for Jordan Grand Prix, a pair of Semco three-axis milling machines with their simple-to-use Anilam control systems are enabling this Formula One team to mount a consistent Formula One challenge.
In the glamorous, glitzy world of Formula One motor racing, the use of uncomplicated machining processes might seem an anomaly. But for Jordan Grand Prix, a pair of Semco three-axis milling machines with their simple-to-use Anilam control systems are playing a key role in enabling this Formula One team to mount a consistent challenge in the highly-competitive Grand Prix world. While Jordan's headquarters at Silverstone does feature a large-capacity, top-of-the range five-axis machining centre, the CNC milling machines are also considered by machine shop manager, Trevor Lecoche, as equally indispensable.

'All our machine tool purchases are justified on the basis of satisfying a specific production requirement while balanced, of course, by the available budget,' he says.

'That policy has not only seen our machine shop expand in six years from having two people and two machines (a turret mill and a lathe) to today's nine operators, but it has also prompted our investment in further CNC machines.

'The machining centre was purchased to enable us to machine gearbox casings complete, rather than having to rely solely on sub-contractors.

The milling machines, on the other hand, were installed for a totally different reason.' Explaining that, in addition to gearbox production, the prime function of the machine shop is to machine prototype parts and to produce one-off modifications, Trevor Lecoche points out how the need for flexibility is paramount when any new machine purchase is contemplated.

'We never know exactly from one day to the next what is coming through the door, so we need machines that can cope with all types and sizes of components - from the tiniest gearset, for example, through to floor planks measuring over 2m.' This, he says, was the criteria when he identified the requirement for a new milling capacity.

With 17 races in the Formula One season, and since Jordan this year instigated a two-car test programme, the machine shop is faced with a heavy, widely varying workload.

After each race, the cars are stripped down and, depending on need, component modifications are made to suit.

It goes without saying that these modifications are required quickly.

Jordan works in an environment of constant development - very few of the components featured in this year's cars will be used in the exact same form next year, so Trevor Lecoche and his team process a continual flow of workpieces of varying materials, sizes and shapes.

'The machine shop must therefore be flexible and able to respond to what our design and engineering colleagues need.

So, our machines - and the way we use them - must reflect that flexibility.' Following Jordan's success with a Semco LC-195-VS three-axis turret mill having Anilam 3300 MK control, the resulting good relationship with machine tool distributor, Derek Robinson Machine Tools (which also supplied Jordan with a two-axis Colchester Tornado lathe) came to the fore again nine months later when Jordan was looking to extend its milling capacity.

'While we liked the capacity and flexibility afforded by the Semco turret mill, and ideally wanted to retain that in some form, we also needed the flexibility of a manual quill.

We want to avoid lengthy and complicated set-ups, preferring the simple and quick approach where all we need to do is to clock a face and drill a hole, for example.

'Very few machines could offer that 'in-between' capability - in fact, most are high-end CNC types - and at first we weren't necessarily thinking about a bed mill.

But after outlining our machining requirements, and budget, to Derek Robinson Machine Tools, the three-axis Mastermill bed mill fitted the bill perfectly - especially because its 125mm quill travel can also be activated manually.' The Mastermill 800 has a table of 1,270mm by 318mm, and X, Y and Z axes travels of 800mm by 500mm by 500mm.

Spindle speeds are 70 to 3,800 revs/min and rapid traverse rates are 5m/min.

Corresponding figures for the turret mill are a table area of 1,270mm by 254mm, axes of 800mm by 430mm by 430mm and spindle speeds of 50 to 3,750 revs/min.

'Importantly,' adds Trevor Lecoche, 'while the machine specification is important, we are not too concerned about how long a certain machining operation will take.

We're more bothered about having the flexibility to handle a varying workload and being able to produce quality parts.' That apart, the fact that both machines feature Anilam controls also weighed heavily in the choice of the machines.

'Everyone here - myself included - has experience of the powerful functionality, yet user-friendliness of this control technology.

Anilam's conversational Machinist Language is easy to follow and makes shopfloor programming of even quite complex tasks so simple.' 'Some 75 per cent of the programs are created off-line by 2/2.5 and 3D CAM then DNC-fed to the machines, but the remainder are programmed on the shopfloor.

This is where the Machinist Language really comes into its own.' Trevor Lecoche also highlights the control's range of canned cycles as being particularly appealing.

These include: Irregular pockets - a simple routine of prompts produces clearances of shapes; Geometry - the geometry calculator, for determining points, lines and circles, automatically forms the program foundation; Bolt hole pattern and drill cycles are created by simple question and answer routines; and Graphics - program verification with user-friendly graphics and program text and CNC status displayed together.

'In conclusion,' says Trevor Lecoche, 'the Semco machines and their Anilam control systems have given us exactly the machining capability we wanted - and at the right price.'