A prominent mould manufacturer supplying parts to the automotive sector has significantly improved productivity with Yamazaki Mazak’s new high-speed spindle solution.
“The range of materials and parts we manufacture is highly varied, so we need machine tools that are extremely versatile,” says Gianluca Cannoniero, Mechanical Engineer at Micromeccanica S.r.l (Micromeccanica). “We are required to perform highly diverse operations on the same machine with different types of cutting tool. Moreover, as we work in several very competitive markets, including the automotive sector, high quality processing is essential.”
machining choice
Based in southwest Italy, Micromeccanica was founded in 1980 as a supplier of spare parts for industrial equipment and machinery. The company diversified in the 1990s by specialising in the production of gasket moulds in thermosetting material for the automotive industry. It subsequently extended its offering further by manufacturing injection moulds for plastics and building profile cutting machines.
Micromeccanica has steadily grown and now employs over 100 staff, including 49 technical specialists, at its Salerno facility. This expansion has been fueled by investing in the latest machining technology, with the business having worked with machine tool supplier Yamazaki Mazak for over 20 years.
The company most recently purchased a Mazak VARIAXIS i-700 simultaneous 5-axis machining centre to further increase its mould machining capacity. Designed to deliver reduced in-process time for highly accurate multi-surface machining, the VARIAXIS i-700 is also compatible with Mazak’s new high-speed spindle innovation for the die and mould market, UltraSpindle; an option that was of great interest to Micromeccanica when they purchased the machine.
optimal cutting speeds on small diameter tools
The UltraSpindle is ideally suited to demanding applications that use small tools down to Ø0.3 mm, such as high-speed finishing and semi-finishing for the die and mould sector, which traditionally require long cycle times to complete. It can also be used for the small hole drilling of difficult-to-machine materials such as titanium, which can cause tool breakage without sufficient speed or power.
Additionally, its high-speed, electric motor-driven spindle, which is available in 60,000 rpm and 80,000 rpm 350 watt variants, improves surface finishing while allowing precision and accuracy within a one-micron runout. Consequently, the UltraSpindle can hugely reduce finishing operation cycle times, alongside the need for polishing and hand finishing, providing a more cost-effective solution than other ultra-high-speed spindle machines.
Micromeccanica uses the UltraSpindle to perform processes requiring a high speed and is used with different types of solid corner radius and ball end mill carbide cutters. Cutters of up to Ø1 mm diameter are used in finishing operations, with those measuring between Ø3-4 mm diameter performing semi-finishing and contouring operations.
“When operating the UltraSpindle’s smallest cutters, we are working at rotation speeds of 50,000 rpm, while removing only a few hundredths of a millimeter,” Mr Cannoniero explains. “Being able to use such small diameter cutters means we can get closer to the edges and inside the deep slots of the moulds.
“With the same removal on each cutting edge, we can double the speed per minute when compared to conventional milling. Working with optimal cutting speeds on small diameter tools also allows us to achieve a much better surface finish than with manual polishing, while also enjoying other benefits including the increased tool life and operational capability of solid carbide endmills.”
“Working with optimal cutting speeds on small diameter tools also allows us to achieve a much better surface finish than with manual polishing, while also enjoying other benefits including the increased tool life and operational capability of solid carbide endmills.”
Gianluca Cannoniero, Mechanical Engineer, Micromeccanica
improvement to productivity
The UltraSpindle’s compact design means it can be stored in the Automatic Tool Changer of compatible Mazak machines, including the VARIAXIS i-Series range. As a result, Micromeccanica’s operators can take pressure off the machine’s main spindle by changing over to the high-speed, high-torque option when needed without a manual connection, minimising non-cutting time and enhancing productivity.
Mr Cannoniero concludes: “Semi-finishing and finishing require long cycle times, so we often find ourselves in the position of having to work without the presence of the operator. As such, being able to change the spindle automatically was very helpful. The UltraSpindle’s pressurization system has also proved similarly useful to ongoing operations, as it stopped dirt from penetrating the body of the spindle, meaning we can continue to work even in applications when cooling is required.
“Finally, the interface between the VARIAXIS’s MAZATROL CNC operating system and the UltraSpindle’s controller allows us to completely manage the whole process and check for any errors and malfunctions. We really appreciate this feature, as it means we can further guard against unplanned downtime and further increase overall machining productivity.”
Greg Cocks, Senior Manager, European Sales Engineering at Yamazaki Mazak, adds: “We developed the UltraSpindle with companies like Micromeccanica in mind, so we are thrilled the solution is playing a vital role in its semi-finishing, contouring and finishing operations.
“Precision is crucial when manufacturing moulds, and we are confident that with the machining precision, high rotation speeds and reduced cycle times the UltraSpindle allows, Micromeccanica can continue to thrive in multiple competitive markets.”
