"Four Questions" to be considered before using lying plus

If the manufacturer Party A makes such a request:

They mainly produce compressors, blowers, vacuum pumps, etc.,

Processing tasks involve 70 kinds of parts,

The processing quantity of each kind of parts is only 500～1000,

The parts have precise shapes and high tolerance requirements for alignment

...

If processing on a vertical machining center, so many types of parts require different settings, so it is difficult to achieve tolerance requirements for different shapes, and the overall processing time will be very long. From a functional point of view, a horizontal machining center with dual pallets and four-axis motion functions can be overcome, but the application of new equipment means a change in the entire processing flow for the company. Some issues should be considered when introducing horizontal plus...

▲A kind of double workbench lying plus structure

1. Can the horizontal machining center improve the existing work of the factory?

The advantages of the horizontal machining center are obvious, and the machining tasks of the vertical machining center can be completed. The rigidity of this machine tool can increase the speed and feed rate and reduce the processing time. For the same processing task, compared to the vertical machining center, the machining time when it is first completed on the horizontal machining center is generally reduced by 30%. In addition, when machining on a horizontal machining center for the second time, improvements in programming, tooling, and other aspects usually reduce machining time by 65%.

▲Aluminum alloy parts used in motorcycle handlebar shock absorbers

For parts with a short delivery time, in order to speed up production, vertical machining centers are generally used to process some relatively simple parts, and horizontal machining centers are used to process more complex parts. However, because horizontal addition can reduce the number of settings, direct use in the production of such parts can shorten production time, improve quality, and ensure that the alignment meets a specific reference point.

▲Use of shock absorber

The three components used by the shock absorber may require six settings when using a vertical machining center for processing, while only two settings are required on a horizontal machining center.

2. How much additional cost does it cost to use the lying center?

The cost of horizontal machining centers is higher than that of vertical machining centers. In order to give full play to the potential of horizontal machining centers, additional investment is required. For example, in order to reduce the risk of vibration, it is necessary to provide a large number of deep pads for each horizontal machining center, regardless of whether the workshop can provide space. Horizontal machining centers also require workshops to use screw air compressors to increase the compressed air supply, because standard air compressors cannot meet the air supply requirements of horizontal machining centers.

The use of horizontal plus also requires investment in tool technology. Sometimes, in order to prevent the spindle from hitting the clamping device, the long tool or the flat tool holder needs to exceed the column. In order to reduce the vibration caused by the tool holder extending too long, it is necessary to use a combination of heat shrink and hydraulic tool holder to increase the clamping force.

▲Use heat shrinkable tools to improve tool holding force

Moreover, the use of higher-end tools can take full advantage of the high rigidity of this machine tool, and further increase the speed and feed rate. Because the horizontal machining center is equipped with a multi-station automatic tool changer (ATC), it can load a variety of tools for different machining tasks.

The hydraulic drive column clamping device is used on the horizontal machining center, which can be used for special processing tasks. The hydraulic clamping method can simplify the part loading operation of the operator and reduce the risk of work injury. This workpiece clamping technology can also provide a more stable clamping force and higher parts clamping repeatability.

▲Horizontal machining center for special processing tasks is equipped with hydraulic clamping equipment

3. What changes will the use of horizontal machining centers bring to employees?

If the programmers and operators have never been in contact with a horizontal machining center before, they will need three to six months of learning, including on-site training. In the learning process, it is necessary to rethink how the workpieces processed by the existing vertical machining center are loaded on the horizontal machining center in different ways, and how to use the four-axis rotation advantage of the horizontal machining center to reduce the number of settings and profiling.

In addition, although the operator usually knows how the tool cuts the workpiece on the vertical machining center, the column or other fixtures of the horizontal machining center sometimes hinder the cutting operation. This may make some operators feel inconvenient at the beginning, but they will eventually rely on this processing method.

In addition, before starting a new machining task, the machining program can be simulated offline to prevent collisions. If the machine tool is directly put into production in an unfamiliar situation, a collision of the crankshaft may occur, causing vibration and premature replacement of the crankshaft.

However, the use of horizontal machining centers may be a positive signal to employees, that is, better equipment to help them complete their work more efficiently. For engineers, it will be very frustrating if the processed parts are found to be unqualified after finishing processing on a poor-quality machine tool.

In fact, the scrap rate in the horizontal machining workshop is generally less than 0.5%, and the utilization rate of the spindle can reach 85% (only 40% in the vertical machining center), because the operator can load the workpiece on the pallet outside the extra bed and at the same time on another pallet Machining other workpieces.

4. What impact does more advanced equipment have on the company's long-term development?

The introduction of horizontal machining centers (or more advanced processing equipment) is a process of substantial increase in costs for enterprises in the short term, and both cost and personnel need to be considered.

But in the long run, improving the quality of parts and the speed of production (in part due to the reduction of the number of settings) means that the ability to process orders will start to increase, and the products will receive more recognition.

The company in the illustration in this article originally processed compressors, blowers, and vacuum pumps. With the introduction of equipment, the user base has continued to grow. Now it covers various industries, including automobiles, aerospace, commercial refrigeration, firearms, fixtures, industrial and commercial equipment , Consumer goods, medical care, mold making and sporting goods.

Diversified areas ensure the balance of business. Even if the business provided by a certain industry is reduced, it will not have much impact on the company and strengthen the core competitiveness and market adaptability.