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High Precision Machining, Lower Cost Metal 3D Hybrid Machining of Large Parts

Large scale machining centers from Takumi USA are integrated with Metal 3D Printing Tools from 3D-Hybrid Solutions to break new ground in aerospace, tooling, mold and die applications.

Posted: July 25, 2018

Booth S-338420: The U800 high speed 5-axis gantry machining center from Takumi USA uses a high torque table (800 mm platter) that features an 80 rpm twin-torque motor A-axis and a 100 rpm single-torque motor C-axis to achieve world-class performance for die and mold, aerospace and other high speed applications that require tighter tolerances.

Booth S-338420: The large work envelope and high speed machining capabilities of the H12 double-column machining center from Takumi USA can be integrated with an economical Wire-Arc Additive printing tool from 3D-Hybrid Solutions to create a high precision, lower cost metal 3D hybrid machining center for large scale metal additive manufacturing of very large, high precision parts for tooling, mold and die applications. (first view)

Booth S-338420: Shops can increase production with a heavy duty, high torque V11 machining center from Takumi USA that uses a FANUC H control.

In Booth S-338420, Takumi USA (Indianapolis, IN) will debut their new line of 5-axis machining centers, including the U600 (XYZ/AC travels: 24.4 in x 39.4 in x 19.7 in / +30 deg to 110 deg x 360 deg) and U800 (XYZ/AC travels: 31.5 in x 39.3 in x 29.5 in / ±120 deg x 360 deg). Both machines utilize a trunnion style, two-axis table and a Heidenhain TNC 640 control. The U800 is a high speed gantry machining center over the high torque table (800 mm platter) that features an 80 rpm twin-torque motor A-axis and a 100 rpm single-torque motor C-axis. The U series was developed to achieve world-class performance for die and mold, aerospace and other high speed applications that require tighter tolerances.

The U800 will be featured with a 5-axis simultaneous cutting demonstration of a 20 in tall replica of the famous Venus De Milo sculpture. The reproduction will be produced in 4140 steel to showcase the rigid machine construction, speed and superior part surface finish. Programming of the Venus De Milo will be provided in partnership with Cimquest Inc. (Branchburg, NJ) using Mastercam 5-axis toolpaths. “We decided on this sculpture for the demo because the Takumi tagline is The Art of Productivity, which is a rough translation of the word “Takumi,” and 5-axis illustrates the art of productivity perfectly,” said Maggie Smith, their marketing manager. U800 specifications include:

Table Size 800 mm
Table Load 2,204 lb
XYZ Travels 31.5 in x 39.4 in x 29.5 in
A/C Travels ±120 deg / 360 deg
XYZ Rapids 1,890 ipm
A/C Rapids 80 rpm / 100 rpm (Direct Drive Ballscrews)
Spindle Taper HSK-63A
Spindle 20,000 rpm, 33.5 hp, 88 ft-lb torque
ATC Stations 32
Machine Weight 39,683 lb

Also on display will be a Takumi H12 double-column machining center, the perfect platform to accept the integration of the additive manufacturing process with its large work envelope and high speed machining capabilities. H12 specifications include:

Table Size 59.1 in x 37.8 in
Table Load 5,512 lb
XYZ Travels 53.2 in x 37.4 in x 23.6 in
XYZ Rapids 1,181 ipm (Direct Drive Ballscrews)
Spindle Taper BIG PLUS® 40
Spindle 15,000 rpm (Direct Drive), 20.1/24.8 hp, 105.5 ft-lb torque
ATC Stations 30
Machine Weight 28,600 lbs

Integrated with the H12 will be the Metal 3D Printing Tool from 3D-Hybrid Solutions (Seal Beach, CA), one of the largest and fastest metal 3D printers with full in-process machining capability, according to company founder Karl F. Hranka. “With this large double column machining center and our economical Wire-Arc Additive tool, we will be breaking new ground in the market for a high precision, lower cost metal 3D hybrid machining center,” said Hranka. “Large scale metal additive manufacturing applications will be realized with the technology on this machine.” A demonstration will be focused on matching with the machine’s strengths for producing very large high precision parts found in the tooling, mold and die industries. Why hybrid? Consolidating this AM tool with a CNC machine is filled with value propositions:

Single setup and in-process machining.
Simplified management structure and reduced learning curve.
Greatly reduced barrier to entry for metal AM.
Repair and salvage applications.
Just-in-time manufacturing, feeding wire to near-net-shape production.
Reduced material costs on large parts.
Multi-material parts.

Production metal 3D printed parts require post machining to be joined to mating parts. “We embrace this and focus on evolving and advancing directed energy deposition technologies like 3D-Tools for the CNC environment,” added Hranka. “We offer three metal AM technologies for CNC machines: Wire-Arc Additive Manufacturing, Laser Metal Deposition and Cold Spray. Together, these technologies can handle almost any metal AM application and alloy.” Visitors will also learn how to “make more chips” with a FANUC H control on a heavy duty, high torque Takumi V11 machining center, in a partnership with Greenleaf Corporation (Saegertown, PA). V11 specifications include: