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.

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.

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.

Control software that provides high speed production and die mould type machining in three, four or five-axes features a precision drilling and milling centre.
New control software, significantly improving the ability to provide high speed production and die mould type machining in three, four or five-axes as well as precision milling and drilling for electrode, aluminium, steel and hard metal components, extends the capability of the Fanuc Robodrill Alpha T21I, which is now in D-Series guise. Now available from 600 Centre of Shepshed near Loughborough, the Fanuc Robodrill is an international top-seller by combining a high speed, short-cycling capability with the latest control and drives development from Fanuc to achieve high positioning accuracies and precision surface contours. Indeed, the T21iD now has rapid traverse rates of 54m/min achieved with an acceleration of 1.5G, 1.8 secs chip-to-chip for the 21 tool position magazine and a choice of 10,000 or 20,000 rev/min spindle, which define the potential for highest levels of productivity.

Available in three versions, all with Z-axis travel of 330mm, the ultra-compact D-Series has 300mm travel in X and Y with a 630mm by 330mm table.

The standard D has a 500mm X-axis and 400mm Y-axis with 650mm by 400mm table and the DL, extended capacity version, has 700mm in X with 400mm in Y and an 850mm by 410mm table.

Software improvements to the Fanuc 16i-MB control abound in the D-Series such as Fanuc's optional Auto Intelligence (AI) contour control and nano contour technology which uses RISC processor to read up to 600 blocks in advance.

This capability enables precise control of acceleration/deceleration without variation of feed rate giving a continuous ultra-smooth surface texture.

A jerk control option, with automatic feed rate control at a corner, reduces mechanical shock and, high resolution is achievable through the latest fast response servo motor developments introducing an ultra-precision pulse coder of 16 million pulses per rev.

For five-axis type applications, tool centre point control ensures the command path and feed rate is maintained while tool radius compensation during table rotation negates the need for part program change.

Thermal displacement compensation in the Z-axis is carried out in 'real time ' by monitoring the operational status of the spindle and predicting any elongation along the vertical axis while tool monitoring and tool life control is standard.

As part of the extended capability of the latest Robodrill, deep hole drilling can be performed to create precision holes as small as 0.1mm diameter to a depth some 30 times the hole diameter.

To help improve performance for deep hole drilling with small tools and high speed milling, the standard 5.5kW spindle delivers 10,000 rev/min but a faster 3.7kW 20,000 rev/min high speed option ensures higher productivity and cutter security.

Both spindle types have BT30 taper and through coolant is an option.

High speed rigid tapping at up to 6,000 rev/min is standard with a quick, 20 times override tap extraction rate.

Fast setting and changeover is helped by new control features such as set-up file able to hold 30 sets of program data with automatic initialisation.

A quick editor using the full screen display operates in similar vein to a PC with functions such as copy, move, search and cursor jump.

Meanwhile, a custom PMC function allows simple control of peripheral devices giving fast programming and editing on the 10.4 inch full colour LCD screen.

By injecting a special type of concrete into the massive sidewalls of a travelling gantry CNC miller-boring machine excellent stability and vibration damping is achieved.
By injecting a special type of concrete into the massive sidewalls of a travelling gantry CNC miller-boring machine excellent stability and vibration damping is achieved when machining large, long workpieces. To achieve optimum milling results on large workpieces - such as mould and die work or aircraft structures - F Zimmermann is injecting a special type of shear-resistant concrete into the high sidewalls of its FZ 37 travelling gantry CNC milling and boring machine. The concrete-filled structure adds extra stability and dampens metal cutting vibrations, producing an excellent surface finish, said the company.

The FZ 37, as shown at the recent METAV show in Germany, had a table width of about 2.5m and an exceptionally large Z-axis clearance of 2500mm under its 2-axis milling head.

The milling head is claimed to be exceptionally stiff owing to the use of axial-radial roller bearings.

It provides a high driving torque in both rotary axes through backlash-free adjustable worm gears.

The standard milling spindle, equipped with oil-air lubrication, operates at up to 24,000 rev/min and uses a HSK 63 A tool holder.

The FZ series is built on modular principles, with a variety of milling heads, drives and control systems.

Control systems used include Fidia, Heidenhain and Siemens.

The company adds that its use of double-guidance in the machine's X-axis guarantees an optimum surface quality on workpieces.

This arrangement supports the linearity of the gantry, consequently the linear axes, X, Y and Z, are exactly right-angled over the entire traversing distance.

