Taiwan's Machining Center Makers Keep Adding Tricks to Their Acts
2009/05/04 | By Ben ShenFor as long as anyone in the industry can recall, the leaders from Japan, Germany and the USA have always occupied enviable roles in supplying the most precise, state-of-the-art machining centers globally. And it has been the motto for the sector in Taiwan to try to develop machining centers that can rival functionally those from advanced nations and yet be offered at more attractive prices. In fact some in Taiwan claim that such seemingly impossible feat has been achieved.
Machining centers, being multifunctional, are one of the most sophisticated categories of metalworking machine tools designed and manufactured in Taiwan. Over the past one year, some manufacturers claim that they have been successful to improve their machining centers by tapping expertise culled from developing other products as CNC (computer numerically controlled) milling machines and CNC lathes.
On the one hand Taiwan makers of machining centers have come a long way in product upgrading, but on the other they still rely on imported technology for the heart of such machine tools-preferring to use industry-trusted CNC controllers from Fanuc, Mitsubishi, and Siemens for their high-performance. While a few in Taiwan have devised PC (personal computer)-based CNC controllers, some veteran manufacturers admit such controllers still lack the razor-sharp sophistication needed for machining centers. In Taiwan, these single-priced PC-based controllers are used in plastic injection molding machines, woodworking machines, and some textile machines because such machines don't require as high machining accuracy as metalworking machines.
Exports Grow 13.7%
Seemingly immune to the global downturn, the Taiwan Machine Tool Foundation (TMTF) figures show that Taiwan exported US$1.054 billion of machining centers in the first 10 months of 2008, up 13.7% from US$927.04 million a year earlier. Despite such double-digit growth, the TMTF anticipates that the grow would not continue and may even dip into the negative due to the current uncertainty surrounding the global economy, especially considering that major industries as automaking is being battered.
Vertical Machining Center
Huey Long Precision Machinery Co., Ltd., founded in 1989, is an experienced maker of a range of vertical machining centers in Taiwan, in addition to CNC (computer numerically controlled) lathes. The company is formed by a group of specialists with experience gained from working for major machine tool makers on the island.
With an in-house R&D team, the company concentrates on developing innovative models by using quality parts and sophisticated software, and markets under its own brand "Starway."
Huey Long builds strengthened columns on its vertical machining centers, which feature slideways hardened to HRC50-55 standards, abrasion-resistant bearings for enhanced action and durability.
Huey Long started up producing electric discharge machines for domestic manufacturers on an OEM (original equipment manufacturer) basis, and diversified into, a few years later, developing vertical machining centers, which is now the mainstay in its line.
The company's vertical machining centers are designed for mold-making and metal-processing, with some being dedicated to the former.
Besides using Fanuc, Mitsubishi, and Siemens CNC controllers to assure top-notch accuracy in its CNC machine tools, Huey Long also, to enhance machining capability, been cooperating with a domestic software developer to build CAD/CAM (computer aided design/manufacturing) software which is suitable for the mold-making industry.
Versatile Machining Center
L&W Machine Tools, Inc. supplies CNC machine tools specially designed for tooling room, small-batch mold and die production, and automotive and aerospace industries.
The company's current range includes vertical turning centers, vertical machining centers, slant-bed lathes, teach-in lathes, and bed-type milling machines, the latter of which are used for aluminum-wheel machining and a variety of mechanical parts for jet engines and automotive application.
L&W says it is dedicated to producing affordable, reliable, and comprehensive machine tools for global customers. Always prioritizing customers' interest, the company develops CNC machine tools that adopt sophisticated and advanced control system for enhanced functionality.
Victor Wang, chairman of L&W, says his company has a professional R&D team of experienced technicians who know the importance of staying on top of the latest technologies in the global industry.
Supplier to Alcoa
The company's CE-approved machines are exported worldwide through its wholly owned offices in Italy, Spain, the U.S., the United Kingdom, and Singapore. Since 1999, the company has been supplying CNC vertical turning centers, vertical machining centers, and horizontal machining centers to Alcoa, the world's largest aluminum wheel manufacturer, which uses L&W machines to machine forged aluminum wheels for trucks.
"We have consistently been developing innovative machine tools to meet global needs," Wang notes. "For instance, we offer a wide range of vertical lathes suitable for making large automobile parts."
So far, L&W has exported more than 2,000 machines globally, proving its ability to meet worldwide demands. The company is known for developing various CNC machine tools with state-of-the-art control systems that are regarded as some of the most sophisticated, flexible on the market.
Over the past year, the company has landed new accounts from Poland, the Czech Republic, Argentina and Croatia, some of which, Wang says, were found at the EMO show held in Hanover, Germany in September 2007.
APC-equipped Machining Center
With high-tech parts and components makers demanding machine tools with specialized, dedicated functions, suppliers are pressed to meet such needs by building advanced features as automated pallet changer (APC) and five-axis functionality into products. One such ingenious maker is Pinnacle Machine Tool Co., Ltd., which stands out for its manufacturing of heavy-duty vertical machining centers featuring high performance and high machining accuracy.
To better develop bigger machining centers, the company moved its factory from Tantze Township to Shenkang Township of Taichung County, central Taiwan in March 2006, where the new plant is 72,000 square feet, four times that of the old one.
