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Entry-level multi-spindle auto heralds new chapter for UK manufacture
It is now possible to buy a six-spindle CNC automatic (multi) for around twice the cost of a high-end sliding-head lathe, according to Richard Kingsbury, MD of Geo Kingsbury Machine Tools, the UK agent for the German-built range of Index turning machines. His comment follows the EMO debut in September 2007 of the Index MS22C, a new multi for mill-turning parts up to 22 mm diameter.
He makes the point that many UK manufacturers have the preconception that the price of a multi is too high. While it is true that they are not cheap machines, the price in real terms has been coming down steadily over the years.
Now, with the introduction of the MS22C, the technology is within reach of a much wider section of manufacturing industry.
"The CNC multi-spindle range is proving so popular that Index will increase production in 2008 to 200 units across all sizes of multi. Of these, 80 will be in the 22 mm category. Four fifths of them are destined for Germany, France, Switzerland and Italy."
He points out that British manufacturers have been falling behind in adopting the technology, but has high hopes for an increased level of order conversions in 2008, due to the introduction of the competitively priced MS22C. OEMs and subcontractors alike are beginning to see the productivity advantages, having noted the big strides in capability of the machines.
Mr Kingsbury is particularly encouraged by the fact that, once a customer has been won over, not one has stopped at a single multi; they have all gone on to buy a second, third, fourth and even a fifth machine.
He continued, "A few years ago, people cottoned to the fact that modern CNC sliding-headstock lathes could make a lot of money. Many firms invested, mostly in multiple machines and some subcontractors have as many as 25 or more.
"But where is the competitive edge now that so many firms use them? I suggest that if component length-to-diameter is 4:1 or less, the next big thing in British turned parts manufacture will be the CNC multi, with its extensive prismatic machining and endworking capabilities, coupled with the flexibility to run batch sizes of just a few thousand.
"The competitive pricing has placed these machines in the mainstream of manufacturing, and both programming and operation have been demystified to the point where operation is almost as simple as running a single-spindle CNC lathe."
About the Index MS22C multi-spindle automatic
The six-spindle mill-turning centre has been added to the lower end of the Index range, which until now comprised machines with maximum bar capacities of 32, 42 and 52 mm. According to configuration, the MS22C can have up to 62 CNC axes, including 12 compound slides with X and Z travels of 62 and 85 mm.
Each spindle is configured with a full C-axis and a number of Y-axis slides can be added according to customer requirements.
Simultaneous back-working is achieved using one or two scara robot arms carrying synchronous pick-up spindle(s) that present the parted-off components to six separate tools, four of which can be driven.
As the MS22C's tool carriers/slides are arranged in a V shape, two CNC slides can work on one spindle simultaneously. This is in contrast to the configuration of multi's from other manufacturers. Each of the 12 slides can perform internal or external turning, or boring, or driven tool work. Workshops are therefore not locked in to running one kind of tool in one position, because there is no set order as to where to run which tool. Only the toolholder determines the type of machining. This flexibility of tool layout plays a key role in optimising machining times, according to Index.
Although the machine can be extended to the full 62 axes, this is rare in practice. The standard configuration would be with a single NC control capable of controlling 31 programmable axes, more than adequate for the vast majority of small turned parts. It is a specification that offers all the benefits of phenomenal production rates without the restrictions in flexibility that are normally associated with multi's.
This is because, in common with other Index CNC multi's, the new machine has the ability to optimise feed rates and cutting speeds at each 14 kW / 10,000 rpm spindle, avoiding compromised machining conditions and so maximising productivity as well as tool life. The MS22C is therefore ideal for economical production of components in materials such as high temperature alloys that previously could not easily be machined on a multi.
Control is by the INDEX C200-4D, a derivative of the Siemens 840D which is easy to program on the shop floor and automatically performs collision checking including for the pick-up spindle(s). Comprehensive diagnostics for the machine and control are included, and it is possible to specify tool monitoring and a teleservice connection to an INDEX engineer for troubleshooting.
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