The direct linear measuring systems, with well-proven, air pressurised Heidenhain seal linear encoders are integrated in all three axes.

Zimmermann offers eight different types of sidewall gantry machines and claims it has the broadest range of state-of-the-art machine tools for the modelling and mould and die industries.

Under the new ownership of Sachman, Italy, Rambaudi's new projects were shown at the BIEMH machine tool show in Bilbao, Spain, including a mid-range high speed, 3-5 axis machine.
Rambaudi's new projects were shown at the BIEMH machine tool show in Bilbao, Spain. Rambaudi, probably the oldest and most famous among the italian companies manufacturing milling machines, after the acquisition by Sachman Spa, has restarted operation with Rambaudi Spa name more than one year ago. The range of the existing high speed 5 axes milling machines is being enlarged with a lot of brand new models, as everybody who visited last EMO 2003 in Milan, could see.

Rambaudi choose last week exibition in Bilbao to show the first middle size machine of the new generation.

This machine line is using the coventional motor and linear motor technology toghether.

The Ramfast line is a new generation of high speed, heavy duty vertical milling machines in 3 and 5 axes.

Rambaudi, which has already experience with linear motor on linear axes, has introduced that technology on the rotary axes, which will add a lot of advantages to application with extremely high demands for speed, accuracy and duty cycles.

The success and the interest reached at the 23rd BIEMH confirm that line of machines will have a bright future!

Of ten machines shown under power, a twin pallet VMC has the latest manual guide CAM while two updated two axis lathes will be hard turning aerospace components to 'super precision' finish.
Visitors to Ward Hi-Tech on stand 5280 will see a total of ten machines, under power, ranging from standard two-axis CNC lathes through to powerful multi-axis driven tool turning centres; large capacity vertical turning lathes through to horizontal and vertical machining centres and universal head bed-type and travelling column CNC milling centres. Among them will be several new models and others that benefit from significant upgrades. * New - the Dah Lih DMV-800 twin pallet travelling column vertical machining centre, featuring a Fanuc OIMB control system with latest manual guide cam software and colour graphics, benefits from a large rotary pallet arrangement and is capable of performing both heavy-duty and high speed machining.

Axis travels of 800mm (X) and 560mm (Y and Z) are supplemented by a spindle speed of between 80 and 8000 rpm and a 32-position toolchanger.

This model will be shown machining a stainless steel valve body under heavy-duty conditions as well as demonstrating the high-speed machining of aluminium, highlighting the versatility of the DMV-800.

CME's FS-0 ram-type universal head machining centre with Heidenhain I530 control provides a rigid platform from which to make best use of its speed and accuracy.

With its 1200mm (X) and 750mm (Y and Z) axes travel, 5000 rpm spindle and universal head the FS-0 will be machining a mould for an automotive alloy wheel, a process involving heavy-duty cutting in steel.

* Updated - new from Doosan will be the updated S280N and S310N two-axis lathes.

The S280N features a maximum turning diameter of 280mm combined with a turning length of 320mm and a maximum spindle speed of 6000 rpm.

Manufactured with rigid box ways, 10 position turret and axis travels of 160mm (X) and 330mm (Z), the S280N will be demonstrating its ability to 'hard turn' an aerospace component to a 'super precision' finish.

The larger S310N has axis travels of 185mm (X) and 500mm (Z) with a maximum turning diameter of 310 mm and length of 480mm, while the turret increases to a 12-position unit.

Promoting the rigid box way design, the S310N will be demonstrated cutting a steel billet under heavy-duty conditions.

Two axis Horizontal and Vertical lathes - Ward Hi-Tech will also be showing the Doosan S670L heavy-duty two-axis slant bed lathe, which with a maximum turning length of 1850mm is ideal for shaft work.

The S670L has a maximum chuck size of 762mm and a turning diameter of 670mm, while its 50HP main motor and four-speed gearbox delivers full power from 64 rpm.

Confirming its suitability for heavy-duty application, it can accommodate 32mm2 shank tooling and up to 60mm diameter boring bars.

Vertical turning is also catered for with the Doosan V550 single-spindle, two-axis vertical turning lathe.

With a maximum turning diameter of 550mm (610mm chuck) and turning length of 610mm, the V550 provides ease of loading and a heavy-duty machining capability.

The V550 has become a well respected model throughout the automotive industry and will be demonstrated producing commercial vehicle brake drum components for a well known name within the industry.

* Multi-axis turning centres - Doosan's S310SMLY six-axis turning centre features a y-axis turret arrangement along with c-axis control of the main and sub-spindles.

