Event Highlights Automotive Production Solutions
Makino recently highlighted various examples of its latest automotive production technology and detailed strategies for responding to the pressure faced by manufacturers in that industry.

On Display at Automotive Day
Click through the pictures below for a brief overview of what I saw at Makino’s recent “Automotive and Part Production Day” event, hosted May 8 at the company's headquarters in Mason, Ohio. 

Event Highlights Solutions for Aero Structural Parts
The thin walls and deep pockets common to structural aerospace parts make machining challenging. A recent event at Makino’s U.S. headquarters highlighted solutions for effectively machining such tricky aluminum and titanium components.

Makino to Host Automotive and Part Production Day
The event will offer solutions for greater profitability.

Precision Micromachining Center Features Temperature Control
Makino’s iQ300 precision micromachining center uses 0.005 micron scale feedback for increased sub-micron accuracy.

Shop-Wide Automation Approach Enables 24/7 Machining
Using a flexible manufacturing system (FMS) and a 24/7 hour machining approach has enabled Micro-Mechanics to make production changes on the fly and virtually eliminate downtime

VMCs for Large Workpiece Manufacturing
Makino’s F-series of vertical machining centers includes the F8 and F9 models for large production parts.

Fast-Hole Drill EDM for Aerospace Blade and Vane Machining
The EDBV3 fast-hole drill EDM from Makino is designed for discharge machining of cooling air holes and shaped diffuser holes in aerospace blade and vane segments.

What JIMTOF Had to Show Us
We present here some of the interesting and visually appealing snapshots from JIMTOF 2012.

Five-Axis HMCs for Aluminum Machining of Structural Aerospace Parts
A-series five-axis HMCs from Makino are designed for high-speed, high-efficiency aluminum machining.

Five-Axis HMC Reduces Setups
The G7 i Grinder five-axis HMC from Makino provides a flexible, single-platform solution for grinding, drilling and milling of aerospace blades, vanes, turbine disks and complex grinding applications.

Creative Demos Showcase Capabilities of Both Micro-Scale Machine Tools and Machines for Massive Parts
Makino’s Booth S-8700 is full of various machine tools performing live cutting demonstrations in applications including a medium-to-high-volume automated production system for automotive parts, a robot-tended small machining center for orthopedic part production, and a machining center with grinding capability performing aircraft blade and vane machining.

Makino Lunch-and-Learn Schedule Announced
Enjoy lunch while hearing how a user of sophisticated machine tools is succeeding with technology. Makino offers a different presenter, along with lunch, on each weekday of the show. Sessions run from 12 to 1 p.m. in Room S104B (South Building, first floor).

Makino Pushes Social Media Engagement
The company encourages manufacturers to describe how they "Make What Matters."

Five-Axis VMC for Aerospace Machining
Makino’s D300 five-axis is designed specifically for small, complex, 3D contouring of high-quality parts typically for aerospace, medical, job shop and die/mold applications

Fully Committed to Zero Stock Machining
Milling critical mold surfaces to final size (or even a “tenth” undersize) literally leaves no margin for error. This takes absolute confidence in every aspect of the machining process, as well as absolute confidence that the results are worthwhile.

Sinker EDM Technology Speeds Deep-Rib Roughing
Makino’s SuperSpark IV sinker EDM technology is designed to reduce roughing times in deep-rib applications.

VMC Eliminates Vibration for Micromachining Applications
Makino’s V22 VMC is designed to eliminate vibration, rotational deflection and thermal distortion to ensure precision, accuracy, reliability and stability

Building on the Right Foundations
One of the largest vertical turning and milling centers in the country will be installed in this Cincinnati-area job shop. Although installing the foundation for this huge machine was a massive undertaking, the company is building on other “foundations” as well.

Technology Improves HMC Productivity
Makino’s Inertia Active Control (IAC) technology for HMCs optimizes B-axis rotation of the direct-drive rotary table to reduce non-cut time, resulting in improved efficiency and profitability for manufacturers.

