips and coolant to the rear of the machine, discharging them into a scraper-drum lift-up chip conveyor. Various, optional through-spindle coolant systems can be provided to further enhance the capability and performance of the machine. The F8 and F9 vertical machining centers employ the Makino Professional 5 Control, which affords the perfect balance of a Windows CE graphical user interface (GUI), touch-screen selection offering instant access to information at one's fingertips, user-friendly, efficient PC-like capability for data management and editing, and the networking and storage capability of a data center. As an option, the machine can be arranged with Makino's proprietary, nextgeneration Super Geometric Intelligence (SGI.4) software developed specifically for high-feedrate, tight-tolerance machining of complex, 3-D contoured shapes involving continuous, tiny blocks of NC data that ensure production rates faster than standard CNC systems while maintaining high accuracy. SGI.4 helps provide the lowest cycle times and costs achievable by reducing machining cycle times by as much as 40 percent, according to the company. For more information from Makino of Mason, OH, phone 800-552-3288 or visit makino.com. High-Speed Roller Cam Rotary Table The HRC210 from Haas Automation is a high-speed, cam-driven rotary table that provides cutting and indexing speeds up to 830 degrees/second. It provides 110 ft-lb (149 Nm) of spindle torque for synchronous four-axis machining, and has a pneumatic brake that yields 134 ft-lb (182 Nm) of holding torque for stationary work. Indexing accuracy is plus or minus 20 arc-sec, with repeatability of 4 arc-sec. The 8.27" (210 mm) platter of the HRC210 has a center height of 6.000" (152.40 mm), with a 2.00" x 1.91" deep (50.8 mm x 48.5 mm dp) pilot bore and 1.77" (45 mm) through hole. Six radial T-slots simplify fixture and workpiece mounting, and both manual and pneumatic tailstocks are available for additional workpiece support. According to the company, adding a fourth-axis rotary table to a machining center is a proven way to boost productivity, reduce setups, and increase accuracy on multi-op parts. Adding a fast rotary table to a fast machine creates a high-speed package that slashes cycles times even further, the company reports. 90 MoldMaking Technology July 2013 The HRC210 is driven by a high-performance roller cam system that uses a high-torque servomotor to drive a globoidal cam meshing with cam followers equally spaced around the diameter of a roller gear. Needle bearings in the cam followers provide smooth contact with the cam, and a precision-engineered cam profile ensures accurate speeds and motion. Because the roller drive is preloaded during assembly, the system yields high stiffness, high torque, and high speeds, while providing low wear characteristics and reducing maintenance, the company adds. For more information from Haas Automation of Oxnard, CA, phone 805-278-1800 or visit haascnc.com