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 describes how coolant properties affect the cut. MQL might work, but water-based coolant 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

Innovative Fixturing: Closing Summary Transcript
I hope that all of you could identify with some of those examples, with some of the applications and challenges that you come up with in your own manufacturing environment. So we took a look at fixture economics and looked at several examples of case studies applying some of the more innovative technologies for

Innovative Fixturing: Transmission Case, Case Study Transcript
This is a transmission case for an automotive manufacturer. This is one part per fixture. It again is an integral pallet and fixture design, using Continuous Pressure Hydraulics. But the unique thing about this particular fixture is this: You can see in the picture that this fixture is about halfway between the

Innovative Fixturing: Air Brake Compressor Housing Case Study Transcript
This is an air brake compressor housing for an over-the-road truck manufacturing application, a four-position hydraulic fixture. A lot of the challenge that this part gave us was that we have to run 15 different part numbers on this fixture. And the configurations of these parts, as you can see by looking at th

Innovative Fixturing: Steering Knuckle Case Study Transcript
You're looking at a solid drawing, solid model drawing of this particular fixture. This is a steering knuckle, also over a million parts per year in production volume. Again, we went with an eight-position hydraulic fixture. These are aluminum knuckles and there are three different part numbers that have to run

Innovative Fixturing: Steering Gear Fixture Case Study Transcript
This fixture that you're looking at now is a steering gear fixture; it is a nodular iron steering gear housing, a rather large piece. This is an extremely high-volume application, one million parts plus per year. We're using an eight-position hydraulic fixture, expanding locators inside of those parts in order

Innovative Fixturing: Machine Cell Setup Case Study Transcript
This is showing a machine cell setup with our CPH system. Part of the CPH system, and obviously CPH is an option on the machines, is visual control. Now how that basically translates is on this CPH-ing machine you have an auto door option. In this particular case at a customer's facility they're running automot

Innovative Fixturing: High Production Workholding Case Study Transcript
When we look at high-production workholding there's a few different areas of concentration that we need to think about. Obviously, robust and easy loading is one of the largest concerns that I see; it's probably one of the most overlooked areas of fixturing, especially during design. It's not often that the fix

Innovative Fixturing: Robot Loaded Cell And Fixture Combination Case Study Transcript
This is an example of a robot-loaded cell and fixture combination on one of our machines. You can see that this particular operation uses CPH, automatic robot loading, and a few of the other features that we've been talking about. That's a good look at the CPH trunion. And there is the coolan

Innovative Fixturing: Oil Pan Fixture (Part II) Case Study Transcript
As I mentioned earlier, this is just showing that same fixture looking head-on. You can see how the oil pan is rotated to access the compound angle features. We've eliminated the need for a second operation; we don't need a fifth axis. Obviously, there's no off line work. A lot of times customers, instead of cr

Innovative Fixturing: Oil Pan Fixture (Part I) Case Study Transcript
This is an automotive oil pan fixture. It is similar to the video that you watched earlier showing the tip axis or rotate axis that we've incorporated onto some of our fixtures. This is a one-position fixture and it looks rather complicated; you see an awful lot of hydraulic lines on there. Obviously, we're usi

Innovative Fixturing: Power Steering Gear Housing (Part II) Case Study Transcript
This is the same power steer gear housing used in; it's a second operation fixture, again it's a two-position fixture. We're using the Continuous Pressure Hydraulics again. We've got part seated detection; that it is different from part presence sensing. We have part presence sensing on this fixture as well, ag

Innovative Fixturing: Power Steering Gear Housing (Part I) Case Study Transcript
This is a power steering gear housing that was done for an automotive application. You can see that we have two parts up in a vertical orientation. The use of CPH, look at the top of that picture; you can see our twelve-port trunion. So we're using the Continuous Pressure Hydraulics for that actuation of this f

Innovative Fixturing: New Technology In CNC Workholding Transcript
I'd like to talk about some of the newer methods, as Bob said, which really gets into systems with higher reliability and lower maintenance. One system that we see becoming very popular is something that we call Continuous Pressure Hydraulics, or CPH. With this type of a system you often see the potential for i

Innovative Fixturing: High Production Workholding Transcript
In a high-production workholding environment there are different types of clamping. The traditional method of hydraulic clamping and unclamping still remains very popular. Within that family of hydraulic clamping there are several different slices or different flavors of hydraulic clamping that you can have. On

