Improving Manufacturing Cycle Times Through Machine Tooling
When it comes to increasing manufacturing cycle times, the machine tooling that is used to create parts has a significant impact on production. This article will discuss how machine tools can work with CAD-CAM software and improved design layouts to make manufacturing cycle times shorter. Read more to learn how improving your company’s machine tools will affect the success of its products!
Improving Manufacturing Cycle Times through Machine Tooling
Extended manufacturing cycles are not only frustrating for those who partake in them, but they also lead to lost opportunities and profits. However, these prolonged cycles may be shortened by optimizing choices in machining equipment--namely by choosing high quality machines.
The most important step in choosing the right machine is taking the time to evaluate and assess what machining processes will be needed. This is where solid understanding of CAD-CAM software comes in, as the hundreds of available equipment and tool choices may easily become overwhelming. By knowing which machining processes are used to create parts, you’ll be better able to make the correct tooling decisions that will shorten cycle times and increase profits.
To appreciate the value of machine tools and the impact they have on cycle times, let’s look at a fictitious part created in MachTen Pro. This part was created to mimic common air-cooled cylinder heads for automobile engines. This is a relatively simple part that utilizes many machine processes. The part geometry was first designed in CAD software to be created by cutting using a CNC machine tool.
The following images show the general model file set up for this part, and how it would appear after it has been created on the cutting table of a CNC machine:
In order to cut this geometry correctly using standard high-speed machining processes, the cutter’s material must meet certain criteria. The required material must be able to maintain a machinability index of “9” or greater. This means that the material is strong enough to resist cutting forces, but also has the ability to deform without breaking.
If the part was created using more complicated geometry, additional machining processes would have to be used. Because several processes are needed in order to create this type of part, machine tool design and optimization are important. If the equipment is not well designed, the cycle times for producing this part will be long.
Let’s look at how to select the correct machine tools for this job. In order to choose specific machine tools which will improve cycle times, it is first necessary to understand how they function together:
The most basic of all machine tools is called a turning center. Turning centers are used to make cylindrical shapes by cutting a work piece in rotary motions on a horizontal axis. Turning centers may be broken into smaller categories of toolroom turning centers and production turning centers based on their capabilities.
Toolroom turning centers, sometimes referred to as turret lathes, are smaller and faster machines that are used in toolrooms for rapid prototyping and small production jobs. Production turning centers, also known as conventional turning centers, may be broken down into two classes--standard production lathes, which are capable of speeds up to 1250 RPM and high production turning centers (also known as high-speed lathes), which can reach speeds of 8000 RPM or more.
In order to complete cutting cycles fast enough to be profitable in today’s market, you need a large selection of CNC turning center options. This is the only way to be able to complete all the necessary machining processes in a reasonable amount of time.
Another type of machine tool that must be considered is a milling machine. Milling machines are used to cut cylindrical shapes using rotary movements on an axis perpendicular to the part being cut. Milling machines may also be broken down into smaller classifications. Smaller milling machines such as knee millers and drill presses have simple designs that limit maximum speeds, while larger lathes with servo motors, like CNC vertical machining centers (which are sometimes referred to as CNC vertical turning centers), are capable of high feed rates and high cutting speeds.
In order to speed up cycle times, machine tool options must be abundant and flexible. This means that they should have both the sizes required by the part geometry, as well as several tools which are capable of cutting in different directions and using different cutting motions.
Another important consideration is how machine tools will be used. For example, some machines are better suited for production while others perform better when used as prototyping equipment. Taking these factors into account will allow you to make manufacturing cycle time calculations based on the amount of business you expect to receive.
The final piece of the puzzle involves how these machine tools will be used. For example, you may need to cut a large number of small parts that need to be accurately aligned while others require many different combinations of materials. With this knowledge, you can avoid purchasing unnecessary equipment and thus increase productivity.
Since machine tools are so important to manufacturing cycle times, it’s crucial that you choose them with care. In order for your decisions to be correct, it helps if those who have designed your machines are able to communicate effectively with those managing them--especially when it comes to process design changes which can lead to much faster cycle times.
Or perhaps you have a need to create a large number of parts with intricate geometry. This is where CAD-CAM software’s ability to provide complete 3D solid models becomes even more valuable.
In either case, it’s important to understand that the decisions you make today will directly impact your company’s ability to compete in today's global market place. This is why it’s vital that machine tool choices be coordinated between the designers and the managers of manufacturing shops. Failure to do so can result in lost sales due to higher prices for consumers, as well as lost business because customers will move to competitors who can deliver faster cycle times at lower prices.
Knowing how to select the best machine tools for cutting parts is important. You’ll soon find that these skills will be valuable to you and your company. For more information on how machine tools can make you more competitive, contact us today.
Machining Inertia Machines In Lean Manufacturing Systems
By Fredrick C. Newsom, Vice President & CTO November 27, 2011 At its core a lean manufacturing system should consist of employees who become better at their jobs through continuous improvement and innovation
The Problem
How do we ensure that the machines become more efficient? To do this we need to understand what causes waste within the factory environment.
Conclusion
If we only think about failure rates and not the most important part of the process then we may be missing a major source of waste. For example, adding inspection can add value if it leads to improved parts which do not have to be scrapped. However, if the inspection process is not working correctly then more scrap is introduced. When you think about that almost 90% of scrap is related to machining issues, it should make us all concerned.