An Italian subcontractor has been able to expand into new markets, including the fashion industry, by opting for Yamazaki Mazak’s new high-speed spindle innovation.
The Officina Meccanica Stucchi Flavio (Stucchi) was established in 1992 as a subcontractor specialising in turning applications, making small batches of complex parts for clients across multiple industries and sectors. The Lombardy-based company has continually grown over the past three decades, employing more and more staff at its site in Brignano Gera d’Adda.
diversifying operations through machine tool investment
Stucchi has traditionally carried out its machining work on Mazak INTEGREX Multi-Tasking machining centers, having been a loyal customer of the machine tool supplier since 1994. As the needs of its client base have evolved, so too has the Stucchi-Mazak partnership, with the company recently investing in two solutions from Mazak’s VCN range of vertical machining centers, a VCN 510C-2 and a VCN-430A.
With the addition of these new machines, Stucchi has been able to diversify its operations across additional markets and produce small moulds for special components in the automotive and motorcycle racing sector, as well as the fashion industry.
“We are always looking to innovate and grow, which is why we invested in vertical machining technology to sit alongside our existing Mazak machine tools,” explains Flavio Stucchi, Stucchi’s owner. “Yet, while increasing our production capacity and capabilities has brought welcome additional work, we have also had to change the way we approach machining.
“Specifically, we moved from classic processing with traditional tools to a new way of working with additional objectives and priorities. For example, moulds for the fashion industry require high-quality finishes, and supplying components to the automotive racing sector involves the processing of more complex parts. This, in turn, requires the use of spindles with a small footprint and small diameter solid carbide tools.”
LIGHTS-OUT MACHINING FOR DEMANDING APPLICATIONS
This demand for small diameter machining resulted in Stucchi implementing Mazak’s new UltraSpindle solution on its Mazak VCN 510C-2 machining center, which is equipped with a fourth rotary table. Ideally suited to demanding applications such as high-speed finishing and semi-finishing, the UltraSpindle reduces the traditionally long cycle times associated with the die and mould sector. Thanks to its compact design, the spindle – which is available in 60,000 rpm and 80,000 rpm 350 watt variants – can be automatically exchanged in the Mazak machine’s tool magazine.
Mr Stucchi explains: “The UltraSpindle can be automated by Mazak’s MAZATROL CNC operating system, so installing it on one of our VCN machine tools has allowed us to implement lights-out machining where an operator does not need to be present. This has proved invaluable when we are processing more complex parts, which may require longer working times.”
The UltraSpindle has also allowed Stucchi to reduce cycle times and provide high-quality surface finishes, especially when machining fashion accessories from non-ferrous metals. Working with solid carbide milling cutters measuring Ø1-3 mm in diameter, it can achieve processing speeds of approximately 30-40,000 rpm.
The company’s operators can further increase the spindle speed to 60,000 rpm when working with tools of a Ø0.5 mm diameter, which is used to engrave logos on components for the fashion industry. Here, the majority of workpieces are made of aluminium alloy, meaning coolant is required as part of the machining process. Crucially, the UltraSpindle’s pressurisation system prevents liquids and dirt from entering the spindle, enabling the company’s operators to work in complete safety.
“We are always looking to innovate and grow, which is why we invested in vertical machining technology to sit alongside our existing Mazak machine tools. Yet, while increasing our production capacity and capabilities has brought welcome additional work, we have also had to change the way we approach machining.”
Flavio Stucchi, Stucchi’s owner
“The UltraSpindle can be automated by Mazak’s MAZATROL CNC operating system, so installing it on one of our VCN machine tools has allowed us to implement lights-out machining where an operator does not need to be present. This has proved invaluable when we are processing more complex parts, which may require longer working times.”
“Traditional machining would be impossible under these conditions. However, using the UltraSpindle, we have been able to carry out this challenging work. Additionally, its high number of revolutions prevents the spindle from rotating, reducing possible wear. Consequently, the tool breakage is markedly reduced, and the total lifetime of our specific tools has improved significantly too, further enhancing productivity.”
PRODUCTIVITY IMPROVEMENTS
Stucchi also uses the high-speed, UltraSpindle to work with difficult-to-machine materials that, without sufficient speed and power, can cause tool breakages. Specifically, the company has been able to drill Ø0.5 mm holes to a depth of 23 mm on titanium parts at 30,000 rpm.
“Traditional machining would be impossible under these conditions,” Mr Stucchi concludes. “However, using the UltraSpindle, we have been able to carry out this challenging work. Additionally, its high number of revolutions prevents the spindle from rotating, reducing possible wear. Consequently, the tool breakage is markedly reduced, and the total lifetime of our specific tools has improved significantly too, further enhancing productivity.”
Greg Cocks, Senior Manager, European Sales Engineering at Yamazaki Mazak, adds: “Stucchi is an excellent example of an organisation taking the next step and investing in new technology in order to open up new sectors and opportunities. We have every confidence that using this technology, Stucchi will continue to go from strength to strength.”
