Large Parts – No Longer a “Special Problem”

The sizes of the parts we machine today are getting larger. Heavy equipment, aerospace, and agriculture are just a few of the industries requiring larger CNC machine tools to complete these parts in a timely manner. At the same time, accuracy requirements have become more stringent, which requires CNC machining functionality that’s more sophisticated.

Problems with Large Parts

Unfortunately, the offerings of large, efficient machine tools have traditionally been rather limited. A great many of these machines were geared toward very small lot sizes and require a great deal of operator attendance throughout the CNC machining process. A good example is the use of manual or semi-manual boring mills to machine large parts, which is a very common practice. But this is a slow and labor-intensive practice in most cases.

In Europe, universal CNC machining techniques were developed and adopted some time ago, and this is now the typical standard. What’s holding us back in North America? First (and this is just my opinion, but it’s based on decades of personal field experience), most manufacturers are very settled into a comfort zone, and cling to the familiarity of “this is how we’ve always done it.” Second, tool builders need to step up to the plate and offer more compelling CNC machine options for large parts.

New Large Frame CNC Machining Centers

Recognizing this need, Okuma has developed a new series of large frame CNC machining centers that offer the ability to process large parts just like any other smaller part. Very often, offering the ability to complete that part in one set up. The best news is, these machines can now deliver all the advantages and functionality of other Okuma machines, including the open architecture OSP-P control, Matrix ATC and single-source support, to name a few.

The new MB-10000H is a one-meter pallet machine that comes standard with a two pallet APC. This machine is a true machining center in every way. It offers all the productivity advantages of a horizontal machining center, as discussed in my previous blog post “Why Your Next VMC Should be an HMC.” In addition to the APC, it offers ATC capacities from the standard 40 tools up to 285 if required. Additionally, it can accept pallet pools or even be connected to a flexible manufacturing system (FMS) at any time after initial purchase. Expandability after the installation has become very important in today’s world, as we never know what’s coming into our facility next.

Early Adoption Pays Big

The MB-10000H is new, but already it’s gaining popularity much more quickly than I anticipated. A great example is a recent project in the die mold industry. This customer was using very large VMCs and experiencing all of the traditional VMC problems. Low spindle efficiencies, high operator skill levels to operate the machines, a limited offering of this size VMCs to choose from, and constant operator attention to their VMC (adding uncontrolled cost to each part).

The MB-10000H they installed is a practical and immediate solution to all of these problems. The most important advantage is a significant reduction in operator attention/skill level to maintain a quality process. To date, the MB-10000H runs at an approximate 30% higher efficiency and is anticipated to reach 50% to 60% efficiency as the process is optimized. This gain is mainly achieved by the machine’s ability to operate largely unattended.

With consistent accuracy, power, and speed now readily available, this CNC machine offers a solid solution to traditional “bottlenecks” in the large part manufacturing process. No longer is there a need to treat large parts as a “special problem.”

What are your large part challenges? Comment below or contact us and let’s look at how the latest CNC machining technology can pay big for you.

Jim Endsley is Machining Center Product Specialist, Okuma America Corporation.