What Are the Advantages of Horizontal CNC Machining Center Supplier？

A machining centre is a critical component of any modern machine shop, and choosing between a Vertical Machining Center (VMC) and a Horizontal Machining Center (HMC) can significantly impact productivity, profitability, and machining efficiency. Many manufacturers have long relied on vertical machining centres, but the benefits of horizontal machining centres are becoming increasingly evident. 

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This article explores the considerations when expanding or upgrading your CNC machining centre. 

Why Adapting to Change in Manufacturing Matters 

As technology evolves, so do machining techniques and strategies. Manufacturers must carefully consider the advantages of new machinery to maintain a competitive edge. The ability to compete in today’s market depends on investing in efficient machine tools that optimise uptime, throughput, and precision. Whether you are expanding or upgrading your CNC capabilities, considering the advantages and disadvantages when expanding is crucial to making an informed decision. 

The Debate: Vertical Machining Centers (VMC) vs. Horizontal Machining Centers (HMC) 

We’re building a case for how an HMC is the most cost-efficient investment for your machining needs. However, we will go through the features of both VMC and HMC, and suggest with evidence which one suits well for which needs. 

Vertical Machining Centers (VMC) 

A quality VMC may be the machine of choice for many businesses due to its affordability and ease of use. Vertical CNC machining is a cost-efficient solution for manufacturers producing simple workpieces that require minimal part handling. However, VMCs often have longer cycle times and require more human intervention, which increases labour costs and potential human error. 

Horizontal Machining Centers (HMC) 

HMCs, on the other hand, provide significant advantages in complex machining applications. One HMC instead of multiple VMCs means fewer fixtures, reduced setup times, and improved throughput. Horizontal machines are designed with a horizontal spindle, which allows for greater access to the workpiece, making them ideal for machining operations that require precision and accuracy. 

The ability to perform multiple machining techniques in a single operation enhances productivity and surface finishes, making HMCs the preferred choice for high-quality machined parts. 

What Are the Benefits of an HMC for Your Business? 

1. Increased Productivity and Efficiency 

One of the key benefits of horizontal machining centres is their ability to handle multiple workpieces simultaneously. The rotating cutting tools in an HMC allow for fixture-to-fixture transitions with minimal downtime, resulting in higher uptime and improved machining technology. Instead of multiple VMCs means fewer fixtures, which streamlines the milling process and enhances throughput. 

2. Better Precision and Accuracy 

HMCs offer superior precision and accuracy, reducing human error and ensuring consistent material removal from a workpiece. This makes them an excellent choice for industries requiring high-quality machined parts. The horizontal orientation of an HMC provides better access to the workpiece, making it easier to produce complex parts with intricate designs. 

3. Cost-Efficient Solution with Reduced Setup Times 

HMCs can replace three VMCs by performing multiple machining operations in a single setup. This eliminates the need for multiple fixtures and reduces setup times, making HMCs a cost-efficient solution for businesses looking to optimise their machining needs. The ability to machine a six-sided part with only three touches by the operator significantly improves efficiency and reduces part handling. 

4. Improved Tool Life and Surface Finishes  

Horizontal and vertical milling processes differ in their impact on tool life and surface finishes. In an HMC, chips fall away from the cutting tool and workpiece, preventing recutting and extending tool life. This results in better surface finishes and higher-quality products. The horizontal milling process also enhances the ability to remove material from a workpiece more efficiently. 

5. Optimal Use of Floor Space 

Manufacturers must consider the optimal use of floor space when choosing between an HMC and a VMC. Horizontal machines typically require less floor space compared to multiple VMCs, making them ideal for facilities with limited room. Their efficient layout improves workflow and ensures that machining centres offer the best possible use of available space. 

Conclusion 

Choosing the right machining centre for your business requires careful analysis of machining technology, machining operations, and part handling needs. While VMCs have their place in the industry, the benefits of horizontal machining centres outweigh the disadvantages when expanding or upgrading. 

HMCs provide increased productivity, reduced labour costs, and superior precision, making them the preferred choice for complex machining applications. That’s why it’s important to carefully consider the advantages and disadvantages before investing in a CNC machine. 

