Delcam, developer of PowerMILL, the world's leading multi-axis machining software, has released a free guide to high-speed machining.
Delcam, developer of PowerMILL, the world's leading multi-axis machining software, has released a free guide to high-speed machining. The guide, which is issued in CD format, contains details of the newer strategies now recommended for high-speed machining, together with guidance on the selection of the most appropriate strategies for a particular manufacturing operation. To obtain a copy, please e-mail marketing@decam.com.

The guide has been prepared in association with cutting tool specialists, H.R.

Pearce, Mitsubishi Carbide and Sandvik.

It highlights that there is much more to HSM than simply making the spindle turn faster and emphasises the need for a completely new approach to machining.

A range of examples is described in depth, with details of the machining strategies used and videos of the cutting process.

Delcam's PowerMILL machining software has long been regarded as the leading system for the generation of NC programs for high-speed machining.

As Delcam's experience of high-speed machining has grown, it has become increasingly apparent that companies introducing this technology cannot rely solely on a faster spindle speed to give the results they want.

Instead, a major change is needed in the fundamentals of the whole machining process before users can gain the full benefits of any investment in high-speed equipment.

The main requirements of the machining strategies are to keep the load on the cutter as consistent as possible, and so maximise the life of the cutter, and to minimise any sudden changes in the cutting direction that will necessitate a slowing in the cutting operation.

One of the basic changes in strategy needed to achieve these conditions is the use of offset machining for roughing rather than the traditional raster approach.

Whenever possible, machining should be completed from the centre of the job outwards to minimise any need for full-width cuts.

The initial advice for high-speed machining was to keep both the step-over and step-down small compared to conventional machining.

Recent developments in cutting tool technology mean that the latter restriction no longer applies.

Roughing with deeper cuts is now possible by using a ball-nose cutter with four or six flutes that can cut with the side of the tool.

The step-over, however, must still be comparatively small.

Cutting with the side of the tool can also be used to optimise finishing routines by working from the bottom upwards when finish machining steep walls.

Climb machining is recommended for all roughing operations, as this will reduce tool wear.

Although this approach does involve extra air moves, this time can be made up by maximising the speed of the cutting moves.

A combination of conventional and climb machining can be used safely in finishing operations where less than 0.3mm of material is being removed.

With both rough and finish machining arcing moves should be used when approaching and leaving the job.

Plunging onto the surface of the part should be avoided as this slows down the cutter and leaves a dwell mark on the surface.

When cutting corners, the radius of the cutter needs to be considerably less than the radius of the corner, so that the maximum contact distance can be kept to less than 30% of the circumference of the cutter.

This allows sufficient cooling to take place and also avoids a sharp increase in the load on the tool as it enters the corner.

For many shapes, finish machining can be carried out most effectively with a 3D spiral strategy.

This avoids the frequent changes in direction that can occur with both raster and offset finishing strategies, and so allows faster machining and reduces the wear on the cutters.

Support for all these strategies is, of course, available within PowerMILL, as part of Delcam's commitment to provide the complete machining solution for both toolmaking and production machining.

To expand its aerospace sub contracting machining services, Avionic Components has invested GBP390,000 in a 6m long-bed CME travelling column CNC bed mill.
Long-bed mill ups subcontractor's capabilities To expand its aerospace sub contracting machining services, Avionic Components has invested GBP390,000 in a 6m long-bed CME travelling column CNC bed milling facility. The facility gives Avionic to machine complex 2m3 workpieces on a 'pendelum' basis or the longer structural ribs and members. Avionic has consistently followed a planned growth pattern in terms of the size and complexity, explained Manufacturing Manager, Derek Dehany.

'We began business machining components up to 250mm3 and now we have a minimum capability of 2m3 and are also able to machine the longer structural ribs.

We acquired the CME CNC bed mill to take on larger and more complex work.

Much of our machining is in the more 'exotic' stainless steels, nickel- and magnesium-based alloys.' Within a week or two of commissioning, Avionic won a contract to machine rear mounting ring forgings for a leading aircraft turbine engine OEM.