Other features include a 12-station VDI driven tool turret, maximum turning diameter of 310mm and length of 750mm and a 65mm bar capacity.

This model will be shown producing complex VDI toolholders complete, in an example of 'one hit' machining throughout the show.

The second Doosan multi-axis lathe on display will be the Z290SMY eight-axis twin turret, twin-spindle turning centre.

The main and sub-spindles are fully synchronised and can be fitted with a combination of chuck or collet chuck.

The 12-station turrets can accommodate up to six driven tools in any combination while the main and sub spindle both have full c-axis capability.

Maximum turning diameter is 290mm and length is 580mm with 65mm bar capacity.

The machine at MACH will be coupled with a magazine bar loader and will highlight its y-axis capability with a thread milling operation.

The Z290SMY is a high-speed producer of volume components ideally suited to around the clock production requirements.

* horizontal machining centres - Ward Hi-Tech will be represented in this sector by the Doosan HM45H twin-pallet horizontal machining centre.

The machine is equipped with twin 450mm2 pallets and a 60-position fast moving toolchanger.

Axis travels on this moving table machine are 600mm (X) and 560mm (Y and Z), with the X and y axes sharing an H section carriage.

Another feature of this machine, which will be demonstrated producing an aluminium mobile 'phone holder from solid (roughing and high-speed finishing), is its two-speed built-in 30HP motor and its numerous optional features, which make it ideal for integration into a variety of alternative production cells.

A powerful DXF file converter, that has automatic gap closing within the software to minimise the time spent converting the CAD file, will be shown alongside the latest CNC machine tools at MACH.
At long last the recession which has afflicted British machine tools appears to be lifting, but funding growth after a period of downturn can be difficult. At MACH 2004, XYZ will be demonstrating its comprehensive range of affordable machines which will provide greatly improved productivity and enable the user to better service existing contracts and take on additional ones. Demonstrated under power, the XYZ machines enable the user to improve productivity and profitability by offering easy set up, greater accuracy and competitive cycle times.

One of its most popular machines at the moment, the XYZ Mini-Mill, is capable of handling all typical machining jobs but requires only half the floor space.

With a tiny footprint of just 6ft2, the heavily ribbed XYZ Mini-Mill has a big working envelope and the largest Z axis of any of the small machining centres.

Travel in X is 560mm, 400mm in Y and 500mm in Z.

Rapid traverse is 25m/min.

Spindle speed is 8000rpm (1200 optional) and spindle taper BT40.

The tool carousel has 10 pockets; a 16 station arm-type toolchanger is optional.

Table load is 350kg.

Being introduced at this MACH are a new DXF file converter, a new 2.5D Edge, and a new XYZ200TC turning centre, which is an up-rated version of the XYZ150 turning centre and provides a larger capacity from a smaller footprint.

The powerful new DXF file converter, believed to be one of the simplest and easiest to use on the market today, is virtually a plug and play system and is the only system known to have automatic gap closing within the software to minimize the time spent converting the CAD file.

It offers a significant improvement in productivity because the simplicity of converting the CAD file into a machine program reduces set up time enormously.

An optional extra with any of the XYZ ProtoTRAK machines, the new DXF file converter uses intuitive plain English language, so simple prompts on the screen enable the operator to quickly and easily program the control.

The system converts CAD files into programs in a quick and easy process which can be learned, literally, in minutes.

The entire file can be viewed on screen and the operator selects which layers he wants to machine.

Also on show is the new 2.5D Edge.

Using plain English commands and intuitive programming it can be used easily by operators unfamiliar with CNC machines.

It retains handwheels to give the inexperienced operator confidence, essential for productivity in the early days of using any machine.

It provides all the features commonly used in an engineering shop without the additional, and often unnecessary, features which make other systems complicated or confusing to use.

The new 2.5D Edge will be fitted to a new Bed Mill, the Edge DPM 2.5, a 2.5 axis bed mill, Also being demonstrated are the ProtoTRAK mills and ProTURN lathes, proven over many years to dramatically improve productivity.

Offered in three milling versions, the entry level EDGE, the SM and VM (with spindle speed control), the VL is offered for lathes.

The system can accept CAD/CAM data from any recognised cam system and, with no limitation on memory capacity, it eliminates the need for DNC (drip feed).

The ProtoTRAK system has been designed for ease of use so even operators with no previous CNC experience can learn to use it in just a few hours.

