September 21, 2012

Mikron Multistep XT-200: deep hole drilling with maximum precision and cost-efficiency

Agno, September 2012 - Using the Mikron Multistep XT-200 machining system, maximum-precision components can be produced rapidly and cost-efficiently. Even challenging deep hole drilling tasks can be carried out fully automatically within the shortest possible time. Take, for example, a Chinese automotive supplier that manufactures nozzle holders for injection engines.

In a common-rail engine, the diesel-air mixture is propelled through the injection nozzles and into the cylinders at pressures of up to 1600 bar. The nozzles are just 1.5 millimetres wide, a fact that placing correspondingly high demands on the Chinese automotive supplier's nozzle holders. The company manufactures a total of 400,000 nozzle holders a year in three different variants. Previously, the manufacturer bought in nozzle holders from an outside supplier. But now that it has a Mikron Multistep XT-200 machining system, the company is able to produce these demanding parts itself.

60 times the diameter
The Multistep XT-200 converts the hardened and tempered steel blank into a ready-to-install nozzle holder. All the essential machining processes - drilling, milling and deburring - can be carried out in a single clamping operation. This ensures precision and cost-efficiency. The central feature of a nozzle holder is the through-bore, just 1.5 millimetres wide and 90 millimetres long. With one of the variants, this can be produced by deep hole drilling from both ends. For the other two variants, however, a bore 60 times longer than the holder's diameter has to be deep hole drilled through the component. This is where Mikron Machining's extensive experience of the interaction between machine and tool comes into play: the Multistep XT-200's single-lip deep drill eats its way rapidly and accurately through the steel. Deep drilling oil that has been brought up to the correct temperature by an add-on to the machining system is constantly injected through the integral cooling channel. Later in the machining process, a second deep-hole drill deburrs any cutting waste caused by transverse drilling. After just 50 to 80 seconds - depending on the variant - the Mikron Multistep XT-200 has produced a finished nozzle holder.

Mikron Multistep XT-200
The Mikron Multistep XT-200 machining system combines the productivity of a transfer machine with the flexibility of a machining center. The system consists of a loading and unloading module and of up to four machining modules. The machining modules contain two working spindles, each of which can access a magazine disk with 18 tool slots. Workpieces with dimensions of up to 200 x 200 x 200 millimetres can be machined on up to five and a half sides without the need for re-clamping, even when being transported between modules. The chip-to-chip time is less than one second. A range of measuring and monitoring systems, the clamping device with EROWA interface, the rigid design and the stable B/C axis all guarantee maximum precision.

Video: Multistep XT-200 in action

Brief profile of Mikron Machining
Mikron Machining, a division of the Mikron Group, is a leading supplier of customized, highly productive machining solutions for the manufacturing of complex high-precision components made of metal. The division's most important market is Europe, primarily Germany. The Asian market is becoming increasingly significant. Mikron Machining comprises three production companies, namely Mikron SA Agno (Switzerland, headquarters), Mikron Tool SA Agno (Switzerland) and Mikron GmbH Rottweil (Germany), as well as the sales and service company Mikron Corp. Monroe (USA). It employs around 500 people. Mikron Machining is part of the Mikron Group.

Mikron SA Agno, Axel Warth, Head of Marketing and Business Development Phone +41 91 610 62 45,

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Deep hole drilling with maximum precision and cost-efficiency (pdf)
Tiefbohren mit höchster Präzision und Wirtschaftlichkeit (pdf)