An internationally renowned manufacturer of moulds for the plastics industry has further enhanced its finishing operations by purchasing a Yamazaki Mazak 5-axis vertical machining centre with a new high-speed spindle innovation.
Founded in 1975 in Belluno, northern Italy, OCS Moulds S.r.l. (OCS) has established itself as a leading mould maker for plastic products in the automotive and optics industries. An integral part of the company’s success has been its long-term partnership with Mazak.
“We have been a Mazak customer since 1998, and we pride ourselves on investing in the best systems and equipment available on the market,” says Mr Davide Levis, Procurement Manager at OCS. “Our partnership with Mazak has helped us establish and retain a reputation as an international reference point in mould design across multiple industries, and our pursuit of perfection in processing is a key part of this.”
MACHINING CHOICE
With a view to increasing its production capacity and reducing lead times, OCS recently invested in a Mazak VORTEX i-630V/6 5-axis vertical machining centre. A high-productivity unit equipped with the latest MAZATROL SmoothX CNC, the VORTEX i-630V/6 is designed for high-efficiency machining of large, complex and heavy workpieces. Crucially, it is also available with Mazak’s new high-speed spindle solution, UltraSpindle as an option – a key factor in OCS’s decision to purchase the machine.
“We have been a Mazak customer since 1998, and we pride ourselves on investing in the best systems and equipment available on the market. Our partnership with Mazak has helped us establish and retain a reputation as an international reference point in mould design across multiple industries, and our pursuit of perfection in processing is a key part of this.”
Mr Davide Levis, Procurement Manager at OCS
Mr Levis explains: “Of course, it is vital that any solution we select can carry out the heavy machining of large workpieces while allowing for high swarf removal rates. Beyond this, however, it needs to be able to perform high-quality machining operations with small diameter tools operating at high spindle rotation speeds.
“This is especially the case when manufacturing plastic moulds and automotive lighting optics, which is the reason we opted for the UltraSpindle. To guarantee better surface finishes, it is vital that work can be performed safely at high speeds without vibration, especially as the tools become smaller in diameter.”
The UltraSpindle is driven by an electric motor designed for demanding applications with small tools down to Ø0.3 mm, and is available in 60,000 rpm and 80,000 rpm 350 watt variants. The high-speed spindle is therefore able to carry out highly accurate and precise work to a runout of less than a micron, while ensuring an excellent surface finish.
These qualities made it the ideal solution for OCS, which required cutters for optic moulds that could reach Ø0.3 mm while working at 60,000 rpm. The company also uses the UltraSpindle with larger, 2-4 mm cutters, achieving between 25,000 and 35,000 rpm – performance levels above those possible with standard spindle.
Such levels of performance demonstrate the UltraSpindle’s status as an attractive, high-performance innovation for finishing and semi-finishing in the die and mould sector, that can markedly reduce the lengthy cycle times associated with this type of work. Additionally, its ability to process difficult-to-machine materials such as titanium, which can cause tool breakage without sufficient speed or power, makes it an appealing solution for companies looking to diversify their production capabilities and expand into new markets.
LIGHTS-OUT MACHINING WITH HIGH ACCURACY
The compact design of the UltraSpindle means it is compatible with the Automatic Tool Changer that can found on multiple Mazak machine ranges, including OCS’s VORTEX i-630V/6.
“Working cycles will always vary in duration depending on the size of the mould and the surface quality required,” Mr Levis concludes. “Because the UltraSpindle can be changed automatically without manual input for the operator, work can continue regardless of this variation. It has therefore had a great impact in making our semi-finishing and finishing operations more efficient, while also extending tool life. On top of this, the improved surface quality it can achieve means we can save time in the subsequent manual finishing phase of the moulds, leading to even greater efficiencies.”
Greg Cocks, Senior Manager, European Sales Engineering at Yamazaki Mazak, adds: “The UltraSpindle was designed with the aim of improving multiple processes, including the intricate semi-finishing and finishing operations required by OCS Moulds.
“We are very pleased with the performance of the UltraSpindle. As a high-speed, innovation, it has played a major role in making the OCS’s processes even more efficient. Its ability to provide machining in multiple materials, alongside precise, small-diameter operations at high rotation speeds, means it can be highly beneficial to organisations working in the die and mould sector.”
“Working cycles will always vary in duration depending on the size of the mould and the surface quality required. Because the UltraSpindle can be changed automatically without manual input for the operator, work can continue regardless of this variation. It has therefore had a great impact in making our semi-finishing and finishing operations more efficient, while also extending tool life. On top of this, the improved surface quality it can achieve means we can save time in the subsequent manual finishing phase of the moulds, leading to even greater efficiencies.”
Mr Davide Levis, Procurement Manager at OCS
