Included in the series of new machines and innovative high-speed spindle and machining head options in a Spanish milling machine portfolio, is a heavy duty bed-type with a high quality build.
Included in the series of new machines and innovative high-speed spindle and machining head options just announced by Ward CNC for Soraluce's world-leading milling machine portfolio, the TA-20 bed-type mill will be making its UK public debut at MACH 2002. With X, Y and Z axes of 2000mm by 800mm by 800mm, the TA-20 has a feed range of 20mm/min to 10m/min and a speed range of 20 to 3000mm/min. It features Heidenhain TNC 410M CNC and digital drives, and the 21.5kW spindle produces 25 to 3,000 revs/min.

Feed range is quoted as 20mm/min to 10m/min and rapid traverse rates are 20m/min.

As expected of machines developed under the auspices of the Danobat Group's IDEKO research and development, this new machine combines high-quality build and technologically advanced features for unmatched heavy-duty milling performance.

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

In addition to Soraluce milling machines, Ward CNC is the exclusive UK agent for Union horizontal live spindle machining centres, Toshulin vertical boring, turning and milling machines, Kia CNC lathes, turning centres, and vertical and horizontal machining centres as well as Cetos CNC cylindrical grinders and Hankook Protec two-axis CNC lathes - representatives of which will also be on show at MACH 2002.

When a fabricator won a Swiss cryogenic vessel contract it had to quickly install the appropriate machining capacity and a machine tool quickly installed a travelling column, floor-type miller.
When Stainless Metalcraft won a new contract to produce cryogenic vessels for a customer in Switzerland, it not only needed to develop the appropriate manufacturing processes within super fast timescales, but it also had to quickly install the appropriate machining capacity. The answer was a Soraluce FP8000 travelling column, floor-type milling machine from Ward CNC. The fabricated vessels, which are used for particle acceleration, also contain various tubes, forgings, castings and other items.

These components are 'prepped' machined by Stainless Metalcraft before being welded by the company into the finished fabricated structures.

Knowing there were few machines that could provide the required bed capacity to accommodate the 5200mm long by 550mm diameter vessels, and having seen the Soraluce at MACH 2000, Stainless Metalcraft's project manager John Tadman recognised that the machine's 8000mm X axis would comfortably accommodate the large workpieces.

He also saw how the machine's 28kW spindle motor - and its Y and Z axes travels of 2000mm and 1200mm, respectively - coupled with the use of Soraluce's 4,000 revs/min universal head, would result in the most cost-effective machining of the stainless steel vessels.

'Equally importantly,' he says, 'because the machine was available ex-stock, we were able to have it delivered with minimal lead time direct from Ward CNC's Sheffield showroom.' Adding that the universal head is a particular asset, John Tadman highlights the production benefits of utilising its 2.5 degree incremental positioning in both vertical and horizontal planes.

'Also, we subsequently purchased an indexing table - a fourth axis - as well as non-contact Renishaw job probing, to further extend the machine's capabilities,' he comments, 'and Ward CNC's integration of these was impeccable.' Developed under the auspices of the Danobat Group's IDEKO research and development facility in Spain, the Soraluce FP8000 features high-quality build for unmatched heavy-duty milling performance, with its characteristic stability and rigidity being based on heavy-duty cast iron construction.

Two years on and John Tadman's confidence in the machine has been justified, he says, 'since it has lived up to expectations in every department'.

So much so that Stainless Metalcraft is this year looking to purchase another, larger capacity Soraluce from Ward CNC to replace existing equipment at its site in Chatteris, Cambridgeshire.

This will complement an already impressive plant list that includes a Ward CNC-supplied Toshulin vertical turning and boring machine that was recently installed to give increased machining capacity.

The last eight years have seen Coatbridge-based KRG Precision transform itself from an also-ran general engineering subcontractor into one of Scotland's leading heavy machining specialists.
The last eight years have seen Coatbridge-based KRG Precision transform itself from an also-ran general engineering subcontractor into one of Scotland's leading heavy machining specialists. The metamorphosis has been achieved through a combination of vision, skill and commitment from within the company, and development of a unique relationship with Mills Manufacturing Technology in Norwich. Since 1994 all but two of KRG's major machine tool purchases have been sourced from Mills in an ongoing, multi-million pound investment program.

This has allowed the company to switch its emphasis to oil and gas industry work, notably medium-to-large, complex, high precision, high value-added components and sub-assemblies in small batches.

As a result, the company's turnover is on target to exceed GBP 5.5 million in 2001/02, up from GBP 1.4 million in 1997/98.

Jim Hughes founded KRG in 1978 and the company grew slowly through the 1980s and early 1990s.

'We moved into these premises in 1994,' he said, 'at which time we were developing and building special purpose machines and doing some low volume, non-CNC subcontract machining.

'However we bought our first two CNC lathes soon afterwards, a Daewoo Puma 10 and Puma 12 from Mills.

