Horizontal Machining Center produces near-dry chips.

Press Release Summary:

HORKOS HFN-R40H machining center, with Minimum Quantity Lubrication (MQL), consumes just 20 to 50 mL per hour and minimizes concerns associated with cutting fluids when drilling, reaming, boring or tapping. It has 40-taper spindle and 20.8 x 22.0 x 20.8 in. work area travel. Rigid z-axis ram carries 5.5, 7.5, or 15 kW, 12,000 or 15,000 rpm direct-drive spindle. Machine has automatic tool changer with 16- or 24-tool magazine. Chip-to-chip time is 3.8 sec.

Original Press Release:

Near-Dry Machining Center Hikes Holemaking Throughput, Reduces Cutting Fluid Related Costs Up To 75%

A new Minimum Quantity Lubrication (MQL) machining center for automotive and other manufacturing operations equals or betters wet machining throughput in holemaking operations, yet cuts coolant-related operating costs by 75% or more. The machine has a 30+ unit installed base in Japan and the Pacific Rim, and is now offered for the first time in the U.S.

The HORKOS HFN-R40H horizontal CNC machining center from Marubeni
America Corp. is ideal for parts that require multiple holemaking operations that usually consume large quantities of coolant. It produces near-dry chips when drilling, reaming,
boring and tapping steel, aluminum, and cast iron. In holemaking operations, the machining center's MQL system consumes just 20 to 50 mL per hour, and eliminates environmental, housekeeping and safety concerns associated with cutting fluids. It simplifies chip disposal by generating uniformly tiny chips that flow away by gravity or through a patented vacuum system.

In Japanese operations and US pilot tests, the unit has proven especially successful drilling high-aspect oil holes in forged steel crankshafts. Compared with wet machining penetration rates of 4 to 6 ipm, the HORKOS HFN-R40H produced the difficult holes at a penetration rate of 22 ipm. The MQL also achieved longer tool life and lower tool cost per hole.

Clean Productivity

The HORKOS HFN-R40H mixes programmed quantities of lubricants with shop air to deliver a fine mist through cutting tools with coolant channels. Quantities of cutting fluid can be individually set for each operation.

Such near-dry machining eliminates the wasteful flood coolants that typically account for 7 to 17% of total machining costs. The efficient, near-dry machining system ends the need for precise fluid mixing and temperature control, and it eliminates fluid odors, work-area bacteria and mess, and costly recycling. It also saves on electrical power commonly required to run coolant pumps. The small amount of fluid released in the work enclosure does not require shop mist collectors. The integral vacuum chip collector and work-area chip conveyor recover virtually dry chips that can be sold at a premium because they require no further processing. Machine beds feature steep slopes
to facilitate gravity chip disposal.

Integrated System

With its patented internal spindle mixing technology, the HORKOS MQL system responds quickly to changes in machining conditions and tools. The new HFN-R40H with 40-taper spindle has 20.8 in. by 22.0 by 20.8 in. (530 by 560 by 530 mm) work area travel. A rigid Z-axis ram carries a 5.5, 7.5, or 15 kW, 12,000 or 15,000 rpm direct-drive spindle. The machine has an automatic tool changer with a 16- or 24-tool magazine. Chip-to-chip time is just 3.8 seconds. The FANUC numerical control package provides
linear, circular, helical, and exponential interpolation routines. An optional automatic pallet changer is available.

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