The length of the CME long bed allowed Avionic to set up the four or five different operations in a progression from one end to the other.

'There are four and five set types of this engine mounting ring,' said Derek Delany.

'We were able to process batches of rings through the fixtures, with the machine working almost continuously.' The engine mounting rings are ring forgings in titanium alloy.

Each is 1.5m OD and contain recesses and different patterns of slots, holes and profiled location surfaces.

The raw forgings have a section of approximately 110mm wide by 95mm deep.

Standard machined features include four sets of parallel slots on the ID, of 29mm width and about 20mm deep contained in a profiled projection about 100mm wide and 250mm long.

The rings are progressed through four or five fixtures on the CME bed mill's bed.

Each ring requires about 16h of rough milling and 8h of finishing on the OD.

The slots have to be rough- and finish-milled, so the total machining time exceeds 30h.

Verification of location areas and positioning of the fixtures and post-process inspection is carried out using a Renishaw MP7 touch-contact probe.

A typical roughing operation would use a 125mm face mill at 120 rev/min and feed of 50mm/min taking a 10mm depth of cut.

Avionic uses the OOptimill1 feature in the machine1s CNC which maintains a constant cutting load on the spindle and adjusts the feedrate to suit different depths of cut.

'Optimill has certainly extended the life of the tips,' commented the operator.

'It is a good, sturdy machine and can take big roughing cuts, which is what we needed it for.' Derek Delany added that the CME bed mill is not an expensive machine in relation to its size.

Avionic Components.

Avionic Components is one of a family of a dynamic group of companies belonging to Hampson Aerospace (Hampson Industries plc) and working primarily in the Aerospace and Defence industries.

The company is an approved supplier to Rolls Royce, Garnett Turbine Engine Company, BMW-Rolls Royce and BAe and Airbus Manufacturing.

Components manufactures include air inlets/ducts, compressor casings, split bearing casings, housings, safety critical rotatives, structural ribs, engine mounting rings, seal rings and VIGV rings.

Materials machined include cast irons, Waspalloy, Nimonics, Titanium and its alloys and magnesium.

Machining capacity now ranges up to 6000mm by 1500mm by 2000mm with a maximum part weight of 4 tonnes.

Avionic Components also carries out advanced adhesive bonding techniques and complex mechanical assembly and testing.

The Gildemeister Group achieved its best ever financial performance in 2000, while DMG (UK) has also got off to a flying start in the first six months of 2001
The Gildemeister Group achieved its best ever financial performance in 2000. Consolidated sales soared by 34%, from Euro 232.9 million to Euro 923.3 million. The Group is particularly pleased that despite intensive competition, it was able to increase its international market presence.

Export sales grew by 56%, from Euro 158.5 million to Euro 439.9 million.

Total exports now represent 48% of output - an increase of 41% on last year.

Deckel Maho milling machines, machining centres and laser machines were again responsible for 50% of sales.

Although not the premier financial performers, turning machines and centres nevertheless recorded an increase of 29% from 21% in the previous year.

The Group e-business also showed impressive returns particularly in relation to universal machine sales and the provision of technical services.

In line with expectations, this upward trend has continued into the 2001 business year.

Order intake, sales and profit increased again in the first quarter.

Orders totalling Euro 315.3 million were received - +57% on 2000 - with consolidated sales in that period amounting to Euro 233.3 million (+51%).

The company is naturally expecting a significant sales boost from the up-and-coming EMO 2001 Exhibition.

Several new products will be featured, a trend set last year with the introduction of no less than 20 new machining concepts.

DMG (UK) Ltd., have also got off to a flying start in the first six months of 2001.

Order intake is up 22% on last year and revenue is up 28%.

With the UK market only predicted to grow 3.6% this year according to the MTTA, this is clearly an excellent achievement.

The second half of the year is underway and there is no sign of the 'talked up ' recession affecting the progress.

Richard Blake, Managing Director of DMG UK, states, 'everyone is talking about a recession in manufacturing and the temptation is to believe it.