New control software, significantly improving the ability to provide high speed production and die mould type machining in three, four or five-axes, features the latest CNC miller/driller.
New control software, significantly improving the ability to provide high speed production and die mould type machining in three, four or five-axes as well as precision milling and drilling for electrode, aluminium, steel and hard metal components, extends the capability of the Fanuc Robodrill Alpha T21i which is launched at MACH 2004, by 600 Centre of Shepshed near Loughborough, in D-Series guise. Robodrills have progressed from the 1970's to become an international top-seller by combining a high speed, short-cycling capability with the latest control and drives development from Fanuc to achieve high positioning accuracies and precision surface contours. Indeed, with the launch of the T21iD, rapid traverse rates of 54m/min are achieved with an acceleration of 1.5G, 1.8 secs chip-to-chip for the 21 tool position magazine and a choice of 10,000 or 20,000 revs/min spindle, define the potential for highest levels of productivity.

Available in three versions, all with Z-axis travel of 330mm, the ultra-compact D-Series has 300mm travel in X and Y with a 630mm by 330mm table.

The standard D has a 500mm X-axis and 400mm Y-axis with 650mm by 400mm table and the DL, extended capacity version, has 700mm in X with 400mm in Y and an 850mm by 410mm table.

Software improvements to the Fanuc 16i-MB control abound in the D-Series such as Fanuc's optional Auto Intelligence (AI) contour control and nano contour technology which uses RISC processor to read up to 600 blocks in advance.

This capability enables precise control of acceleration/deceleration without variation of feed rate giving a continuous ultra-smooth surface texture.

A jerk control option, with automatic feed rate control at a corner, reduces mechanical shock and, high resolution is achievable through the latest fast response servo motor developments introducing an ultra-precision pulse coder of 16 million pulses per rev.

For five-axis type applications, tool centre point control ensures the command path and feed rate is maintained while tool radius compensation during table rotation negates the need for part program change.

Thermal displacement compensation in the Z-axis is carried out in 'real time ' by monitoring the operational status of the spindle and predicting any elongation along the vertical axis while tool monitoring and tool life control is standard.

As part of the extended capability of the latest Robodrill, deep hole drilling can be performed to create precision holes as small as 0.1mm diameter to a depth some 30 times the hole diameter.

To help improve performance for deep hole drilling with small tools and high speed milling, the standard 5.5kW spindle delivers 10,000 revs/min but a faster 3.7kW 20,000 revs/min high speed option ensures higher productivity and cutter security.

Both spindle types have BT30 taper and through coolant is an option.

High speed rigid tapping at up to 6,000 revs/min is standard with a quick, 20 times override tap extraction rate.

Fast setting and changeover is helped by new control features such as set-up file able to hold 30 sets of program data with automatic initialisation.

A quick editor using the full screen display operates in similar vein to a PC with functions such as copy, move, search and cursor jump.

Meanwhile, a custom PMC function allows simple control of peripheral devices giving fast programming and editing on the 10.4in full colour LCD screen.

With X, Y and Z axes travels up to 2500mm by 2500mm by 1600mm, table-type horizontal boring and milling machining centres offer cost-effective five-axis machining of prismatic workpieces.
With X, Y and Z axes travels up to 2500mm by 2500mm by 1600mm, the Union T table-type horizontal boring and milling machining centres available from exclusive UK agent, Ward CNC of Sheffield, offer a range of technology options for the cost-effective five-axis machining of prismatic workpieces. For example, automatic tool changers, built-in NC facing heads and automatic pallet changers that can accommodate work weighing 16 tons all add to the T range's versatility. There are three main series in the range: T and TC 100/110 types; T 105; and T and TC 130/150.

T designates machines without auto tool change; TC those with ATC; and TU for models having built-in NC facing head.

Control options include Heidenhain TNC 426 and Fanuc 16iM.

All 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, 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.

As an example, the TC 110 features X, Y and Z axes travels of 1500mm or 2000mm by 1250mm or 1600mm by 1000mm or 1500mm, while W axis (spindle stroke) is 550mm and the B axis (rotary table) can be indexed in 360,000 positions.

Powered by a 22kW main motor, the machine features infinitely variable speeds of 8 to 4,000 revs/min and a torque of 2000Nm.

Feed rates for X, Y, Z and W axes are 5 to 15000mm/min, while table rotation is 3 revs/min.

The 1000mm by 1250mm table can accommodate loads of 6000kg.

This machine features the optional compact coolant unit, 16 bar through-spindle coolant and 40- or 60-tool ATC.

