Manufacturing Engineering June 2001 Vol. 126 No.

Where is the Transfer Line?

This is the first of a two-part series of articles covering high-volume parts

production. This article looks at the types of machine tools and systems
available to process high-part volumes efficiently.

By Russ Olexa, Senior Editor

Is the transfer line dead? Now that there are Flexible Manufacturing Systems (FMS) using CNC
machines that have roughly the same capabilities as the transfer line, is there any need for it?

In fact, according to Roger Cope, VP of business development at Lamb Technicon (Warren, MI),
the transfer line of 20 years ago is gone. Today it has a new mission and name--high-volume
modular manufacturing system (HVMMS)--and has changed the face of high-production parts
manufacturing. Now it offers the flexibility that was difficult to achieve with previous systems.

What was the old transfer line like? At one time it was the most advanced equipment that could
be offered for high-volume parts production. It married custom-built milling machines with
precision fixtures, and a transfer system to move the part through multiple operations. These
operations could include milling, multiple drilling, reaming, tapping, boring, deep-hole drilling, line
boring, and special operations such as feed-out heads to bore multiple holes down the centerline
of a transmission case, washing stations, and others, depending on the part's complexity. They
were true technical marvels and many are still operating after 35 years or more. But what they
didn't offer was a great amount of flexibility. After the part's life cycle was over, transfer lines
usually weren't economical to retool. But the equipment could usually pay for itself within a few
years, so scrapping it wouldn't hurt the company's bottom line.

The new system is exactly what the name implies, modular for high-volume parts machining, but
now Cope says it can even do one-off parts within a family of parts, attesting to its flexibility. If
part volumes exceed what it was originally designed for, no problem, just make some minor
modifications like bolting in another machining
module.

Flexibility is the key word for transfer line systems

that are now called high-volume modular
manufacturing systems like this one produced by
Lamb Technicon, a UNOVA Co. Individual plug-and-
play stations can be fork-lifted and shipped on
flatbed trucks, then quickly reassembled on the floor
when part volumes change.
These types of systems are primarily used by automotive manufacturers and small engine
builders because of the complexity and volume of their parts, which include engine blocks,
cylinder heads, transmission cases and related products. Today, part life-cycles aren't what they
used to be. OEM auto manufacturers previously built engines on production lines that operated
for ten to 15 years, making it possible to produce volumes of tens of thousands per year. Part
cycles have become shorter and automotive OEMs are now marketers and assemblers, pushing
part production to Tier One and Two suppliers who work on production contracts that could
vanish at any time. So they demand manufacturing flexibility.

Flexibility solutions come in many different forms. For Lamb Technicon it required a total revision
of the old-style transfer line, updating it by using CNC technology and machining modules, along
with palletized parts and modular movement systems. Even the transfer bar, which moves the
parts, was modularized so it can be broken apart and moved around like a Lego set. The
challenge was to create a family of cost-effective single-spindle HMCs that are configurable as
both high-volume modular manufacturing modules and stand-alone machines. They had to be
capable of high-force, high-speed machining, and optimized for a range of materials from
aluminum to cast iron.

This type of machine was designed by examining a whole series of machining requirements
obtained from the specifications of previous Lamb systems. Data were collected on spindle power,
speed, and torque, tool geometry, and axis travels required to process aluminum cylinder heads,
blocks, and transmission cases as well as cast-iron heads and blocks. Machine duty cycles were
analyzed, cutting forces were calculated, average axis travel distances were examined, and the
mass and stiffness of the machine's components were investigated to improve the structural
design. With this information, an initial design proposal for the machine's architecture was
developed. Called the Jaguar HMC, the machine is a relatively standard ram-type layout using a
single vertical ballscrew with two rails supporting a quill. It's designed with the Z axis on the
spindle-side of the machine so part presentation is no problem, and the machining area is easily
accessible by the operator.