Innovative Fixturing: Methods Of Modular Fixturing Transcript
Now we're taking a look at a very different kind of a modular fixturing for larger parts. This is really not new, and the title of our presentation is for innovative fixturing, so I'll just touch on this. This type of modular fixturing is big with aerospace applications. On the left there you see a vacuum

Innovative Fixturing: Fixture Economics, Modular Fixturing Transcript
I'll talk briefly about some modular fixturing concepts and then get into a couple of traditional fixture designs. This video is courtesy of Curt Manufacturing, their Industrial Products Division. What we're showing here is something many of you may be familiar with. It is more less a manual, modular type fixtu

Innovative Fixturing: Fixture Economics, Orientation Of Parts Transcript
The meat and potatoes of this presentation, from a fixture designer standpoint, begins with what we like to call fixture economics. Inside of fixture economics we're looking at cycle time versus the number of parts per fixture. Basically we're trying to figure out exactly where and how many parts we should have

Innovative Fixturing: Introduction, Part II Transcript
Other key elements include the machine performance and size, work zone considerations, part volume, quality requirements required, part process considerations in how you'll process a part with a stand-alone machine, manual or hydraulic or automated fixtures versus a more of a cellular approach or an automated p

Innovative Fixturing: Introduction, Part I Transcript
Welcome to Makino's seminar on Innovative Fixturing. I am Tim Jones, product line manger for Horizontal Machining Centers at Makino, and your other host is Bob Kuzner. Bob has over twenty-five years of fixturing experience in the manufacturing environments and we're hoping you can benefit from his experience, k

Solutions For Hard Milling: Learning The Right Techniques Transcript
Next what we want to talk about is technology transfer. What we refer to by technology transfer learning the details of how to hard mill. One way we do this at Makino is a die/mold process training class. In this class, we share information that we have acquired in testing, in time and use, and through partners

Solutions For Hard Milling: Examples Of Hard Milling with Video (Part II) Transcript
This video is of a 62 Rockwell piece of A2. We are cutting using a collapsing tool path starting from the inside and going outward doing a Z-level roughing routine. This tool path is also utilizing Trochoidal roughing, creating little arcing motions and morphing out on the part as it goes along. The cutter

Solutions For Hard Milling: Examples Of Hard Milling with Video (Part I) Transcript
This die punch is at a hardness of 62 Rockwell. The material is A2, so it is a die type material. The cutter that we are using is a Hitachi TH coated. The cutter is a 12 millimeter diameter. It is a flat, six fluted cutter. The 45 degree angle on it is why the chips are coming off and looking the way that they

Solutions For Hard Milling: Determining Feedrate Transcript
The best way to figure out feedrate is to use the guide that the manufacturers give to you as a starting point, but then acquire your own knowledge. Take good notes and pay attention to processes that have worked in the past. Every hard milling application is different, and feedrate is really where machining ex

Solutions For Hard Milling: Determining RPM Transcript
Now we are going to talk about spindle speeds and some of the considerations that go along with the different types of materials. I basically just kind of broke this down on material (see chart in presentation). Not to say that every tool can be ran at these rpm's, but this is at least a guideline to help get y

Solutions For Hard Milling: Cutting Tools Video Transcript
The video is of a piece of A2 at 60 Rockwell. The cutter itself is a four-fluted ballnose endmill. It is the true ball design by OSG. It is a 12 millimeter diameter ballnose endmill, cutting at a spindle speed of 5,040 rpm. The feedrate is 76 inches per minute. The step over is four thou worth of stock or step

Solutions For Hard Milling: Cutting Tools Transcript
When cutting 60 Rockwell, be aware that there are cutters specifically designed for this material. Using anything less will cause unwanted results. If you want to get to a bench-free surface finish and want that part to have an accuracy based on being able to shoot a mold, you need to be mindful of the tol

Solutions For Hard Milling: Tool Holders Transcript
We need to talk about tool holders and some of the considerations that go with tool holders when dealing with hardened materials. The mill chuck is a very effective roughing tool holder for 60 Rockwell materials. When I am roughing I am creating vibration. That vibration has to be absorbed somewhere. This t