The cost-effectiveness, build quality and technical specification of a Union TC 110 horizontal borer were the main selection criteria used by CTL Engineering of Stockport.
The cost-effectiveness, build quality and technical specification of a Union TC 110 horizontal borer were the main selection criteria used by CTL Engineering of Stockport when it needed to expand its machining capacity. With an already impressive portfolio of large- and medium-capacity CNC vertical and horizontal borers and machining centres, managing director Ian Booth identified the need for a mid-range horizontal borer to accommodate an increasing order book for medium-sized workpieces. 'We looked at three different options,' he says, 'and, on paper, the Union scored 10/10 in every department.

When we subsequently inspected the shortlisted machines, the Union outshone the rest.

'It clearly reflected modern design and build principles - featuring linear ways and high (15,000mm/min) rapid traverse rates, for example - as well as being operator friendly in terms of both control technology (Heidenhain TNC 430M) and easy access.' 'We couldn't fault the machine - in fact, we saw advantages in every aspect of it!' In addition, CTL's purchase decision was swayed by Ward's impressive service and back-up record, of which CTL has experience since a secondhand vertical borer from the Ward Retrofit division is already in use.

The final clincher, adds Ian Booth, was after visiting Union's new manufacturing plant in Chemnitz, Germany.

'We were very impressed,' he says.

With X, Y and Z axes of 2000mm by 1600mm by 1500mm, the Union TC 110 CNC horizontal table-type boring and milling machine is scheduled for delivery at CTL this month.

It has a W axis (spindle stroke) of 550mm and a B axis (rotary table) that can be indexed in 360,000 positions.

It is powered by a 22kW main motor and features infinitely variable speeds of 8 to 4,000 revs/min and axis feed rates of 5 to 15,000mm/min.

Family-owned CTL Engineering was established over 45 years ago, initially as a general sub-contractor and manufacturer of jigs and fixtures.

In more recent years it has expanded into the oil sector, producing a range of subsea and exploration components, as well as into the scientific, aerospace, defence and transport markets producing items such as mass spectrometers, undercarriage components, underwater systems and train couplers.

The cost-effectiveness, build quality and technical specification of a Union TC 110 horizontal borer were the main selection criteria used by CTL Engineering in machine choice.
The cost-effectiveness, build quality and technical specification of a Union TC 110 horizontal borer were the main selection criteria used by CTL Engineering of Stockport when it needed to expand its machining capacity. With an already impressive portfolio of large- and medium-capacity CNC vertical and horizontal borers and machining centres, managing director Ian Booth identified the need for a mid-range horizontal borer to accommodate an increasing order book for medium-sized workpieces. 'We looked at three different options,' he says, 'and, on paper, the Union scored 10/10 in every department.

When we subsequently inspected the shortlisted machines, the Union outshone the rest.

'It clearly reflected modern design and build principles - featuring linear ways and high (15,000mm/min) rapid traverse rates, for example - as well as being operator friendly in terms of both control technology (Heidenhain TNC 430M) and easy access.' 'We couldn't fault the machine - in fact, we saw advantages in every aspect of it!' In addition, CTL's purchase decision was swayed by Ward's impressive service and back-up record, of which CTL has experience since a secondhand vertical borer from the Ward Retrofit division is already in use.

The final clincher, adds Ian Booth, was after visiting Union's new manufacturing plant in Chemnitz, Germany.

'We were very impressed,' he says.

With X, Y and Z axes of 2,000mm by 1,600mm by 1,500mm, the Union TC 110 CNC horizontal table-type boring and milling machine is scheduled for delivery at CTL this month.

It has a W axis (spindle stroke) of 550mm and a B axis (rotary table) that can be indexed in 360,000 positions.

It is powered by a 22 kW main motor and features infinitely variable speeds of 8 to 4,000 revs/min and axis feed rates of 5 to 15,000mm/min.

Family-owned CTL Engineering was established over 45 years ago, initially as a general sub-contractor and manufacturer of jigs and fixtures.

