MODIG places great importance on extrusion machining, a fundamental part of their operations. They were the first company in the world to manufacture and introduce an extrusion machining center that included rotary tables, and they have since then perfected their process to achieve unmatched speed and resource optimization. In this blog post, we will exclusively focus on MODIG's unique approach to extrusion machining.
The local radio in Kalmar, Sweden, whispers an intro from the past, still giving me goosebumps as I watch the HHV extrusion machining center in action. I know there's something in the wake of your smile. I get a notion from the look in your eyes, yeah. You've built a love, but that love falls apart. Your little piece of heaven turns too dark... You have probably already figured out the song from the late 80s with Roxette and a fun fact is that the official music video was recorded in the Borgholm Castle, only 15 km (9.32 miles) from Kalmar, where Modig's headquarters is located. See for yourself.
But, while standing on the production floor and singing quietly to myself, the Swedish style, I made an exciting realization. There are similarities between an immortal pop song and an effective machining process. Just like a song's lyrics and music must harmonize and hold significance to resonate with the audience, a machine's components must collaborate flawlessly to ensure optimal efficiency. Only some songs become timeless, and some machining processes succeed. Listen to your heart is a classic, and the Modig extrusion machining process is equally remarkable, according to the Modig website, with up to 70% cycle time reduction. What sets this process apart, and what is the key to its many benefits?
Extrusion machining: the Modig way
To clarify the distinct Modig process, I utilize the HHV machining center. With its four or five axes and one or two spindles, this horizontal machining center is designed for high-volume production. The HHV can machine any extrusion shape up to 6 x 10 inches (150 x 250 mm) in size, with no limit on length.
The machine is standing idle, just as prepared as a 100-meter runner waiting for the starting shot in the Olympic game final. Ready, steady, go. Let the machining process begin. The raw material is loaded from the left in a precise procedure that looks like passing a sewing thread through a needle eye. The loading could be done manually or with an automatic infeeder or robot solution to improve productivity.
After the raw material is loaded, the machine performs its magic and automatically pulls it into machining positions without the need for pre-cutting. This aspect distinguishes the Modig process, setting it apart from other extrusion processes that require pre-cutting before machining. With HHV, as I understand it you can easily machine extrusions at full length and machine multiple parts, all from the same piece. This not only saves time but also reduces raw material waste significantly.
Complete parts in one setup, no work holding
One of the secrets behind the efficient Modig way of extrusion machining is the ability to complete parts in one setup, in contrast to standard machines that often require multiple setups. The rotary chucks are the superheroes that clamp, rotate, slide, push, and draw the part/profiles during the machining process so the operator does not have to stop the machine and turn or adjust the workpiece during the machining process. The HHV enables the spindle to access and machine all sides of the workpiece automatically, resulting in a significant reduction in machining time and improved quality of the finished part. After machining, the machine delivers the finished parts into a part catcher.
Automatic tool change and automation
All tools are switched automatically without human intervention during machining. But what undoubtedly ensures that the operator has time for a Swedish fika is the option to combine HHV with an in- and out-feeder, robot solution, or a complete production cell.
The secret to Modig's extrusion machining process's success lies in automation. Their innovative approach, letting you reallocate personnel to more labor-intensive tasks, allows parts to be produced in one setup without any pre-cutting or work holding requirements. The outcome is often a decrease in machining time and an improvement in the quality of the finished product.
Learn more about the Modig way of extrusion machining!