A recent contract involving the rough machining of a large, heavy mould tool part for the automotive industry shows how Lodestar Engineers' correct combination of CNC machining technology and producti
A recent contract involving the rough machining of a large, heavy mould tool part for the automotive industry shows how Lodestar Engineers' correct combination of CNC machining technology and production engineering capability enables the company to compete effectively with heavy-duty sub-contract precision machinists at both home and abroad. Using a large capacity Soraluce SP8000 CNC milling machine supplied by Ward CNC of Sheffield, Lodestar Engineers was charged with the rough machining of one half of a mould tool for the upper cargo deck for a planned new sports car. The one-off P20 tool steel blank measuring 1,930 mm by 1,170 mm by 310 mm thick and weighing 5,500 kgs was hardened and tempered to 230-325 BHN.

The steel was produced in Germany and shipped to Lodestar's Sheffield site, to be roughed out to within 1.5 mm of finished size - and reduced to 3,250 kgs - then returned for finish machining.

Says Tony Rushforth, general manager of Lodestar Engineers: 'To satisfy the customer's exacting requirements for both quality and delivery, we processed the mould in a single setting on our Soraluce SP8000 travelling column, bed-type CNC milling machine.

'Using CAD data from a CATIA model fed directly into the machine's Heidenhain 426 CNC system, we ran the machine non-stop around the clock, stopping only to change carbide tool tips.

Indeed, even with the high and constant rate of metal removal, no downtime was incurred for cleaning because the Soraluce's swarf conveyor more than coped.

'The capability of the Soraluce machine meant we were not only able to meet the demands of this contract but it also illustrated to the customer the wisdom of our 'job in-job out' philosophy.

This consistently proves the most cost-effective machining route for the wide range of medium to heavy machining applications we process.' Equipped with indexable head and 40-station automatic toolchanger, the Soraluce SP8000 at Lodestar is one of a range of Soraluce CNC milling machines supplied by Ward CNC.

It has a 28 kW spindle and a working area of 8,000 mm by 1,100 mm.

Developed under the auspices of the Danobat Group's IDEKO research and development facility in Spain, Soraluce machines combine high-quality build and technologically advanced features for unmatched heavy-duty milling performance.

With characteristic build qualities of stability and rigidity based on a heavy-duty cast iron construction, the resultant high-accuracy machining is ideal for applications in the heavy machinery, fabrication, power generation, equipment, heavy sub-contract and aerospace industries as well as mould and press tool manufacture.

Ward CNC's Soraluce CNC milling machines are available in three variants - TL, TR and TF travelling table types; SL, SP and SM travelling column, bed types; and FP, FS and FR travelling column floor types.

Capacities range from 1,500 mm to 16,000 mm plus in the X axis, from 1,000 mm to 3,600 mm in Y and up to 1,500 mm in Z, with the latest linear guideway technology offering rapid traverse rates up to 15,000 mm/min.

Of five- and six-axis configuration, high-speed models with electro spindle are also available.

Other options include universal or orthogonal automatic indexing heads and two-axis gyroscopic head for five- and six-axis applications.

Automatic toolchangers with up to 80 stations or more can be provided.