CNC Machine Evolution: How Not to Become Extinct

How many people start up a CNC machine shop and aren’t able to survive in this very competitive business? One of the rules of success in any area is: “stay focused on the big picture.” What is the big picture in the CNC machining industry? Is it a MA-12500H, MCR-C or a VTR-350A? Heck yeah, these machines are big. But most important is the vision and ability to evolve. Let’s say a shop owner starts his one-man operation with an engine lathe, and after some time, he sees more business opportunities and realizes the necessity to upgrade to a CNC machine. So he acquires a computer controlled machine tool and the business grows.

Early Stages of Evolution

Where do you evolve next as a turning shop? Natural progression to the next level could be a 4-axis lathe. If such a machine is efficiently programmed and paired with smart process, it can deliver 40% and more in cycle time reduction, as we demonstrated during Okuma Open House in Charlotte last December and Morris Madness in Chicago a couple weeks ago (2- vs. 4-axis turning). Here is a list of the benefits of dual turret lathes:

• Shorter cycle time
• Quicker changeover
• Better machine utilization
• Higher workforce productivity
• Efficient floor space utilization

A Next Step

How about machining centers? In what direction can you go after one has upgraded to a CNC mill from a Bridgeport? As the machine shop grows and needs to be more competitive, Okuma offers their horizontal machining centers (MA, MB, and Millac). On top of their speed, precision and powerful spindles, they have a thermally-stable design and intelligent controller. The advantages of horizontal machining centers are:

• 3 sides can be machined
• Much better spindle utilization than VMCs
• More work done per loading (4- and 6-sided tombstones)
• Less operators needed
• Speedier return on the investment
• More rigid construction (ability to cut tougher materials and use bigger tools)
• Gravity helps chip evacuation (no chip recutting)
• HMCs are typically configured with options to improve efficiency (4th-axis table rotation, pallet changer)
• Read our white paper “Vertical vs. Horizontal Machining Centers – An ROI Comparison” to learn more…

CNC Machine Consolidation

Once the shop masters turning and milling, they may think about combining both operations in one CNC machine. Okuma’s MU series of mills offer simultaneous machining in 5-axis. This combined with the turning function opens up all kinds of possibilities. Another example of multifunction machines is a MULTUS lathe. Equipped with a lower turret, subspindle and a full contouring C-axis for additional capability increases throughput and process balance.

Highly-Evolved 5-Axis

Even though 5-axis machining is often associated with complex shapes, it’s more common that five-axis CNC machines are used for five-sided machining because they:

• Reduce setup time
• Eliminate the typical flipping of parts required on 3-axis machining centers
• Shorter and more rigid tools can be used (higher speeds and faster feeds, while loads are reduced)
• Less fixtures needed
• Lets you increase the profit margin per part
• Increases accuracy since parts are not moving between multiple machines and fixtures

In a competitive world, if you can’t keep your cool, “think big,” and find a way to win against all odds, you’re toast. If you’re not evolving, you might become extinct. Here at Okuma we can help you evolve, grow, achieve your goals, and thrive in your business.

What evolutionary steps have you taken? Or perhaps you enjoy life as T. Rex? We welcome your thoughts, please comment below and share them. If you’d like some help moving up the food chain, feel free to contact us, or your local distributor.

Mark Hamielec is Applications Engineer, Okuma America Corporation.