On Precision. - Makino Europe GmbH

On Precision.
Precision.
Makino D500
A-axis indexing accuracy (repeatability): ±0.0005 degrees
2
Precision.
Makino a61nx
Spindle run-out: 2 µm
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Our world runs like clockwork – with incredible
precision: wild geese in flight, planets in orbit, electrons
moving around a nucleus. A Bach fugue. A Zen garden.
A jet aircraft.
4
At Makino, precision is a mindset. Our technology is precise. We listen
precisely, work precisely and develop precise solutions. The results are
revealed in the long-lasting quality, reliability and stability of our products.
Welcome to Makino!
5
Splitting the µ*
After I started working with my first D500,
I realised what accuracy in 5-axis applications
really means.
Javier Escribano
Mecanizados Escribano
6
The need for components with tolerances measured in microns,
or even nanometres, is steadily increasing: parts in digital
cameras, mini-motors or microvalves in automotive brake
systems. Makino has the technologies needed for such ultraprecision machining.
Look at the 1 mm holes in the carbide
plate. Their pitch and diameters vary by
less than ±0.5 µm. An outstanding
achievement.
But how much is a micron (µm) in the fi rst place? Or, more to the
point, how little? Here are a few examples:
150 µm:
60–80 µm:
2 µm:
0.003 µm Ra:
The thickness of a letter
The diameter of a human hair
The thickness of a red blood cell
The surface finish achieved by a Makino iQ300
Perhaps it is now obvious why moulds manufactured by Makino
machines hardly ever need reworking. They emerge from the
machine in perfect shape and meet even the strictest
specifications – precisely.
150 µm
70 µm
2 µm
The
The
The
thickness
diameter of
thickness
of a letter
a human hair
of a red
blood cell
* 0.000001 m
Sub-micron accuracy with the iQ300:
Machined with 0.1 μm differences in pitch,
each surface segment reflects the light
differently. Best surface quality achieved:
0.003 μm Ra.
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The machine
We pushed the start button three months ago and since
then the machines have worked without any interruption.
These machines just run and run.
Jan Berg
Westinghouse Electric Sweden AB
8
“Quality First” is our corporate motto. We pursue “quality fi rst”
in all our products and services with a “strong belief in mutual
trust among everyone involved in building, selling and using
Makino products”. In practice, this differentiates Makino from
other machine tool builders. It is reflected in our product development as well as our manufacturing philosophy. Our machine
parts are manufactured with utmost precision. Our machines
are assembled in a quality-centred and highly efficient process
characterised by a strictly controlled workflow and skilled
personnel motivated by individual responsibility and creative
craftsmanship. For example, a Makino machine is always
assembled in its entirety – by an ‘old hand’ and a young employee.
This way, our “craft of assembly” skills are passed on from
generation to generation.
For more than seven decades, Makino has been developing and
building the machine tools required for pioneering manufacturing
technology. Our unique market position today is based on core
competencies in spindle technology, motion control and temperature management. Software tools developed for production
processes, intelligent machine functions and manufacturing
system technology round off our portfolio.
T series HSK-A125 spindle head:
an incredible 200 litres of coolant per
minute fl ow through the spindle at a
pressure of 70 bar.
700
patents on innovative technologies
have been awarded to Makino to date.
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The process solution
If the MC50s have been our workhorses,
those A55s and a51s are our racehorses.
Karl Hacker
Hacker Feinmechanik
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Even with a fi rst-class machine you need application expertise
to carry out a job in optimal fashion and maximise utilisation
of the machine’s technological potential. Every Makino
machine offers you the chance to exceed conventional
performance expectations in terms of precision, quality and
reliability – provided you have the necessary application
know-how. This is precisely why Makino employs a
particularly large number of application engineers to support
our customers. The more complex a workpiece is, the more
perspectives and possible solutions there are. Through smart
programming adaptations we can increase your productivity
by up to 40%. That is just one example of how our application
engineers deliver technical and commercial benefits.
15%
of our employees worldwide
are application engineers.
