FEATURE u CNC Machines Steps toward five-axis automation
Automating five-axis work has always been complex, but a new generation of machines, combined with automation solutions and new software developments, are finally breaching the barrier, says Alan Mucklow, Managing Director at Yamazaki Mazak UK and Ireland.
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ive-axis machining is more complex than a simple three-axis turning centre solution in terms of its programming, tool paths and compatibility with automation solutions – an issue becoming increasingly important for machine users. Often involving a high mix of components
with low volumes, five-axis work is not easily suited to standard machine-tending robot solutions as multiple fixtures, workpiece types and programmes are required. Indeed, our own research suggests many machine users regard their operations as unsuitable for automation because they work predominantly with small batch sizes. As such, five-axis work tends to be
infrequently automated, but a combination of macro-economic factors, such as labour costs, ambitions for greater productivity and innovative technology are finally coming through. A key driver for the development of five-axis automation solutions has been its potential to extend the productive day for a machine into more unsociable hours with the introduction of unmanned and lights-out running. Increasing machining time from up from eight to potentially 24 hours offers an immediate increase in machine shop capacity, productivity and profitability. For example, an eight-hour day with 240
productive days per year (Monday to Friday with four weeks of holiday) offers 1,920 machining hours that can be sold to a customer. If the machine in question can operate for 16 hours over the same number of productive days, 3,840 working hours are available doubling capacity. Furthermore, an automation system capable of extending machining operations into more unsociable hours, with 24-hour working plus weekends and holidays, can increase productive hours to 8,760 per annum – an over four-fold increase in capacity. A second big driver is labour costs. CNC operators are highly skilled, so it makes sense to minimise the number of repetitive tasks they undertake and maximise the more valuable tasks, such as programming. In fact, research suggests that without automation, up to 70 per cent of an operator’s time can be taken up by repetitive and unskilled tasks such as the loading and unloading of fixtures, workpieces and finished components.
30 May 2022 Irish Manufacturing
Mazak’s CV5-500 can be integrated with a turnkey five-axis automation solution, specifically a MA robot for workpiece loading and unloading.
The obvious answer is to automate the five-
axis work, but there can be barriers. For example, feedback from machine users has highlighted an understandable concern that automation requires complex setup and programming – specialisms many machine users do not have in-house. In fact, Yamazaki Mazak’s own customer survey earlier this year suggests that as many as one in 10 machine users do not automate due to concerns over their lack of expertise. However, new software innovations such as Mazak’s Robot Setup Assist and Robot Cell Controller are making it easier to connect and programme the robot. These software options, which are part of the CNC, aid installation and make the maintenance of automation solutions much simpler. In-house expertise is no longer a pre-requisite for automation. One way around this specific problem is to specify a turnkey five-axis automation solution, such as Mazak’s CV5-500, equipped with an MA robot solution for workpiece loading and unloading. In operation, the MA robot’s design offers immediate productivity improvements, delivering five-minute changeover between workpieces. The software enables rapid changing of stacking plates and robot grippers make it ideal for five-axis small batch runs. By far the biggest barrier to automation is the perception that it is expensive. However, there
are two key considerations. Firstly, the investment cost of automation, particularly robots, is falling dramatically, subsequently reducing potential payback periods. This view also fails to take into account the impact automation can have on five-axis productivity. Alongside the potential for machine tending to increase unmanned and lights-out running, automation can also help reduce unproductive waiting times for machines while operators undertake other tasks. With a robot dedicated 100 per cent to
tending, the machine asset utilisation can be maximised, ensuring continuous production with no reloading stoppages. The alternative – having operators solely aligned to each five-axis machine – would maintain productivity but may negatively effect on competitiveness and profitability. In the past, automated five-axis work has been the exception, not the rule. However, if machine users are to continue to compete and derive the quickest payback for their investment in five-axis machines and maximise profitability, then a new generation of machines and automation solutions are demonstrating a way forward. Irish machine users only need to look at high-productivity Asian nations to see what the future holds if they are willing to grasp the opportunities.
Yamazaki Mazak UK Ltd
www.mazakeu.co.uk.
www.irish-manufacturing.com
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