Backed by Union's over 140 years' of manufacturing know-how in Chemnitz, Germany, the T range is being offered alongside Union's latest generation floor- and cross bed-type CNC horizontal live spindle boring and milling machining centres by Ward CNC, a company with vast experience of the brand in the UK.

A wide range of milling machines and machining centres are being offered at attractive prices from germany and the Czech Republic for toolmaking purposes.
C Dugard Machine Tools distribute, install and support a wide range of machines which are ideally suited to the tool making industry including the Hedelius vertical machining centres and the TOS Kurim CNC milling machines. Hedelius Vertical Machining Centres - Hedelius (a German company) designs and manufactures three distinct types of vertical machining centres (all available in the UK and Ireland through C Dugard Machine Tools): 1: Standard 3-axis Travelling column vertical machining Centres These are available in various models offering a choice of specifications including: * 'X' axis of 1200mm to 6500mm. * 'Y' axis of 620mm to 1000mm.

* Spindle speeds of up to 24,000rev/min.

* Spindle power of up to 55kW.

All the 3-Axis travelling column models feature an automatic toolchanger mounted inside the column to ensure short chip-to-chip times.

Pendulum loading is also available to increase the uses for the machines.

In addition, a full range of 4th axis and right angle attachments are available for this range together with full enclosed guarding and extraction units.

Prices start from GBP 86,000.

2: 5-Axis RS Models - Hedelius offers three different 5-Axis RS models available with rotary tilting tables of 600mm x 600mm and 800 x 800mm and featuring two fully-controlled axes.

Prices start from GBP 120,000.

3: Kombi Models - the third range is the Kombi models: these are effectively a combination of the plain table and rotary/tilting table machines.

The Kombi models have an extended bed with a plain table at one end and the rotary/tilting at the other.

This, combined with Pendulum Operation, allows unloading and loading at one station whilst machining is taking place at the other.

Prices start from GBP 140,000.

TOS Kurim CNC milling machines - TOS Kurim are a well-known company from the Czech Republic which has been supplying toolmakers with milling machines for many years.

Its current product range also comprises of three main types of CNC milling machines (all available in the UK and Ireland through C Dugard Machine Tools): the Bed Type, Travelling Column machines and Gantry configurations.

1: Bed type milling machines are available in three table widths: 800mm, 1000mm and 1250mm.

The range offers a choice of table lengths (and 'X' axis) of: 2000mm, 3000mm, 4000mm and 5000mm.

Prices start from GBP 150,000.

2: Travelling column machines are available in two widths: 1000mm and 1250mm.

Table lengths range from 5000mm to 14000mm with the 'X' Axis traverse ranging from 3000mm to 12000mm respectively.

Prices start from GBP 250,000 Standard features and options are available on bed type and travelling column machines.

On both the bed type milling machines and the travelling column machines, an automatic indexing head is supplied as standard.

Optional 5-Axis simultaneous heads are available to suit the customer's application.

Both Siemens and Heidenhain control systems are offered on these models.

3: Gantry Machines - the TOS Kurim Gantry Machines offer widths of 2000mm, 2500mm and 3000mm, with table lengths ranging from 6000mm up to 20000mm, giving 'X' Axis travels of 5000mm upwards.

The gantry machines have a 5-axis head fitted as standard, with the option of an interchangeable head being available.

If the customer chooses the interchangeable head, a range of 5-axis and right angle heads are available with spindle speeds up to 12,000rev/min.

A series of new CNC milling machines also offer a range of innovative high-speed spindle and machining head options.
Ward CNC of Sheffield, the exclusive UK agent for Soraluce of Spain's range of milling machines, has announced a series of new machines as well as a range of innovative high-speed spindle and machining head options from the world-leading manufacturer. The four new machines - which include two high-speed, up to 30,000 revs/min electro-spindle models - are headed by the FS-8000 floor-type machine that features a novel concept of three-head machining/auto-changing to complement its X, Y and Z axes specification of 8000mm by 1600mm (optionally 2800mm) by 1250mm (optionally 1500mm). The three heads - automatic indexing, orthogonal and horizontal - are automatically moved into/from the working area via a newly-developed head changing unit.

Each head has different levels of capabilities to suit a variety of tasks, for example: * 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 degrees, capable of positioning in both rotating planes at 0.001 degree increments.

* The34 kW, 18,000 revs/min orthogonal head is rated at 102Nm and, again, has two indexing joints and similar positioning capabilities.

* The 30kW, 3,000 revs/min horizontal head can rotate in the vertical plane at 0.001 degree increments.