These made us aware of the possibilities available with CNC equipment but we were reluctant to simply graduate from being a general subcontractor without CNC machines to being a general subcontractor with CNC machines - which is what a lot of other companies did.' It was apparent to Mr Hughes Snr and to his son, production director Kevin Hughes, that if KRG was to be a really successful company it had to develop services and capabilities that were uncommon or unavailable elsewhere.

They realised that the building from which the company now operates gave them a significant advantage.

It had previously been a heavy engineering works so a 15 ton capacity crane was already in place and the floor was suitable to support large capacity, heavy machine tools without need for special foundations.

'Even in a bad year the oil production and offshore exploration industry is hard put to find local companies with sufficient large machine tool capacity to satisfy demand,' Mr Hughes explained.

'We did some basic market research and it was apparent that if we developed this type of capability we could expect to see a good level of business.' Armed with this information, KRG was able to formulate a business plan that was used to support an application for a Regional Selective Assistance grant.

This helped to purchase from Mills a Kuraki KBT-11W-AP horizontal borer with six tonne table capacity and twin pallet changer, and a pair of Daewoo Puma 450 lathes capable of turning components up to 700mm diameter and 1575mm length.

At GBP 400,000 this was the largest investment made by the company - although the company has subsequently invested over GBP 2 million in new machine tools.

Said Kevin Hughes, 'Although the machines were a big advance over anything that we had previously operated we were very confident of our ability to get the best from them.

This was partly due to the fact that KRG has always had a strong skills base within the company, and partly due to the high level of training and technical support that Mills promised and delivered.

This has been ongoing and our relationship with Mills is almost a partnership; whereas other suppliers would probably have us wait up to a year for the sort of machine that we need to buy.

Mills has always been able to schedule delivery to coincide with our need for additional capacity.' The first of what are now two Kuraki horizontal borers was installed in May 1998.

Mills gained this important first order partially on rapid availability of the machine, while the pricing was competitive, even when compared with rebuilt machines from alternative suppliers.

The machine offers a work envelope of 2000mm in X by 1500mm in Y by 1450mm in Z and has a 500mm quill, enabling use of Davis-type facing heads.

Table capacity is 6 tonnes and the machine has a 40 tool ATC.

In production the machine has shown itself capable of holding a tolerance of =/-25 microns over a 1200mm by 600mm area.

This is a considerable level of performance given the types of material that are routinely machined at KRG, including stainless steel, Inconel, Monel and other exotic alloys.

'Once the machines were installed we got an immediate response from customers,' Mr Hughes Snr recalled.

'The machine is equivalent in performance to the equipment used by major oil and gas industry OEMs so they have been happy to source major components from us.

That's partly because we have set our stall out to offer the full package of documentation, traceability and parts marking required by the industry.

That in its turn has gained us more work and led us to develop our own supplier base for specialist coating services so that we can act as lead contractor for a ready-to-assemble turnkey package.' KRG has invested heavily in CAD/CAM, DNC and job tracking software as well as in machine capacity.

In addition it has strong engineering support capabilities, designing and fabricating its own steadies for turning and developing its own facing head.

By matching its do-everything philosophy with a do-everything capability, KRG has developed to the point where it can supply customers with complete kits of components to include in finished assemblies.

Along the way the company has installed additional machining capacity.

In 1999 an O-M VT5-16N vertical turning centre was installed with a 75kW spindle and a 1600mm diameter table capable of supporting workpieces up to 10 tonnes; in 2000 the second Kuraki horizontal borer was added.

In between times, two Daewoo Puma 350s and a Puma 250 plus two Daewoo machining centres were also installed.

'Single sourcing from Mills offers us a lot of advantages,' remarked Kevin Hughes.

'We know that we can rely on efficient installation and commissioning services, and that the back-up will be very good.

From a training point of view all of the controls and operator panels are similar and we can also plan routine maintenance more efficiently then if we had machines from a lot of different suppliers.

From Mills standpoint, I guess you could say that we provide them with an excellent demo facility.' Thus far the company's investment has been directed towards overall flexibility as a high proportion of KRG's throughput has been based on small albeit high value-added orders.

However the next stage of commercial development is a move into contract based manufacturing.

'We've reached the point now where order quantities are such that we will be able to specify some of our future machine capacity against specific jobs,' Kevin Hughes confirmed.

'That will give us the opportunity to consider machines with second-operation capability, as batch quantities will justify the longer set-ups and allow us to achieve higher production efficiency.'

A Soraluce CNC milling machine installed by Ward CNC of Sheffield at JCB Heavy Products has reduced cycle times by at least 15 per cent on a key machining operation.
A Soraluce CNC milling machine installed by Ward CNC of Sheffield at JCB Heavy Products has reduced cycle times by at least 15 per cent on a key machining operation for this world-leading manufacturer of excavators. Such is the success of the single-spindle Soraluce SP-5000 travelling column-fixed bed machine over existing twin-spindle machining centres, that the Soraluce is now being used to rough and finish machine all the fabricated arms manufactured at the company's Uttoxeter site. Producing a mixture of tracked and wheeled vehicles rated at 7 to 46 tonnes, JCB Heavy Products' level of design and manufacturing expertise can be gauged by its continually expanding order book and the recent accolade of a Queen's Award for Enterprise in the International Trade section.

