Fixture Maker Capatilizes on Okuma MB-66V's Capabilities

Fixture Maker Capatilizes on Okuma MB-66V's Capabilities
  • Industry: Contract Manufacturing, Die & Mold
  • Process: Milling
  • MGI Division: Morris Great Lakes
  • Outcome:

    “We use the new Okuma MB-66V in radically different ways from the way the machine would normally be run,” says Walt. “We have to be as inventive with our own production methods as we are with the special fixtures we design and build. Time compression is key. With the new Okuma machining center, we have been able to run that machine and our complex programs faster and with superb accuracy, getting more operations out of the machine in one setup than one would think possible. A fixture that had taken us 8 or 9 weeks to manufacture before, we can now complete in 3 or 4 weeks. Productivity on every level…that’s what it’s all about.”

 » Challenge

Concentrating on the manufacturing processes and applications of CNC machine tools, PRZ has designed and built an extensive range of jaw packages, tool supports, offset tool holders and multi-ID tool blocks for lathes and turning centers and a wide variety of hydraulic and manual fixtures for machining centers.  They have designed and built specialty machines that include a three-axis milling machine, a tapping machine, a high-speed drilling cell and a long blade serration grinder and perform modifications on standard CNC machine tools to meet customer specifications.  PRZ’s customer base includes aerospace and automotive industries and job shops of all sizes. 

 » Solution

Among the new Okuma’s features that are critical to improved efficiency in machining PRZ’s long components, in addition to the generous 59” travel in X (26” in Y and Z), is the ability to handle the larger CAT-50 tooling along with a 32-tool carousel.  Other aspects of the machine especially beneficial to machining these components are through-the-spindle coolant, through-the-spindle air, automatic tool offset, chip wash and a chip conveyor.  A spindle probe for work piece gauging allows the operator to inspect the part right on the machine.  “I also appreciate Okuma’s THINC control,” says Walt.  “The macro logic programming is great.  We can always rely on the logic working and never miss the last pass.  Some of our programs run up to 4 GB.  Before, we would have to break the programs down to several segments.  With Okuma’s control, we just load in the total program and go.”

 » Assessment

Walt Przybyl and his team have developed some of the most effective manufacturing cells in the machine tool industry and specialize in the types of projects that pose considerable challenges, such as work holding or tolerance issues, parts that are difficult to hold, or parts that distort easily.  It is this growing area of specialty fixtures that gave rise to the need for a machine tool that would allow PRZ to machine larger-than-usual components with speed and efficiency.  For example, a side rail for a PRZ swing clamp trunnion fixture requires intricate sculpting and measures about 3” by 10” by more than 55” long.  The material is A36 carbon structural steel with 36,000 psi yield strength and up to 80,000 psi ultimate tensile strength. It was taking multiple setups and more than a day just to rough the cutouts.

 » Results

“We use the new Okuma MB-66V in radically different ways from the way the machine would normally be run,” says Walt.  “We have to be as inventive with our own production methods as we are with the special fixtures we design and build.  Time compression is key.  With the new Okuma machining center, we have been able to run that machine and our complex programs faster and with superb accuracy, getting more operations out of the machine in one setup than one would think possible.  A fixture that had taken us 8 or 9 weeks to manufacture before, we can now complete in 3 or 4 weeks.  Productivity on every level…that’s what it’s all about.”

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