While a choice of control systems are offered on the FS-8000 - including Heidenhain, Siemens, Fidia and Selca - Soraluce's new high-speed SV-8000 HSC travelling column, fixed-table milling machine features Heidenhain TNC430M CNC as standard and digital drives to achieve rapid feed rates of 25m/min across its X,Y and Z axes of 7000mm by 1600mm (optionally 2000 mm) by 1200 mm.

This machine can utilise a 27/30kW, 4,000/6,000 revs/min orthogonal head rated at 570Nm and having two indexing joints - vertical and horizontal to spindle centreline.

This is capable of positioning to 1 degree in both planes (360 by 210, or 360 by 210,000 positions).

Two new bed-type mills have also been announced, models TA-20 and the high-speed TR-35 HSC.

With X, Y and Z axes specifications of 2000mm by 800mm by 800mm, the TA-20 has a feed range of 20 to 10000mm/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 3,000 revs/min.

With rapid feed rates of 25,000 mm/min and a feed range of 5 to 15,000 mm/min, the new high-speed TR-35 HSC is a 3500mm by 1000mm (optionally 1600mm) by 1200mm X, Y, Z capacity machine, again with digital drives and featuring the Heidenhain TNC 426M control.

The machine is fitted with a 28kW, 4,000 revs/min spindle motor and can have an 800Nm automatic indexing head which has two indexing joints - one vertical and the other at 45 degrees to the spindle centreline and capable of 2.5 degrees positioning in both rotating planes.

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

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

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

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

As well as a wide range of options that includes automatic toolchangers for up to 120 tools, the machines' five- and six-axis capabilities can be extended by the use of high-speed electro-spindles (15,000 to 30,000 revs/min) and by a series of machining heads.

Automatic heads are available in 28, 30 or 37kW versions, rated at between 1070Nm and 1530Nm and up to 2,000 to 4,000 revs/min with various positioning options.

Orthogonal heads are available in 28, 30 and 37kW versions with Nm ratings between 800 to 1410 and capable of 4,000 revs/min.

Fixed horizontal heads of 28, 30 and 37kW are rated at 1070 to 1530Nm and capable of 2,000 to 4,000 revs/min.

Table-type horizontal boring and milling machining centres offer a range of technology options for the cost-effective five-axis machining of prismatic workpieces.
With X, Y and Z axes travels up to 2500mm by 2500mm by 1600mm, the Union T table-type horizontal boring and milling machining centres available from exclusive UK agent Ward CNC will be represented at MACH 2002 by the TC110 horizontal borer. This, like all machines in the Union range, offers a range of technology options for the cost-effective five-axis machining of prismatic workpieces. For example, automatic tool changers, built-in NC facing heads and automatic pallet changers that can accommodate work weighing 16 tons all add to the T range's versatility.

The TC 110 features X, Y and Z axes travels of 1500mm or 2000mm by 1250mm or 1600mm by 1000mm or 1500mm, while W axis (spindle stroke) is 550mm and the B axis (rotary table) can be indexed in 360,000 positions.

Powered by a 22kW main motor, the machine features infinitely variable speeds of 8 to 4,000 revs/min and a torque of 2000Nm.

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

The 1000 mm by 1250 mm table can accommodate loads of 6,000kg, and the machine has optional compact coolant unit, 16 bar through-spindle coolant and 40- or 60-tool ATC.

It is 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, 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.

One measure of the machine's cost-effectiveness, build quality and technical specification concerns the recent installation of a TC110 at CTL Engineering of Stockport.

With an already impressive portfolio of large- and medium-capacity CNC vertical and horizontal borers and machining centres, managing director Ian Booth identified the need for a mid-range horizontal borer to accommodate an increasing order book for medium-sized workpieces.

'We looked at three different options,' he says, 'and, on paper, the Union scored 10/10 in every department.

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

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

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

'We were very impressed,' he says.

The TC110 is one of a number of Union boring and milling live spindle machining centres available from Ward CNC as well as Cetos cylindrical grinders, Hankook two-axis turning machines, Soraluce travelling column and travelling table milling machines and bed mills, Toshulin vertical boring, turning and milling machines as well as Kia CNC lathes, turning centres, and vertical and horizontal machining centres - representatives of which will also be on show at MACH 2002.

