Highest accuracy and best surfaces for demanding workpieces

26.09.2019

Okuma offers advanced machine tools for the high demands of the die and mould sector. As a centre piece of its booth at this year’s EMO Hannover (16-21 September 2019), the Japanese manufacturer exhibits the latest double column machining centre, MCR-S. Together with many more machines, software solutions and Smart Factory applications, Okuma presents a rich portfolio of solutions tailored to the demanding needs of the die and mould sector

Impressive dimensions, outstanding accuracy

The new double column machining centre, MCR-S, allows for extreme precision and highest surface quality when producing large workpieces. Its rigid double column structure made of cast iron offers high stability and vibration-dampening properties. For smooth and streak-free surfaces, the machine possesses Okuma’s Hyper-Surface. The Premium Solution automatically detects and corrects disturbances in the CAM-output machining data. This results in ready-to-use surfaces that make further post-processing obsolete. A swivel image sensor measures the tool length and prevents cutting edge position errors, further improving manufacturing quality and increasing process reliability. In comparison to its predecessor, MCR-BIII, the MCR-S achieves a 10 % higher surface quality and a dimensional accuracy of less than 20 µm. The large table size of up to 2,500 mm x 6,500 mm predestines the machine for manufacturing press dies that are used in the automotive industry for producing car bodies. Currently, the vast majority of car manufacturers all over the world uses Okuma double column machining centres for this demanding task.

Cycle times shortened by 25 %

When developing the MCR-S, Okuma gave special attention to productivity and profitability. The machine tool offers average continuous feed rates of 20 m/min for the X- and Y-axis, and 10 m/min for the Z-axis. In addition, the powerful spindle with a maximum output of 26 kW achieves a chip removal rate of up to 710 cm³/min. For optimal feed rates and acceleration, the MCR-S comes equipped with SERVONAVI, an Intelligent Technology that automatically estimates table loads to adjust for the best acceleration speed. As a result, the MCR-S offers cycle times 25 % shorter than those of its predecessor. The overall high dimensional accuracy and surface quality also contribute to the productivity by eliminating the need for time-consuming and costly post-processing.

Thermally stable by default

For best dimensional accuracy possible, all Okuma machine tools are equipped with Thermo-Friendly Concept. It combines control technology and hardware design to minimise the amount of heat generated during the cutting process, and to deal with the heat that cannot be eliminated. This is especially important for manufacturing dies and moulds as the machining process can take up to several days, making it vulnerable to thermal deformations. The Thermo-Friendly Concept also improves productivity significantly as it eliminates the need for warm-up operations, manual adjustments and post-processing. This standard makes most Okuma CNC machine tools suitable solutions for producing dies and moulds. With the brand-new vertical machining centre GENOS M660-V-E and the latest 5-axis machining centre GENOS M460V-5AX, Okuma showcases two exemplary highlights for this demanding task. Both machines are extremely rigid and offer high manufacturing quality at an affordable price point. The GENOS series machines provide high productivity in a small footprint, which qualifies them for the die and mould industry.
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