One of the huge advantages of a Hurco is the architecture used in the control system. Not just the fact that the control is a full PC, but the way it is integrated into the control hardware. The servo’s, drive’s, amplifiers and all the components that make up the “motion control” are what would be called the “architecture.” On a Hurco it results in faster cycle times by around 30%. They print that directly into the brochures and on the quotes. They stand by it. I usually guarantee 20% knowing that I will beat it. Even though it is something well documented with plenty of YouTube videos to back it up, its hard to understand how. If its the same g-code on both machines and you do not change anything, use the same tools, how is it faster?
I was delighted with the chance to put the numbers to the test when the head of Hurco Engineering approached Gage Machine Tool with a cycle time study. They needed a customer with a new Haas VF2 to run a specific set of programs with no alterations for a comparison to a Hurco. I happened to have a customer close by that had a new Haas VF2SS and figured that would be a perfect fit. You can see a below what the part program looks like out of Hypermill. Hurco Germany had been tasked with making a set of programs for machining the sample part. The study was actually being done for a large potential customer in India. (programs are in metric)
The way that Ultimotion works on the Hurco can be thought of as driving a sports car down a country road. The road curves up and down and around hills and you can only see so far ahead. You wish you could take the road at the posted limit of 60 MPH but you have to slow down for the curves otherwise your off the road and into a ditch. This is the way motion control works on every g-code CNC on the planet. Its called block look ahead. The control can only see so far in front of it and has to react as quickly as possible for the curves. The Hurco however has “infinite” block look ahead. Before the first tool is even cutting the control has read the entire program and knows the track better than Dale Earnhardt. On a g-code machine it has to slow down just a touch to make that curve, this does not happen on a Hurco. The graphic below shows how Ultimotion improves on a standard move from one location to another and can hit full rapids with a slight arc move. The graphic is drawn to exaggerate the arc and show how it is above the retract plane. There are simply fewer times that the machine has to stop and start. (6 versus 3)
This becomes obvious when you look at the differences in cycle time below as compared on the Haas VF2SS and a Hurco VMX24.
Program 1 (21% reduction)
Haas: 49 min 59 sec
Hurco: 39 min 27 sec
Program 2 (7% reduction)
Haas: 1 min 35 sec
Hurco: 1 min 28 sec
Program 3 (39% reduction)
Haas: 41 min 41 sec
Hurco: 25 min 33 sec
Was not needed
Program 5 (49% reduction)
Haas: 1 hour 14 min 59 sec
Hurco: 38 min 15 sec
Program 6 (40% reduction)
Haas: 2 hours 1 min 7 sec
Hurco: 1 hour 12 min 28 sec
The more complicated the geometry and the longer the cycle time is has some impact but that is not the whole story. By a percentage it would be better to look at it as a curve where you almost reach 50% reduction in cycle time. The geometry itself plays a role in how much time you save. If you think back to that country road it starts to make since.
A simple part that has a 3 minute cycle time on a g-code machine would see a small reduction in time on the Hurco, perhaps down to 2 minutes and 30 seconds. Maybe that’s trivial for a 5 part run? True, I’ll give you that. But if you can save say 15 seconds of run time or more on every single part you run for the whole year with out any effort on your part, what’s that add up to? Let’s look at some numbers since we are all numbers guys really.
15 seconds X 1000 parts = 15000 seconds = 250 minutes = 4.17 hours
I know you run more that 1000 parts a year on one machine but I’m being conservative. If we run the numbers again with something more like what a typical job shop run they would look like this;
6.5 hours of up time on a CNC Mill per day
5 minute average cycle time (IF this sounds slow or fast for your parts then change it)
78 parts per day
220 days of operation per year
17,160 parts in a year.
So that sounds high? How about we cut that in half for the sake of the argument. I don’t know about you but if my machine was only running 3.25 hours a day I would fire someone (and I have).
So that puts us at 8,580 parts a year off the machine.
