There are three main advantages to using a horizontal Machining Center in production.
• The Pallet rotates, allowing for multiple operations
• Typically there are two Pallets, allowing for one Pallet to be loaded while the other is in the cut.
• Gravity allows better chip evacuation from hole and cavity operations, allowing for increased productivity and better tool life.
There is, however an advantage that trumps all others and will enable your Horizontal to perform the Lions share of the mill work in your Shop: Flexibility.
The flexibility in the Horizontal cell requires implementation of a work holding system.
The Tombstone method, pictured above, allows for quick release, dedicated fixtures to be installed in minutes. The key is to run repeat production jobs, not necessarily high volume, but repeat. There is an initial investment in developing dedicated fixtures for each part number, but the payoff is immediate, as setups no longer require highly detailed communication or interpretations as to which jaws or parallels to use and where to pick up zeros. There are no zeros to pick up in this setup, even the first time. All work fixture offsets are controlled in the CNC Program. The setup person literally bolts a fixture plate into place, loads the correct cutting tools into the magazine and presses cycle start.
The flexibility is in the speed of setup. It becomes possible to setup and run only the parts needed for the current order. Additional sides of the tombstone can be used to fit in a rush job without breaking down a setup.
The flexibility in the Horizontal cell requires implementation of a work holding system.
The Tombstone method, pictured above, allows for quick release, dedicated fixtures to be installed in minutes. The key is to run repeat production jobs, not necessarily high volume, but repeat. There is an initial investment in developing dedicated fixtures for each part number, but the payoff is immediate, as setups no longer require highly detailed communication or interpretations as to which jaws or parallels to use and where to pick up zeros. There are no zeros to pick up in this setup, even the first time. All work fixture offsets are controlled in the CNC Program. The setup person literally bolts a fixture plate into place, loads the correct cutting tools into the magazine and presses cycle start.
The flexibility is in the speed of setup. It becomes possible to setup and run only the parts needed for the current order. Additional sides of the tombstone can be used to fit in a rush job without breaking down a setup.
My goal is always the completion of a finished part in one machining cycle. The throuput advantage is huge, as finished parts can move directly to deburr, plating and delivery. Work in process inventory is slashed and those dollars are transferred directly to your bottom line.
We added our first Horizontal Tutorial to our educational database today, and we will build out the whole story over the next few months, beginning with programming the Horizontal in Mastercam and moving into work holding, tooling and presetting, Quality control, file management, communication, best practices in horizontal and selecting the right Machines or cell systems for your shop. If you would like access to our training program, please subscribe to eapprentice.net
We added our first Horizontal Tutorial to our educational database today, and we will build out the whole story over the next few months, beginning with programming the Horizontal in Mastercam and moving into work holding, tooling and presetting, Quality control, file management, communication, best practices in horizontal and selecting the right Machines or cell systems for your shop. If you would like access to our training program, please subscribe to eapprentice.net
Derek