Look for an easy, reliable, and safe machine loan option that will help your business scale up. 

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FAQs 

What is a horizontal machining centre (HMC)? 

A horizontal machining centre (HMC) is a CNC machine designed with a horizontally positioned spindle. This setup is well-suited for high-volume production, heavy-duty cutting, and machining multiple surfaces efficiently. 

How is an HMC different from a vertical machining centre (VMC)? 

The key distinction between the two lies in spindle orientation: an HMC features a horizontal spindle, whereas a VMC has a vertical spindle. HMCs excel in large-scale production, accommodating bigger workpieces and ensuring superior chip evacuation. 

Why should I consider investing in a horizontal machining centre? 

Choosing an HMC comes with multiple advantages, such as quicker production cycles, enhanced chip removal, improved surface quality, and the capability to machine multiple sides of a part in a single setup, boosting overall efficiency. 

Which industries benefit the most from horizontal machining centres? 

HMCs are widely utilised in sectors such as aerospace, automotive, heavy machinery manufacturing, and medical device production, where precision, efficiency, and the ability to handle complex or large parts are essential. 

How does an HMC enhance productivity? 

HMCs streamline machining by enabling multi-side processing within a single fixture setup, reducing setup time. They also offer higher spindle speeds, quicker tool changes, and superior chip management, leading to shorter cycle times and greater production output.

Changing a three-axis machining process from a vertical machining center (VMC) to a horizontal machining center (HMC) offers many benefits including increased spindle utilization time, less part handling, and expandable automatic tool changers (ATC) and automatic pallet changers (APC).

These advantages result in increased tool capacity and manufacturing productivity.

For example, horizontal CNC machines are equipped with massive ATCs compared to their vertical counterparts that ultimately drive a machine shop's productivity.

"The more tools you have on a machine, the more jobs you can have lined up," said Bernie Otto, Methods Machine Tools’ director of technical product support. "And that means less manual intervention and less changeover time.”

Many horizontal machine tool brands are equipped with ATCs that can be expanded the field. Machine tools offered by KIWA Machinery Co. LTD. have ATCs with a capacity of 120 tools. With technology from Methods, this capacity can be doubled. In as little as a day and a half, Methods' can upgrade that capacity to 240 tools. Similarly, CNC machines from OKK Corp. can be outfitted with another tool rack, raising the tool capacity from 60 to 120 tools.

“Expandable ATCs are versatile options that allow you to scale your machining capability as your shop grows,” Otto explained. “You don’t have to pay for anything you don’t need upfront, and when the extra work comes, you can double your tool capacity almost overnight.”

With a tool capacity well into the double digits, it's easy for a machine to handle many different jobs or implement redundant tooling to ensure a machine can run lights-out for extended periods.

Otto said that even without expandable ATCs, most horizontal machines are equipped with more tools from the get-go. Vertical machines typically start with 30 to 40 tools, while horizontals come with 60 to 90 tools standard.

“In most cases, going from a vertical to a horizontal machine automatically gives you a tooling advantage,” Otto added.

Expandability

APCs are another aspect of horizontal CNC machines that machine tool suppliers can expand in the field. The majority of horizontal machining centers come equipped with a two-pallet pallet changer (PC2).

The reduction of part-handling alone is a stark difference. A stand-alone vertical machining center can reach about 40% efficiency, while a horizontal CNC machine equipped with a standard PC2 has an efficiency of about 85%.

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While vertical machines can also be outfitted with APCs, horizontal machining centers are more adaptable.

“If you put a pallet changer on a vertical machine, the net floor space could be greater than a horizontal,” said Bob Meier Methods’ technical product manager. "Plus, once you integrate an APC into your vertical machine, the price becomes comparable to a horizontal machine with a pallet changer."

Additionally, Otto said, horizontal CNC machines are more suited to linear pallet systems. These options are well designed for machines sharing a pallet pool or adding a significant number of pallets and pair well with a horizontal machine.

“Most verticals do not easily lend themselves to this kind of format,” he added.