Since its establishment three decades ago, Pinnacle has been concentrating on the development and production of high-end machine tools, with its current range consisting of milling machines, vertical machining centers, and turning centers. The company says it has five production lines, three of which are geared for flexible production.
The company began producing turret-type milling machines in its early years, but has added vertical machining centers to its line by fully tapping its core-manufacturing technology.
The founder J.N. Hsieh and general manager Allen Hsieh have successfully steered Pinnacle towards developing innovative products to meet special requirements worldwide. "Seeing many downstream machinery users having moved production to mainland China, we saw a need to build vertical machining centers that seem to be popular in such overseas market," says Hsieh.
Since the beginning of last year, Pinnacle has been focusing on developing automated machine tools and sophisticated five-axis machining centers. And this January saw the company launch the LV85APC vertical machining center equipped with automated pallet changer for enhanced automation.
TIMTOS Debut
Having fully built the five-axis machining center at the end of September 2008, Pinnacle will showcase the cutting-edge machine at the Taipei International Machine Tool Show (TIMTOS) in March 2009, as well as believe that most of the mid- and large manufacturers of CNC machine tools will focus on developing such models in the future.
"Demand for machining centers equipped with APC is clearly rising in Taiwan and Southeast Asia," says Hsieh. "This high-value-added machine can help users boost production efficiency as it can reduce mold-changing time, making such machine particularly suitable for processing small parts."
The company can install all-gear head in the LV85APC model, if ordered, to enhance torque capacity, making it suitable for processing aluminum alloy parts for the metal has high tensile strength. "I believe machines equipped with all-gear head have excellent potential in the future as demand for lightweight, small parts is on the rise worldwide," comments Hsieh.
One notable model is the VMC500 featuring 510 x 254 x 305mm of X-Y-Z-axial travels, built-in 24,000rpm spindle, and X-Y-Z axis linear guideway, with such machine not only suitable for large-scale production lines, but also ideal for smaller machine shops. This machine capably handles making watch and timepieces, 3C (communication, consumer electronics, computer) parts, as well as molds for joints, teeth and bones in the medical industry.
Returning Customers
About 75% of its output is machining centers, Pinnacle reserves some capacity to make CNC lathes and turret-type milling machines, with 15% to 20% of the latter being exported to the U.S. The company boasts customers have returned asking for turret-type milling machines over the past two years realizing that Pinnacle delivers better quality than made-in-China products.
Hsieh says that his company has been expanding global market shares in the past few years for its high-end machine tools can rival those made by European industrialized nations and the U.S., as well as having successful tapped emerging markets as Vietnam and Brazil.
Pinnacle tries to achieve the virtually impossible goal of total quality: it uses wide linear guideways on three axes of machining centers to ensure excellent accuracy and rigidity, fast operation, efficiency, and specially-designed motor to assure maximum stability.
The company says its machining centers are CE and EMC certified, features cutting feed-rate reaching 12,000mm per minute, and pre-tensioned three-axis ballscrews to avoid deformation that may compromise machining accuracy.
Being ISO9001 quality-assurance approved helps to build trust globally. And over the past few years, the company has invested in state-of-the-art laser detectors and many other inspection instruments to lower defective rate.
Pinnacle's monthly output is 30 sets of vertical machining centers and will reach 50 sets in half a year; while the company says it has set up a warehouse in China to meet the fast-growing demand.
High-end Five-axis Machining Center
Kamioka Corporation, founded in 1965 by K.S. Huang, is one of Taiwan's most specialized manufacturers of high-value-added machine tools, including CNC five-axis machining centers, CNC lathes, and precision surface grinders. Ever since its inception, the company has been known for developing machines with enhanced structural rigidity that exceed those made by domestic peers.
Marketing under its own Kamioka brand, the company boasts it is one of the earliest manufacturers of machinery parts in Taiwan. With decades of development and manufacturing experience, the company has a diversified line including high-value-added products as vertical machining centers, machinery accessories and quake-prevention equipment.
Kamioka claims it has successfully built the FNS-5AG CNC five-axis simultaneous- control machining center which is ideal for complicated machining of precision parts as lens die or impeller turbine blade.
Being compact at 1,216 x 1,450mm, the FNS-5AG takes up less space but is highly efficient; while its cast base-mineral construction is eight times more vibration-resistant and 20-times better thermally-insulated than cast-iron counterparts. For better axial location and maximized rigidity in the compact body, the three-axis (X/Y/Z) and two-axis (A/C) are mounted on the upper gantry columns and lower part of the main frame, respectively.
For more powerful and efficient action, this model is specially equipped with twin servo system, meaning two servomotors and two ballscrews are installed on both left and right sides of the Y-axis; while the travel is 450X500X200mm along X-Y-Z
axis.
Three Factories
With a well-established R&D department, the company currently runs three production facilities spread over some 108,000 square feet, as well as taking pride to consistently upgrade products by combining innovative designs.
In addition to selling own-branded products, Kamioka also fills OEM and ODM (original equipment/design manufacturer) orders, all of which are strictly inspected before delivery. The company currently concentrates on the U.S., European and Southeast Asian markets.
To ensure high quality production, over the past several years Kamioka has installed many state-of-the-art machine tools, including five-face machining center, CNC double-column horizontal machining center, horizontal machining center etc.
Kamioka boasts its vertical machining centers feature boxway and linear guideway for X, Y and Z-axis action, hence enabling a variety of high-precision cutting, engraving etc.