A six-axis table-type horizontal boring and milling machining centre is not only maintaining, but also enhancing a subcontractor's reputation as a leading supplier of precision machined products.
A six-axis table-type Union TC 110 horizontal boring and milling machining centre supplied by Ward CNC is playing a key role in not only maintaining, but also enhancing Beaufort Engineering's reputation as a leading supplier of precision machined products to the aerospace industry. With the sixth axis being provided by an NC rotary table, the TC 110 was selected by Beaufort's manufacturing manager, Steve Scotney, 'because nothing else could match the machine in terms of specification and price'. Nottinghamshire-based Beaufort Engineering specialises in the provision of engine and landing gear parts for first-tier aerospace companies, and the Union complements an array of other CNC machines - including a Ward CNC-supplied Kia KH63G horizontal machining centre.

These process a mix of aluminium and exotic materials including titaniums, nimonics, Jetheat and 300M aerospace steels.

The company is also a specialist single-source supplier of ready-to-line workpieces, utilising a range of finishing processes such as etching and alocroming as well as non-destructive testing.

With X, Y and Z axes of 1500mm by 1250mm by 1000mm, the TC 110 has a W axis (spindle stroke) of 550mm and a B axis table rotation of 360,000 positions.

It also features a 60-tool automatic toolchanger and Fanuc 16iM CNC.

'In particular,' adds Steve Scotney, 'the W axis is of great benefit in terms of allowing us to use shorter length tools, which therefore makes it easier Powered by a 22kW main motor, the machine features infinitely variable speeds of 8 to 4,000 revs/min and a torque of 2,000 Nm.

Feed rates for X, Y, Z and W axes are 5 to 15,000mm/min, while table rotation is 3 revs/min.

The 1000mm by 1250mm table can accommodate loads of 6,000kg.

All Union 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.

High-speed version of a travelling column CNC milling machine, with a head changing unit is the first in a range that features linear ways.
TOS Kurim, the well known Czech manufacturer of CNC milling machines, introduced an additional range of CNC milling machines at the recent Brno Trade Fair. The model shown was the FF100/125A, a high-speed version of its travelling column CNC milling machine with a head changing unit. This machine, which is the first in a range that featuring linear ways, will be closely followed by the models FS80/100 and 125, which are bed type CNC milling machines.

The FF series of travelling column machines is available with 2 table widths of 1000 and 1250mm.

Table lengths and 'X' axis travels ( both are the same ) range from 3000 to 12000mm.

For the 'Y' axis, strokes of 1250 and 1500mm are available; for the 'Z' axis, strokes up to 2200mm can be provided.

Rapid traverse rates and programmed feed rates of up to 20 metres/min.

are now standard.

The FS series of Bed Type Machines is available in three table widths of 800;,000 and 1250mm.

Table lengths and 'X' axis travels range from 2000 to 5000mm.

Rapid traverse rates and programmed feed rates up to 20 metres/min.

are standard.

All models are supplied with the 'O' type Automatic Indexing Head, which has indexing increments of 2.5 degrees.

A further range of heads, fully controllable in the A and B axes, allows five-axes machining.

Spindle speed up to 18,000 rpm are available on this range.

Spindle power is 30kW.

As a further option a Quill can be provided in place of the milling head.

For the travelling column machines, there is also the option of a head changer, for which there is a wide range of heads to suit different applications.

Easo of loading is ensured by positioning the table 500mm above floor level, which we understand will be the future C.E.

regulation for these types of machine.

Tos Kurim claim to be the first company in Europe to comply with this.

Many features such as twin ballscrew drive and hydraulic counterbalance to the ram ensure maximum accuracy.

Linear scales are standard on all linear axes again ensuring maximum accuracy.

A full range of rotary tables which are manufactured by Tos Kurim is available for these machines.

College students in Bristol are to set up and run their own company, under a Year 14 project in which they design and manufacture parts, prototypes and products for local companies.
Students at John Cabot City Technology College in Bristol are to set up and run their own company, under a Year 14 project in which they design and manufacture parts, prototypes and products for local engineering companies, other organisations and direct sale to consumers. The company will be based at the college's new state of the art manufacturing centre, which is equipped with a number of machine tools from Unimatic Engineers' eduCam range. These are actually industrial machines, which, because they are used by manufacturing organisations around the country, allow students to seamlessly cross the education/industry divide.

Six A-level students are to stay on an extra year to set up the business and take it through its initial phases.

They will be working closely with Head of Technology and Art, Nathan Jenkins, the ICT Development Manager, Colin Coles, and sponsors such as Rolls Royce.

'Apex Pumps, who make centrifugal pumps are to be joint sponsors with Rolls Royce, and several others are in the latter stages of signing up too,' says Jenkins.

