Smart Machining from Mikron

Lincolnshire, IL, USA.--arrival March 26, 2004-- Mikron has introduced "Smart Machining", an intelligent new approach to high speed machining that is designed to improve process reliability, optimize machining performance and allow reliable, unmanned operation.

New to the industry, Smart Machining received very positive reviews from machinists this fall when it was debuted in Milan, Italy at EMO.

The Smart Machining program includes various machine modules such as an advanced process system for monitoring and recording spindle vibrations, an intelligent thermal control system to automatically compensate for thermal deviations, and an operator support system for optimizing the machining process according to workpiece requirements.

Sensors, integrated with the spindles of Mikron's High Speed Machining Centers, in addition to software and trackball control, permit operators to obtain exceptionally subtle, extensive degrees of machining control. Communication is also greatly enhanced with a remote notification system, allowing real-time control / access at any location for reliable, unattended machining. This level of information and efficiency is unattainable with conventional machine technology.

"Operators typically feed their programs / input into a machine and by trial and error, hope for the best results. These limitations are eliminated with Smart Machining, because machinists have access to a wide range of real time in-process information. Now it is possible to achieve the absolute maximum level of productivity, quality and ultimately, cost-effectiveness demanded today" said Mr. Mal Sudhakar, Vice President of Mikron. Intelligent Thermal Control, a key function of Smart Machining, automatically compensates for thermal deviation when machining, so the operator only needs to concentrate on the specific requirements of the workpiece. This saves 15 to 30 minutes of valuable time, as so-called pre-heat cycles are eliminated. In addition, high surface and form accuracy can easily and consistently be achieved on the same machine, even with different operators.

Another key Smart Machining component is an Advanced Process System which features a built-in vibration sensor in a diagnostic spindle module. The vibration sensor measures vibration levels at the bearings during the milling process and the diagnostic module records the information, which can also be displayed on the CNC control monitor. Vibration limit values can be preset, issuing either warnings or even shutdown during machining when levels are exceeded, preventing damage to the machine and workpiece. This monitoring process also increases tool and spindle life, reduces downtime and improves cycle time savings. Workpiece quality is also greatly improved because surface chatter marks are eliminated, especially on inner radii.

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