Cell’s Benefits Derive From Sum of Its Parts
This shop’s experience with implementing a cell consisting of four robot-fed HMCS demonstrates that success depends on more than automation alone.

A Big-Picture View of Micromachining
 Matrix Tooling makes injection molds for components that have features you cannot see.

Sinker EDM Technology Provides Faster Roughing of Deep Ribs
Makino’s SuperSpark IV sinker EDM reduces roughing times in deep-rib applications.

Engineering a Production-Oriented VMC
Extended VMC cycle times due to modest spindle performance and slow non-cutting functions can increase costs for high-volume applications. However, new VMC offerings can minimize cycle times while maximizing competitiveness for production work.

VMCs Increase Productivity, Quality
Makino’s PS-series VMCs for production machining are designed to reduce cycle time, increase productivity, improve quality and minimize capital investment.

What Makes for an Effective, Production-Oriented VMC?
Extended VMC cycle times due to modest spindle performance and slow non-cutting functions can increase costs for high-volume applications. However, new VMC offerings can minimize cycle times while maximizing competitiveness for production work.

Precision Micromachining Center for High Speed Machining
Makino says its iQ300 precision micromachining center incorporates the latest advances in machine and spindle design, thermal control and precision. 

How Effective is MQL for Drilling Titanium/Aluminum Stacks?
Titanium expert Mark Larson describes how coolant properties affect the cut. MQL might work, but water-based coolant is typically best in titanium.

Makino imX Focus: Titanium, Micromachining
To break through the past limitations of low metal removal rates and limited tool life, Makino' ADVANTiGE technologies and the new T-series 5 axis horizontal machining centers incorporate new spindle technologies, coolant delivery, vibration damping, machine rigidity and cutting strategies, the company says.

Real-Time Data Management Software Maximizes Productivity
Makino’s Machine Productivity Maximizer (MPmax) is a process monitoring and data management software that connects multiple machines on a single network to a centralized computer, enabling manufacturers to retrieve, store and analyze high volumes of machine data in real-time.

Five-Axis HMC Machines Titanium
Makino’s T2 five-axis HMC with Advantige technology is designed for mid-sized titanium aerospace part production.

Make Maximum Use of the Magazine
This shop streamlined its selection of cutting tools to machine a number of parts on a pallet system. Cutting down on cutters delivered other benefits as well.

EDM, Metrology System Pairing Opens New Doors
Seeking a solution for producing and measuring smaller, more intricate parts, this shop combined a ram EDM unit and optical 3D metrology system. Each provided significant benefits on its own, but the pairing of the two technologies enabled the company to achieve new levels of precision and productivity.

Disaster in Japan: A Spirit of Generosity Will Prevail
Despite last week’s horrendous disaster, Japan will carry on.

Tool-Related Considerations for More Efficient Machining of Titanium
The expert in our Titanium Machining Zone offers advice related to coolants and coatings.

How Do You Equip a Startup Micromachining Shop?
A response to a reader’s question includes a checklist for launching a small shop focused on micromachining.

Machining Complex Parts on a Five-Axis VMC
Makino’s F5-5XR VMC combines high-performance hard milling with multi-axis capability for increased accuracy, speed, flexibility and productivity.

Precision Metrology Supplier Relies on HMC Accuracy
Global metrology supplier Quality Vision International produces critical measurement equipment components in-house to control quality and accuracy. HMCs from Makino enabled the company to not only achieve the precision required for components of one multi-sensor system, but also significantly reduce cycle times.

Controlling Burr Formation within Small Intersecting Holes
A reader struggles with burrs between intersecting holes 1 mm and less in diameter. MMS Online’s micromachining expert offers advice.

Ram EDMs Designed for Long, Unattended Operation
The EDAF series of ram EDMs features a new mechanical design for increased rigidity and reduced thermal distortion.

Ram EDMs Designed for Long, Unattended Operation
The EDAF series of ram EDMs features a new mechanical design for increased rigidity and reduced thermal distortion.

Webinars Cover Latest Technologies, Techniques
Makino (Mason, Ohio) has released the schedule for its summer seminars, which cover topics including milling, EDM and automation as well as the company’s latest machining technologies.

Hard Milling Reduces Lead Time, Manual Labor
Investing in a hard milling machine from Makino has enabled this fineblanking manufacturer to reduce lead time by 55 percent, reduce manual labor and improve part quality.

Taking on Titanium
The challenge for the aerospace machine shop is to produce titanium parts productively and profitably. The challenge for the machine tool builder is to help such shops meet this challenge.

VMC for Die/Mold and Medical Markets
Makino’s F series VMCs are designed to provide stiffness and rigidity for chatter-free cutting; agility for high-speed/hard-milling; and accuracy for tight tolerance blends and matches typical of complex, 3D contoured geometry associated with die/mold and medical production.

Makino Hosts Global Titanium Day
Makino will host a Global Titanium Day on Thursday, May 20th at its Mason, Ohio Global Titanium R&D Center.

What is the Best Process for Machining a Small, Precise Hole in Aluminum?
This small hole is actually large enough that any of three different processes might be used.

Automated Fixture Plate Distribution System.
Makino’s MMC-R automation system is designed for robotic fixture plate distribution in HMCs and VMCs.

VMC For Complex Geometries
Designed to machine complex geometries, Makino’s F3 VMC is designed for rigidity and micron-range positioning accuracies and repeatability.

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Dial Down or Dial Up?
Vibration analysis may be the machining center’s missing piece. If you haven’t performed this analysis on your high speed machine, you probably don’t know what the machine can do.

When to Mill Keeps Changing
Technology improvements steadily expand the range of tool and die parts that justify high speed machining.

A Significant Cell
Manual loading of heavy housings was this manufacturer’s prime bottleneck. It had limited experience with automated cells, but decided to install a big one. A look at the manufacturer’s $13 million cell reveals an intriguing layout and blend of technologies.

Coping With Today's Economic Pressures
 Shops and plants can't afford to overlook any opportunity to cut costs and improve their financial picture.

The Hidden Cost Of EDM Wire Consumption
 Excessive wire consumption on a wire electrical discharge machine is costly. Technology that allows slower unspooling speeds without compromising results appears to be the answer.

Shifting Gears To Integral Drive Adds Productivity
Machines with geared-head spindles are typically employed for machining titanium and other tough materials that require high torque. However, replacing such models with integral-drive HMCs from Makino has enabled this contract manufacturer to significantly improve productivity on time-sensitive aerospace jobs.

Makino Broadcasts 100th Online Seminar
Makino’s online seminar series reached a new milestone June 4 with the 100th seminar broadcast. All 100 seminars are available at the company’s online seminar library.

What’s Ahead For The North American Auto Industry
Here are highlights from a presentation by an auto-industry observer at Makino’s recent technology expo.

Does Small-Hole Drilling Demand a Fast Spindle?
A reader with a 10,000-rpm drill press can drill a 0.019-inch hole in stainless, as long as all the contributors to runout are controlled.

How Do You Get The Cutting Parameters Right For Small End Mills?
A reader recently asked about speed, feed rate and depth of cut when using small tools in steel.

Using Small End Mills In Steel Without Breaking
A reader wants to mill with small tools on a straightforward VMC used for full-sized work. MMS Online’s micromachining expert offers advice.

Expo Features Machine Demos, Speakers
Attendees to Makino’s Advanced Manufacturing and High-Precision Technology Expo will have the opportunity to gain industry-leading advice and witness machining demonstrations from Makino and other prominent suppliers, the company says. Scheduled for September 16 and 17 at the company’s Auburn Hills, Michigan Tech Center, the event will feature presentations from speakers including Kim Korth, IRN owner and president; Conrad Winkler, Partner of Booz & Company; and Dr.

Five-Axis Aluminum Machining Centers
Makino’s next generation of MAG series five-axis machinery, the A7, provides increased accuracy and reduced cycle times for large complex aluminum monolithic parts for aerospace structural applications. The A7 is designed with extended X-, Y- and Z-axis travels of 276" × 99" × 40" (7,000 mm × 2,500 mm × 1,000 mm) to accommodate parts as large as 276" × 79" × 28" (7,000 mm × 2,000 mm × 700 mm) that weigh as much as 11,024 lbs (5,000 kg).