If we stick to the 20% faster cycle time that’s a whole minute saved. On a Hurco it would be 4 minutes instead of 5 minutes. Run the equation again;
60 seconds X 8,580 parts = 514,800 seconds = 8,580 minutes = 143 hours
If you shop rate is 80/hr (seems kinda low) then you just saved $11,440 worth of production costs on all your parts. Even if you are just running the machine 3.25 hours a day. You can do the math and figure out how much you save if you run your machines all day across two shifts, three.
If you want a personal demonstration of how this works you can download the g-code program yourself and run it on your machine. See the cycle time you get and then come look at it on a Hurco. You can do that at one of our showrooms or at one of our customers. Just give a call or send us an email.
We spent a day with Dan McMurray from Alpha Industrial Supply trying to break his tools. Bottom Line, we could have, but decided to stop once we hit 482 ipm feed rate in 32Rc 4140. You heard that right. Those sound like common feed rates for Aluminium, but it was 4140. We also slotted a 1/2” Endmill, 3/4” Deep in that same 4140, ran it at 47 ipm at 4800 RPM’s. The finish was incredible. Dan has been looking for machines he could really load up his tools on and show what they could do. He stressed that there best fitted for a CAT50 machine with a ton of torque. He was amazed that our little VMX24, CAT40 12k Spindle took it like it wasn’t even there. It wasn’t until we hit that 482 ipm that we got above 80% spindle load. Have a look.
Even on simple parts, 5-Axis is the future of machining because it can reduce set up time and speed production. Product Specialist Mike Cope covers many of the benefits of using a 5-Axis machine for small batch, quick turn around jobs.
Dirk Gage Got to be a part of the 50th Anniversary party at NASDAQ
Hurco executives rang the closing bell at the Nasdaq stock exchange June 13, 2018, as part of its 50th anniversary celebration. In addition, Hurco was featured on the NasdaqTower and Marquis in New York City. (Skip to the end of the video above to see footage of Hurco appearing on the building’s giant projector screen.)
The Pocket Rocket
Hurco has been making updates and changes to there line in an almost continuous fashion for years now. This year alone has seen new software released for the mills, updated ballscrews on the VMX lines for faster rapids and travels, an update to the design for the VC 5 axis machines and now the addition of the "Plus" option to the VM line.
Standard Hurco VM10i - 10k spindle
New Hurco VM10i Plus - 12k Spindle with a chiller
This update also applies to the VM20i and the VM30i as well.
It actually makes for a tough decsion on which Hurco to buy since the VMX24 and the VMX30 have 12k spindles as well. It really comes down to torque between these machines. If you need higher torque, then the VMX line os for you. But if your like most job shops and run into a variety of materials and the torque loads are not really a major factor, then the VM line, now with a 12k CAT40 Big Plus spindle just may be a perfect fit for you.
Select models of Hurco CNC machines are made in the USA with globally sourced components. At our facility in Indianapolis, Indiana, the VMX42i and VMX6030i are fully assembled by Hurco employees. The build team hand scrapes machined surfaces; grinds mounting and surface plates; aligns castings, ball screws, mechanical housings, rails, and tool changes; drills and taps assembly and mounting holes. Additionally, the Indy build team completes a comprehensive inspection and certification process for each machine.
What are the main reasons you buy any machine? Do you buy the same type of machine as what you already have? Do you buy what your father always bought? Why do I keep buying those same crappy chips for Cinco de Mayo? Sometimes you need to step outside of the box you made for yourself and really questions why your doing what your doing. A better way may save you a ton of money, and make for a better Cinco de Mayo. (I swear thats how you spell it, but I am reading it may-o)
A beautiful quick little video on how well Fusion 360 works for complex parts on a Hurco 5 Axis. MJK is a real success story on how you can accomplish anything on the right platform.
Last week we held our first ever online training course. That sounds really stupid, it's 2018, where the hell have we been since like 2005? Anyway, we got our first one in the can. It went really well with a total of 9 attendees by the time we got finished. There were a few guys who couldn't make it on but that's okay! Because we have it right here for everyone to watch, and re-watch. We would love to hear your feedback on the class either here, on youtube or just send us an email directly.