'Our students will be working with them to design and develop prototypes and possibly even production parts.

This will all be done in a commercial environment: a company will be formed and they will have to make competitive tenders to win the work.' The students will receive a small bursary during the project and it is hoped that sufficient revenues will be generated to finance a second year for another group of students.

However the overriding objective is not to make money but to give the students an unrivalled set of experiences that will stand them in good stead throughout their adult careers.

One of the practical attractions for the sponsors is access to the college's manufacturing centre, which will free them from having to find time for one-off and short-run jobs on busy production machines.

The college has been using eduCam equipment for about five years, and was happy to equip the new centre with further units from the range.

Unimatic also supplies all the software for the associated computers.

This is mainly the Pro/DESKTOP suites of programmes, although there has been some bespoke programming to match Cabot's precise requirements.

Like the machine tools, Pro/DESKTOP is also used extensively by practising engineers and designers, who like the simplicity and clarity of its graphical interface and the speed with which it creates CAM (computer aided manufacturing) instructions from CAD (computer aided design) drawings.

'Unimatic has recently installed for us a fairly large CNC (computer numerically controlled) router, upgraded an existing router and supplied one of its smaller machines, an eduCam 2,' says Jenkins, 'which we are busy demonstrating to lots of other schools in the area.' The eduCam 2 is used by the whole college, right down to 11-year-olds in Year 7.

Many of the schools coming to see it are the feeder primaries, which encourage children with an aptitude for science and technology to apply to John Cabot.

So successful is the technology college that last year there were 800 applications for the 100 first year places.

Asked about the potential success of the new project Jenkins bubbles over with excitement.

'We already have younger kids in the school interested for when they have completed their A-levels; there is real enthusiasm amongst the sponsors, and potential sponsors are contacting us of their own accord.

But best of all is that we already have a track record: one of the students has already designed a ascender for abseiling, which is going through the process of being patented and we have several manufacturers lining up to license the design for production!

A new CNC gantry mill is achieving high accuracy and already fast turnaround times have been improved further on large machined items up to 5m in length, says a West Midlands subcontractor.
Despite the generally slow industrial economic climate, Machined Fabrications based in the West Midlands are thriving thanks to the purchase of a new Zayer KP 5000 gantry milling machine from Viking Machine Tools. Their increased capability in providing specialist subcontract manufacturing for one-off and short run large parts such as machine tool bases has justified the investment. High accuracy results are now achieved more easily and improvements have been made to already fast turnaround times on large machined items up to 5m in length.

MD of Machined Fabrications, Matthew Wild commented, 'we needed to replace an old travelling column bed type milling machine and we believe the Zayer machine is one of the best quality gantry mills on the market.

Having previously had a good experience when buying machines from Viking, we were pleased that they were the UK agent for Zayer.

Their mechanical and electronic service support is excellent and the response time is very short.

This is particularly important to us as we operate 24 hours a day.' The Zayer machine is fundamentally more accurate than a moving column design because the milling head remains fixed to a gantry, which is a far more rigid structure than a column arrangement where the machining head extends on a ram.

The gantry mill bed moves longitudinally on precision ground guides and so tolerances are maintained over long machining distances.

This feature is crucial according to Ian Hinton, Machined Fabrications Machine Shop Manager, 'the finishing tolerances required by our customers for machine tool parts are often within a few microns over very large surface areas, up to 5m2 for example.

To achieve this accuracy in terms of 'flatness' it helps to have a milling head that remains rigidly fixed during the machining operation'.

Ian adds, 'the Zayer machine has a number of other features that have enabled us to increase production performance; we specified our KP 5000 machine with interchangeable straight and right-angle machining heads, allowing us to machine five surfaces on a work-piece without moving it from its initial workholding position on the bed.

This has saved a huge amount of set-up time and completely removed the issue of compound machining errors that can be caused by having to move the piece for each machining operation and re-orientate the milling head each time.

The milling heads also have through-spindle cooling, allowing us to perform high speed drilling operations and also helping the milling head to maintain optimum cutting speeds for extended periods.' 'Having invested in this machine, the overall benefit for us is in being able to achieve consistent, accurate results more quickly and more efficiently.

The new machine has also increased our overall production capacity.

Machined Fabrications operates on very short lead times, as we take a design from our customer and deliver a finished item including the purchase of materials, welding, shot blasting, machining and painting.

Most of our machines work on a 24hr basis and so faster production improves our service to our customers and enables us to take on more work.' William Savin, Joint MD of Viking Machine Tools isolates other reasons for the success of the Zayer gantry milling machines, 'These are premium quality machines, available in many different sizes with bed lengths from 3-36 meters, each one is built around a solid cast base, providing maximum rigidity for the whole structure.

