Modern Machine Shop

OCT 2017

Modern Machine Shop is focused on all aspects of metalworking technology - Providing the new product technologies; process solutions; supplier listings; business management; networking; and event information that companies need to be competitive.

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90 MMS October 2017 FEATURE like porting (machining the internal contours of intake and exhaust chambers) required another step: adding a fifth axis of motion in the form of a rotary table the face of one tombstone. Producing cylinder heads on this palletized HMC system requires three significant operator inter ventions: initial setup (three tombstones with three workpieces each), flipping the parts for spindle access to features previously blocked by the tombstone, and finally, moving the parts to the rotar y-table tombstone for finishing. In contrast, the five-axis machining center would be able to cut the part entirely uninterrupted if it weren't for mid-process, off-machine operations like valve-seat installation. Nonetheless, Mr. Warga says there are plans to abandon cylinder When it's not finishing cylinder heads transferred over from a pallet-changing HMC, the shop's newest five-axis, trunnion-table-style machining center offers the flexibility to machine any number of other components. Both machines feature pneu- matic zero-point workholding system that ensures accurate, repeatable mounting by simply mounting pre-bored billets to pull studs and engaging the air pressure, as demonstrated by the HMC tombstone in the inset. head production on the HMC. Likewise, cylinder heads weren't the only parts that the team had i n m i n d w h e n DS R p u rc h a s e d th e f i ve -a x i s machining center. Despite its advantages for setup consolidation, the five-axis requires setting up one part after another while the spindle sits idle, he explains. The HMC may require more intervention overall, but it also offers capability to cycle through lengthy, unattended roughing routines on 18 parts at once. That's a significant advantage at volumes of 130 parts per year at minimum. The five-axis machine, meanwhile, is free to cut other parts, like donuts and flywheels. When the time comes for finishing a cylinder head, moving the component to the five-axis doesn't add any more time than moving

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