JCB - Europe's largest manufacturer of construction equipment - sells its products in 140 countries.

'The business has grown rapidly over the past four years,' says Director and General Manager Mark Turner, 'and rather than simply absorb that capacity by 'doubling up' on existing machines, we began looking at our machining centre throughput in a completely different way.

'We'd been studying attachment machining for some time, and we knew that we had achieved optimum cycle times with twin-spindle machines.

But we wanted to improve machining times.' He continues: 'We targeted cycle time savings of 15 per cent to maintain competitiveness but without jeopardising product quality.' Says Mark Turner: 'Key to JCB's success is its philosophy of looking at business with a long-term view, and on that basis the selection of the machine and its supplier was very much based on our requirements for service and support in the future.' Powered by a 28 kW spindle, the Soraluce FP-6000 travelling column floor-type machine has X, Y and Z axes traverses of 6,000 mm by 2,000 mm by 1,200 mm.

Component fixtures are mounted on a separate tee-slotted floor plate in front of the machine.

It was subjected to a very tight specification in terms of cycle times and tolerances - 'which it achieved with no trouble', adds Mark Turner.

In addition to switching from twin-spindle operation to single-spindle machining in a different plane, Ward CNC worked closely with tooling suppliers and JCB to introduce dry machining and various helical boring routines, for example.

The portal design Hermle C1200 can be specified with either a rigid table or NC swivelling rotary table to cater for complex aircraft type components or mould and die work.
The portal design Hermle C1200 can be specified with either a rigid table or NC swivelling rotary table to cater for highly sophisticated aircraft type components requiring five-axis machining in small and medium batches or die and mould machining. In either case, a choice of 10,000, 16,000 or 24,000 rev/min spindle is available and high acceleration rates of 4m/sec2 in each axis to 30m/min rapid traverse minimise lost spindle machining time due to repositioning. Now available from Traub Heckert UK of Brackley, the C1200 V has a 1,400mm by 900mm table and a machining volume of 1,200mm in X, 900mm in Y and 500 mm in Z.

Meanwhile, the C1200 It has been developed to provide five-axis simultaneous machining for which seven have just been installed in the UK.

The machine features an 800mm diameter NC rotary table with + 15deg to -97deg swivel and axis travels of 1,200mm in X, 800mm in Y and 500mm in Z.

The extremely rigid, closed back portal design of bed and column structure is manufactured from a mineral casting, which has low thermal conductivity and high vibration damping qualities.

It provides the ideal platform to optimise contour machining accuracy and surface finish while providing the basic criteria to achieve high levels of tolerance and repeatability.

Here, through direct linear scale measurement, the resolution is qualified as being 0.0001mm.

The standard spindle on both machines is 25 kW giving 20 to 10,000 rev/min.

It has water cooling and options of SK40 or HSKA63 taper.

Torque is high at 159 Nm and, as standard on both this and the 16,000 rev/min optional spindle, collision protection is fitted to the Z-axis.

The 16,000 rev/min spindle develops 130 Nm of torque at 1,100 rev/min from the 15 kW AC drive while the optional high speed machining 23 kW drive powers a 20 to 24,000 rev/min spindle.

Tool magazines are of a ring design with 30 pockets which are mounted under the cross beam of the main mineral cast portal frame.

In addition, by using additional magazines these can be expanded to 87 tools.

All tools are protected from the working area and automatic change takes 6.5 secs via a spindle pick-up process which avoids the use of toolchange arms.

Maximum tool size is 300 mm long by 80mm diameter or 125mm diameter with adjacent pockets vacated.

A laser system enables precise automatic tool length and size measurement and provides tool breakage monitoring.

Control is by Heidenhain TNC 430 contouring system with integral hard disk, 3-D interpolation and real time graphical simulation or Siemens S840D with NURBS- Interpolation.

Within three months of installation a Fanuc Robodrill, Raytheon Marine Company based in Portsmouth calculated savings of GBP6,000 on components it produced due to faster set ups.
Within three months of installation a Fanuc Robodrill, Raytheon Marine Company based in Portsmouth calculated savings of GBP6,000 on components it produced due to faster set ups and cycle time reductions of between 25 and 60 per cent. By the end of the first 12 months, additional savings from bringing in-house subcontract machining that was previously put outside due to increasing demand and insufficient capacity, will raise a further GBP10,000 while already bringing to an end, concerns over quality control and delivery. The Fanuc Robodrill T14iA has increased Raytheon's milling and drilling capacity by 250 per cent and is predominantly used on aluminium alloy components.

These are used in marine autopilot systems which are part of the company's world leading capability in marine electronics including radar, satellite navigation, autopilots, chart plotters and fish finders.

Raytheon, originally trading as Nautech, was founded in 1974 by Derek Fawcett, the inventor of the first Autopilot.