The machine controller specified on this example is an industry leading Heidenhein unit and the whole package allows the machining of single pieces up to 10tonnes.

As a package, this machine offers improved quality and can reduce overall cycle times by up to 50%.' Viking Machine Tools provides a complete service for metalworking machine tools from basic turret mills to large scale turning and milling machines.

This includes expert advice on machine choice and specification, to commissioning and highly responsive same-day technical support, both electrical and mechanical support services are available on-site and in-house at Viking.

High-frequency spindles of 60,000 revs/min, feed rates of 25m/min and acceleration speeds of 1.5m/sec2 suit a travelling column, fixed table milling machine to mould and die machining.
High-frequency spindles of 60,000 revs/min, feed rates of 25m/min and acceleration speeds of 1.5m/sec2 make the new Soraluce SV-HSC travelling column, fixed table milling machine the ultimate contender for ultra-effective mould and die work. Available exclusively from UK agent Ward CNC of Sheffield the SV-HSC range joins an already extensive portfolio of Soraluce milling machines. The SV-HSC is available in the four model variants of 5000, 6000, 8000 and 10000 - designations that reflect the machines' table lengths in mm.

Table widths are 1100mm as standard (optionally 1350mm), Y axis traverse across the range is 1600mm (optionally 2000mm) and the Z axis is 1200mm.

X axes range from 4000mm up to 9000mm, depending on model.

The use of high-frequency spindles boosts the machines' high-accuracy finishing capabilities, and production flexibility on a range of different parts is further extended by the available choice of machining heads: * The 30kW, 4,500 revs/min automatic indexing head has a torque rating of 855Nm and two indexing joints - one vertical to the spindle centreline and another at 45 deg, capable of positioning in both rotating planes at 0.001 deg increments.

* The 30kW, 4000 revs/min automatic indexing head has 2.5deg by 2.5 deg positions, programmable in a perpendicular plane to the spindle line and at 45deg.

* The 34kW, 18,000 revs/min automatic orthogonal head has 0.001 by 0.001deg positioning (fourth and fifth axes) on two perpendicular planes.

* The 30kW, 4,000 revs/min fixed boring head is suitable for deep, high-precision boring operations.

With AC digital drives, Heidenhain direct linear transducer and Heidenhain TNC430M flat screen CNC as standard, the new Soraluce SV-HSC range represents an unrivalled combination of flexibility plus speed and fine finishing.

A popular and proven CNC controller, enabling users to at least double their machining output, is now available as a retrofit package for most turret millers.
XYZ Machine Tools has announced that the popular and proven ProtoTRAK Edge CNC controller is now available as a retrofit package. Whilst DROs are undoubtedly old technology - they have been around for more than thirty years - they are still proving popular because they can easily and inexpensively be retrofitted to existing conventional machines and productivity be significantly enhanced. The ProtoTRAK Edge controller is as easily retrofitted to most turret mills and conventional knee mill but provides far greater productivity - typically output can be doubled and in some applications trebled, and can parts can be produced which cannot be attempted economically on a manual mill.

It provides 2 axis CNC control and up to 4 axis DRO display.

The ProtoTRAK Edge uses plain English conversational programming, so the operator does not need any CNC experience to use it.

Only part geometry has to be defined; the controller defines the tool path automatically.

Using the teach option, the operator can turn manual moves into programmed events automatically.

The Edge controller accepts CAM data from all the top brands of software.

Set up is easy and simple.

Canned cycles include profiles, arcs, pockets, holes and frames.

19 maths help routines enable the operator to quickly and easily calculate intersections, tangencies, centres etc, and are far easier to use than either a calculator or trig.

A parts library can be built up easily using the floppy drive; programs can be shared with other ProtoTRAK controllers.

The retrofit ProtoTRAK can be installed either by XYZ installation engineers or by a customer themselves.

The kit includes the controller, motors, ballscrews, cables, brackets and table guards.

A half day training - all that is needed - at any one of XYZ's premises is included.

Parts warranty is for twelve months; if XYZ engineers install the retrofit a twelve months labour warranty is also included.

A very flexible, continuous five-axis, bi-rotary milling head machine has been designed for aerospace, mould and die, graphite or resin-type applications.
Launching the continuous five-axis bi-rotary milling head machine from Fidia for aerospace, mould and die, graphite or resin-type applications, where maximum advantage involving the total flexibility of the head and its 60,000 revs/min capability can be achieved, 600 Centre of Shepshed near Loughborough brings one of Europe's leading single source solution companies for machine building, control and software engineering to the UK. The Fidia K165 can also be specified with an indexing bi-rotary head having 17kW, 30,000 revs/min or in a more simple three-axis format with an 18kW, 24,000 revs/min drive. In all three versions, the machine is constructed around 'high bed' technology which enables constant operational forces to be maintained and optimisation of servo settings are constant and totally independent of workpiece weight.