Solutions For Hard Milling: CAM Systems: Re-machining, Gouge Checking Transcript
Re-machining, to me, is the most critical part of cutting 60 Rockwell materials. To be effective your re-machining has to be intelligent enough to go back in and pick out only the excess material. This is where stock model recognition comes into play. Without it, you can't go back in there and remove the materi

Solutions For Hard Milling: CAM Systems: Requirements, Trochoidal Transcript
We want to look for a cam system that is specifically designed for 60 Rockwell materials - a system that utilizes solid model recognition and is very good at re-machining. Ultimately we are looking for a system that can provide a highly accurate tool path and gives us the different processes and approaches that

Solutions For Hard Milling: CAM Systems: Lead-in, Arc-fit Transcript
Next we want to talk about lead in and lead out. A few examples are helical ramp in, vertical ramp in, and horizontal ramp in. All of these are extremely effective for coming into material. Ultimately what we are trying to do is eliminate any entry marks. If I'm doing a roughing routine and I'm starting on

Solutions For Hard Milling: Machine Tool, Spindle, Control Transcript
I would like to talk about now are the requirements in order to get to 60 Rockwell high performance machining: machine construction, spindle construction, control technology, tool holders, cutters and cam software. So these are the things it really takes to get to the high performance machining or hard metals.

Solutions For Hard Milling: Introduction Transcript
Welcome to the presentation on Solutions for Hard Milling. I'm Craig McQueen, machining center application team leader out of Makino's die/mold headquarters for North and South America located in Auburn Hills, Michigan. First, let's talk about the benefits to hardmilling. One of the primary benefits to har

High Energy Applied Technology (HEAT): Interview: Intricate EDM of Columbia, PA Transcript
As I stated at the beginning I would like to introduce you to one of our customers, Mr. Tom Frick. We have recently added HEAT to his machine. I would like him to tell some of his experiences. TOM FRICK: My name is Tom Frick, I'm the owner of Intricate EDM in Columbia, Pennsylvania. I purchased a Makino

High Energy Applied Technology (HEAT): Real-World Examples of HEAT Transcript
Right now I would like to get into to some real world applications that are taken directly from customer request and also demos. Many of these examples that we are showing you guys today involve poor flushing conditions. This is a trim dye for the automotive industry. You can see our average rough speed is abou

High Energy Applied Technology (HEAT): HEAT Performance Transcript
This is a great little chart here that shows not only do we gain that speed but we also have a tolerance that's over two hundred millimeters, we are looking at five microns. So not only does our cutting speed increase but also we are maintaining this with superior accuracy. This is another chart that comp

High Energy Applied Technology (HEAT): Applying HEAT Transcript
These are certain applications that you could associate for the HEAT technology. We are basing it around poor flushing as I mentioned. So you can see some of the various punches here and parts that are associated with this kind of condition. This is a performance chart that show traditional technology. What I m

High Energy Applied Technology (HEAT): Results of HEAT Applications Transcript
The results that we have came across now utilizing this technology is that we've increased our speed and accuracy on our first pass also on our second pass utilizing the ten and twelve thousandths wire. With one pass we are getting straightness's of TIR about five tenths with one pass. Those of you in the busin

High Energy Applied Technology (HEAT): HEAT Technology Advancements Transcript
Some of the technology enhancements that we have done to the machine are as follows. We took our flushing nozzle technology into a better design to help with the flow to the work piece. We have improved upon our flushing capabilities themselves doing some things to our pump systems. We have also extended the li

High Energy Applied Technology (HEAT): Introduction Transcript
Before we started this technology development we wanted to set some targets and as far as real world kind of targets. We wanted to standardize to ten thousandths and twelve thousandths diameter wires. We wanted to focus on technology using brass and coated wires and paraffin or non paraffin types of wires and m

Error-Proofing Your Production Manufacturing Operation: Summary Transcript
Those are the examples I wanted to present to you today. To summarize the purpose of today’s topic was to pursue zero defects in the manufacturing process. You can do that and make a more efficient, lower cost process, as part of the pursuit of zero defects through effective error proofing. This is something th

Error-Proofing Your Production Manufacturing Operation: Monitoring The Machine Transcript
Another method of error proofing the machine process is monitoring system on the machine controllers today. Specifically, I've got a case study and it’s one of my favorites and really a wonderful example of a Poka-yoke process that saves you a lot of money.  This customer was applying a spindle load moni