Universal bed-type and travelling column CNC milling centres and high speed, 5-axis bridge-type machining centres, manufactured by CME, Spain, are now being marketed by Ward Hi-Tech.
Universal bed-type and travelling column CNC milling centres and high speed, 5-axis bridge-type machining centres, manufactured by CME, Spain, are now being marketed by Ward Hi-Tech. CME heavy duty milling centres have X-axis travels from 1400mm to 10m and can be supplied with automatic universal milling heads, automatic tool changers, built-in rotary tables and high speed electro-spindles. According to ward Hi-Tech's UK sales manager, Mike Burke, there are over 40 different models in the CME range.

He says: 'We are really excited about taking on this excellent new product family, which will allow us to expand our sales activity into an area of the market which demands larger capacity machine tools such as the mould and die industries.' The company showed a model IFS2 universal milling centre equipped with Heidenhain 426 digital control system at MACH 2002 last week.

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

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

Pearce, Mitsubishi Carbide and Sandvik.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Investment in a Mikron VCP710 high speed CNC machining centre has opened up new opportunities for Walsall-based Speedform Tools (Midlands).
Investment in a Mikron VCP710 high speed CNC machining centre has opened up new opportunities for Walsall-based Speedform Tools (Midlands). The company, established in 1972, has developed extensive expertise in the design and manufacture of pressure die moulds in Mazak, aluminium and plastics, mainly for the automotive, security and UPVC window ironmongery industries. In addition Speedform produces cold-heading work, carbide and steel punches and dies, for spark plug and fastener manufacturers.

The company realised that, in a rapidly changing market place, it needed to reduce costs and delivery times.

Managing Director Keith Hall and Works Manager Tony Peake undertook the task of assessing the options for purchasing a CNC high-speed machining centre.

The company already owned a Mikron WF32c CNC milling machine that had provided excellent value, reliability and accuracy since its purchase 10 years ago.

Keith Hall takes up the story, 'Against very strong competitive opposition, Mikron not only came out tops with the VCP710 machine, but their sales and applications staff gave valuable advice on appropriate CADCAM systems to utilise the machine's full capabilities.

Since its purchase in 1999 the VCP710 has exceeded our expectations in terms of machine times, quality and reliability.' 'Machining in hardened die steel, up to 56 Rockwell, we have reduced the time taken by previous methods of manufacture by up to 60%.

Products not suitable for high-speed milling are created using CNC spark erosion.

Our electrode manufacture for cavity, core work and customers' special surface finish requirements has been greatly enhanced by the machine's technology.

With its 30-position tool-change cutter holder, the VCP710 makes unmanned overnight and weekend production the norm.

This increase in productivity means we can expedite a greater variety of work more quickly and efficiently.

Having the Mikron VCP710 machining centre has opened new markets for us, changed our thinking and approach to 'lights out working'.

It is all part of our long term strategy of looking to the future and staying ahead of the game.'

Specialising in the sub-contract machining of precision components, Valco UK in Essex has invested heavily in a subtle blend of CNC machine tools over the last three years.
Specialising in the sub-contract machining of precision components, Valco UK in Essex has invested heavily in a subtle blend of CNC machine tools over the last three years. This has seen the 50-strong company progressively install 20 vertical machining centres and 10 CNC turret mills at its factory in South Woodham Ferrers. All the CNC mills are ProtoTrak models, supplied by XYZ Machine Tools of Devon, and these versatile machines form a vital link in Valco's manufacturing chain.

For as well as carrying out various preparatory operations for the VMCs, the mills also perform numerous small batch, 2D machining tasks in their own right.

Around 60% of the company's work load involves machining plastics components from sheet material to general tolerances of around 0.1mm.

Parts such as insulator panels, boards,channels, connectors and carriers are produced for customers in the telecommunications, marine, fibre optic, transport and defence sectors in average batch sizes from 10 to 500 off.

With a separate electronics division,many of Valco's projects involve machining components for sub-assemblies.

While the more complex plastics parts, and most metal ones, are produced on the VMCs, a wide range of standard components are now being effectively produced on nine ProtoTrak PRO 2000 CNC mills (with the AGE 2 control) and an EDGE 1500 CNC mill (with the new EDGE control) - which have been brought in over the last three years.

As production manager Gareth Irwin explained, the XYZ mills form a key element of the whole manufacturing operation.

'These CNC machines carry out a wide range of tasks and about 25% of their time is spent on blocking-up and other datuming type operations on plastics billets destined for the VMCs -- so as to optimise production efficiency.

However, they are also used to produce prototype components, before they go into full production, and simpler 2D type parts such as covers, plates, spacers which are usually required in fairly small batches.

Moreover, the machines also perform secondary operations on components produced on the VMCs.