In more recent years it has expanded into the oil sector, producing a range of subsea and exploration components, as well as into the scientific, aerospace, defence and transport markets producing items such as mass spectrometers, undercarriage components, underwater systems and train couplers.

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.'

Of travelling-column floor-type design, the Union P/PC range of horizontal live spindle boring and milling machining centres are believed to be the most flexible machines for large workpieces.
Of travelling-column floor-type design, the Union P/PC range of horizontal live spindle boring and milling machining centres from exclusive UK agent, Ward CNC of Sheffield, are believed to be the most flexible and universally applicable machines for processing large workpieces accurately and consistently. This is courtesy of features such as auto head and tool changers (up to 80 tools) and the optional NC facing head, pick-up system and NC rotary table - coupled with Union's established build principles of cast iron construction for rigidity and up-to-date linear guideway technology that promotes both high specification and performance. Between them, the P/PC 130 and 150 variants have X axes travels from 4000mm up to 10m and larger, Y axes from 2000mm up to 3500 mm and Z axes of 800mm.

W axis (boring spindle) is 750mm and the 50/60kW motor produces maximum speeds of up to 3,000 revs/min.

The machines are constructed with heavily-ribbed beds featuring backlash-free compact roller guides of the table saddle and column infeed motion for precise, stick-slip free motion.

The column assembly is of rigid box-type cast iron construction, again with precisely machined faces for the preloaded, compact roller guides.

Of solid cast iron construction, the headstock accommodates a high-precision main spindle system by means of preloaded spindle bearings with lifetime lubrication.

Boasting hardened and ground gears for automatic speed range changes, the gearbox is thermally stabilised.

Backed by Union's over 140 years' of manufacturing know-how in Chemnitz, Germany, the P/PC machines are being offered alongside Union's latest generation table- and cross bed-type CNC horizontal live spindle boring and milling machining centres by Ward CNC, a company with vast experience of the brand in the UK.

Holroyd, has used one of its own unique milling centres to complete work on a pair of giant helical rotors destined for an environmentally friendly application in the USA.
Helical component and machine tool specialist, Holroyd, has used one of its own unique milling centres to complete work on a pair of giant helical rotors destined for an environmentally friendly application in the USA. With a finished diameter of almost 650mm, the first of three pairs of giant rotors were machined from billets weighing over 3 tonnes each, making them some of the largest rotors ever produced. The order presented an ideal opportunity for the Rochdale-based company to apply the expertise that makes it one of the world's leading manufactures of helical components and the machine tools on which they are produced.

The pair of stainless steel rotors were machined on a Holroyd 8A milling centre, one of only several centres in the world capable of handling components of this size.

The rotors will be used to compress waste gases created as a by-product of styrene production, enabling compliance with US legislation designed to help safeguard the environment.

An overseas consultant has made regular visits to Holroyd's plant in order to monitor production of the rotors, whose rough milling was performed with standard slitting cutters before the rotors were precision finished to a tolerance of 0.1 - 0.135mm around a 9 point profile.

The enormous size of each rotor made meticulous manual inspection the only practical way to check the component's precision finish, and required the rotors to remain in Holroyd's checking centre for a total of 3 days each.

Applications Engineer, Simon Rhodes, explained some of the special challenges presented by a project of this nature.

'The rotors were too big for conventional transportation around the plant and could only be moved using the overhead crane.

Three specially made, dedicated cutters were used to define the profile of each rotor and a phosphorous bronze outboard bearing support was produced specifically to hold the rotor's journal without causing wear to the component itself.

Production of each rotor lasted 17 days, with a week of 24 hour per day roughing and the remainder spent semi-finishing and finish milling until the required standard was achieved'.

Machine Tools Sales Director, Paul Hannah, explained, 'Holroyd has earned a world-wide reputation for the production of both high quality helical rotors and the machine tools used to make them.

The successful completion of these unusually large precision rotors, using one of our own machines, reflects the company's ability to fulfil the most demanding orders while illustrating the unrivalled performance offered by Holroyd's milling centres'.

