By Paul Savides, Managing Director, PBS Machine Tools
Generally, to meet High-Mix Low-volume production, you require numerous standard machining approaches that need to use drawn-out, multi-step processes with single-spindle machines, which are not a great fit for high-precision engineering shops, especially, those looking to expand from one-offs to production orders.
Parts with complex milled features or multiple milled faces that require a secondary machining operation on a separate machine after initial turning not only extended cycle and setup times but also introduced the risk of tolerance stacking and alignment errors, due to re-fixturing or relocating to the second operation. Even parts with seemingly larger permitted tolerances can require closer attention to dimensional stacking, demanding even tighter tolerances.
As an example, to make medical parts, even in the hands of a skilled machinist, creating the tool paths that can accurately machine these part shapes, is ineffective. Unfortunately, the part geometries are mostly outside a standard CNC machine’s capability range, due to time-consuming processes on single-spindle, single turret machines.
Multitasking – Where High Requirements Meet High Volumes
Purchasing a Multi-Tasking machine to handle complicated turning geometries like gear cutting, five-axis work and more.
Twin-spindle, twin-turret setups with live tooling and Y-axis machining capabilities provide more flexibility than most machine shops are familiar with.
While machine rigidity will prove useful right away for you, it will take time before you fully trust the machine’s advanced features and then fully utilize them. By cautiously experimenting with simultaneous Pinch-Turning and Pinch-Milling, you will be amazed how processing this way maintains tight concentricity and straightness, especially on long, thin parts and how it cuts cycle times, by enabling simultaneous roughing and finishing operations.
Pinch-Turning can also reduce setup times by eliminating the need for steady rests and rotating centers for some operations, making you more agile and efficient as it progressively allows for increased annual part volumes.
New Features, New Parts
High Dynamic and Eccentric Milling capabilities sharply cut setup and cycle times, and therefore, by taking advantage of Tongtai Group’s numerous Multi-Tasking solutions that provide rigidity, advanced cutting features and a done-in-one architecture to reduce setup and cycle times, will make you more competitive.
Our TMS series represents Tongtai’s commitment to process integration and machining efficiency. Designed as a full multi-tasking turning center, TMS combines live tooling, symmetric Y-axis movement, dual spindles and substantial structural rigidity, making it ideal for gear machining and complex shaft-type components.
The C-axis indexing accuracy and servo synchronization between spindles ensure precise angular positioning , essential for gears and coupling components. Five-axis milling integrated into a multitasking platform, significantly reduces the need for multiple setups and fixturing and will have a substantial impact on repeatability, throughput and overall process efficiency, especially for high-value, low- to mid-volume components.
Cycle times can be reduced by up to 50% and setup time by up to 75%, depending on part complexity.
High Dynamic and Eccentric turning can be particularly impactful
In Dynamic turning, programmers can adjust the approach angle of the cutting tool in mid-operation. Also, tools with different cutting edges, suited to roughing, profiling and finishing, can mean performing multiple operations without tool changes.
Eccentric turning enables the machining of off-centre bores without specialty off-centre work-holding thus, eliminating the cost of custom fixturing and work-holding, while improving productivity, accuracy and setup time.
Bonus Features
While Multi-Tasking machines can expand your current capabilities, it can help you gain a foothold in gear cutting. Across South Africa’s manufacturing landscape, gear production plays a vital role in industries, such as mining, heavy equipment and the automotive aftermarket.
These sectors demand gears and splined shafts that meet tight tolerances. They must be produced efficiently, despite smaller batch sizes and growing part complexity. Implementing Gear cutting and the newer High Dynamic and unconventional Eccentric turning features will require use of digital twin simulation software and advanced Espirt Edge CAD/CAM software, to match the physical machine and its kinematics, so every tool index or collision risk that could exist is anticipated and addressed in the programming office.
Servicing an Ever-Increasing Pace
As these complex machines can complete nearly every part that crosses the shop floor, downtime could significantly hamper operations, most of it due to user error or lack of maintenance, however, thankfully Tongtai machines rarely see downtime. Even in these situations, our Intelligent Software assists with a troubleshooting feature that displays likely problem areas, such as Axis overloads and oil levels etc., while operators can quickly bring the machine back online, making a service call unnecessary.
To meet the production levels for newer jobs, it’s feasible to run two 12-hour shifts, one staffed and one unstaffed.
To prevent issues with outdated programs and help with traceability for high-requirement jobs, it is recommended to setup a programming department to ensure all changes to part programs are done in the right environment.
All these machine features will help expand your business significantly. By adding robotics, a custom ERP and continued investment in capable machines will help users grow even further.
We’re not just suppliers — we’re solution partners.
At PBS Machine Tools, we specialize in helping partners upgrade production, optimize capacity and access reliable equipment, not just by offering good pricing, but by delivering fit-for-purpose solutions, tailored to real production goals.
With our 35-year network of long-standing manufacturers and engineering teams, we support:
- New and certified pre-owned machines
- Custom-built lines for special parts or applications
- Spare parts, tooling, installation and post-sale support
- Government-level cooperation on industrial programs
We’d be glad to learn about your current focus, whether you’re exploring upgrades or future investments.
Special Note: I’d like to leave you with this:
From Defining to Preventing Errors
Four techniques to have in your toolbox for averting errors are
For more information please contact PBS Machine Tools – Tel: 011 914-3360.
