Five-sided manufacturing of large workpieces

ombining several high-end features, the machine tool is perfectly suitable for machining press dies to the highest standards. The machine also unites subtractive and additive manufacturing methods allowing for process-intensive production.

 

With its newest double column machining centre MCR-S, Okuma offers a machine tool that fulfils the demanding requirements of the automotive industry. When producing car bodies, manufacturers require press dies that are as precise as possible to achieve not only an extraordinary dimensional accuracy but also surfaces of the highest quality. As labour costs are on the rise, perfect surface quality needs to be achieved without manual polishing.

 

High dimensional accuracy

 For great rigidity and close tolerances, MCR-S possesses a solid cast iron double column structure. Equipped with Okuma’s Thermo-Friendly Concept, unnecessary heating-up can be prevented and thermal deformations are compensated. When manufacturing press dies, this is especially important because the machining process can take days or even weeks, making it vulnerable to changes in temperature. By using a Swivel Image Sensor that rotates relative to the indexing angle of the tool, highly accurate measurements of its cutting edge position can be provided, improving accuracy even further. The sensor also helps to ensure traceability by recording the captured images.

 

Creating perfect surfaces economically

 Okuma’s Premium Solution Hyper-Surface eliminates the costly need for hand-finishing by creating die surfaces that are instantly ready-for-use. It achieves superior surface qualities by automatically detecting disturbances in the CAM-output machining data and correcting them on the CNC while maintaining the required shape accuracy. In this way, Hyper-Surface also increases throughput since raw material is processed in shorter time frames.

 

To allow for cost-efficient manufacturing, Okuma increased the productivity of MCR-S by shortening cycle times. The machine possesses a heavy-duty cutting capacity reaching a chip removal rate of 710 cm/min when face milling. Average continuous feed rates of 20 m/min for the X- and Y-axis, and 10 m/min for the Z-axis contribute to the machine’s productivity. In addition, the Intelligent Technology application SERVONAVI autonomously maximises table acceleration according to the workpiece’s weight. As these features contribute to the machine’s productivity, the total cost of ownership (TCO) can be reduced to a minimum.

 

Additive and subtractive combined

 For super process-intensive manufacturing, the machining centre can be equipped with a laser that allows for additive manufacturing via laser metal deposition (LMD). This way, subtractive and additive manufacturing methods are combined in one machine enabling manufactures not only to produce highly complex parts but also to repair defective pieces. The laser can also be used for surface treatments such as laser hardening. This also increases productivity as multiple setups on different machines become obsolete.