Tornos Introduces Radically Different Turning Concept with MultiSwiss at EMO 2011

3 October 2011

With the launch of the MultiSwiss 6x14 at EMO 2011, Tornos now presents its first numerical sliding headstock multi-spindle machine. Based on a "fully integrated" concept and featuring innovative front access, this new machine is designed with three types of customer in mind, users of numerical multi-spindle turning machines and cam-operated machines, and users of single-spindle turning machines.

At the beginning of 2008, the multi-spindle product department at Tornos put in place an ambitious project with clear objectives: To create a multi-spindle turning machine with 14mm capacity at an attractive price offering unrivalled efficiency and a rapid return on investment. The machine also had to be flexible, accurate and easy to use. The new technologies chosen could not compromise the renowned benchmark reliability of Tornos' cam-operated multi-spindle turning machines. Other market requirements included a reduced footprint, increased product efficiency and of course, the machine had to be very easy to use with a user-friendly design. Three and a half years later, Tornos has launched its MultiSwiss 6x14 at EMO 2011 in Hannover.

Specifications met!
Discussing the new machine, Rocco Martoccia, the Tornos Product Manager says: "Four machines have been trialled by our customers over several months now and the results demonstrate that the MultiSwiss 6x14 keeps all its promises and matches up well to the specifications that we were given. We used the basic model as a springboard from which to create a new machine featuring innovative technologies while holding on to our objective and focussing on the prize to be won at the end, which was the product. First and foremost, we designed new components that were individually tested for over a year. Next, we assembled a prototype to validate the solution as a whole. For example, our revolutionary new barrel that is a world first on a multi-spindle turning machine." Featuring new, faster and quieter torque motor technology, this barrel was tested over 40 million cycles before being awarded its validation certificate.

Fundamental changes
In a global approach to finding a 'fully integrated' solution, Tornos had to make choices, some of which involved a change of approach on the part of our customers. The first change was loading the machine with 1.5m bars. On this subject Mr. Martoccia clarifies: "There were several advantages in this choice: it reduces the machine footprint by 35%, it makes it easier to handle the bars, and we can reduce the level of noise and vibration produced by the machine. However, we had to overcome certain obstacles such as the loss of efficiency owing to the number of feeding operations required (twice as many as for bars that are twice as short). We were able to resolve this issue very effectively as we can now feed a bar four times faster than the integrated bar feeders currently available. Another point to tackle was the loss of material at the end of the bar as there is twice as much scrap generated. We found a very interesting solution to this issue too, as the scrap generated is three times shorter than with current solutions. That only left us with the long-standing custom amongst our customers and suppliers of supplying 3m bars. We contacted several of them and on reflection most agreed that it would be possible to supply 1.5m bars".

Tornos also investigated the possibility of cutting the standard bars in half. The second important change was the machine's ergonomics. With completely open access at the front, Tornos had clearly pushed accessibility further than any other solution on the market by offering a design that enabled the operator to 'get right inside the machine'. The tool holders with integrated spray via the slides and the option to change the grippers from the front of the machine enable users to change the set-up as quickly as on a single-spindle machine, which opens up new possibilities. As all the slides are 'vertical', the swarf naturally falls directly onto the evacuator, which increases the efficiency of the machine and reduces swarf removal operations for the operator.

All inclusive
Another strength of the machine is the seamless integration of all the necessary peripherals. As standard, the MultiSwiss includes the feeder, the management system for swarf and oil with dual filtration incorporating a paper filter system (filtration to 50µ) in addition to an ultra fine filter (5µ). The list of options has been reduced as the oil mist extractor, chip conveyor, fire prevention system and high pressure pump have been designed to integrate seamlessly into the machine. The fact that this integration has been incorporated into the machine from its very design means that its footprint is reduced taking up no more space than a single-spindle machine of equivalent capacity.

Precision and heat regulation
The machine's temperature is fully controlled via the cutting oil which is monitored by a plate heat exchanger. The machine core is kept at a constant temperature, even when stopped. This ensures normal operation during production. To improve efficiency, the regulation system can be pre-programmed in order to reduce the machine's standard heating times. As standard, the MultiSwiss features a plate heat exchanger designed to be connected to the company's centralised network. This type of system means that cooling systems do not need to be fitted to each machine, which fits perfectly into many companies' energy saving policies. Mr. Martoccia clarifies: "In terms of cooling, the trend looking forwards is to have a centralised cold water circuit. The MultiSwiss is designed to be connected directly into the central network whatever its temperature, without compromising its precision, as extremely accurate regulation is guaranteed in all cases. Nevertheless, as many companies do not yet have this technology, the machine has been designed so that a cooler can be integrated to enable the machine to work autonomously. This option also enables interested companies to fit an external cooler in confined spaces with the peace of mind that Tornos will manage the temperature regulation".

Silent operation
The technological choices made by Tornos have also had a positive effect on the noise level and the working conditions of the MultiSwiss. "We have often found that when the machine is connected to the water supply there is no noise from the refrigeration, it is only when we look at the screen that we realise the machine is actually running at 8,000 rpm. Using smaller bars reduces the noise level and the new barrel locking system is also very quiet. This aspect is also very important for user comfort," explains Mr. Martoccia.

Integrated PC and ergonomics
As on other Tornos numerical multi-spindle turning machines, the MultiSwiss includes an integrated PC. This system offers a very user-friendly interface with a large colour touch screen. Programming is carried out on TB-Deco. The integrated PC offers a great deal of flexibility. If some small program changes are required, these can be made directly on the machine. The PC offers other services as well, for example, all the machine documentation is instantly available. The servicing instructions, user and maintenance manuals are also loaded onto the PC. In the event of an alarm, the user can immediately display the file on-screen and read all the comments relating to this problem. Everything is at your fingertips and it is easy to navigate. In case of problems, remote maintenance means that the machine can be controlled remotely by a specialist, which in some cases will mean that it won't be necessary to call out a service engineer or to perform more precise diagnostics to optimise the work in every case.

What Can it Do?
With a 14mm capacity, the machine can hold up to 15 tools in operation and 3 in counter operation. Each shaft and each spindle can be independently programmed, which enables standard tools to be used at the ideal cutting speed for each. The controlled position of each spindle enables drilling and milling operations with precise angular location even between stations. The bar feed is performed via Z-axes integrated on each powered spindle (sliding headstock). "All machining configurations are possible: our machines can obviously turn, but for those who are very keen to use the machine for indenting, the use of hydrostatic technology provides much-needed damping and also enables this type of operation to be carried out," states Mr. Martoccia. Different devices complete the machining capacities, for example, the polygon operation device or the high pressure drilling/milling systems for operation and counter operation.

In terms of productivity and ease of use, operators are unanimous in their praise of the machine's excellent performance. Many production tests have been carried out and the results produce dimensional variations in the order of 4 to 5 Microns. To shorten the heating times as much as possible, the MultiSwiss features an oil circulation pump start-up option. This means that all the components can be harmonised even before starting work. "With this system, we can be operating in the centre of the tolerance range in under 30 minutes" explains Mr. Martoccia.

New approach, new advantages
With the MultiSwiss, Tornos is proposing a new approach to working on multi-spindle turning machines and the first customers to use this new machine have been very positive. Mr. Martoccia compares the arrival of this machine with the launch of the first Deco machines in 1996: "it's innovative, efficient, attractive, ergonomic and at a very affordable price."

"This is the first time we have presented a new machine at a show which has already been intensively used by customers over a long period" concludes Mr. Martoccia.