Through preventive maintenance, we help to maximise your
machine’s uptime with a minimum of resources, effort and
expense. And if a Makino machine is not running as expected
– a rare enough event – you can always rely on our Customer
Support. This is how we earn the loyalty of customers, who
invest in our technology over and over again.
20%
of our staff in Japan work in
research & development.
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Makino in five minutes
Precise numbers
01 Historical overview
1937 Tsunezo Makino founds Makino. 1958 First NC milling machine in Japan. 1964 Listed on the
Second Section of the Tokyo Stock Exchange (capitalised at 200 million yen). 1966 First machining centre in
Japan. 1967 Opening of the Atsugi production plant. 1971 Listed on the First Section of the Tokyo Stock
Exchange (capitalised at 1 billion yen). 1972 First flexible manufacturing system in Japan. 1975 Foundation
of Makino U.S.A. Inc. 1976 Foundation of Makino Europe S.A. 1978 Initial holding in Heidenreich & Harbeck
GmbH, Hamburg, Germany. 1979 First Makino NC wire EDM. 1980 First Makino NC sinker EDM. 1987
Opening of the Katsuyama production plant. 1992 Foundation of Makino Asia Pte Ltd. in Singapore. 1997
Foundation of Makino Italia S.r.l. 1998 Foundation of Makino France S.A.S. 2000 Opening of Technology
Centre in Kirchheim unter Teck, Germany. 2007 Foundation of Makino s.r.o. in Slovakia. 2007 Opening of
new European Headquarters and Technology Centre in Hamburg. 2010 Opening of International R&D Centre in
Singapore. 2010 Opening of Technology Centre in Mexico. 2011 Opening of Representative Office in
Moscow, Russia. 2011 Opening of Technology Centre in Cavenago Brianza, Italy. 2011 Foundation of
Makino Iberia S.l.u. in Spain.
02 Revenues/Employees
03 Functions worldwide
2.0
4,000
1.5
3,000
1.0
2,000
0.5
1,000
15%
20%
Service
Application
12%
2003 2004 2005 2006 2007 2008 2009 2010
Revenues in billion US $
Employees worldwide
12
Research
& Development
53%
Other
04 Locations worldwide
Makino Europe GmbH
Makino China Co., Ltd.
Makino Inc.
Makino Thailand Co., Ltd.
Makino Milling Machine
Co., Ltd., Head Office
Makino Canada
Makino Korea Co., Ltd.
Makino Mexico
Makino India Pvt. Ltd.
Makino Asia Pte Ltd.
PT Makino Indonesia
Makino do Brazil Ltda.
Makino Asia Pte Ltd.,
Vietnam office
05 Locations in Europe
Hamburg
Kirchheim unter Teck
Bondoufle
Makino has branches in 19 countries
around the world, seven of them in
Europe, as well as agents and licensed
technical support staff at many more
locations. Wherever you are, Makino
is just around the corner.
Cavenago Brianza
Barcelona
Prague
Bratislava
Moscow
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Makino in five minutes
Industries served
Makino is the only machine tool manufacturer with expertise in milling,
electrical discharge machining (EDM), grinding and automation. What is
more, many Makino machines offer users the flexibility to produce parts
for a wide range of industries and help them in successfully developing
new business.
This adds up to a competitive advantage and an extraordinary return on
investment for our customers.
DM
DM
Die and mould
Makino’s roots lie in die and mould making and our name is synonymous with the precision this sector demands. Makino is one of the few
manufacturers worldwide with know-how in all key technologies:
metal milling, graphite milling, wire EDM and sinker EDM. And Makino
sets the benchmark in automation as well.
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AS
AS
Aerospace
Makino sets the standards for state-of-the-art manufacturing technology in the high-performance and high-speed cutting of aluminium and
titanium. Multifunctional machining centres designed for machining
and grinding turbine parts in their entirety round off our aerospace
portfolio.
HV
HV
High-volume/Automotive
Ever-greater quality at lower cost, i.e. a maximum return on investment: that is what counts in high-volume production and the automotive supplier industry – ideal conditions for Makino machines, systems
and technologies.