'High bed' also gives the Fidia design superior dynamic performance due to its low moving mass, particularly in the 1,000 mm linear X-axis.

Building on its reputation for advanced control technology, Fidia has been able to match its class C control to maximise the performance of the Pentium III and Motorola processors and the Windows NT operating system.

This enables multi-tasking sequences to be performed including digitising and networking its tool presetting software, Hi-MILL (registered trademark) 3-D cam software and teleservice support.

And, with the capability to match and optimise control system and drives with an exceptionally rigid machine build, Fidia claim 20 to 30 per cent improvement in speed and accuracy through the ability to adapt the specific dynamic characteristics of the machine through the 'active' tuning and damping software functions.

Each of the spindles in the K165 range uses ceramic ball bearings with temperature controlled cooling.

The continuous bi-rotary head is very compact having a width of just 368mm.

It has a B-axis travel from +110 (degrees) and a 360 (degrees) C-axis.

Axis feed rates are 5,000 (degrees per minute) and the 60,000 revs/min drive is powered by a 6 kW motor with HSK 40E taper.

The indexed bi-rotary head has an HSK 50E taper with 17kW, 30,000 revs/min spindle giving a universal operational capability with B-axis travel of + 25 (degrees), a B-axis pitch of 5 (degrees), a C-axis travel of +180 (degrees) to - 177 (degrees) and a C-axis pitch of 3 (degrees).

In three-axis mode, the K165 is powered by 18kW electro spindle developing 24,000 revs/min at the HSK 63 taper tool drive.

The Fidia K165 machine has overall travels in X, Y and Z of 1000mm by 620mm by 500mm with 40m/min rapid traverse in X and Y and 30m/min in Z to a positioning accuracy of 0.008mm.

Acceleration of the milling head is 10 (square metres per second) which falls in line with the high dynamics of control and drive system.

Tool change is carried out within the bed of the machine where it is protected from coolant and swarf and tools can be easily loaded to the 20 or 42 tool option chain conveyor from the rear of the machine.

In addition to the three options for head type, high capacity suction is available for graphite and resin machining and incorporated in the basic design of the K165 is total freedom from slideway contamination due to their positioning away from the working area.

Designed to fit into a corner of a machine shop a compact milling machine has a surprisingly large working envelope and comes with a choice of CNC systems.
XYZ Machine Tools is introducing a new Mini-Mill in response to customers demand. 'We have found that companies are seeking the fast production offered by machining centres but do not have the floor space to commit. With costs around GBP 30 per square foot to build and at least GBP 6 to rent, machine footprint is critical to profitability for many companies.

The Mini-Mill has been designed to fit into a corner of a machine shop' Nigel Atherton, MD of XYZ said.

The new XYZ Mini-Mill, designed and built for XYZ by King Rich, has a 6ft square footprint and a working envelope of 550mmin X, 400mm in Y, and a substantial 500mm in Z, accommodating the vast majority of components.

It accepts BT40 tools in the 10 station tool changer and has a 10HP spindle motor.

Rapid traverse is 20m/min.

Spindle speed is 8000rpm as standard, with 12,000 and 15,000rpm available as an option.

The robust, ribbed cast iron carcass is built to the same standards as other machines built for XYZ by King Rich and weighs 2800kg.

The box slides are induction hardened and ground and slideways are turcite-coated to ensure longevity, rigidity, vibration absorption, and good surface finish on the workpiece.

Control is either by Fanuc or Siemens.

A swarf conveyor, Renishaw probing, and through spindle coolant are optional on the Mini-Mill.

The new Mimi-Mill complements the other machines in the XYZ range, and reflects the XYZ philosophy of providing value for money machines which meet the customers' need for cost effective productivity.

Low cost CNC machines bring high performance machining within the reach of schools and colleges - and yet meets the requirements for prototyping work in industry.
The eduCAM Series of CNC machines from Unimatic brings high performance machining within the reach of schools and colleges - and yet meets the requirements for prototyping work in industry. The range employs an open-system philosophy for complete flexibility in use, making eduCAM exceptionally versatile. Starting at less than GBP 3,500, the range starts with the eduCAM 10 engraving and routing machine, supplied with high visibility protective enclosure.

The floating engraving head has 300x400x100mm travel and a T-slot machine bed complete with clamps.

For engraving and laying of sheet metal, an engraving mat is also available.

Four further eduCAM models are available, each with an extremely robust steel construction, with an isolated machining area, for safety, and a CE marked interlock door.

Each model provides direct PC control for drilling, milling, engraving, dispensing or routing.

They are suitable for machining of light metals, plastics, wood, wax or resins and are therefore ideal for both educational and prototyping purposes.