To be able to machine both aluminum and ferrous workpieces in either an HVMMS or a stand-
alone environment, the design had to be very massive. It required an overall stiffness of 106,818
kg/in with the ram fully extended--a value usually much greater than what is offered by standard
HMCs. Lamb's Jaguar comes with either three or four-axes (with rotary B-axis table) or as a
three-axis machine module. Two models are offered, one with 650 X 650 X 500-mm X, Y, and Z-
axis travels, the other with 1030 X 850 X 560-mm travels. It offers 1G-acceleration/deceleration
capabilities and 45 m/min rapid traverse speed on all axes. Pallet size for the smaller machine is
500 X 500 mm and 850 X 630 mm for the larger model. The Jaguar uses a cartridge-style spindle
design, which allows changeover from a 12,000-rpm, 39-kW spindle that might be used for
ferrous metals to a 24,000-rpm, 45-kW spindle for machining aluminum. Lamb's Jaguar 500 uses
an HSK-63A toolholder, and the 630 uses an HSK 100A (ISO-50 optional). Toolholder capacity
for the 500 is either 12 or 36 and the 630 can store either 10 or 36.

For higher-volume applications, Lamb produces a set of modular-slide units that all use the same
base regardless of stroke, and have common trucks and rails. Only the platen width is changed to
accommodate different strokes. Center and wing bases, control locations, and all electrical, air,
and control system connections are also standardized.

The idea is to produce custom systems from a set of standardized modular components that are
essentially interchangeable, and require a minimum of custom engineering. Customers gain both
lower initial costs and improved capital reusability from this approach. These machines and
modular part-moving equipment are used in various configurations with palletized parts,
depending on the customer's needs.
According to Mark Tomlinson, vice president of technology integration, Lamb Technicon now
uses reconfigurable robots in manufacturing solutions that are scaleable, modular, and flexible in
nature. "This allows us to configure systems at one volume, say 50,000 units per year, but protect
the system for higher volumes at a later date by adding more machining modules and robotic
transfer devices."

Lamb has recently installed such a system at an auto OEM's plant for machining aluminum
transmission cases. Based on 30 Lamb twin-spindle Mach I HMCs, the flexible system is
arranged in cells of four machines each. A robot moving on an overhead beam loads and unloads
four machines in a cell. This compact arrangement meets the critical machine time cycle. It also
enables the system to be expanded as production volume increases by installing more machines
in the cell and adding a second robot arm to the beam. The robot's rotating wrist, combined with
the other axes of motion, enabled Lamb engineers to reorient the part from fixture-to-fixture, as
necessary, to present different faces of the part to the machine spindles for maximum processing
efficiency.

"Which type of automation to use depends upon the crossover point between the investment for a
flexible system using HMCs with robots, and the investment for a high-volume system using
modular machines with drop-in transfer-drive technology," says Tomlinson.

At Cross Hüller (Sterling Heights, MI) flexibility is also very important to achieving high-volume
parts production. However, according to Ronald Quaile, vice president proposal engineering, they
are still in the business of making dedicated transfer lines using their modular machining systems,
if customers want them." For higher levels of flexibility, the company offers HMCs for mid through
high-volume agile manufacturing systems, but without pallet systems for part mounting. Parts are
moved between machines using overhead gantry systems. Quaile says, "Parts are precisely
fixtured on adapter-plates to eliminate pallets and the variability issues with them. At the same
time, we have simple robust fixtures with identical locate and clamp points on every fixture, so we
have part repeatability without much complexity. Once the adapter plate is clamped in the fixture,
we have a zero-clearance technique that pushes the part in three planes, eliminating all the
clearances normally associated with pallet fixtures. Fixtures use hydraulic automated clamping
with locating surfaces flushed with coolant, and then checked for final location using part seating
air switches."

This Twinflex from Turmatic Systems Inc., a Thyssen

Production Systems Co., offers a machining spindle with
multiple tools, which eliminates a toolchanger for faster
cutting and flexibility for high-volume parts production

Cross Hüller uses their SPECHT HMC as the basis for

their agile modular manufacturing systems. This machine
also offers an internal four-pallet changer when used as a
single cell or part of a small multi-machine cell. When
used as part of large system, it uses the adapter-plate
system mentioned above. Four models are offered, with
the SPECHT 500 having either a single or double-spindle
configuration. The SPECHT 500 features 630 X 630 X
600-mm X, Y, and Z-axis travels while the SPECHT 630
offers 1000 X 750 X 630-mm travels, and the SPECHT 1000 has 1800 X 1000 X 630-mm travels.
A SPECHT 1600L has 2000 X 1600 X 500-mm travels. Most offer 1G acceleration/deceleration
capabilities with the larger machines having 0.5G abilities. Rapid traverse varies from 100 - 60
m/min for X and Y axes. Pallet clamping area for the smaller machines is 400 X 500 mm and
1000 X 1250 mm for the larger models. Spindle speeds vary from 16,000 rpm for the smaller 22-
kW machines to 10,000 rpm for the 33-kW larger machines. Cross Hüller's SPECHT 500 uses an
HSK-63A toolholder. Their 630 uses an HSK 100A, and the 1000 employs an HSK-A 125.
Toolholder capacity varies from 24 - 103.