IC
IC
Industrial components
Makino machining centres are renowned for their production performance in pump and compressor parts, hydraulic and pneumatic systems, printing presses and much more. Despite the large variety of
parts required for such products, what they all have in common is
precision and cost-efficiency.
HP
HP
High-precision parts
In the electronics, optics, medical, automotive, mechanical engineering and
aerospace industries, the levels of accuracy and complexity are progressively increasing. Thanks to our broad product portfolio in milling, grinding,
wire and sinker EDM, as well as our experience in both toolmaking and parts
machining, Makino offers the best manufacturing solutions in these fields.
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Makino in five minutes
Machine series
We manufacture unique products in six segments.
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HP a series, A series, J series, MCD series, MCC series, MCF series, A/MAG series, T series
Horizontal Machining Centres (HMC)
0.9 sec. tool-change time for an a51nx
30% less energy consumption in a61nx
Makino HMCs are known to be extremely accurate,
fast and reliable. Like all Makino machining centres,
they feature an original Makino spindle, and a large
variety of spindle configurations are available to suit
any application. We offer both general-purpose and
specifically customised models, e.g. for aerospace
applications.
–
–
–
–
AS
Available with 4–6 axes
Travel: 560–20,000 mm
Everything from stand-alone machines
to fully automated systems
Maximum on-table payload: 15 tonnes
HV
IC
HP
DM
HP V series, D series, F series, PS series, iQ300, FB127
Vertical Machining Centres (VMC)
Pitch accuracy <1 µm with iQ300
5AX volumetric accuracy in D300 <5 µm
AS
HV
IC
Makino‘s VMC portfolio is suitable for applications in
all kinds of industries and since these VMCs originate
in die and mould making, they are a reference for
accuracy. Their unmatched thermal stability ensures
sustained precision, even after hours of continuous
or non-continuous operation. The combination of our
unique spindle technology and perfectly adjusted axis
control allows the highest level of surface quality to be
achieved.
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–
–
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Available with 3–5 axes
Travel: 320 – 2,000 mm
Everything from stand-alone machines
to fully automated systems
Specific models available for graphite applications
HP
DM
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HP EDAC1, EDFH1, EDAF series, EDNC series, EDBV86
Sinker EDM
No Z-axis safety allowance
required anymore
Smallest corner radius on a part
machined by an EDAC1: 5 µm
We have developed a great deal of groundbreaking
EDM technology since the end of the 1970s when we
started producing electrical discharge machines.
Makino SEDMs simplify an operator‘s life since most of
the cutting technology is contained inside the machine.
The operator merely chooses the right variables (e.g.
material to be cut, desired surface quality, etc.) and the
machine does the rest.
–
–
–
–
AS
HP
DM
Outstanding technology for steel and carbide machining, using copper, graphite and tungsten carbide electrodes
New EDCam software enables even inexperienced staff to operate the machine
Travel: 220–2,000 mm
Everything from stand-alone machines to fully automated systems
HP DUO series, UPj series, W-FB series, UPV series, UPN-01, UPJ-2/UPH-2, U series
Wire EDM
Ra 0.03 µm in carbide
achieved with UPV-5
Smallest wire diameter
on UPN-01: 15 µm
AS
HP
DM
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Just as with sinker EDM, we have developed a great
deal of groundbreaking wire EDM technology since the
late 1970s.
Makino Wire EDMs are fast, accurate and produce
high-quality surfaces. Thanks to H.E.A.T. (High Energy
Applied Technology), our machines deliver the fastest
results without wire breaks and surface marks, even
under extreme conditions such as ‘both-nozzles away’
machining or on parts with different cutting heights.
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Available with different guide systems
(round and V-shape guides)
Available with different dielectric fluids (water or oil)
for better application suitability
Vertical and horizontal wire configuration
Z-axis travels: 50–620 mm
HP iGrinder G series
Grinding
250 mm³ /mm pro second MMR
of iGRINDER G10
iGRINDER machines have set a new trend in grinding. In
addition to conventional grinding processes, the iGRINDER
series also performs ultra-high-efficiency VIPER grinding.