Coolant And Center-Drilling Considerations For Machining Small Holes
Through-spindle coolant is good if you can get it, but the spot drilling might not be necessary. Try a pilot hole instead?

What is the Best Process for Micro-Deburring?
Various techniques address the challenge of getting a clean machined feature at microscopic scales.

HMC Efficiently Machines Titanium
Makino’s T4 five-axis HMC combines lean manufacturing methods with increased metal removal rates for aerospace applications. It is specifically designed for the production of large titanium and titanium alloy aerospace parts including edge frames, pylons and bulkheads.

How Do You Machine a 30:1 Hole in Stainless Without the Drill Wandering?
An expert in micromachining says one answer is to check various aspects of the drilling process. Another answer is not to use a drill at all.

Five-Axis VMC For Accurate Hard Milling Applications
The company offers a five-axis version of its V33i hard milling VMC, the V33i-5XB. The VMC will be integrated with an Erowa robot at the show to demonstrate how shops can utilize automation in high-accuracy hard milling applications.

Too Small To Touch
Hummingbird takes on machining work that is too small for most shops to handle. In fact, Hummingbird tries not to handle it either. To accurately machine the tiniest parts, this shop relies on processes that are as hands-off as possible.

Compact HMC Provides High Speed, Reliability
The a51 HMC is designed for performance and reliability. According to the company, the simple-to-operate machine is compact, easily maintained and quickly deployable for manufacturing applications that require maximum throughput and dependability. The machine is suited for medium- to high-volume production shops, first- and second-tier automotive parts suppliers and general-contract machining operations.

Offline Program Solution Software
Makino has launched version 5 of its EDcam offline programming software, which provides shops with more options in a wider array of applications. This update adds to features from previous versions, upholding the value of continuous machine run time and operator multitasking. New features include expanded model data, machining conditions technology upgrades and new electrode material types to encompass a larger number of application needs.

Keeping Things In Focus
Machine-mounted video cameras are part of a system that help a shop owner get more work done while spending less time in the shop. He can monitor and control what’s happening on his machines remotely. He’s also developed strategies for reacting to events such as unexpected tool wear or sudden tool breakage without returning to the shop to fix the problem.

Makino Offers Online Educational Resource
The success of Makino’s online seminar program has led to the creation of the Online Seminar Library, a multimedia educational resource designed to further the manufacturing competitiveness of North American shops. The library features more than 60 online seminars broadcast by Makino applications engineers since the program’s inception two years ago. Upcoming live events are expected to bring the total number of seminars to 100 by the end of the year.

Improving Five-Axis Performance
Makino's D500 five-axis VMC is designed for complex part production where part quality is paramount, the company says. The work zone for the center is 500 × 450 mm. The X, Y and Z axes provide strokes up to 550, 1000 and 500 mm respectively. Rotary table axes A and C provide rotational motion of +30 to -120 degrees

HMC For High-Precision Aluminum Machining

Hard Milling VMC With Increased Stiffness And Rigidity

Hard Milling By The Numbers
Here are some speeds, feed rates and depths of cut for a productive hard milling process.

Challenges In Cutting CGI
Compacted graphite iron is increasingly used for diesel and racing engine components. The choice of cutting tool can dictate how effective shops are able to machine this challenging material.

You Are Not Selling Just A Mold
High-end manufacturers know the frustration of watching customers base buying decisions on price. Pursuing low price has sent companies searching the globe for suppliers, and some have been disappointed in the result.

HMCs For Large, Complex Parts
Available in four sizes, Makino’s MCF series of HMCs  are designed for production work on complex parts as large as 5,300 mm in diameter and 3,000 mm tall.  Each model features an 18,000-rpm spindle, feed rates as fast as 16 m per minute and the company’s Geometric Intelligence technology. Average positioning accuracy is 2 microns in the X axis, 1.