The speed with which they can be set-up and programmed, combined with their ease of use and all-round versatility make the ProtoTrak mills virtually indispensable.' Prior to the arrival of the first XYZ CNC turret mill in 1997, Valco relied on manual milling machines to carry out such production functions.

But as workloads increased and the company bought more VMCs, the use of manual machines and rotary tables was proving less effective in terms of productivity and repeatable accuracy.

Back to Mr Irwin again.

'The introduction of the CNC mills showed us the way forward as we cut cycle times by at least a factor of three, significantly improved repeatability and quality levels and could respond more quickly to customer demands.' All programming is done at the machine on these easy-to-use, two-axis CNC systems.

Most of the components produced on the CNC mills are fairly simple 2D items, yet they still have to be produced as efficiently as possible.

A typical part is a 38 by 32 by 2.5mm thick magnetic support plate machined from SRBP sheet and required in batches of 25 off.

These parts entail profiling, machining a central 12.7mm wide slot and drilling four 3.6mm diameter holes.

Produced on a PRO 2000 mill the complete batch of plates can be processed in just 1 hour (some 40% faster than before).

While a 50 by 26 by 13mm thick PTFE spacer, which requires tenon type sections and four, 4mm diameter holes, is now being produced in a cycle time of just 6 min per part.

Although required in batches of 250 off, it's still more economical to machine the spacers on a CNC mill as even a VMC cannot produce the complete form in a single operation.

The XYZ machines are also used to produce flat plate plastics developments which are subsequently heated and bent to the desired form.

As well as producing sized blanks for the VMCs and carrying out secondary operations, the CNC mills are also used to finish part-machined components.

One example of this concerns a small aluminium box lid where the top face is profiled and drilled on a VMC and then transferred to a PRO 2000 to face the reverse side and machine recesses around the drilled holes.

Required in batches of 22 off, reverse side machining could have been performed on the VMC, but it would have taken almost 1 hour to set-up and program the machine.

With a programming time of only 5 min and a cycle time of just 1 min, it is far more effective to carry out such operations on one of the turret mills.

All-in-all, the mills have proved to be a profitable and versatile investment and the company is well pleased with the level of service and back-up it has received from XYZ MachineTools.

Valco always tries to have one of its CNC mills spare so that it can accommodate rush jobs without disrupting planned production schedules.

While on the versatility front, the PRO 2000 mills really proved their worth on a recent project which involved machining high quality ebonite fishing rod reels.

For as well as producing the prototypes (before production was switched to VMCs) several of the machines have also been used to polish the100mm reels after machining.

Newbury-based 3T RPD has been reaping the benefit of its investment in a combination of the latest EDM and HSM technology from a single high technology supplier.
Newbury-based 3T RPD has been reaping the benefit of its investment in a combination of the latest EDM and HSM technology from a single high technology supplier, with an AGIE Innovation 2 die sinking machine and a top-of-the-range Bostomatic 12G high speed mill, fully equipped to cut graphite and metal at speeds of up to 30,000 rev/min and 15m./min. The company was formed in 1999 with the aim of providing manufacturers with access to rapid prototyping and development tooling, with no limitation in tool life, with texturing if required and with tolerances similar to production tooling, but with a delivery time usually within 3 to 4 weeks. Several significant factors have combined to create strong demand for 3T RPD's services; increasing development process complexity, rapidly reducing time-to-market expectations and supply chain fluidity are all putting manufacturers under ever-greater pressure.

The success of 3T RPD's strategy is proven by its rapid expansion.

The company is already looking to move into larger premises, the workforce has grown from an initial single employee to eleven-strong and the company has big plans for the future.

3T RPD provides 'functional prototypes', as close to the real part as possible, but built in prototyping timescales.

The company has customers in almost every vertical market sector, from automotive, including under-bonnet and under-dash items, aerospace, with wind tunnel components, electrical enclosures, and the latest developments in domestic appliances.

For development tooling the company's usual methodology is to create an initial prototype in sintered nylon.

When the preliminary environmental and aesthetic criteria have successfully been met the development tools are created on the Innovation 2 using graphite electrodes milled on the Bostomatic.

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Word of the company's abilities is spreading rapidly as Tim Plunkett describes, 'Early this year we had a project from a major automotive OEM, for tooling for two parts of an instrument cluster.

The customer was stunned when we completed the job in 23 days.

Our turn-around time provides our customers with vital competitive edge and we aim to continue to shave time off our already dazzling delivery schedules to assist them further.'