Through their sister company, Hessapp, Cross Hüller, also offers a conventional line of vertical
turning machines, inverted-spindle turning machines, self-loading spindle configurations,
opposed-spindle through-part transfer, and the ability to machine a part from two sides, requiring
two clampings, but without a turnover position.

One machining center that both Lamb and Cross Hüller still produce that doesn't offer a great
deal of flexibility is a multispindle head to drill, ream, tap, or bore a number of holes in one
operation. If part cycles are low enough, this type of machine would usually be replaced with an
HMC. But with high part volume, it's still one of the best ways to achieve fast cycles, accuracy,
and repeatability.

When part volumes are too small for large HVMMS and stand-alone machines, a production cell
using a number of machines with integrated part loading and unloading can be used. Both Cross
Hüller and Lamb also build these smaller systems using modular components.

A line of modular-machining systems for boring and turning called Revolution used in low-to-high-
volume parts-production systems and cells has been developed by PCC Olofsson (Lansing, MI).
Because the systems are modular, they can be built for one particular part for high volumes with
an integral-parts feeding system, or they can be designed as stand-alone machines for job-shop
work. Three main modules make up each machine, a column for Z-axis movement, a X-axis base,
and a 22-kW spindle. With this configuration, more than 30 different versions can be produced.
By splitting the X and Z axes, it's possible for one machine to do both vertical and horizontal
turning.

A single machine can have two vertical-turning spindles (left and right) or two horizontal-turning
spindles (left and right) that can run individually or simultaneously. Space-saving bases come in
two sizes-1.75 X 2.28, and 3.56 X 2.28 m. Cast iron is used for the bases, and both vertical and
horizontal slides have roller-bearing linear systems with ballscrew drives. "The Revolution's top
vertical column provides true flexibility," according to Stephen Ross, director of engineering. The
columns can be outfitted for a milling spindle, block tooling, gundrilling, probe gaging, turret
tooling, Y-axis slide movement, or a grinding spindle. Two columns can be accommodated on the
single-machine base and four on a double base.

Standard HMCs can be integrated into cells using a

pallet system for high-volume part production. Here a
Mazak Co. (Florence, KY) Palletech System is being
used for this type of production.

Because of the Revolution's modular capability and

integral parts loading/unloading, bases can be
designed for a transfer-type system. A part can be
chucked in a lower vertical spindle and then moved
along the X axis through successive machining
operations using upper-mounted vertical spindles on
one machine. Quality is enhanced because the part
never leaves the chuck.

Machines for high-volume manufacturing for either modular systems or cells are also built by
CellCon Cellular Concepts (Detroit). "Reconfigurable is the new term used in the special machine
business, which is different than flexible." says George Simon the company's president. "In the
future, can the machine's hardware configuration be changed to adapt to another product? This
means that the machine has to be mechanically changed perhaps by putting a different type of
spindle on it, not just the software and tooling." he adds.

"We supply three-axis, small-to-large machining modules configured various ways with horizontal
or vertical spindles that provide full flexibility and reconfigurability for an HVMMS or cell. Typically
our customer builds special machine's for high-volume parts production. We're giving them a
preengineered module offering CNC control and high accuracy so they can deliver a system
faster to their customers. We also have machine modules used as plug-and-play systems for
inline or rotary-transfer cells that have part indexing at each station and integrated material-
handling systems. Parts are mounted on tombstones and a rotary-dial table is used to off load-
parts," Simon declares.

Simon added that once the part's life-cycle is over the machine cell can be taken apart, retooled,
reprogrammed, different spindles added or changed as needed, and then put back in service as
another cell--or the machines can be used as stand-alone units.

Besides offering single machines based on their flexible/reconfigurable machine bases, CellCon
offers two milling-machine platforms models (400 and 500) for high production. Both machines
have X, Y, and Z axes built into the frame, so parts can be moved around on any type of transfer
system in front of them. They can be configured as an HMC or VMC, or as a platen head for
custom mounting needs such as multispindle heads.

