How to Increase Throughput by 300% or More with FlexCNC and Allied Tooling

Throughput is the number one metric for assessing the quality of a production line, and increasing throughput on a CNC means increased profitability. Flex Machine Tools is always looking for ways to help manufacturers and fabricators speed up production and increase throughput. The FlexCNC Vertical Machining Center, paired with Allied Machine & Engineering tooling, increases productivity and lowers the cost per part by decreasing tool changes, improving cycle times, and eliminating spindle downtime.

The FlexCNC is more efficient and has a higher throughput rate than other machines because it allows for 100% spindle uptime, which means the spindle never stops. The pendulum mode allows an operator to add and remove parts while the machine continues to run at the other end of the bed. An operator can load the bed with as many parts as they want, and never have to stop the machine. This results in a higher throughput rate than machines that must stop every time the door opens.

Part before being drilled and chamfered

An easy way to increase throughput even further is by speeding up the cycle time. This can be accomplished by eliminating tool changes and second passes with a combination tool. We tested the Allied Machine & Engineering combo drill/chamfer tool on the FlexCNC because we wanted to see how much we could increase the throughput rate by speeding up the cycle time.

Allied Drill/Chamfer Combo Drill Test 

Allied drill/chamfer combo tool
Allied drill/chamfer combo cutting tip

Allied Drill Tool Body – 60117C45-075F

We ran the part at 350sfm (1992 rpm) feeding it at .012”ipr (24ipm)

Drill insert diameter – 43/64” (.6719) 

Chamfer diameter – 1.00”

Results 

The cycle time for this part was 1 minute 47 seconds, which comes out to 3.5 seconds per hole. Using a drill and a separate chamfering tool would have added a significant amount of time to the machining process. The added tool change time and travel time would have made the cycle time approximately 4 minutes 30 seconds. However, using a combo tool resulted in a time savings of almost 300%.

Part after being drilled and chamfered with the Allied combo tool.

Save time and money by increasing your throughput with FlexCNC and Allied Machine & Engineering tooling. Eliminate spindle downtime with Pendulum Mode, improve cycle times and eliminate tool changes with Allied combination tools. If you are interested in increasing your throughput by 300% or more give us a call at 1-800-837-2503 or contact us today

https://youtu.be/l1l5BURqjyw

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Standard Features

  • Hand Pendant
  • 22″ Touch Screen Monitor
  • Omron FlexCNC Controller
  • Mobile Control Panel
  • Through Spindle Coolant 
  • Auto Tool Changer 
  • Flood Coolant
HP
Max RPM
FT/LBS
Series

18

4000

92

C-20-02 / C-10-02

18

6000

61

C-20-02 / C-10-02

33

12000

61

CM-20-02

Auto Stand-Off – This is currently defined to be surface stand-off and not to be confused with vector stand-off in 5-axis mode. The current auto stand-off is based on a changing surface and will adjust vertically based on the angle of the “A” Axis, so there is five (5) axis taken into account during the calculations, but this is not the same as the tool vector stand-off. There is the ability to do the vector stand-off change while the machine is running manually with buttons on the screen.

Z-Reader Probe – The Z-Reader is a device for mapping the location of the surface. It can be controlled manually & programmatically. The option is NOT active while cutting & is retracted out of harm’s way. It can be triggered to verify the surface at every pierce before the cutting process starts, or it could be used to drive surface mapping of the whole part before cutting starts. It begins with initialization or zeroing of the device to the surface at the beginning of a program and then accumulates or tracks the difference from that zeroing effort.

Automatic Edge Finder – The edge finder is or can be utilized manually (Jogging Method & Screen Buttons), programmatically (M & G codes), or fully automatic routine (dedicated program). This option sets offsets & program rotation to match the orientation & location on the cutting table.

AC Unit Installed on Electrical Cabinet – The unit is mounted on the cabinet’s High Power (480v) side. It is close to the location where the drives are mounted. This option keeps the cabinet temperature stable and allows heat dissipation faster. The servo drives for all axes are the most significant contributors to heat inside the electrical cabinet.

5-Axis Renishaw CalibrationThe calibration unit is a Renishaw model APCA45 with a modified spherical stylus. The device has a retractable cover and air purge to clear debris & dust during the activation process. It mounts to a swing arm controlled by a pneumatic rotary, so it is out of the way during regular operation and swings into the calibration position for calibration only. 

HP
Max RPM
FT/LBS
Series

18

4000

92

G-20-06 / G-10-06

18

6000

61

G-20-06 / -10-06

40

4000

217

GM-20-06 / G-20-06 / G-10-06

40

6000

145

G-20-06 / G-20-06 / G-10-06