It was purchased by US defence giant Raytheon in 1992, which subsequently fuelled significant growth within the organisation.

Today, it has sales of over GBP139 million, employs around 300 people at Portsmouth and produces around 2,000 Autopilot systems per week of which 75 per cent of the navigation products are exported to America.

Raytheon's machining mostly involves aluminium alloy and aluminium bronze components for the 15 different basic types and a number of variants of the Autopilot system.

This can include the production of various parts for hydraulic pumps, ballscrews, gearbox assemblies, wind vanes, clutch assemblies, plates and covers.

Batch sizes are typically around 150 to 200 and tolerances are down to 10 microns.

Most machining cycles involve light profile milling along with extensive drilling and tapping for which the largest components a non-ferrous cast motor cover plate takes around 10 minutes.

Most other production operations are usually fairly short at between two and three minutes each.

Senior production engineer Neil Panter outlined the background to the purchase of the Robodrill.

'We are strongly committed to pursuing lean manufacturing with the machine shop supplying manufacturing cells on Kanban principles.

This has led to much smaller batches and increased set-ups which, in turn gives quicker throughput times.

But we needed extra capacity on light milling, drilling and tapping to meet increasing demand and after a thorough examination of the small vertical machining centre market we opted for the Fanuc Robodrill.

Its cost to performance ratio, high productivity, capability and ease of set-up were strong arguments for purchase.' The machine was installed in May 2000.

Other factors which influenced the decision in favour of the T14iA were the interchangeability of spindle and fixture tooling with the company's existing machines and the popularity of the Fanuc control with operators.

The Robodrill has been positioned adjacent to an existing vertical machining centre to form a two machine cell for Autopilot components and is manned by a single operator.

The cell runs 24 hours a day for five days a week; while the machine can be used to produce any of the Autopilot components, it is mainly the more complex and high tolerance parts that are machined.

Says Neil Panter: 'The introduction of this machine has eliminated our capacity problems to such a level that we are now using it for tooling and prototype work which makes full use of the Fanuc CAP programming system on the machine control.

A prime example of savings made is the 56 per cent reduction in floor to floor time of a 150mm by 250mm by 50mm aluminium alloy linear motor plate.

It requires 14 different elements for the machining cycle involving profile milling, thread milling, drilling and tapping.

Major reasons for the faster time against the existing vertical machining centres is the 48 m/min rapid positioning, the 8,000 revs/min spindle speed of the Robodrill and its ability to rigid tap at 5,000 rev/min.

On another job, two basic slot milling operations on a cast iron linear clutch mechanism are now being carried out some 62 per cent faster on the Robodrill.

In addition to the minimal lost time in positioning typical milling and drilling feed rates are between 1.5 to 2m/min.

The installation of the Fanuc Robodrill has done much to streamline machining efficiency and improve quality standards to which Neil Panter adds: 'The machine has exceeded our expectations due to its ease of set-up, speed of operation and the rate with which it can accurately mill, drill and tap with minimal non-cutting times.

With the highly productive DMU 50 / 70 eVolution, DMG has added a new dimension to universal milling and drilling machines designed to save up to 20% on machining times.
With the highly productive DMU 50 / 70 eVolution, DMG has added a new dimension to universal milling and drilling machines designed to save up to 20% on machining times. The DMU 50 / 70 eVolution types are powerful universal milling and drilling machines designed for the exacting machining of flat and prismatic workpieces using a vertical work spindle. Positioning and tool changing time have been significantly reduced thanks to 1G acceleration in the linear axis, 50 m/min rapid traverse, 40 % higher rotational speed of the NC swivel rotary table, and a tool changer which is twice as fast as its predecessor.

Customers will save up to 20% machining time.

With spindle speeds of 18.000 rpm the DMU 50 / 70 eVolution comes standard with the classic high speed cutting (HSC) features.

In addition to the HSK 63 A tool mounting it offers the economical SK 40 version for using tools available in the workshop.

Thanks to a new design of the machine structure coolant dispersal has been optimized and swarf removal significantly improved.

Thus the machine concept is ecological and meets growing demands for ensuring minimum tool lubrication.

Also working with the innovative DMU 50 / 70 eVolution is even more convenient than before.

Coolant tank and swarf conveyor are supported on wheels and easily movable.

Manual cleaning of the screen for the internal coolant supply is replaced by automatic cleaning and the tool changer can be operated directly on the loading side.

The control of the new DMU 50 eVolution is the Heidenhain TNC 430 or the MillPlus IT.

No less than 20 new control features offer more application advantages, such as integrated internet access and planar transformation, an Ethernet interface via TCP/IP protocol and an extended 'look-ahead' function.

Traditional customers of tool and die making will consider the DMU 50 / 70 eVolution also a safe investment thanks to its high performance and accuracy.

As a machine which is designed for 5-sided and 5-axis-machining it is increasingly moving into new industries, such as medical, aeronautical, automotive and electrical engineering.