Where Is Your Wiggle Room?
"Lights out" doesn’t require an intense commitment. This job shop achieves flexible unattended machining when it needs it using palletized HMCs.

Custom Solution Enables Quick Production Of Knee Component
This maker of implantable medical components can now machine the entire outside surface of a knee component in one setup.

Where New Machines And Methods Overshadow The Old
Eclipse Mold makes a good case for high-end machining centers as the basis for effectively machining to zero.

Vertical Machining Centers For Slanted Hole Machining

HMC Offers High Torque, High Thrust

The Hard-Milling Imperative
A job shop that specializes in hard milling shows why this technique is becoming indispensable for mold manufacturers. Hard milling allows mold components to be machined in the hardened state, thus skipping several expensive and time-consuming processes such as electrical discharge machining and hand polishing. Hard milling requires a certain type of machining center, tool holding system and programming software. The requirements for each of these elements are explained.

Measuring Tool Length For Micron Accuracy
Measuring the length of the cutting tool in the spindle is critical.

Multitasking Ram EDM
Multitasking capability is coming to EDM. This ram EDM unit can switch from ram to wire EDM to produce holes as small as 0.03 mm in diameter.

Drilling And Beyond
This collection of hole making-technologies offers some new, unusual and overlooked ways to make holes in machined parts. One of these tools might be the solution you're looking for. All of them will help you rethink your approach to hole making.

Produce Good Surface Finishes Without Tool Breakage

VMC Excels At High Speed Milling

Unplug-And-Play Hydraulic Workholding
An OEM and contract shop have found value in an unconventional, untethered hydraulic workholding method that uses mechanical energy transfer to charge a fixture's sealed hydraulic circuit. Free and easy HMC pallet movement is the result.

Who's Afraid To Cut To Zero?
Most U.S. mold shops still leave extra stock on the cores and cavities of the molds they machine. This practice is unnecessary and wasteful, say proponents of advanced machining technology.

Wire EDM Machine Is Useful For Intricacies

Getting To Submicron Accuracy
Machie tools designed for submicron accuracy and subminiature workpieces are following design strategies that depart from conventional practice. The Hyper2J from Makino is described as a case in point.

Wire EDM Goes Horizontal
Wire EDM (electrical discharge machining) has been configured with the wire in a vertical orientation for decades, so the appearance of a wire machine that orients the wire horizontally is truly a novel development.

VMC Designed For High Accuracy

Reduced Need for EDM - Hard Milling
HSM can let milling serve as an alternative to EDM for making dies or molds from the hardest materials (50+ Rc).

Machining Center For Fuel-Cell Mold Plates

How To Pay For That New Machine Tool
Innovative approaches to funding help shops and plants acquire the technology they need.

VMC For Mold Shops

Cutting The Learning Curve
A grinding shop in western Pennsylvania uses self-teaching CNCs to boost productivity.

Six Advantages Of Horizontal High Speed Machining
Large monolithic aircraft parts may be machined more productively one at a time instead of three at once.

HMC s Yield Big Gains For Mold Base Shop
This shop was pleasantly surprised to discover that, besides making chips faster, its new horizontal machining centers also enabled them to eliminate a time-consuming, secondary operation.

A Boring System For Non-Round Holes
Machining an out-of-round bore is easy if you're not particular about the location or magnitude of the roundness error. But accurately machining a hole that has a precisely defined non-round profile is a capability that would seem to be well beyond what a standard boring bar can accomplish.

New Fixture Multiplies Productivity Of Horizontal Machining Center
The setup for batch processing of each stem version and time expended in load/unload for the second operation created a production bottleneck that became more critical as market demand for the part took off.

On The Path To Automation
Implementing an integrated tooling system proved to be this mold shop's first step toward automated operation of its electrical discharge machines and graphite mills. Today, the shop's robotic cells can run around the clock in an unattended mode.

Better HSM For Big Parts
'High speed machining' is accepted and commonplace in many shops. HSM is so widely used, in fact, that its acceptance is beginning to affect the design of machine tools.