Benefits of the B-Axis

Of course, the most apparent feature of a horizontal CNC machine is the B-axis, which allows users to machine multiple parts simultaneously using a tombstone.

A tombstone compared to a vertical machine offers more productivity, said David Moore, an applications engineer at Method Machine. While a cycle runs and machines numerous parts, the operator can prepare the next tombstone to maximize production.

“You can hit multiple parts in one setup instead of having to do each part individually,” he said.

Adding that axis opens up a world of machining possibilities. Whether you're looking to take on a larger workpiece, cut down your current cycle time, or accept a job with complex tool paths, horizontal machining should at least be an option.

“Anything with multiple setups that need to have three sides machined should be a candidate for horizontal,” added Moore.

Making the Switch

Horizontal machining edges out vertical machining in several ways. But implementing a new machining process is a little murkier. Transitioning from vertical to horizontal isn’t as easy as flipping a part on its side.

“You have to open yourself up to new ideas and consider new options,” Moore said. “One of the worst things you can ever hear is ‘we’ve always done it this way.’’

One of the essential steps in determining if making the switch is appropriate for figuring out the return on investment. A horizontal machine may cost more, but it’s up to each shop owner and general manager to determine if greater throughput and lower cycle times are worth the money.

Feeding the Beast

Other challenges, Methods’ Otto noted, include programming multiple parts per pallet and programming probe cycles. Horizontal machines feature side-faced programming, which allows you to program a specific tool path for each side of the workpiece.

You probably have to introduce more probing into your cycles, especially if you plan to run unattended,” Otto said.

To keep your spindles running as much as possible, it's important to have material ready to load for each fixture, ensure other departments can handle the increased activity, and have a stable chip management system.

“Feeding the beast is the number one challenge,” Otto added.

Working out the Kinks

One company that is reaping the benefits of switching to horizontal machining is Alicat Scientific, which  manufactures precision mass flow instruments such as flow controllers, mass flow meters, and differential pressure controllers.

In July , Greg Camron, machine shop manager at Alicat Scientific, began looking at ways to increase throughput. Too many machine tool suppliers told him unimaginative ways he had already tried or told him it couldn't be done.

“The only thing I knew at the time was vertical machining, so that’s what they showed me,” he said. “Nobody else was encouraging me to try new things.” Nobody except Tony Harrod, general manager of Methods’ Phoenix, Arizona, technical center.

"Tony talked to me about different ways to machine our product," said Camron. “I found many different methods to do things, but only Tony showed me the benefits of horizontal machining and the great footprint.”

Alicat was equipped with five vertical CNC machines, one of which had a PC2 and a fourth axis. Camron found that the KIWA KMH 300 fit his machine shop's footprint and addressed machining challenges.

“The prices and the sizes were the factors that were limiting me,” he said. “Until I found the KMH 300, everything was huge. But in terms of floor space, switching from two vertical machines to one horizontal was a no-brainer.”

There was some trial and error with the first machine. Between figuring out the best way to implement tombstone tooling and workpiece holding, Camron ended up working 80 hours per week for a few weeks. Other aspects, however, were more straightforward. Since Camron used many "if/then" statements and loops in his CNC programming, the programs transitioned seamlessly to horizontal machining.

Learning the ins and outs of horizontal machining paid off. When other managers and directors realized the output one KIWA KMH 300 gave them, they asked Camron how soon they could get another up and running.

Less than two months later, the shop had another KIWA KMH 300. By the time Alicat received the second machine, Camron already had his fixtures and tombstones dialed in. The second KIWA was mass-producing quality parts within three days.

Soon, Alicat purchased two more KIWA KMH 300 machines, this time with PC6 pallet changers. The speed and versatility of the horizontal machining centers combined with standard automation solutions allowed Camron to shave approximately 50% off his cycle times compared to the vertical machines. Additionally, the automation allowed the shop to run lights-out during off-hours.

“The tombstone added a whole new dimension to our capabilities,” he said.

Eventually, Camron switched every machine to a horizontal machine.

“After the first one, I realized the restrictions of a vertical machine,” Camron said. “My imagination just opened up to everything possible in a horizontal."

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