Axis travels of the DMU 50 eVolution are 500 by 420 by 380mm in X, Y and Z respectively.

Rapid traverse rates are 50m/min in all axes and feed range is up to 20,000mm/min.

Main spindle drive (AC-motor spindle) is rated at 15/10kW (40%/100% duty cycle) The DMU 70 eVolution has a similar specification to the DMU 50eVolution except that axes travels are 750 by 600 by 520mm

A Soraluce CNC milling machine installed by Ward CNC of Sheffield at JCB Heavy Products has reduced cycle times by at least 15 per cent on a key machining operation.
A Soraluce CNC milling machine installed by Ward CNC of Sheffield at JCB Heavy Products has reduced cycle times by at least 15 per cent on a key machining operation for this world-leading manufacturer of excavators. Such is the success of the single-spindle Soraluce SP-5000 travelling column-fixed bed machine over existing twin-spindle machining centres, that the Soraluce is now being used to rough and finish machine all the fabricated arms manufactured at the company's Uttoxeter site. Producing a mixture of tracked and wheeled vehicles rated at 7 to 46 tonnes, JCB Heavy Products' level of design and manufacturing expertise can be gauged by its continually expanding order book and the recent accolade of a Queen's Award for Enterprise in the International Trade section.

JCB - Europe's largest manufacturer of construction equipment - sells its products in 140 countries.

'The business has grown rapidly over the past four years,' says Director and General Manager Mark Turner, 'and rather than simply absorb that capacity by 'doubling up' on existing machines, we began looking at our machining centre throughput in a completely different way.

'We'd been studying attachment machining for some time, and we knew that we had achieved optimum cycle times with twin-spindle machines.

But we wanted to improve machining times.' He continues: 'We targeted cycle time savings of 15 per cent to maintain competitiveness but without jeopardising product quality.' Says Mark Turner: 'Key to JCB's success is its philosophy of looking at business with a long-term view, and on that basis the selection of the machine and its supplier was very much based on our requirements for service and support in the future.' Powered by a 28 kW spindle, the Soraluce FP-6000 travelling column floor-type machine has X, Y and Z axes traverses of 6,000 mm by 2,000 mm by 1,200 mm.

Component fixtures are mounted on a separate tee-slotted floor plate in front of the machine.

It was subjected to a very tight specification in terms of cycle times and tolerances - 'which it achieved with no trouble', adds Mark Turner.

In addition to switching from twin-spindle operation to single-spindle machining in a different plane, Ward CNC worked closely with tooling suppliers and JCB to introduce dry machining and various helical boring routines, for example.

Being supplied by Ward CNC, two new Soraluce FP8000 travelling column floor-type milling machines and a pre-owned Marafuku travelling-table machining centre are en route to Newburgh. Engineering Co -
Being supplied by Ward CNC, two new, Spanish-built Soraluce FP8000 travelling column floor-type milling machines and a pre-owned Marafuku travelling-table machining centre are en route to Newburgh Engineering Co - a Derbyshire, Peak district-based specialist medium-duty machinist and fabricator - to satisfy a long-term, high-volume machining contract. The new Soraluce machines are scheduled to join the already-installed Marafuku in the summer and, in the meantime to meet the throughput demands, Newburgh is utilising a re-sited horizontal borer and a Zayer bed mill that is on loan from Ward CNC. Of travelling column design, the Soraluce FP8000s purchased by Newburgh have 30 kW spindles and X, Y and Z axes travels of 8,000 mm by 2,000 mm and 1,200 mm.

The machines are fitted with orthogonal auto-indexing heads that offer 144 by 144 programmable positions on two perpendicular axes, thus enabling the machining of X parallel angled faces - an essential requirement of Newburgh's contract.

Additionally, the machines are to be equipped with automatic indexing tables for pendulum machining, and will feature auto component recognition and hydraulic clamping.

When faced with the selection of the additional capacity to meet the contract, Newburgh did not hesitate long in choosing Soraluce.

The company has been using a Soraluce SP-10000 fixed bed, travelling column milling machine for some time and it has proved a very good machine.

This coupled with Ward's ability to provide a complete turnkey solution, and the confidence gained from seeing Soraluce build machines in their excellent facility in Spain, secured the order.

As expected of a machine developed under the auspices of the Danobat Group's IDEKO research and development facility in Spain, the Soraluce FP8000 combines high-quality build and technologically advanced features for unmatched heavy-duty milling performance based on stability and rigidity obtained via 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 1,500 mm to 16,000 mm plus in the X axis, from 1,000 mm to 4,200 mm in Y and up to 1,500 mm in Z, with the latest linear guideway technology offering rapid traverse rates up to 15,000 mm/min.

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

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

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

The machines are proving ideal for applications in the aerospace, heavy machinery, mould and press tool, fabrication, power generation, equipment and medium/heavy-duty sub-contract machining industries to name but a few.