This entirely new machine concept combines grinding with
outstanding 5-axis milling and drilling so that iGRINDERs
enable intricately shaped workpieces to be machined with
utmost precision.
VIPER (Very Impressive Performance Extreme Removal)
grinding is a highly efficient grinding process that is ideal
for machining turbine blades, vent segments and other
engine components made of nickel alloys and other ultraheat-resistant materials.
AS
IC
HP MMC, VIP, Top-Loader
Automation
15,000 kg maximum weight
on the MMC pallet
AS
HV
IC
By developing and installing some of the first flexible
manufacturing systems (FMS), Makino became an
automation pioneer back in the 1970s.
Since then, we have developed a broad range of
automation modules designed to maximise the gains
in a variety of application scenarios: from large to
small batch sizes; from a small variety of parts to total
flexibility; and from short to long machining times.
However, there is no ‘one-size-fits-all’ solution for
all these applications and the right solution is always
based on the customer‘s specific needs.
Moreover, Makino not only delivers the hardware
required for each application but also supplies the most
suitable system software.
HP
DM
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Delivering added value
How we ensure
customer
satisfaction
Consulting
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Engineering
Applications
Services
The added value Makino delivers is derived from the fact that
our customers actually buy much more than a machine. We see
our machines as part of a process solution and thus invest
significant resources in consultancy, application technology and
support services – with practical benefits for all our customers.
Our highly qualified consulting and sales personnel supply
in-depth advice well in advance of any purchase decision. If
required, we customise our solutions to suit your specific needs.
Our application engineers ensure the machine is optimally
integrated into your working environment and delivers the best
possible performance in the shortest possible time. And though
Makino machines are renowned for their unparalleled
endurance and reliability, our support services are always
available to ensure that they keep running, 24 hours a day, 7
days a week.
e.g.
When you choose a Makino, you are not purchasing a mere
machine, but making a capital investment that can be expected
to deliver an outstanding return. That is the added value you get
from Makino. Some examples of what this means in practice are
described on the following pages.
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For example
EATON Rivarolo CH
EATON Rivarolo CH in Italy was manufacturing cylinder
heads for the water- and air-cooled single-cylinder engines
(125/250 cc) of Piaggio scooters when Makino got involved
in a consulting role to redefine production processes with
the help of cycle-time studies and tool-use analyses.
Makino then went on to develop a fully automated technical
solution involving a production cell with two Makino a51
horizontal machining centres and a Fanuc robot to handle
parts. The new solution brought significant gains: increased
productiv­i ty, a reduction in cost-intensive manual work
(with the associated savings in wage costs) and cycle times
that are 40% lower than with the previous machines of a
similar type.
It is not the only example of the smart solutions Makino has
developed. EATON Rivarolo CH used to carry out camshaft
boring work for VM Motori on a special-purpose machine
only used for this operation – a relatively inflexible and slow
process. Now, the boring operations are undertaken on a
Makino a81 equipped with hydrostatic boring bars. Concentrating the entire machining process on this one machining
centre has significantly reduced cycle time, increased
output, improved process efficiency, reduced the number of
set-ups, speeded up parts‘ handling and, last but not least,
enhanced the quality of the machined pieces (better finish,
less scrap). The 10% increase in productivity generated by
this smart solution is just one example of the added value
Makino makes possible.
Fully automated scooter
cylinder production resulted
in 40% lower cycle times.
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23
For example
Ultratech
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Marek Bujny named his company Ultratech for a good
reason. He is the technology-driven type, the sort of person
who redefines the state of the art – just like Makino. That is
why Marek Bujny was one of the initiators of “Aviation
Valley” in southern Poland. The success of his company
with over 70 employees has been just as outstanding as
their expertise. And Marek really knows how to get the very
best out of a 5-axis D500.
During a visit to the US aerospace industry, he and his staff
were amazed to see what even smaller companies can
achieve using machines from Makino, the world’s market
leader in this industry. These people know that our machines are not only highly precise but also very reliable, so
they put them to work three shifts a day, seven days a week.
Software helps, too. Our exclusive anti-damping software
compensates for any vibrations occurring during machining.