In schools and colleges, students are acquiring skills that are directly relevant to the needs of industry, using software and machines that are identical to those used in high-tech companies.

For prototyping applications, the eduCAM range provides high performance at an entry-level price, with even the top of the range, high-specification eduCAM 50 costing little over GBP 11,000! The eduCAM 20 features a 3-axis gantry system, whilst two models feature a fourth axis, each model having successively greater travel and bigger clamping tables.

Each has high-precision linear guides and a feed rate of 60mm/second on all three axes, with 16dia x 10mm pitch ballscrews (16dia x 5mm pitch for the top of the range eduCAM 50).

Control of the eduCAM 20, 30, 40 and 44 machines is by 4-axis micro-stepping motion control integrated in the machine, the motors being high torque stepping motors, with RS232 communication interface providing computer communications.

Each eduCAM machine can be used with a range of CAD/CAM packages and, as well as being delivered free, the price includes a day's training.

With a launch price of just GBP 19,999 + vat for the first twenty machines ordered, a CNC miller is being demonstrated in a series of roadshows to be held throughout the country during April.
The new XYZ Mini-Mill, with a launch price of just GBP 19,999 + vat for the first twenty machine ordered, is being demonstrated in a series of roadshows to be held throughout the country during April and May. So popular is the new machine proving that XYZ has already received deposits to secure 13 of the Mini-Mills. The new machine has been designed for cost effective production with 560mm in X, 400mm in Y, and 500 in Z despite its tiny 6ft sq footprint.

First of the demonstrations is at XYZ's headquarters in Tiverton, and will be 16th and 17th April.

This will be followed by demonstrations at XYZ's premises in Blackburn (24th and 25th April) and Nuneaton (1st and 2nd May).

There will also be demonstrations at S G Webb and Sons, Stevenage (8th and 9th May) and at the regional manufacturing shows which are taking place around the country.

Weighing 3100kg - significantly heavier than comparable machines - its rigid and robust carcass is extensively ribbed to permit consistent and repeatable accuracy.

Box slides are induction hardened and ground, slideways are turcite coated to ensure longevity, rigidity, vibration absorption and good surface finish on the workpiece.

The Mini Mill is standard with Autolube and coolant chip washdown.

The Mini Mill accepts BT40 tools in the 10 station tool changer and has a 10hp spindle motor.

Rapid traverse is 25m/min.

Spindle speed is 8000rpm as standard with 12,000rpm as an option.

The control is simple, as with all other XYZ machines.

Siemens is offered as standard, with a Fanuc control as an option.

The XYZ Mini-Mill has a 12 month no quibble warranty.

Within months of supplying a HMC and a turning centre to solve the urgent capacity requirements a valves manufacturer introduced extended single set-up machining capability.
Within months of supplying a Kia H63 horizontal machining centre and a Kia Super Turn 28LB turning centre to solve the urgent capacity requirements of Anson, the world leading manufacturer of valves, manifolds and flowline equipment used in the exploration and production of oil and gas, Ward CNC of Sheffield had delivered another machine to not only meet Anson's volume production demands but also to introduce extended single set-up machining capability at the company's Gateshead site. The third machine, a re-engineered Kuraki table-type horizontal boring and milling machine, was supplied by Ward CNC with a CH8 contouring head from Forth Tool and Valve's ITS Division. Utilising the machine's spindle (W) axis movement, the result is that users gain two-axis lathe-type machining via the machine's live spindle.

In Anson's case, this has reduced the reliance on sub-contractors and allowed larger components to be produced in one set-up, including profiles such as ring grooves and bonnet seal areas.

'The added capabilities of the Kuraki-ITS package are undoubtedly producing substantial lead time savings,' comments senior production engineer David Brown.

'They are also freeing up much-needed capacity on our machining centres.' Increasing global demand for the company's products spurred the introduction of the two heavy-duty Kias, to complement a number of machines previously supplied by Ward - ie, a trio of re-engineered Mori Seiki horizontal machining centres and an existing Kia H63 horizontal machining centre.

The latest Kia duo were selected over the competition 'due to their specification and ex-stock availability', says David Brown.

Capable of accommodating components weighing 1,000 kgs, the Kia H63 horizontal machining centre has a one-piece bed and rugged eight-surface slideway system for rigid, accurate machining.

It features X, Y and Z axes capacities of 950mm by 825mm by 760mm and with 22kW spindle is capable of 4,500 revs/min.

Rapid travels are 20m/min and feed rate is 1 to 5,000 mm/min.

Of rigid one-piece box design, the Kia Super Turn 28LB turning centre has a 80mm diameter bar capacity and a swing over the bed of 590mm, a swing over the crosslide of 375mm and a maximum turning diameter and length of 410mm and 1071mm, respectively.

