In manufacturing, improving productivity has always been a central concern. Today’s machining processes are characterized by multi-variety, small-batch production, tight delivery schedules, lightweight components, complex performance requirements, and intricate shapes. To meet these challenges, multi-tasking machine tools have emerged as a key solution. These composite machines allow for complete processing—from raw material to finished product—on a single machine, significantly boosting efficiency.
One of the main advantages of these machines is that they eliminate the need for multiple setups between different CNC machines, which traditionally accounted for 40% to 60% of the total production cycle time. By reducing waiting times and multiple loading/unloading steps, multi-tasking machines not only save time but also cut down on costs. For example, compared to using 2–3 traditional machines, a single multi-tasking unit can reduce steel material costs by more than double, save over twice the production space, and cut labor and energy consumption. Additionally, the one-time workpiece loading improves machining accuracy by minimizing installation errors.
Initially, Japan’s multi-tasking machines were based on lathes with added milling capabilities, as most lathe operations required secondary milling and hole machining. The goal was to combine these processes into one. However, recent developments have shifted the focus toward milling-based machines, with an increasing use of machining centers.
There are two major types of multi-tasking machines: turning-based and milling-based. Turning-based models integrate functions like milling, drilling, boring, grinding, and gear shaping into horizontal or vertical turning centers. Examples include Austrian WFL’s M65, Japanese MAZAK’s INTEGREX series, and German DMG’s machines. These machines feature advanced structures, such as high-rigidity beds and specialized linear guides, allowing for precise and efficient machining.
Milling-based machines, on the other hand, add turning capabilities to horizontal or vertical machining centers. For instance, MAZAK’s INTEGREX e-800V/5 and e-1550V10 models enable full processing of disc-shaped parts in a single setup, while the INTEGREX e-500HS allows simultaneous machining of two short shafts. Other examples include DMG’s DMC60S for bar processing and WILLEMIN’s W-518MT, which incorporate grinding or laser technologies.
Beyond these, there are various specialized multi-tasking machines, including those that combine grinding, laser cutting, stamping, and heat treatment. As these machines become more complex, software support becomes essential. However, the increased functionality brings new challenges, such as managing vibration, heat, and tool interference, which require advanced mechanical design and precise programming.
Maintenance of these machines is also more complicated due to their diverse features and custom accessories. Customers expect not only high performance but also long-term reliability, often demanding 24/7 operation. This makes fast, accurate, and continuous maintenance services critical. Moreover, the complexity of programming and operating these machines requires skilled personnel who can handle high-speed calculations and simplified workflows effectively.
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