Our Autonomic Spindle Technology* measures any displacement and returns to the operating “sweet spot” within 120
milliseconds! For many manufacturers in the aerospace
industry, Makino is the only choice.
Ultratech were able to see for themselves the competitive
advantage of a global know-how transfer partnership only
Makino can offer. They learnt of new approaches in highperformance machining and automation from people who
are just as quality-driven as they are.
The first thing Marek did on returning home was to order a
D500 for machining titanium and other metals – with an
automation option included. As always, a man of action.
The aircraft construction
industry needs parts that
are robust and precisely
machined, yet light in weight.
* Autonomic Spindle Technology: Sensors built into the spindle measure the
displacement caused by excessive cutting forces and transmit the data to
the control unit. Algorithms in the control software process this data at high
speed and the machining parameters are adjusted almost instantly.
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For example
Frank Haug
People in the industry used to say that die and mould makers
could not produce parts. But nowadays, things are different.
With the help of a Makino machine, die and mould makers
can easily conquer new segments. Just one investment can
open up lots of new business fields.
We know all about the customary standards in the
aerospace and automotive industries, the industrial
suppliers‘ sector and microsystems technology. And we
From wire EDM
26
know who needs what and when. If you purchase a machine
from Makino, you also gain access to our powerful support
services. We support any company – from a small firm to a
large multinational enterprise – that sets its sights on
moving into new business fields, whether that involves food
for thought in casual talks, training seminars or specific jobs
carried out on site at the machine. We help to utilise existing
technology in new ways and get the most out of the smart
functions a Makino machine offers.
to new business fields
For instance, at Frank Haug, a company that started off with
wire EDM work. In the meantime, an investment in Makino
High-Performance Cutting (HPC) and the entrepreneurial
decision to enter new business fields have radically broad­
ened the company’s operational spectrum.
And now, as far as we know, nobody at Frank Haug is at all
worried about the future.
Today, the company produces:
– Prototypes for vehicle development
– Injection moulds, with and without standard moulds
– Forming tools
– Active elements for dies
– Packaging tools
– Components in hard-to-cut materials
– Complex geometries via 5-axis machining
– Deep-hole bores up to 40xD
– Electrodes
– Series-production parts for automotive
and mechanical engineering industries
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Our world is a complex interplay of numerous factors. ­
The biological precision nature requires has been
established over millions of years by nature itself. For what
man develops, we need man-made precision; otherwise,
we could not switch on a light, use a phone or fly by plane.
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Though more and more applications demand micron precision, we do not
always need to “split the µ”. Sometimes, it is the output of a high-volume
production system that counts; at other times, flexibility. In each and every
case, it is good to know that you can rely on solutions from Makino – in
every respect, in its entirety and down to the very last micron.
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Precision.
Makino UPV series
Surface quality: Ra 0.03 µm
30
Precision.
Makino iQ300
Linear scale: 0.005 µm
31
Makino Europe GmbH
Essener Bogen 5
22419 Hamburg, Germany
+49 (40) 2980 9-0
Makino GmbH
Essener Bogen 5
22419 Hamburg, Germany
+49 (40) 2980 9-0
4th Dobrininsky Pereulok 8
Office C13-02
119049 Moscow, Russian Federation
+7 (495) 989 82-2
Kruichling 18
73230 Kirchheim unter Teck, Germany
+49 (7021) 503-0
Makino s.r.o.
Tuhovská 31
83106 Bratislava, Slovakia
+421 (2) 4961 2-100
www.makino.eu
Ve Svahu 482/5
147 00 Prague 4, Czech Republic
+421 (2) 4961 2-100
Makino France S.A.S.
ZA Les Bordes
21, rue Gustave Madiot
91923 Bondoufle, France
+33 (1) 69 1163-90
Makino Italia S.r.l.
Strada private delle Orobie, 5
Localitá Santa Maria in Campo
20873 Cavenago Brianza (MB), Italy
+39 (02) 9594 82-1
Makino Iberia S.l.u.
Calle Caspe 130 Planta 0 Desp. 2
08013 Barcelona, Spain
+34 (93) 555 95 15