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250-II MSY multitasking machine, two Integrex i-100S and two i-200S multitasking machines, Variaxis i-600 and i-700 VMCs and a VCU 500A 5X. Te shop’s QTN 250-II MSY’s 35-hp (26-kW), 4000-rpm


integrated spindle motor headstock provides heavy-duty metal removal. Te spindle also serves as a CNC-controlled C-axis that accurately positions parts for square facing and slotting cuts and precisely drilled holes. Te second spindle has a 15-hp (11-kW) motor output and 6000 rpm for high-speed, high-accuracy machining. Te machine’s 12-position drum turret packs a 7.5-hp (5.6-kW), 4500-rpm rotary tool spindle that performs milling, drilling and tapping operations. Both the Integrex i-100S and i-200S machines deliver full


five-axis machining and feature twin turning spindles with equal spindle speeds and horsepower, as well as C-axis turning control. Vertically mounted milling spindles on the machines rotate in the B axis at a range of -30 to +240° for contouring of complex part features. Black Diamond Xtreme’s versatile, full simultaneous


five-axis Variaxis machines perform multiple and complex curved surface machining and allow the shop to easily access all part surfaces. Te machines have spacious Y-axis and X- axis travels and roller gear cam-driven rotary/tilt tables that deliver 360° of rotation in the C axis and +30° through -120° of tilt in the A axis. Both machines come equipped with 40-taper, 30-hp (22.4-kW), 12,000-rpm spindles as well as standard 30-tool automatic toolchangers. As a small-footprint, modular design vertical machin-


A ‘poor-man’s tombstone’ is used in the Variaxis i-600. It employs two vises so the top side of one component and the bottom side of another component can be machined in a single setup.


its Mazak machines. Not only has quality improved signifi- cantly, the shop machines parts faster and with fewer required pieces of equipment. “We get a lot more done on our Mazaks and in a shorter


amount of time. Tey’ve allowed us to increase our pro- duction efficiency by at least 25% compared with standard machines. And without them, we would have had to double our workforce to achieve our current levels of output,” said Jeff Schoenfelder. “Te benefits of single-fixturing part processing are stag-


gering,” he continued. “We’ve improved every component with that capability. And the less we have to handle parts, the more we boost quality and the tighter the tolerances we can consistently hold. Our parts can’t fail. Part failure in the field means one of our customers could be stranded on the side of a mountain in the middle of nowhere.” Black Diamond Xtreme has a Quick Turn Nexus (QTN)


ing center, the VCU 500A 5X gives Black Diamond Xtreme cost-effective productivity. Te machine delivers high-end capabilities through its five-axis rotary/tilt trunion table, 12,000-rpm, 15-hp, 40-taper spindle, automatic tool changer and 30-tool magazine. Black Diamond Xtreme machines most of its parts from


6061 or 7075 aluminums and various steels, one of which is 4140 tool steel. Part sizes range from those that fit within a 2 × 2" (51 × 51 mm) cube to bigger ones within a 24 × 24" (610 × 610 mm) cube, all typically requiring tolerances of ±0.0005" (0.0127 mm) for feature locations in relation to one another and for bored holes. Te shop machines almost all of its parts from billets of


raw material and some castings, and the Mazak machines allow them to run either of these. Some parts require full five- axis machining, however. Schoenfelder said the shop relies on the capability more for positioning to access all necessary part sides without having to refixture. On its twin-turning-spindle configuration multitasking machines, the shop uses the first spindle for front working, then the machine automatically transfers the part over to the second spindle for backworking. “Over 95% of the parts we run on our Mazak multitasking


machines come off complete,” said Schoenfelder. “We load a part and don’t touch them until they are done. To run our parts


Motorized Vehicle Manufacturing 69


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