Processing The Process
The high speed horizontal machining centers in this manufacturing cell represent a very efficient process for machining cast iron transmission cases. How the crew runs and maintains this cell represents a very efficient process for making this cell ever more productive and cost effective.

The Efficiency Effect
Using machining centers that might otherwise mill electrodes, this Minnesota mold shop does its cutting directly in steel. The streamlined process has exceeded expectations and yielded a striking increase in sales.

EDM Vs. Milling In Die/Mold Machining
In many die and mold shops, the choice between ram EDM and CNC milling is far less clear than it used to be. Changing technology is changing the rules.

A Holistic Approach To Cost Savings
To machine holes for less, this shop considers the whole process.

In Latest Version Of
Look-ahead is a common CNC capability today. The term describes the control's ability to read ahead some number of blocks in the program, to anticipate sudden changes in speed or direction and react accordingly. Different CNCs look ahead different numbers of blocks. But are more blocks better?

The Case For Additive Technology In EDM
Producing fine finishes on EDMed surfaces has long been a goal, especially for mold and die shops that operate ram-type electrical discharge machines. Lately, there has been renewed interest in using additives in the dielectric oil to achieve ultra fine finishes with graphite electrodes without excessive burn times.

HMC Helps Optimize Engine Performance And Reduce Time To Track
The precision craftsmanship that goes into building an engine will usually separate the winners from the also-rans at NASCAR's highest levels. This certainly applies to cylinder head development, because so much power from the engine is produced in and around these chunks of aluminum. Cylinder heads are horsepower, and horsepower delivers speed. When an engine builder gets a new cylinder head in at the shop, there's a lot of work that needs to be done to get it into racing condition.

High Speed Machining Helps Modernize Bulkhead Manufacturing
Raytheon Aircraft recently decided to set the competitive standard rather than follow it. In turn, the company is modernizing its manufacturing plants and processes to ensure continuous improvement.

The Practically Dedicated Flexible Cell
Machining centers make sense for this high volume process, even though the machines have continuously produced just one part for years.

Additive Solves EDM Surface Finish Problem
This new process utilizes a semi-conductive powder mixed into the dielectric fluid and produces superior surface finishes in significantly shorter time. It achieves a uniform surface finish over larger workpiece areas, reducing polishing times and associated direct labor.

Interpolating Curves
The ability to import complex curves into CNCs promises to let shops finally get beyond old limitations imposed by contouring with linear interpolation. Faster and smoother cutting will be the result.

Cycle Time Is In The Cut Now
High volume machining centers have become so efficient outside the cut that the widest margin for productivity gain is within it.

It's Within Your Grasp -- It Will Extend Your Reach
Though high speed machining means different things to different people, all of the diverse applications of this process involve performing operations fast enough to break into a new realm of possibilities.

Graphite Milling Shifts Into High Gear
Mold makers and injection molders are riding a wave of increasing demand for molded plastic and cast metal parts in consumer products. Yet efficient production requires parts that need little processing or finishing after molding or casting. The challenge for die/mold makers today is to satisfy the contradictory demands for intricacy and speed.

High Speed Machining Of Dies And Molds
These tips from an experienced pro will help shops take some of the mystery out of the process of high speed machining.

• Video: Five-Axis Machine’s Atypical Pallet Changing System

  Makino’s a61nx-5E five-axis machine features an atypical pallet changing system that brings effective ergonomics to five-axis machining.

• 50-Micron Milled Channels

  Video captured with a microscope shows that a full-scale machining center is capable of micro-size milling work.

• Electrode Loading for Fine-Hole EDM

  The Makino EDFH1 is a fine-hole EDM machine capable of machining holes as small as 10 microns in diameter using a 6-micron-diameter electrode. One user of this machine is Hummingbird Precision Machine in Lacey, Washington. This video taken at Hummingbird shows how the electrode is loaded.

• Threading A Horizontal Wire EDM

  A wire EDM machine designed for micromachining uses negative air pressure to thread the fine wire.

• Video: Helical Interpolation Vs. Drilling

  A machining center able to maintain precise control at high feed rates makes it practical to machine holes through helical milling as an alternative to drilling.