Committed to apprentice training for over 30 years, a defence equipment subcontractor emphasises the need for strict conformance to quality standards when machining and fabricating.
For more than 30 years IPE of Southend-on-Sea, Essex, has been committed to apprentice training, recruiting as many as six youngsters every year. As well as teaching them the requisite engineering skills, this sub-contract companys training programme emphasises the need for strict conformance to quality standards when machining, fabricating and assembling components destined for critical defence and aerospace applications. It is here that machine tools supplied by XYZ Machine Tools play a vital role, one that began several years ago when Nick Frost, Machine Shop Manager, began looking for a machine that could provide apprentices with a fast but safe transition from manual to CNC machining.

While on a visit to the headquarters of a Formula One parts manufacturer, he found that not only were XYZ machines installed, their performance was described as being 'as good as gold'.

'So we decided to buy a KRV3000 milling machine and since then we have bought a number of XYZ mills and turning machines, including a Proturn 350 manual/CNC lathe.' Although the initial purchase was made with apprentices in mind, the scheme misfired somewhat because Ian Springett, the former apprentice who first operated the KRV3000, refused to be parted from it.

'So we bought a second machine and the same thing happened,' recalls Frost.

'In the end we bought another two machines and earmarked them for apprentice use only!' These four XYZ turret mills, a mix of KRV3000 and PRO3000 turret mills equipped with the Prototrak MX2 control, continue to be operated by a successful blend of highly skilled machinists and enthusiastic trainees.

Programming takes place on the machine, and the Prototrak's question and answer format has proved especially helpful to the younger operators.

'Apprentices these days are fully conversant with computers,' says Frost, 'but unlike CNC systems that use G codes and require operators to push the appropriate buttons without necessarily understanding why, this particular control teaches them the basics of machining and the correct way to construct a machining program.' The average batch size of prototype, test and pre-production components produced on the four turret mills is between 15 and 20-off, typically in aluminium, although stainless and other steels are also machined.

'These are the lowest cost machines we have ever bought,' says Frost, 'but they work seven days a week and have never let us down, despite often having the equivalent of a learner driver working on them.' Such reliability is important to the family-owned Ipeco Group, which prides itself on its creative approach to satisfying customers' demands and its project management expertise.

IPE has over 40 years experience of design and manufacture for the defence, electronics and aerospace industries, while Ipeco has emerged as the world's leading supplier of flight deck and specialist aircrew seating.

These seats are the preferred choice of more than 300 airlines, with more than 27 000 seats in service.

The current portfolio features some 50 models of seat, ranging from simple designs for utility aircraft to de luxe fully adjustable and individually shaped versions for executive jets.

ISO 9001 accredited IPE is responsible for producing the complex and tightly toleranced components needed to withstand gravitational forces up to 16G.

It is also a key player in the Ipeco Group's strategy of component commonality, the objective being cost effective production and predictable performance for seats that are specific to particular aircraft types and constructed to individual customer requirements.

The 75 000ft2 Southend-on-Sea plant, which in addition to machining a wide variety of complex components also produces fabricated sheet metal assemblies and a variety of intricate salt bath brazed components such as wave guides, is equipped with around 70 machine tools.

As might be expected, many of these are highly sophisticated and relatively expensive CNC machines.

However, as Arthur Blake, Support Team Leader, puts it: 'You do not have to spend a quarter of a million each time you need a new machine.

You just need to be aware of what you need it for and then make sure you buy the most suitable and cost-effective machine for the purpose.' On this basis, he adds, the XYZ machines in daily use at IPE, whether conventional or shopfloor programmable, have proved an unqualified success.