Automotive industry supplier Donnelly Hohe Schleiz relies on the Mikron HSM 700 high-speed milling machine to machine dies for die-cast automotive components.
Automotive industry supplier Donnelly Hohe Schleiz relies on the Mikron HSM 700 high-speed milling machine to machine dies for die-cast wing mirrors, exterior and interior door handles and boot catches for a customer base that includes the major international car manufacturers. The company is one of the main producers of car mirrors in the world and in 1999, with a workforce of 290, the company achieved sales of SFr 83 million. Unlike many other automotive suppliers, Donnelly Hohe Schleiz has not sub-contracted tool-making, for which it relies on high speed milling.

This creates definite competitive advantages, above all in time and flexibility.

In this fiercely competitive market it is no longer enough to restructure isolated areas of production, only when all the stages in the process are streamlined in a unified structure can maximum productivity be achieved.

Across the board co-ordination, from CAD/CAM to the chucking equipment, provides significant increases in efficiency in die-casting.

The injection and die-casting moulds that Donnelly Hohe Schleiz specialises in are extremely complex, with deep, filigree contours.

'The parts for which we make the moulds,' says Klaus Dietsch, head of the tool-making section, 'are sometimes so complicated that the moulds cannot be manufactured using any traditional straightforward technique.' In a market sector, which is subject to enormous time pressure, imposed by the international car manufacturers on their suppliers, the most important things are, in his opinion, 'quality and speed'.

For over a year, Donnelly Hohe Schleiz has been using a Mikron HSM 700 high-speed milling machine.

'Even with hard metals we can work without using spark erosion.

We mill virtually everything,' says Dietsch.

The main advantage is that all the machining can be done in one chuck set-up and on just one machine without having to change procedures.

That shortens the processing chain, avoids re-chucking and set-up procedures and increases speed and accuracy.

Surface quality is also improved because, for example, the thermal damage to the edges which occurs during spark erosion is avoided.

Depending on the mould, there is now a reduction of about a third in the spark erosion time, a third in the manual work required, and of course also a saving in the material for the electrodes.

Only rarely now, for special moulds with very deep, narrow contours, does the company fall back on a combination of milling and erosion.

Naturally, the great potential of HSM milling for saving both time and money can only be fully exploited if the whole processing chain is upgraded.

The HSM 700 is so fast that at least two NC programmers per shift are required.

R.M Tool and Die (RMT) was founded in 1987 to provide a rapid response service to industry. Three CME CNC bed mills ensure on-time delivery of moulds.
R.M Tool and Die (RMT) was founded in 1987 to provide a rapid response service to industry. Then, as now, lead times are decreasing and on-time delivery ever more critical. UK toolmakers' are also constantly under threat from the strength of the pound and labour intensive Far East toolrooms promising the earth.

However, specialising in tools for the automotive industry, RMT has steadily expanded, and now occupies four sites at the heart of the Midlands communications network in Coventry and achieves a 98% on-time delivery.

RMTs expansion has been remarkable considering the economic climate and the resultant threat from toorooms worldwide.

Organised in four 'Unit Cells', the ability to produce a high quality mould mirrors the company's portfolio of automotive clients - Aston Martin, Ferrari, BMW, Honda, Rover and Volvo.

Pattern making, detailed CNC work, and EDM operations, are situated in three of the 'unit cells'.

However, the main site, is dedicated to the design and manufacture of a wide range of press tools, resin injection mould, blow mould, P20 tool steel RIM moulds and so on.

It houses three CME BF03 bed mills, installed by Yuasa Warwick Machinery to cater for the expansion and aid on-time delivery, as RMT Managing Director, Mike Walton explained.

'All the units are served by the expanding CAD/CAM facility here in Unit 2.

Electronic data currently accounts for the majority of incoming designs, although we have the facility to handle 'old-fashioned' paper designs.

Typically, we will examine the design data and discuss relevant detail with the client.

Unlike most companies our CNC machining technicians are involved at the design stage using Catia 4.2, Delcam Power Shape and Work NC.

Not only does it give us greater flexibility but the operators gain a closer understanding of each project.

As well as our 'blue chip' automotive clients we have seen a growth in moulds for fast-moving consumables, the leisure industry and the defence sector.

However, we project-manage each job, and aim to deliver the component, whether for a top-secret military project or a prototype for an international sweet manufacture, in the required time frame.

Although our strength is in producing a variety of automotive moulds, we can produce a twin impression aluminium blow mould for a garden slide using the latest machine tools and manufacturing techniques in less than five weeks.

We can also use traditional manufacturing techniques with CAD/CAM technology to produce cost-effective blow mould tooling.

In all cases the three CME BF03's are essential to our business, machining the bulk of the tools.' In Unit 2, one of the CME BF03s was machining a resin prototype model held in bespoke jigs and fixtures whilst a second was machining out the cavities for an aluminium bumper mould.

In the latter the BF03 was 'water lining', machining small cuts very quickly, utilising the Lemoine system fitted to two of the machines - allowing travel up to 8 metres/min at speeds of 10,000rpm.

