In a multi-task machine, you can combine several cutting processes and set-ups in one single machine. Multi-task machines are very effective and can help you reduce your cycle times and lead times. In a horizontal multi-task machine, the component is rotating around a horizontal axis.

Horizontal multi-task machine configuration

The horizontal mill/turn machine is based on a lathe design. The component is rotating around a horizontal axis with the B-axis spindle above holding stationary and rotating tools.

Generally, the component has a large amount of machining to be carried out around the center of symmetry. The components can range from just a few millimeters long up to 3 meters long (118 inch) and 600 mm (23.62 inch) in diameter.

Combining all operations on one machine is the primary benefit of this machine type, reducing component set-ups. Additionally, it is often found being used for its 5-axis machining capabilities.

To succeed at combining multiple and complex applications, there are some key options that should be considered.

Spindle

The mix of static and rotating tools requires the broadest spindle capability with a combination of a traditional machining center and a lathe. High bending stiffness, torque transmission and accurate tool center position is why Coromant Capto^® is the most common interface for this machine concept.

The large component and machine size range has lead to Coromant Capto^® spindles being employed throughout the entire span, from C3 (32 mm (1.260 inch) flange diameter) up to C10 (100 mm (3.937 inch) flange diameter).

In addition to providing the best stability, Coromant Capto^® allows for the shortest gauge line and lowest tooling cost by removing the need for machine interface adapters.

Read more about how to choose a spindle

Magazine

A multi-task machine can replace a lathe and a machining center and produce various components. It is important to allow ample space for tools in the magazine for all operations and components, to support a quick changeover from one job to another without the need to change tools.

Multi-tool position

Multi-tool position – using turning holders with multiple cutting edges has the double advantage of saving indexing time as well as magazine space. Spindle orientation, measuring and offsets of multiple positions are needed in the control.

Tool holder offset function

Tool holder offset function (bottom turret) allows for a pre-measured tool to be put in the machine, which can save measuring time and reduce scrap components. When pre-measuring the tools outside the machine, it is important to have on optimized zero position for each turret position, to be able to cut correctly from the first component produced.

Sub-spindle/lower turret

To be able to complete a part, machining from both sides using the sub-spindle is often required. This is most suitable for shorter components that do not require a steady rest. The lower turret can increase productivity significantly for machines with sub-spindles.

The drawbacks of the lower turret are reduced component diameter and increased programming and set-up time, making it suitable mainly for smaller multi-task machines producing higher volume components.

Tailstock/steady rest

Long, slender components with internal machining require a tailstock and steady rest instead of a sub-spindle and lower turret. The long boring bar adapter is a natural choice, depending on the length of the bore to be machined.

Long boring bar adapter

The normal magazine and automatic change has a limitation on the length of tools possible to change. On larger machines, there can be a storage and tool change function for long boring bars. With automatic tool change, also for cutting heads at the end of the boring bar, flexibility and automation can be achieved.

High-pressure pump

Most machines offer a high-pressure coolant capability around 70 bar (1015 psi).Read more about coolant aspects

Multifunctional tools

The most important benefit for multi-task machines is the possibility to combine all operations on a component in one machine. However, drawbacks include increased tool indexing time compared to a turning center, accessibility due to the B-axis head and compromised magazine space.

Multifunctional tools are developed for multi-task machines that address these issues to ensure that machine capabilities are maximized.