Distance between centres is 1100mm.

Spindle speed is 25 to 3,000 revs/min.

As standard the machine is fitted with a 10-position tool turret.

Ward CNC is the exclusive UK agent for the Kia CNC machine range that embraces a wide selection of vertical and horizontal turning and machining centres, many of which are available ex-stock.

The company's Sheffield site is also home to an experienced applications engineering team, and their expertise was once again highlighted by the Kuraki-ITS solution supplied to Anson.

Complete with cam lock adaptor housing, the ITS package was fitted, tested and interfaced by Ward engineers with the machine's Fanuc 11MF CNC, providing Anson not only with an X, Y Z axes boring and milling envelope of 2000mm by 1500mm by 1450mm, but also a machine with turning capability to complement the 40-station automatic toolchanger.

Horizontal borers and floor borers, the latter with X-axis up to 20m, can be equipped with automatic head changers and other systems, while manually operated machines are also built.
Tos Varnsdorf one of the leading European suppliers of horizontal boring machines recently celebrated their 100 year anniversary. The company was formed back in 1903 by Arnault Plauert and steadly increased their manufacturing facilities and product range through the years to become the leading exporter of machine tools in the Czech Republic. Today the company is in private ownership with the chairman being Jan Rydl, formally the companie's Technical Director and the driving force behind the current product range.

650 people are employed at Varnsdorf producing in excess of 240 machines per annum.

The product range extends from the manual W100A machine which has a spindle diameter of 100mm and a table size of 1250 X 1250mm.

The largest machine is the WRD150 floor borer, with a spindle diameter of 150mm, X axis up to 20m and Y axis up to 4000 mm.

In between there are various models of table type machines that can be equipped with facing heads, automatic pallet and toolchangers.

Control systems supplied are from Heidenhain, Siemens and Fanuc.

Varnsdorf took this opportunity to introduce the all new Tos-tec range, the Tos -tec models bring to horizontal borers all features that are normally associated with smaller horizontal machining centres allowing for greater productivity from larger capacity machines, but still allowing the machine to be customized to suit individual requirements.

Varnsdorf currently export to 50 countries world-wide and are very confident that the new Tos-tec range will carry them forward to yet another succsessful century.

XYZ recently sold 2 turning centres to a company which had previously bought top of the range Japanese machines because of the flexibility and productivity compared to one high cost machine
Customer Bill gives subcontractor Fred a hologram of the part he wants. Fred's molecular disintegrator extracts the hologram and produces the part in seconds. A retina scan confirms Customer Bill's identity and authorises payment to Subcontract Fred's bank account.

58 seconds, job done.

Bill thanks Fred and says I remember when that used to take two weeks.

'If I quote three minutes now the job will go elsewhere' says Fred.

Rather exaggerated you think, but the manufacturing industry has already moved a long way in that direction and continuing to do so.

Order books are getting shorter and shorter, quantities smaller and smaller, delivery dates closer and closer, more and more customers can't wait a couple of weeks so take their work elsewhere.

The two or three week order book is here to stay.

The two or three week order book is here to stay, but work for twelve months made up of 26 two weeks' worth of orders at any one time is just a profitable - if not more so - than the twelve months' work made from three month order books.

Have you actually run out of work, or just found that as the work is being finished more comes through the door?

The only significant difference between a forward order book for two weeks or for three months is that although a two week order book can be frightening at first, it almost always offers better margins.

To take full advantage of the changing market and to reap the substantial rewards (instead of enduring the misery) a subcontractor needs to be able to handle a variety of work quickly, efficiently, competitively and profitably by investing in CNC machines which are faster, have a lower piece part rate, higher throughput and greater versatility.

The investment does not have to be high: better to have a variety of machines such as a ProtoTRAK mill or a ProTURN lathe, which give fast production of one-offs and small batches and above all provide versatility.

For instance, XYZ recently sold 2 turning centres to a company which had previously bought top of the range Japanese machines.

Their reason was that two XYZ machines gave more flexibility and productivity than one high cost machine so provided better overall value even though the Japanese machine was faster.

One company which grasped the nettle and never looked back is Advanced Vehicle Design Ltd, which saw its business tumble by 80% following September 11th.

Bob Dixon, Managing Director and founder of the company, said 'In ten years of business, we have never seen such a sharp decline or such a rapid recovery.

I attribute the dramatic recovery to a change in the way we run the business, and that is almost entirely due to the purchase of two machines from XYZ Machine Tools'.

Another example is Kevin Edgington of GM Precision Engineering, who said 'If I had not invested in a CNC turning centre from XYZ, I would not have been able to keep the business going.

When I bought this company nine months ago the first task was to make a profit on the jobs we had and to free up machine time to take on the additional work.