Aluminium bumper tools are manufactured for low volume manufacture such as the Aston Martin DB7, whereas steel tools are required for larger production runs such as BMW and Rover.

'All our customers are happy for us to generate our own NC paths without referral.' states Walton cutter paths are networked to PC's situated by the machines and NC data is 'drip fed' to the relevant machine.

The BF03 can take a table load of 5500kg and with a machining capacity, 2 metre x 1metre cubed, it is ideal for the work we carry out.

Although our automotive tolerances are typically +/- 0.1mm we can rely on the machine's inherent accuracy - repeatability and positioning to +/- 0.01mm - when machining blow moulds to tighter tolerances.

We will also carry out finished quality control checks using a Stiefelmayer 3D co-ordinate measuring machine, plotting out a picture of each component and outputting a record of achieved tolerances.' 'We pride ourselves on our technical back-up and to date our controlled growth has seen us purchase the technology that has met the increased capacity and aided our on-time delivery ethos.

To that end, the machining technology and 'toolroom knowledge' at Yuasa Warwick is invaluable as we meet the continuing needs of our customer.' concluded Mike Walton.

The new Mikron HSM 400 is raising the standards for high speed milling machines. It provides automation, workpiece accuracy, ergonomics, and process reliability says Mikron.
The new Mikron HSM 400 is raising the standards for high speed milling machines. Providing automation, workpiece accuracy, ergonomics, and process reliability, this new portal machine offers major technological benefits as well as outstanding value for money. Heralding a new generation of machines from Mikron, the HSM 400 is the product of the company's many years of experience and knowledge in the field of high-speed machining technology.

Probably the most outstanding development among a wealth of technological advances, is the incorporation of an integrated workpiece changer, enabling the unmanned operation of the machine and therefore offering purchasers vital competitive-edge benefits in productivity and cost/part.

The HSM 400 has been designed and built to the highest specification.

Every machine is prepared for both wet and dry machining, laser measurement of diameter and length is incorporated as standard and the motor spindle delivers 42,000 rev/min with high load capacity, long-life ceramic hybrid ball bearings and temperature sensor for thermal compensation and vector regulation system.

Excellent machining precision and surface quality result from the outstanding component stability provided by this uncompromisingly robust machine.

The portal construction type is an enclosed O-form, the Y-Z column saddle has a rigid, high-ridged cast construction and the concrete polymer construction provides a six-fold improvement in damping qualities and a twenty-fold improvement in thermal stability compared to conventional, gray cast iron.

The HSM 400 also provides the highly dynamic axes that are vital, particularly for efficient mould manufacture.

The motor spindles provide extremely rapid acceleration and deceleration and control units incorporate digital drive technology to all driven axes, which are of a lightweight construction.

Furthermore, the HSM 400 has been designed to provide the optimum 1:10 ratio of driven to static masses.

Claimed to be the most accessible portal machine in the world, the HSM 400 has been designed for optimal ergonomic functionality, resulting in a radical, modern unit, with a total space requirement, including the integrated pallet changer, of only six cubic metres.

The single, easily manipulated door provides access from three sides, for straightforward manual or crane loading, unrestricted by the automatic workpiece handling system.

The machine provides an optimum table height of 900mm and ideal positioning depth, together with steeply angled, easy-to-clean stainless steel covers, to prevent swarf build-up.

A large window provides an unrestricted view of the workpiece and there is a single control unit for both machining and automation.

The new, fully integrated workpiece changer has a minimum of moving parts and is situated outside the working area to avoid the build-up of swarf, dust and coolant.

Programming is carried out directly at the machine control unit.

The HSM 400 has been designed and constructed to produce the highest levels of reliability and process security.

Well protected components, maintenance-free ball screws and linear guides and a carefully thought-out swarf management system all add to a truly robust and reliable system capable of tackling demanding work-loads day in, day out.

In summary, Mikron's new HSM 400 is a radical new development in high speed milling machines, providing superb precision, accuracy and reliability for a wide range of applications including: prototyping, electrode production, plastic injection and die-cast moulding, and die-forging.

The integrated work-piece and tool changing functions of the machine make 24 hour, unmanned working a realistic proposition to a greater range of companies than ever before.

Machine specification details include: working range: a.

X axis 400mm b.

Y axis, 450mm c.

Z axis 350mm d.

Tool holder HSK E40 •Feed drive: a.

Feed rate XYZ 0 to 40000 mm/min b.

Spindle acceleration (a) 10m/s2 •Work table: a.

Clamping surface - Depending on pallet b.

Workpiece weight max 200kg.

•Control system - Heidenhahn TNC430 •Automatic control: a.

Tool-changer, number of tool stations 18,36,72 b.

Pallet changer, magazine capacity, depending on pallet size: 7,20, 48 c.

Laser tool measurement - standard • Weight, net, including tool-changer approx 6500kg •Options: a.

Chip conveyor b.

Coolant distribution c.

Vaporised oil mist extraction d.

Dust extraction e.

