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then that can be a negative factor.” If Kern’s Micro is small, its palletized toolchanger is just the opposite. The company has made the machine’s tool cabinet large enough to hold up to 209 tools, and convenient to use because of its glass front. Quick-change tool pallets can be assembled for individual jobs and stored separately. “For years now, the industry has recognized the advan- tages of modular fixturing and management in automated situations,” said Zurek, adding that tool management can be a stumbling block in a highly productive environment. “Kern has applied this same technology to managing toolholders by palletizing them and managing them directly on the Heiden- hain control.”


The advantage is an easily managed and trouble-free sys- tem that contributes to the efficiency of the entire production cycle by significantly reducing setup times, Zurek said. If toolchanging is fast, so is setting up the Micro. It’s designed to be plug-and-play, with four connections required during setup for the machine, whose units are almost fully inte- grated: An optional water chiller is a stand-alone component. “When the machine arrives, making it productive is a top priority for the company and its customers,” said Zu- rek. “Kern’s development team realized this important fact and made it possible for a remarkably quick, trouble-free installation by using the same philosophy behind plug- and-play technology.”


With its HSK 40 spindle with internal coolant lubrication, not only can shops achieve micron-level precision on micro- size parts, they can also cut more than 70 lb (31.5 kg) of steel in an hour. An HSK 25 spindle is available as an option. Further, due to an integrated fourth and fifth axis table in a traveling column machine design, the Micro can handle workpieces up to almost 356 mm in diameter.


Horizontal Wire For ultraprecision machining and the surface finish capa- bility of small/fine wire operations, Makino offers the UPN-01 wire EDM.


The machine features the company‘s unique horizontal


wire drive system that enhances wire threading performance, and is capable of reliably threading start holes as small as 0.03 mm, and can operate with wire diameter sizes ranging from 0.1 mm down to 0.015 mm. Makino has specifically configured its horizontal wire


system around the needs and requirements of micro-medical component manufacturing. The horizontal design provides significant versatility and advantages to extending produc- tive untended operation, which is ideal for producing medical


marker bands, as well as intricate grippers, augurs and clamps used in microsurgery. Maximum workpiece size is 150 × 150 × 40 mm, and maximum weight is 8 kg. The UPN-01 can achieve accuracy at the submicron level in part because of its pneumatic slideway mechanism. The mechanism is made of lapped granite that uses a 10-µm cushion of air to make a frictionless bearing. Zero friction means the machine has a great degree of movement control.


“I don’t think we can get down to nano-technology with waterjet.”


“Its ten-nanometer minimum increment of movement is unmatched in the industry,” said John Bradford, microma- chining research and development team leader. The machine can achieve surface finishes as low as .


0.1 µm Rz


Because Makino incorporates its unique horizontal wire system in the UPN-01, slugs are not an issue. Instead of po- tentially falling into the lower head, they fall harmlessly to the bottom of the worktank without interfering with the machine’s operation. This eliminates the need for manual intervention, and extends the untended productivity of the machine. The UPN-01’s CNC system is Makino’s Hyper-i, which


features a 24" (610-mm), user-friendly touch screen that looks and works like many smartphones or tablets, with pinch, pull and drag operations. The software includes digital manuals and an on-board training tutorial system for the operator, as well as many other streamlined and helpful functions that reduce the number of keystrokes and workload on the operator. Also, Hyper-i auto- matically records and translates production process data into pie and bar charts that make assessing machine utilization time quick and intuitive, essentially turning the Hyper-i into a piece of management software. The UPN-01’s X, Y and Z-axes are 160, 160, and 50 mm,


respectively; Its U and V axes are both ±7 mm. Makino’s sinker EDM, EDFH-1, often sits side by side with the UPN-01 in medical manufacturing shops. With its machining guide arm, high-speed rotating spindle (up to 2000 rpm) and high-pressure pump, the company designed it to provide the capability and precision machining for both fine- hole EDM drilling and standard sinker EDM applications. “It can machine start holes as small as 10 µm,” said


Bradford.


29 — Medical Manufacturing 2015


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