Error-Proofing Your Production Manufacturing Operation: BTSOMA Transcript
Another method of error checking on the machine itself is something we call, ‘BTSOMA.’  That is an acronym for Broken Tool Sensor Outside the Machining Area. We supply a lot of these features on our horizontal machines because it’s a good error checking process. It adds liability to the process and basically wh

Error-Proofing Your Production Manufacturing Operation: Machine Error Checking Transcript
Now, moving on to the machine itself and what can be done on the machine to reduce errors. The first thing I want to point to is a system that we call, ‘Automatic Pallet Confirmation.’ Automatic Pallet Confirmation takes the location of the pallets and the machine tool to an extra level of error proofing.  I ha

Error-Proofing Your Production Manufacturing Operation: Off-set checks Transcript
Another technique in the Poka-yoke process that can be applied to tooling would be something that when we deliver turnkey projects we incorporate and call, ‘Offset checks,’ into our part programs. What an offset check is, it’s use of a macro program designed to check and offset value and verify it is within a n

Error-Proofing Your Production Manufacturing Operation: Tooling Transcript
Moving on to tooling. Tooling is an area of the highest frequency of errors that might occur in the machining process. You have diameter and length associated with each and every tool, and sometimes you’ve got a complex part with 20-30 tools, and everything has to be perfect.  Remember back to that slide that a

Buyer Beware: Summary Transcript
Unfortunately, there is no recognized standard that everyone can agree on. That means that you, as a buyer, will need to understand and properly compare specifications, keeping in mind the differing standards of measurement and how the specs interact with one another. You’ll need to determine your own wa

Buyer Beware: Other Specs Transcript
There are hundreds of other issues, including pallet change time and pallet repeatability. Pallet change time can greatly impact your “floor-to-floor” time, and the overall part cycle time and ultimately the cost per part. Some people measure pallet change unloaded, which can distort the actual times you

Buyer Beware: HP and Torque Transcript
A common misunderstood area is horsepower and torque specifications. An interplay exists between horsepower and torque, though horsepower says little about cutting performance. Torque is really what controls potential metal removal rates because it determines the available amount of force to support cutting act

Buyer Beware: Tool Change Specs Transcript
Tool-change specifications are another aspect that must be examined. They can represent a significant amount of cycle time, and it’s non-productive time because you’re not in the cut. If you have 50 tools in a part, you’re adding more and more non-productive time every time that tool is changed out. How you ana

Buyer Beware: Rapid, Acceleration and Deceleration Transcript
Another issue that must be considered is what other machine characteristics will affect your cycle times, like rapid, acceleration, and deceleration. You can spend a significant amount of time in non-cut, or non-productive times, that are very dependent on rapids, acceleration, and deceleration. You have a lot

Buyer Beware: Accuracy Transcript
I think everyone assumes that basic accuracy specs are the same on every machine tool. Just about everybody’s seen laser checks, and everyone assumes that the specs are relatively universal. If you go back in history, you can see from the 1960s to the 1990s there was significant improvement in positionin

Buyer Beware: What is a Specification? Transcript
I’d like to start out by explaining what a specification is. If you look in the dictionary, basically a specification is a means to define, or a description. Specs are used by machine tool buyers to compare different products and predict expected performance. Standards Consumers needed a way to evalua

Buyer Beware: Introduction Transcript
Our topic is “Buyer Beware: Are Specifications Really What They Seem?” First, we’re going to talk about what a specification is and why it is needed. The next topic is where are specs now, and what that means to you as a buyer. We’ll also take a look at how specs are used as an evaluating tool for key perfo

Error-Proofing Your Production Manufacturing Operation: Safe Start Programming Techniques Transcript
Staying with the programming theme, there have been some things that we’ve done here at Makino. Historically, we do turnkeys for a lot of our customers; we’ve done around 450 different part configurations for our customers. I have a lot of experience with processing and programming, myself. One of the things we

Error-Proofing Your Production Manufacturing Operation: Selecting a product Transcript
Now that you’ve seen the software, and if you have been thinking about addressing the programming stage of your process with verification software like this, there are a couple checklists of what you might look for when you look for products out on the market.  First, does it verify G-code programs? All