High-performance yet cost-effective CNC moving column machining centre and bed-type milling and boring machines will be unveiled at this year's EMO exhibition.
Ward CNC of Sheffield, the exclusive UK agent for the Soraluce range of CNC milling machines, has announced that the Spanish machine tool builder will be unveiling three new high-performance yet cost-effective models at this year's Milan EMO exhibition. The SP-8000 fixed-bed, moving column milling centre as well as the TR 35 and TA20-Automatic bed-type milling machines will all be making their public debuts when the show opens its doors. Described as one of the most versatile milling machines available, the new SP-8000 is designed for one-hit machining of parts from heavy-duty cutting through to finish machining.

With X, Y and Z axes of 6500mm by 2000mm by 1200mm and a table of 8000mm by 1100mm, large parts or multiples of smaller workpieces can be processed efficiently by the machine that boasts rapid traverse rates of 25m/min and, as standard, features an automatic indexing head powered by a 30kW, 4,000 revs/min motor.

Combined with a 1000mm by 1000mm rotary table, the head has two indexing planes - one vertical to the spindle, the other at 45deg - and a 60-position toolchanger to enable even the most complex parts to be completed in a single setting.

The machine can also incorporate high-speed electro-spindles rated at 18,000 to 30,000 revs/min, to further hoist productivity levels.

Of the two new bed-type mills, the TR 35 has the larger capacity with X, Y and Z axes of 3500mm by 1400mm by 1200mm, rapid traverses of 20, 000m/min and a table of 3860mm by 1200mm.

A 40-tool automatic toolchanger is standard.

Importantly, this machine features a 5,000 revs/min oil refrigerated automatic indexing head with a feed rate of 10m/min and, coupled with oil-refrigerated gearbox, provides excellent thermal stability for high-accuracy machining.

With X, Y and Z axes of 2000mm by 1000mm by 800mm and rapids of 20m/min, the new TA20 Automatic bed mill has a working area of 2000mm by 800mm and a 22kW/3,000 revs/min automatic indexing head with through-the-spindle coolant.

A 20-tool ATC is standard.

Based on price to performance, this model will be of particular benefit to sub-contractors and relatively small mould and die work.

As expected of machines developed under the auspices of the Danobat Group's IDEKO research and development, Soraluce's new trio combine high-quality build and technologically advanced features for unmatched milling performance.

Their characteristic build qualities of stability and rigidity are based on their heavy-duty cast iron construction.

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 1500mm to 16m plus in the X axis, from 1000mm to 3600mm in Y and up to 1500mm in Z.

Manufacturers of construction plant, large engines and prismatic components can produce ever more complex parts to higher machined tolerances on two CNC table-type, horizontal-spindle borers.
Manufacturers of construction plant, large engines and prismatic components for the petrochemical industry are not immune from the need to produce ever more complex parts to higher machined tolerances. Companies involved in these sectors may therefore be interested in two new, table-type, horizontal-spindle borers launched by the Japanese manufacturer, Kuraki, said to be the most accurate and robustly built machines in their class. The smaller KBT-11WA machine is capable of supporting 6,500kg on the table and is available ex-stock from UK agent Mills Manufacturing Technology, Leamington Spa.

The larger KBT-13A will machine components to 12,000kg.

There are four linear CNC axes with scale feedback for top precision - X for the longitudinal table travel, Y for the vertical motion of the spindle, Z for the cross traverse of the column and W for the boring spindle stroke in the same direction.

An optional rotary table (B-axis) indexes in 0.001 degree increments to provide 5-axis machining.

Working envelopes for the two models are 2000 (2500) x 1500 (1800) x 1450mm and 3000 (4000) x 2000 (2300) x 1300mm respectively, the traverses in brackets denoting optional specifications.

W-axis movements are 500mm and 700mm.

Installed weight of around 30 tonnes gives an idea of the rigidity of these machines.

Various details in the design contribute further to high precision metalcutting, such as the cast slideways for the W-axis which, unlike on many competitive borers, allow heavy duty drilling using boring spindle feed motion.

Many existing Kuraki installations make use of CNC facing heads for complex contouring of bore features.

A long-nose spindle head allows close access to the workpiece with minimum quill extension for heavy duty cutting by powerful spindle motors - 18.5kW (cont) / 25kW (30min) for the KBT-11WA and 22kW (cont) / 30kW (30min) for the KBT-13A.