Installing the XYZ turning centre has changed loss making jobs into profitable work and enabled me to quote for and win other work.

A small business like mine can run it for only two days each week and make it worthwhile.

Following machining demonstrations a prototype, precision machinist and assembly specialist chose a machine tool based on its fast cycling and extremely quick programming system.
Following machining demonstrations at 600 Centre in Shepshed near Loughborough, prototype, precision component machinist and assembly specialist contract engineers HPC (Services) Ltd of Ilkeston, Derbyshire made the decision to purchase a Fanuc Robodrill Alpha T21iC due to its fast cycling and extremely quick programming and setting capability. Says Managing Director Paul Cobb: 'Our machining trials proved it to be even quicker to set the Robodrill and program it for a single part than we could ever achieve by machining them manually.' The machining centre package was ordered from 600 Centre following similar but less successful trials with competing vertical machining centre suppliers. 'They could not even come close to the flexibility, acceleration and high speed cycles of the Robodrill,' he said.

The package included a WDS MicroLoc vice system which will allow HPC to machine in particular 500mm by 300mm clamp plates it produces as well as a host of smaller parts.

The system ideally suits the Robodrill giving added flexibility for fast setting by providing quick and simple datum positioning.

This enables programming and machining of multiples of drilled and tapped holes or milling cycles to be carried out very quickly on a single part or a number of components at the same time.

HPC started trading in 1997 as a precision small part machinist using slide head CNC auto lathes.

It now employs 35 people, has both turning and machining centre production facilities creating sales in excess of GBP 3.5 million.

'We have always invested in higher quality machine tools and have six sliding head Citizen machines, a Nakamura mill/turn centre and some five vertical and horizontal machining centres.

Here the Robodrill fits ideally into the portfolio,' insists Paul Cobb.

The Robodrill Alpha T21 is compact, has a 21 tool capacity with 0.9 secs tool change and an 8,000 revs/min 3.7kW spindle.

Acceleration is 1.2G to maximum traverse rate of 54m/min through the latest 16 i MB control.

A collaborative project between Anilam and RK International has led to the successful installation of a Europa Milltech CNC milling machine at one of the UK's leading modelmakers.
A collaborative project between control specialist Anilam and machine tool distributor RK International has led to the successful installation of a Europa Milltech three-axis CNC milling machine as the 'bridge' technology between a series of manual machines and high speed machining centres at A.T.O.M., one of the UK's leading modelmakers. With x, y and z axes travels of 720mm by 305mm by 115mm and fitted with Anilam 3300 MK CNC, the Milltech 1500VS was chosen over alternative machines for a number of reasons, according to A.T.O.M. director Nick Mines.

'As well as being the most cost-effective solution and providing the appropriate machining performance,' he says, 'it was important that the machine control technology was intuitive and would integrate with our company-wide Windows network.' He continues: 'The machine can be easily switched between manual and CNC operation, and because its Anilam control is a powerful, yet easy-to-use CNC, it is the perfect machine control technology that creates a bridge between our modelmaking craft skills and our high-speed (up to 60,000 revs/min) machining centre expertise.' Required to machine mainly Ureol, the Europa Milltech has a table area of 1,244mm by 230mm and a 2.25kW spindle motor that produces spindle speeds of 60 to 4,200 revs/min.

Importantly, from A.T.O.M.'s point of view, the machine's Anilam 3300 MK control combines user-friendly conversational programming (Machinist Language) with digital signal processing for high-speed data processing and motion control.

The control features a range of canned cycles, including: * 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.

'By making this investment and closing the 'gap' between our manual machines and high-tech machining centres,' adds Nick Mines, 'we have provided our modelmakers with a powerful machine that is so easy to use that some have actually taught themselves to operate it.

That can only be good for their personal development and overall job satisfaction.' A.T.O.M.

(All Types Of Models) has for a number of years been combining manual machining and hand finishing skills with stereolithography and machining centre work for the specialist production of models and prototypes for a wide range of consumer and trade industries, as well as the architectural sector.

Combined with complementary small batch production techniques of vacuum casting and vacuum forming, A.T.O.M.

has steadily expanded to today's 50-plus employees based in two sites at Sunningdale, Berks.

The company's continual success - which includes a DTI Smart Award and a Millennium Product - is based as much on harnessing the latest technology as it is on the skills of its designers and modelmakers.

This includes establishing a Windows 98 network that links all its machine tools.

The network eliminates the potential for machining bottlenecks by ensuring unrivalled speed of machining program download, and it guarantees program security because it uses files that are write- or password-protected on a central hub.

The set-up supersedes the traditional arrangement of having PCs with serial port links for each machine.

In terms of the Milltech Europa milling machine, the integration by Anilam was a relatively straightforward affair since all Anilam control systems are PC-based, have built-in networking boards and have standard networking auto-sensing at 100Mbit per second for data transmission.