Error-Proofing Your Production Manufacturing Operation: Programming Transcript
Moving on from the couple of fixture techniques we just looked at, I wanted to talk about the programming side of it because that’s obviously a key part of the manufacturing process. The thing I want to address here is tool path verification software. This is a good way of simulating and therefore, anticipating

Error-Proofing Your Production Manufacturing Operation: Fixturing Transcript
The other thing we do in this particular example is part seat detection, which validates the setup. That’s the use of the air sensing system that I mentioned before that can detect if this part is properly up against its locators and not miss-set to the fixture so it will be machined properly by the machine too

Error-Proofing Your Production Manufacturing Operation: Hydraulics Transcript
First of all, I talked a little bit on the fixture side of things, and we have a method and a product that we use here at Makino called continuous pressure hydraulics. There are a number of error proofing methods that are applied within this fixturing process which is why we develop it.  We apply these techni

Error-Proofing Your Production Manufacturing Operation: Poka-yoke Transcript
What is Poka-yoke? By definition, it’s the implementation of fail safe mechanisms to prevent a process from producing defects. It’s a pretty simple concept. Error proofing becomes a method of 100 percent inspection at the source, rather than down the line. That’s a little bit misleading the way I stated

Error-Proofing Your Production Manufacturing Operation: Reducing Scrap Transcript
In our business, we’ve discussed some of the typical errors through talking to a number of our customers and simply being around the industry for 25 years. Sometimes process steps may get missed. This may be due to a number of reasons, like familiarity with a process by an individual or some printing issues, or

Error-Proofing Your Production Manufacturing Operation: Errors Transcript
First of all, I just want to kind of talk about errors and mistakes. It’s kind of a negative topic. But errors are something that happen, whether it’s in a manufacturing processes or in our own personal lives.  I have a slide and I just want to mention that errors are inevitable even by knowledgeable peo

Error-Proofing Your Production Manufacturing Operation: Introduction Transcript
Good morning, and welcome to our Webinar this morning with Makino. My name is Tim Jones, I’m the Horizontal Product Line Manager here at Makino. Our topic this morning will be Error Proofing the Machining Process. I chose the topic of Error Proofing the Machining Process because I thought it would provid

Equipment ROI: What Is a palletized operation system? Transcript
So what exactly is a Makino MMC? It’s a palletized automation system. It will take a part from a work-setting station, where a raw part would be loaded, for example, and move that part to an available machine or to a pallet storage system to await an available machine. On the other side, it will take a finished

Equipment ROI: Summary Transcript
The MMC’s primary ROI benefit is improving spindle utilization by keeping new work delivered to a machine. It also concentrates the work on where the work-setting stations are, streamlining workflow, and removing the need to have many operators, each at their own machine. The MMC also provides unattended operat

Equipment ROI: Programming the MMC Transcript
What does it take to get your MMC software running? You’ll need to enter all the required information needed to get it started. These fields are things such as your NC programs, part number data, tooling information, fixture information, pallet information, and production information. Basically, you assign a pa

Equipment ROI: MMC Controller Software Transcript
Using an MMC cellular manufacturing system requires a lot of data to be input and stored to produce the parts you need when you need them. In order to do this, you need an advanced software system. At Makino, we have the Makino Advanced System, or MAS. It allows you to input and store all your part

Equipment ROI: MMC Components Transcript
The MMC consists of several parts. First, the pallet carrier, which is a single-rail, guided vehicle. It can be a single layer or up to three layers, depending on the desired pallet capacity. The work-setting station is where pallet setup and change-out of parts takes place. The pallet stocker is the storage ar

Equipment ROI: Reducing Setup Transcript
Reduced setup time is another important factor with an MMC. With a stand-alone operation, you typically have an operator at each or every other machine. Because an MMC uses a work-setting station, a central location to load and unload parts, you can get much more out of your existing labor and reduce the time i

Equipment ROI: Unattended Operation Transcript
Unattended operation is an important feature of an MMC. Pallets and fixtures can be loaded and stored, awaiting the first available machine. Machining continues through breaks, lunch, and during off-shifts. This allows for minimum interruption of part production, increasing the number of parts produced per mach

