Horizontal Machining Center – The Ultimate Guide

Among the most common CNC machines is the horizontal machining center. It is an advanced technology allowing for diverse machining processes.

In this guide, we will explore all fundamental aspects about horizontal CNC machining center. From advantages, classification, working principle to applications, among other critical aspects.

Let’s dive right in.

What is a Horizontal Machining Center (HMC)

A horizontal machining center allows you to perform various machining operations in manufacturing environments similar to a vertical machining center. However, you find the configuration of tooling different in that it is parallel to the floor.

Advantages of Horizontal Machining Centers

When using a horizontal machining center for your manufacturing works, you are able to execute several milling operations alongside many other advantages:

1. This type of machining centers is efficient in removing chips utilizing gravity assistance. You find this is because of the horizontal orientation which reduces accumulation of chips that can otherwise damage the tool and workpiece.
2. With a single set up, you find a horizontal machining center can perform machining operations on multiple faces of a workpiece. As such, you can greatly cut on the production times of workpieces and support large volume production.
3. Since you can perform a wide range of machining operations on even complex geometries, this type of machining center is highly flexible. You can therefore implement this machine where there’s need for high volume and diverse part production.
4. The capability of a horizontal machining centers to hold numerous tools helps you automatically switch between different machining operations seamlessly. The reduced manual intervention makes these machines highly versatile allowing you to produce a variety of parts with shorter time frames.
5. The efficiency and automation capacity you derive from HMCs reduces need for skilled labor, lowering overall costs. Additionally, their reduced set up times and high productivity makes these machine type cost-effective for large-scale production.

Structure and Components of Horizontal Machining Center

As a modern technological piece, the horizontal machining center features several distinguishing developments. These allow the machining centers to operate with high efficiency and precision. Its primary parts and components include:

• Frame: Consisting of the base and column, the frame of a horizontal machining centers supports the entire machine. The horizontal machining center frame is made from rigid material capable of absorbing vibrations during operation.
• CNC: As the driving force of a horizontal machining center, you find the CNC system interprets and executes machining designs. The CNC system is behind the automatic operation of the spindle and tool change.
• Spindle: The spindle is housed within a head and holds the cutting tool when operating. The spindle can rotate and in a horizontal machining center, you find it moves up and down.
• Worktable: The worktable is where you place the workpiece during operation. You can find rotating worktables allowing you to turn the workpiece for multi-sided machining.
• Tool Magazine: You utilize a tool magazine for tool storage in your horizontal machining center. A tool magazine allows you to conveniently access different tools during operations.
• Control Panel: Through a control panel, you can interact with the horizontal machining center parameters. You can input commands and set parameters while monitoring the machining process.

Working Principle of a Horizontal Machining Center

The working of a horizontal machining center revolves around the removal of material from a workpiece to achieve a desired shape. The machining process is CNC controlled and can be summarized thus:

• You mount the workpiece onto the worktable from whence it will be worked upon by the machine. You can utilize a rotating table to allow rotation of the workpiece.
• Thereafter, you load the CNC program into the machine. The program contains instructions for the machining process.
• Load the required tools for the machining process into the tool magazine. When you start the machine, the CNC system selects the appropriate tool of operation.
• The horizontal machining center removes material from the workpiece according to the CNC program instructions via a rotating spindle. The process is highly precise and repeatable.
• Apply a coolant to the cutting area for lubrication, to reduce heating and removing chips.
• You observe movement of the spindle and worktable in defined axes to achieve precise and complex machining operations. This machine operates along the linear axes (X,Y, Z) and rotational axes (A and B).

Machining Processes Executed by a Horizontal Machining Center

You can undertake several machining processes in a horizontal machining center. Some of these processes include:

• Drilling: Here, you use a drill bit to create holes of different forms in a workpiece. This can be center drilling, spot drilling, and deep hole drilling.
• Milling: In this process, the cutting tool rotates around the workpiece shaping it as required. There are different types of milling operation you can perform such as face milling, slab milling, or end milling.
• Tapping: With this method, you cut internal threads into a drilled hole. A tap rotates advancing into the hole.
• Boring: When boring, you enlarge a pre-existing hole using a boring head or a single-point cutting tool.
• Reaming: This finishing process allows you to enlarge and smoothen a hole’s interior surface to high accuracy.
• Profiling: Allows you to create complex shapes and contours on the workpiece edges.

Types of Horizontal Machining Centers

Horizontal machining centers are available in different configurations allowing you to meet different machining needs and applications. You find diverse basis for classification including size and axes of operation.

• Small, Medium and Large: This classification based on size defines your component sizes while influencing your production volume. You can use small and medium machining centers for low volume compact components. For large and heavier workpieces large machining centers are ideal.
• 3-Axis HMCs: You can operate these machines along the three linear axes: X, Y, and Z useful for traditional machining tasks.
• 4-Axis HMCs: These machines allow you an extra axis of operation alongside the three linear axes usually rotational (A or B).
• 5-Axis HMCs: A machine of this capability will offer you greater reach in machining moving in all the primary linear and rotational axes.

Factors to Consider when Selecting an HMC

When approaching a horizontal machining center manufacturer or distributor, you should consider factors critical to your production needs.  Some of these include:

• Since there are spindle with different speed ratings, chose one that matches your material and production requirements.Tougher materials will require you to engage higher spindle speeds and power.
• Where your designs include several operations with specialized tools, a larger tool magazine is advantageous. With that, you can easily achieve your operations adequately.
• When making large components and parts, the horizontal machining center you select should be capable of handling large workpieces.
• While these machines are CNC controlled, the level of automation differs from one machine to another. When anticipating large production volumes, go for fully automated machines to increase tour production speeds.
• Like any other capital investment, cost is critical. Ensure you do not go overbudget while bearing in mind the operational costs.

Maintenance of a Horizontal Machining Center

It is important for you to undertake maintenance of your horizontal machining center to ensure longevity in performance. This will allow you to extract maximum use of your investment over its useful service life. Some effective maintenance measures are captured below:

• Check the lubrication oil for the spindle and inspect the level of coolant levels refilling when below the expected levels.
• Perform a wear and tear check on all movable parts replacing them where necessary.
• Check the machine’s alignment, recalibrating if necessary to maintain accuracy.
• Inspect hydraulic fluid levels, filters, and lines for leaks or damage lubricating ball screws and linear guides for smooth operation.
• Conduct regular vibration analysis to detect early signs of wear or failure in the spindle, bearings, and other rotating components.

Applications of Horizontal Machining Centers

The versatility of machining centers of horizontal orientation makes them indispensable across a wide range of industries. You can utilize these machines in the following industries to high efficiency and success:

• In the automative industry, you find these machines critical in the machining of engine components like cylinder blocks and transmission systems.
• Large structural aircraft components like wing spars, fuselage frames, and landing gear are machined using horizontal machining centers.
• In the medical industry, you find horizontal machining centers used to make examination equipment and orthopedic implants.
• Weapon systems like missiles, firearms and armored vehicles in the defense industry are machined by horizontal machining centers.
• You find use of these machining centers in making heavy industry and mining equipment like generators and drilling rigs.
• Industrial parts and component manufacture is aided by horizontal machining centers which you find utilized in mold making.

Conclusion

You benefit in many ways when integrating horizontal machining centers in your machining operations. As such, investing in this equipment helps optimize your production while improve quality, thereby enhancing your competitive edge.

More resources:

Horizontal vs. Vertical CNC Machining Center – Source: TSINFA

Horizontal CNC Milling Machine – Source: TSINFA