Toolroom CNC milling machine is low-cost, has many standard features that make it well suited for the production environment with faster speeds, an automatic tool changer and full enclosure.
CNC production miller is low-cost, dependable Toolroom CNC milling machine is low-cost, has many standard features that make it well suited for the production environment with faster speeds, an automatic tool changer and full enclosure. Those who watch the worldwide machine tool market, and manufacturers with cost and production headaches, have recognized the need for a dependable low-cost production mill. The TM-1P Toolroom Mill from Haas Automation, combines the best of both worlds: It is 'easy on the wallet', and has the power and flexibility of full CNC.

This model is based on the shop-proven Haas TM-1, but has many standard features that make it well suited for the production environment.

It comes 'out of the box' with faster speeds, an automatic tool changer and a full enclosure.

Sensible design and utility are characteristic of Haas Toolroom Mills.

The reliable 7.5HP vector drive spindle spins to 6,000 rev/min and uses standard 40-taper tools.

Rapids and cutting feedrates are 400in/min, double that of the non-enclosed TM-1.

The machine's 30in x 12in x 16in travels and a 57.75in x 14.5in T-slot table provide plenty of room for workholding and larger parts, and a 10-pocket tool changer is standard.

The TM-1P operates on either single- or three-phase power, and a one-piece cast-iron base/column damps vibration and provides rigidity - ensuring a high level of precision and repeatability.

One of the most-appreciated features of the TM-1P is the famous Haas Control.

Its easy-to-read color display and logical keyboard layout make it a pleasure to use.

The Haas Intuitive Programming System makes it one of the most user-friendly controls in the industry, and you don't have to understand G-code to make parts.

A number of high-productivity options are available for the TM-1P, including an auger-style chip conveyor, high-flow coolant system, a 20-pocket tool changer, 4th- and 5th-axis drives, rigid tapping and much more.

The rugged TM-1P incorporates the smart design and high quality that have made Haas the largest machine tool manufacturer in North America.

Built in the USA by Haas, the TM-1P is backed by the worldwide network of Haas Factory Outlets - the most extensive system of support and service in the industry.

* Haas Automation at IMTS 2006, Chicago, USA, September 6-13, South Hall, Booth A8000.

A versatile CNC milling machine combines the functionality and simplicity of a manual milling machine with the power and flexibility of CNC suits toolrooms and shops transitioning to CNC.
Toolroom CNC miller has larger travels A versatile CNC milling machine combines the functionality and simplicity of a manual milling machine with the power and flexibility of CNC suits toolrooms and shops transitioning to CNC. Haas expands its line of toolroom products with the new TM-3 Toolroom Mill, a versatile machine that combines the functionality and simplicity of a manual mill with the power and flexibility of the Haas CNC control, making it the perfect machine for toolrooms and shops transitioning to CNC. The TM-3 provides all the advantages of the Haas TM-2 Toolroom Mill, plus a larger table and extended Y-axis travel.

And the Haas Intuitive Programming System makes the TM-3 extremely easy to set up and operate - without knowledge of G-code programming.

The TM-3's 40in x 20in x 16in (X,Y and Z-axis) travels provide plenty of room for machining larger workpieces, and the large table accommodates multiple vises and/or chucks, as well as 5C indexers and rotary tables.

The non-enclosed format and standard T-slots simplify clamping of oversized and odd-shaped parts.

The machine runs on either single- or three-phase power.

The TM-3 features a 7.5HP (peak) vector drive spindle that uses standard 40-taper tooling and spins to 4,000 rev/min.

A push-button tool-release system makes tool changes fast and easy, and either a 10- or 20-pocket tool changer can be added for automatic operation.

Programming and setups are simplified with the Haas Intuitive Programming System.

Operations such as setting tool and work offsets, drilling and tapping cycles, engraving and pocket milling are easily accomplished without knowledge of G-code programming.

Select the desired machining operation, and the control prompts you for basic machining information - tool type, coordinates, feedrate, spindle speed, depth of cut, etc Once the information is entered, just push the Cycle Start button and the TM-3 performs the desired operation.

A Recorder function allows multiple operations to be saved, so that a part can be duplicated.

A wide assortment of options are available for the TM-3, including a 10- or 20-pocket automatic tool changer, a coolant system, a CE-compliant chip and coolant guard, 4th- and 5-th axis drives, chip-pan extensions, a hard-disk drive with Ethernet, and many more.

Another important standard feature of the TM-3 is confidence: Built in the USA by Haas, the TM-3 backed by the worldwide network of Haas Factory Outlets - the most extensive system of support and service in the industry.

* Haas Automation at IMTS 2006, Chicago, USA, September 6 -13, South Hall, Booth A8000.