Equipment ROI: Introduction Transcript
Today we’ll be presenting the return on investment, or ROI, achieved by flexible manufacturing cells. We’ll be discussing palletized automation systems, or in terms of what Makino offers, a Makino Machining Complex or MMC. We’ll also talk about the ROI you can expect to receive from this type of investment. And

Weldless Molding Technologies: Conclusion Transcript
In molding, if you don't control the surface temperature, the resin will not flow correctly, which will cause a weld or seam. There is a new process that allows you to eliminate this problem and create weldless or mold-free parts. In order to do this, you must have much higher control of the mold and its temper

Weldless Molding Technologies: Does It Work? Transcript
Here we have some pictures of parts molded with conventional and weldless processes. You can see in these parts the seam lines that have been eliminated in each part where the material, in the conventional process, did not flow together properly. Some of these images show you how the surface finish can often lo

Weldless Molding Technologies: The Alliance Transcript
Other members of the alliance that create a weldless mold include Sysko Corporation, which is a manufacturer of large-scale heating and cooling equipment. Their equipment is used to heat and cool, and their method of changing from heating to cooling is a changeover valve unit. They came up with a way to quickly

Weldless Molding Technologies: Rotary Smart Vise Transcript
Makino has patented a vise that we've named the Rotary Smart Vise. It is a vise that allows you to place the intermediate plate in between two grippers in grooves manufactured into the plate. By clamping between centers, it isn't necessary to hold the workpiece very tightly because the cutting forces are relati

Weldless Molding Technologies: Manufacturing the Intermediate Plate Transcript
Manufacturing of the intermediate plate creates some interesting challenges. Number one, it's thin, which creates issues to hold it without bowing or bending. Second, it's machined on both sides and on the periphery. One side is very detailed-literally the features you'll mold into your part. On the other side,

Weldless Molding Technologies: The Weldless Molding Process Transcript
First we need to understand the basic process, which is having a mold core or cavity created typically on a high-quality machine and placed in the molding machine. The mold is heated up, the plastic resin is injected, and the mold is cooled. The finished part is then ejected from the mold and the process is rep

Automated 5-Axis Machining: Points To Remember Transcript
There are a few key points from the video I’d like you to remember. First, automation can significantly reduce direct labor costs in the right environment. As you saw previously, in a continuous manufacturing process, it is possible to increase output without increasing the direct labor that you would pay again

Automated 5-Axis Machining: Real-World Examples Transcript
We know of a company with an aero and precision division that machines aircraft parts that recently installed a work-holding pallet system. Let’s take a look at their system. The system they installed consists of two a61-5XR 5-axis horizontal machining centers, one self-propelled transfer robot, two work

Automated 5-Axis Machining: Work-Holding Pallet System Transcript
Makino has developed a new pallet system concept called the work-holding pallet system. This system enables smart workpiece setups suitable for multi-faced machining. A horizontal machining center serves as the core machine. The first machine pallet has a 4-axis specification. There is another 5-ax

Automated 5-Axis Machining: Business Issues Transcript
The business issues here include cutting lead-times. In many cases, we’ve seen people who automate a 5-axis system and cut their lead-times in half. The ability to easily run low volumes is really a big part of this. You can significantly reduce WIP and finished goods inventory, mostly because you can do

Automated 5-Axis Machining: Automated 5-Axis Machining Transcript
What you’re looking at here is our topic for today. We’re referring to the 5-axis machining, which you can see in the sample aircraft airframe part on the left, and on the right is an automated setup with a pallet management system. The idea is to put these two production advantages together to give you

Automated 5-Axis Machining: Lean Principles Transcript
Most of you have probably gotten into lean implementations. Lean is basically about getting rid of waste—time, space, materials, and expense—within your manufacturing setup. For instance, lean manufacturing can lead to reducing inventory and reducing WIP, which is a big deal. With 5-axis machining, you can elim

Automated 5-Axis Machining: 5-Axis Technology Transcript
Moving to higher levels of machining technology, in the context of this presentation, is 5-axis machining. Most of you are probably aware of the advantages of 5-axis machining, but we’ll go over them quickly. First, you can begin reducing setups because you can reach up to five sides of the part in a sin

Automated 5-Axis Machining: Automation Transcript
First of all, let’s talk about automation. These are some quotes we’ve taken from customers over the last couple of years, in testimony to what automation can do for your business. For example, a customer mentioned that he went from 25 to 95 percent spindle utilization on two shifts. You can imagine the