Another company that offers modular machine tool components for cells is Russell T. Gilman
(Grafton, WI). Their equipment provides a 400-mm work cube and accepts 40-taper tooling.
Spindles are offered in three different configurations: 24,000 rpm, 22-kW, high-speed integrally-
motorized; high-torque, motorized belt-driven; or a four-position indexing head. Columns can be
rotated 90º and offer either a roller-bearing or hardened-way axis construction. Cell modules are
CNC-control ready with limit switches, feedback systems, piping for coolant, and wiring
accessories. Other modules including VMCs are available with ISO 30, 40, and 50 tapers, spindle
speeds up to15,000 rpm, and ground ballscrews or hydraulic cylinder drives in various sizes.

For high-volume parts that can fit into a work volume of 250 mm3, Mori Seiki offers an HMC line
called the FM series. It's designed for stand-alone operation or in a series of machines that they
call a Flexible Transfer Line. These machines are only 990-mm wide by 3209-mm deep, and
feature five-axis capability that enables them to machine complex prismatic parts. High-
production parts machining is done by placing multiple machines in lines or cells with palletized
parts being fed through the machines on a conveyor system. A robot can also be integrated for
part load/unload between several machines.

Many of the parts produced by high-volume modular manufacturing systems are used in the
automotive industry. Smaller automotive parts as well as brass fittings like those used for water
and gas transmission, are also produced in the hundreds of thousands to millions per year.
Trunnion and rotary-transfer machines are a typical choice for this type of high-volume machining.

Milwaukee Machine and Engineering (Milwaukee) designs and builds specialty trunnion and dial-
index machines for high-volume production of parts from 102 X 102 mm to 660 X 610 mm across.
"Our typical machine cycles for a complete part can be as little as three seconds or up to 55
seconds on a dial transfer," says Joe Butler. An example of what the company builds is a six-
station CNC dial machine with two offline-finishing stations that machined a diecast-aluminum
upper and lower counterbalance shaft housing every 30 seconds. The machine mills critical
thrust-wall faces in two adjacent half-round bores with a perpendicularity requirement back to a
milled face that had a total tolerance of 0.023 mm. The process attained a Cpk of 1.9. Milling was
done using PCD-insert cutters running at 3048 m/min and 12.7 m/min feed. All spindles use HSK
hydraulic chucks and coolant-fed tools. A trunnion machine they are currently building will use
eight Gilman Model 6500 cartridge spindles mounted to hardened way slides. It will process
nodular-iron drive-shaft yokes at a production rate of 400-pieces per hour. The machine will hold
a bore tolerance of ±0.0089 mm by using in-process gaging, temperature-controlled coolant,
servo-driven axes and spindles, and heavy-duty design.

Another rotary and trunnion machine tool builder is Hydromat Inc. (St. Louis). Their rotary transfer
machines come as a complete turnkey package offering a modular design. Rotary machines are
available in several machine base sizes equipped with either 10, 12, or 16 stations capable of
machining bar stock, coil, and blanks up to 44.5 mm in diam. Since the workpiece is stationary in
the chuck jaws, the table indexes it to each machining unit performing operations such as drilling,
cross drilling, boring, turning, milling, external and internal recessing, threading, tapping, and
broaching.

Hydromat's trunnion-transfer machine cuts bar stock, blanks, castings or forgings as large as a
102-mm diam. They are equipped with eight or 12 chucks, and can machine shafts and irregularly
extruded bar-stock parts as well as small castings.

High-volume turned parts can be processed a number of different ways depending on their
configuration. Screw machines and bar-fed turning centers are two popular ways to manufacture
them. Some turning centers offer two spindles, allowing two parts to be simultaneously produced.
In addition, one part can be turned on the first spindle, which then hands it off to the second
spindle for additional cutting or finishing.

Hydromat's rotary-transfer machine cuts bar stock, blanks,

castings or forgings. It's equipped with eight or 12 chucks
and can machine shafts and irregularly extruded bar stock
parts as well as small castings.

Standard VMCs and HMCs can also be integrated into cells

using an automated part-handling system for high-volume
part production (see Manufacturing Engineering articles on
parts feeding in the April 2001 issue, and advances in
machining cells in the May 2001 issue).

Vertical turning centers, such as the ones Olofsson

produces, are another way to produce high volumes of
turned components when integrated with a parts handling system and machines having two to
four spindles.