Standard tool magazine capacity is 40, although 60, 90 or 120 may be specified.

50-taper tools up to 400mm long and of 25kg maximum weight are exchanged automatically.

Despite their large size, the machines are capable of fast movements and short cycle times.

The KBT-11WA offers cutting feeds to 6m/min and rapid traverse of 12m/min in X,Y,Z, 6m/min in W.

Figures are either the same or only slightly lower for the larger machine.

Large diameter, pre-tensioned ballscrews are directly connected to the axis servo motors to minimise backlash, while all slideways are hardened and ground and mating surfaces are coated with wear-resistant synthetic resin for longevity.

The pendant-mounted control panel houses a Fanuc 16M CNC system to support 5-axis interpolative machining, and also provides manual control capabilities.

That a school was most impressed with CNC machines widely used in industry meant it was giving the pupils real-world experiences and knowledge that is immediately transferable to employers.
A school whose most financially successful old boy helped fund the building, equipping and furnishing of a brand new technology suite and ICT wing, has won Technology Status and is rapidly gaining a reputation as the most exciting and successful school in the region. Amongst the ICT equipment in the new building at Balderstone Technology College in Rochdale are three multi-purpose machining centres for resistant materials and electronics and a library of special operating software, computers and the latest interactive whiteboards. The machining centre was purchased from Unimatic, a company which supplies identical equipment to manufacturing and industry as well as other educational organisations across the country.

Year 11 GCSE pupils at Balderstone are using the EduCam equipment to make not only the circuitry for high tech electronic projects but also the casings in which to mount them and other resistant materials artefacts.

The younger children of the school are also being stretched with an exciting new curriculum.

Balderstone Technology College was granted technology status, having put forward a very strong and well-structured bid to the Department for Education (DfEE).

Long-serving Head of Technology Cecile Biant recalls: 'Our school has developed steadily from its strong base, to the point where it became natural to seek specialist status.

Sports was an option for this, because we have great facilities, recognition and success; but we are also very strong on electronics and technology and we felt this would better serve our existing pupils and the community in general.' Considerable funding was required if Balderstone was to make a real success of the enterprise: GBP 50,000 for the new technology suite, GBP 30,000 for specialist CAD/CAM equipment and another GBP 20,000 for furnishing.

Some of this money would come with the status if the bid was successful, but half of the finance had to be in place before the DfEE would consider the idea.

Fortunately Balderstone had just re-established links with old boy Dr Peter Ogden, a very successful international computer magnate who had set up a charitable trust to support education.

Dr Ogden had publicly said that he thought his old school had closed down, but when the Head Teacher, Mr Wigget, heard this he wrote and invited him to visit.

'Dr Ogden was very supportive of our bid for technology status,' says Mrs Biant.

'However there was no headlong rush.

Instead a carefully considered plan was drawn up including curriculum development with local and regional employers, universities, and parents and coolheaded assessment of resource requirements.' Mrs Biant undertook rigorous market research into the best value for money CNC equipment available at the time for use with resistant materials, which resulted in a clear, unambiguous decision to go for Unimatic's EduCam range of machines.

'We were most impressed that these machines are so widely used in industry.

This means we are giving the pupils real-world experiences and knowledge that is immediately transferable to employers.

It also means, of course, that they can stand up to any amount of use and should serve us well for many years to come.' The operational flexibility of the EduCam was also attractive, as it allows staff and pupils to learn many different production techniques, such as milling, routing, turning, copying, on a huge range of materials, from plastics and resins to wood and metal.

Its software can interface directly with complementary educational systems, such as design software, pupil's own laptops and the interactive whiteboards.

Unimatic is constantly developing its EduCam offering, in both software and hardware, most of which is first proven in industry.

It also has a team of educational specialists who work with each school on a individual basis to ensure that their developing needs are constantly catered for, yet still find time to keep up with advances in the technology industries where some of the students will eventually find employment.