Automated 5-Axis Machining: Introduction Transcript
The topic of 5-axis machining has been hot lately, which is why we wanted to bring it your way. But we also wanted to add the other dimension, which is automation. In response to ever-increasing global competition and competitive price pressure, companies are moving toward higher levels of automation and

Economic Stimulus Package: Things To Keep In Mind Transcript
CHRIS: Some things to keep in mind for 2008. If a company wants to take advantage of the section 179 $250,000 deduction, but they perceive their total purchases may exceed the $800,000 cap, you could utilize a blend of capital leases or purchases with operating lease or tax lease productions. TONY:

Economic Stimulus Package: Example Transcript
C HRIS: Let’s take a look at a few examples. Assuming that a company’s total purchases for 2008 are less than $800,000, and they plan to buy an asset for $125,000. Under section 179, they’d be able to fully deprecate their purchase for the year. TONY : Correct, as long as that deprecation does

Economic Stimulus Package: Bonus Depreciation Transcript
Let’s talk about the bonus deprecation a bit. The bonus deprecation feature allows a tax payer to depreciate 50 percent of any qualified purchase to an unlimited amount. Qualified purchase can be anything from computer equipment to machining equipment with exceptions such as luxury vehicles. TONY : Its

Economic Stimulus Package: Section 179 Business Expensing Transcript
Let’s walk through the Stimulus Package and talk about each point. First, the business expensing is limited to $250,000 for the tax year beginning in 2008. Section 179 Business Expensing Second, the incentives will include 50 percent depreciation allowance for any qualified purchase for 2008.

Economic Stimulus Package: Introduction Transcript
Hello, my name is Chris Lyle. I’m the customer finance manager at Makino. Today, I have a guest, Tony Schweier, CPA of Clark, Shaefer, Hackett & Company. We’re going to be discussing the Economic Stimulus Package 2008 Tax Bill, and how it relates to your business. Tony, I’m sure you’ve been a

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.

• Automated 5-Axis Machining

  Automation and 5-axis machining continue to gain popularity due to their favorable impact on productivity and manufacturing cost reduction. This video seminar presented by Makino will illustrate how to combine both technologies to achieve high productivity while also providing high flexibility and ease of use.

• 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.

• Weldless Molding Technologies

  In this seminar, Makino will demonstrate weldless molding capabilities only possible with new, cutting edge technologies and techniques.

• Equipment ROI: Machining Cells and Management Systems

  Learn about the advantages and features of the Makino Machining Complex(MMC2) palletized part-delivery system and Makino's Advanced System(MAS) cell controller software.

• Buyer Beware: Are Specifications Really What They Seem?

  When buying a machining center, you’re bombarded with specs. What do they really mean, and how do the inconsistent ways of measuring performance truly stack up? Makino's inMotion offers a review issues and tips for buying.

• Economic Stimulus Package

  n this video presentation Chris Lyle, Customer Finance Manager at Makino and Tony Schweier, a CPA of Clark, Shaefer, Hackett & Company discuss the Economic Stimulus Package 2008 Tax Bill, and how it relates to your business.

• Error-Proofing Your Production Manufacturing Operation

  Makino presents error-proofing your process to maximize throughput and speed up your entire operation. You learn how to eliminate common problems in production operations to make a more efficient, lower cost process, as part of the pursuit of zero defects.

• High Energy Applied Technology (HEAT)

  Makino demonstrates how High Energy Applied Technology (HEAT) smokes the Wire EDM Competition in poor flushing conditions, cutting parts 35% to 50% faster while holding tolerances of form and straightness to 0.0002" with one roughing pass.

• Solutions For Hard Milling

  Makino demonstrates the latest techniques and technologies for high-speed machining of hardened materials for die or mold applications. Check out tips, tricks, and new technologies you can use to mill the toughest steels, shortening your lead times, lowering your costs, and eliminating bench work.

• Innovative Fixturing

  MMS inMotion Multimedia Presentation Makino demonstrates the latest techniques and technologies in fixturing. Check out presentations on fixture economics, fixture design, modular fixturing, new technology in CNC workholding as well as case studies of shops using innovative fixturing.