The four-axis sliding headstock automatic lathe presented a dedicated user of cam automatics with a totally new perspective on machining flexibility and is now able to reset jobs in 2-3h.

Prior to installing the first Dugard Eagle 25 sliding headstock lathe that was available in the country at the end of 2005 managing director Paul Francis of Atlas Precision was a confirmed user of single spindle cam autos. Indeed, he is still making cams for his seven mechanically driven machines, but it seems their days could be numbered as he contemplates emptying a bag of 20,000 parts into his palm. The 1.27mm diameter by 2.5mm long parts featuring a 0.075mm spigot are produced from magnetic stainless steel and the batch is worth well over GBP 1,000.

But he maintained: 'I still have to second operation them on a capstan and that is simply not viable today even for a small company like us of five people.' Setting up the company in Sturminster Marshall, Dorset with the seven cam machines giving a capacity of 13mm diameter plus various other items of manual equipment, Francis was keen to enjoy 'being his own boss' and wanted to play golf at least once a week.

He had very little CNC experience and gradually, after employing a freelance salesman to give him more time to set and run the autos rather than interface with customers, he built up a customer base of 10 companies.

However, the downside was that it was taking a day to change over parts on the cam machines and the golf was really suffering.

Then, the chance to win a larger diameter component contract with an automotive related company got him thinking that perhaps newer technology had to be a better solution.

Checking out the sliding head machine market led to a bit of a shock to his planned investment budget and then a chance meeting with the C Dugard technical sales engineer led him to be able to go CNC in a cost-effective manner with a new sliding headstock Dugard Eagle 25.

The machine, with a starter tooling package, was going to cost less than a third of other machines he was considering.

With the contract won and with driven tools on the Eagle 25, Francis realised he was now in a totally different business.

The four-axis Dugard Eagle 25 was sold as a 'ready-to-run' package with an automatic three metre barfeed, parts-catcher and chip conveyor.

The servo-driven counterbalanced sliding headstock design had a maximum turning diameter of 26mm by 165mm long.

With up to 18 tool positions, axial and radial milling attachments, six stationary tools, as well as three driven tools for endworking and four driven tools for external features, Atlas Precision was presented with a totally new perspective on machining flexibility.

Suddenly he was able to reset in 2-3h, run unmanned overnight then go back to the factory after five to six hours to re-bar and check the condition of the tooling and parts.

He said: 'I also found I was able to run a stainless job in the day, breakdown and run brass through the night and change back to stainless.

Then, once I really got into understanding tool life and tolerance drift on jobs, I became confident to change tools before I went home and knew the machine would run for 12 hours or so unmanned, even on some of the stainless materials.

In around four months, I must have run 60 to 70 different jobs on that machine.' He was now producing parts in brass, bronze, plastics, mild and stainless steel, Tufnol and aluminium and so successful was the installation that within four months, the capacity of the Eagle 25 was filling up.

An order for 28,000 model train wheels in nickel silver, involving turning with radii, angles, back forming, drilling and broaching of internal grooves was won just before the MACH 2006 exhibition at the NEC in May, to be followed with an enquiry for 20,000 larger wheel sizes that were out of the capacity of the Eagle 25.

This prompted Francis to take a day out at the NEC with cheque book in hand to extend his capacity.

He said: 'After a few hours scouting, I ended up on the C Dugard stand deciding that the newly launched and larger capacity Eagle 32 best met my needs and budget.

Most importantly for me, this subspindle machine gave me the opportunity to move my business on again by providing 'single-hit' mill and turn complete cycles.

As I have common tooling and control systems I decided to sign up to have the show machine delivered from the stand.' The Eagle 32 has seven axes and carries 22 tools, of which seven are driven.

It has a three metre barfeed, chip conveyor and an outfeed conveyor and a Y-axis cross feed.

the Y-axis has enabled Paul Francis to mill flats giving an added bonus of no longer having to order hexagon bar.

Already, on some parts he has combined five to six separate operations into one cycle.

'This was work I would have previously declined because of the cost and time to tool up even when using simple jigs and fixtures.

Now parts come from the machine into the wash and are packed with no risk of marking or damage.

What also makes it easier for me is that I know the relative position of different features is correct due to the single operation.' Even though the Eagle 32 has not been installed for very long, using the subspindle requires different thought patterns to lay down the best method for a job.

Following training on the Eagle 25 most of the jobs being set simply involve modifying existing programs at the machine control.

Francis cannot believe the transition of his business and he is fascinated by what can be achieved at the machine.

Is he planning to spend more time on the golf course?

Not yet.

'I want to stay small and enjoy the business and a bit later possibly take on a machine setter.

These cam machines have served me well but it has to be CNC for the future of the business,' he maintained.