CMI has 23 multi-tasking machines.Multi-Tasking is when you combine several cutting processes, including turning, milling, drilling, tapping and deep-hole boring, on one machine as opposed to having those same processes handled by multiple machines. Multi-tasking provides single-setup complete part machining, processing from raw material to finished part. With these machines CMI has been able significantly reduce setup time by performing most or all of a part’s machining in one cycle (up to seven operations combined into one). Combining operations also reduces inaccuracies that can occur when moving parts across multiple workstations, as well as eliminates work-in-process inventory that might otherwise linger between standalone machine tools.
Mazak Integrex i-200ST with Gantry Loader
The INTEGREX i-200ST advanced Multi-Tasking machine delivers maximum versatility and throughput for medium to large complex parts. The machine combines the capabilities of a high-powered turning center (with main and sub-spindles to turn both ends of a part) and full-function machining center to produce parts in a single setup.Also, the upper and lower turrets can turn simultaneously reducing cycle times by roughing and finishing at the same time.
CMI’s Integrex cells have a robotic gantry loader to provide fast, high-production loading and unloading. It offers more versatility, flexibility and productivity when managing chuck and shaft work by offering a variety of loading stations and robotic hands.
Star Swiss Lathes with Magazine Bar Feeders and High Pressure Coolant
CMI has 15 Star Automatic Swiss Lathes ranging in size from 16 mm to 32 mm. The Swiss lathe combines turning with the ability to do simple to complex milling depending on the machine model. The major benefit of the Swiss type lathe, besides multi-tasking, is that the raw bar stock is fed through a guide bushing as it is machined. Therefore, the stock is well supported as it is machined resulting in better precision and surface finishes. Another benefit is simultaneous machining on the main spindle and sub-spindle which allows one part to be finished on the sub-spindle while starting a second part on the main spindle reducing your cycle time.
All of CMI’s Star Swiss lathes have magazine bar feeders and high pressure coolant. The bar feeders allow them to run unattended and uninterrupted for increased production time. CMI installed high pressure coolant (up to 3000 psi) on all its Swiss lathes in 2016 resulting in a 25% increase in productivity (so far) due to longer tool life and better chip breakage / clearance.
Mazak 250-II MSY
The MSY machine features milling and Y-axis capability as well as a second turning spindle to process parts complete in a single operation. There are currently 6 MSY’s on CMI’s production floor. CMI utilizes these machines in a similar way to the Star Swiss lathes except for parts that are too large to fit on the Swiss.
Several of CMI’s 3-axis vertical machining centers have been retrofitted with 5-axis trunnions. 5-axis capability allows CMI to machine 5 sides of a part in a single operation eliminating multiple setups and workcenters. The trunnions do reduce the work envelope of the machining center, so larger 5-axis work is done in CMI’s 5-axis Variaxis cell