Ward CNC of Sheffield has been appointed exclusive UK distributor for the Union range of CNC horizontal live spindle machining centres manufactured by Union Werkzeugmaschinen GmbH of Chemnitz, Germany
Ward CNC of Sheffield has been appointed exclusive UK distributor for the Union range of CNC horizontal live spindle machining centres manufactured by Union Werkzeugmaschinen GmbH of Chemnitz, Germany. The Union portfolio of table-, floor- and planer-type machines is the 'perfect addition' to the Ward CNC new machine division's current CNC ranges of Soraluce milling machines, Toshulin VTLs and Hankook lathes, says managing director Simon Whitworth. 'Importantly, too, our appointment reflects Union's confidence in both our applications engineering knowledge of these large-capacity machines and our ability to service and maintain them.

'As a group, T W Ward CNC Machinery has been rebuilding, re-manufacturing, servicing and supporting Union machining centres for some time, and during the past four years alone we have supplied at least 10 re-engineered Union borers to our blue chip customer base.' The Union range currently available from stock at Ward CNC in Sheffield includes TC and T table-type models with X axis travels of 1,500 mm to 2,000 mm, Y axis travels of 1,250 mm to 1,600 mm and Z axis travels from 1,000 mm to 1,600 mm.

W axis boring spindles of 102 mm, 110 mm, 130 mm and 150 mm diameters have travels up to 750 mm.

Union P and PC floor-types have X axis travels beginning at 4,000 mm up to 10,000 mm and larger, with Y axis up to 3,500 mm vertical.

K and KC planer-type models start at X axis travels of 2,500 mm up to 4,000 mm.

Y axis travels are up to 3,000 mm with W axis boring spindle travels up to 750 mm.

Included are models with automatic pallet change, with/without auto tool change and with built-in NC facing heads.

These latest generation machine tools adopt up-to-date linear guideway technology for high specification and performance plus a host of additional modern features and accessories.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Faster production cycles, higher quality surface finishes and 'dual' machining capability are on offer with the new high-speed electro-spindle now available for Soraluce CNC milling machines
Faster production cycles, higher quality surface finishes and 'dual' machining capability are just some of the major benefits on offer with the new high-speed electro-spindle now available for Soraluce CNC milling machines from Ward CNC of Sheffield. The compact 20 kW synchronous spindle motor - which produces 21,000 revs/min - boasts short acceleration times and a constant torque of 18 Nm, plus surface finishes of 0.4 Ra compared with 0.6 Ra with a traditional asynchronous spindle. The result is that Soraluce users can effectively broaden their machining capability by 'doubling up' machine capacity.

This will permit roughing and finishing with the same spindle, or users can quickly and easily swap the new unit with the standard automatic indexing head arrangement used for heavy metal removal, to suit the task in hand.

The 'cold' rotor also extends the lifetime of the bearings - equating to a spindle life of at least 7,000 hours compared with the usual 3,000 hours available from an asynchronous unit.

This is courtesy of the very low levels of vibration generated by this low-inertia unit, and its ability to achieve balance independent of both speed and power.

Available as optional extra on Ward CNC's range of Soraluce CNC milling machines which 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 - the new electro-spindle doubles the effective machining capability of the range at relatively low cost.

Pick up of the electro-spindle, which is located to one side of the machine table, is via the machine's automatic head, followed by automatic clamping then connection using manual quick-switch connectors.

The use of a Hirth coupling makes for an extremely rigid arrangement - and the whole process takes only seconds! Ward CNC's five- and six-axis Soraluce CNC milling machines range in capacity from 1,500 mm to 16,000 mm plus in the X axis, from 1,000 mm to 3,600 mm in Y and up to 1,500 mm in Z.

The latest linear guideway technology offers rapid traverse rates up to 15,000 mm/min.

Spindle motors range from 28 kW to 37 kW.

In addition to the electro-spindle feature, other options include universal or orthogonal automatic indexing heads and two-axis gyroscopic head for five- and six-axis applications.

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

Soraluce machines add another dimension to heavy-duty milling applications.
As expected of a machine developed under the auspices of the Danobat Group's Ideko research and development facility in Spain, the Soraluce FP8000 travelling column floor-type table milling machine available from Ward CNC combines high-quality build and technologically advanced features for unmatched heavy-duty milling performance. With characteristic build qualities of stability and rigidity based on the heavy-duty cast iron construction, the resultant high-accuracy machining is also dependent on the control system technology, which is predominantly a choice of Heidenhain, Siemens or Fidia. This particular machine has a 28kW spindle and X, Y and Z axes travels of 8000 mm by 2000 mm and 1200 mm.

Ideal for applications in the heavy machinery, mould and press tool, fabrication, power generation, equipment and heavy sub-contract machining industries to name but a few, Soraluce machines are also proving a particular success in UK aerospace applications.

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 1500 mm to 16,000 mm plus in the X axis, from 1000 mm to 3600 mm in Y and up to 1500 mm in Z, with the latest linear guideway technology offering rapid traverse rates up to 15,000 mm/min.

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

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

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