To be shown at MACH 2006 is an entry-level lathe alongside a recently launched vertical turning centre and other high production models - including multi-axis mill/turn centres with linear drives.
Advanced machine tools meet many budgets To be shown at MACH 2006 is an entry-level lathe alongside a recently launched vertical turning centre and other high production models - including multi-axis mill/turn centres with linear drives. Whilst DMG is the acknowledged UK market leader for 5-axis CNC milling and high-spec turning, this popular perception belies the true extent of the company's expertise. No other company in the world offers its breadth of range that also includes multi axis mill turn, multi axis turn mill machines for both low and high volume production.

Significantly, it also offers the most extensive range of lower cost entry-level turning and milling machines that compete exceptionally well on price without compromising quality.

The main emphasis of DMG's stand at MACH will therefore be on choice.

Whatever the production need DMG has the model to suit both budget and application and there will be a broad range of machines on show to demonstrate that point, several of them never before seen in the UK.

A new entry-level lathe, the NEF 600 Fanuc, will take centre stage alongside the CTV400, a newly launched vertical turning centre and other high production models with linear drives.

A brand new model of vertical machining centre, the DMC635V will also be launched at MACH.

It appears with established high production favourites such as the upgraded DMU50ev linear for 5-axis simultaneous machining and the twin-pallet DMC80FD mill turn machine.

DMG's ability to provide high quality at the lower end of the market is largely thanks to component rationalisation.

Many of the parts used in DMG's higher specification machines also feature in the less advanced models and as both low and high specification machines are made in the same factories, build quality is also uniform.

'DMG can offer a range of machines and control systems to satisfy almost any manufacturing need from the production of a simple turned part to complex structures for aircraft and aero engines,' explained new managing director Tim Hately.

'We have an extremely strong applications team and work with our customers to find the optimum production solution.

We do not just supply and service, we build partnerships for the long term.' Indeed the long term is particularly important to DMG as in many cases it is still supporting machines that were manufactured before their operators were born! Since his appointment last year Tim Hately has placed considerable emphasis on improving after sales and service support.

'DMG develops more products using new technology such as linear drives than any other manufacturer,' Hately concluded.

'And with the exceptionally high standards we are now setting on the service side of our business, we have so much to offer every sector of the manufacturing community and this will be evident at MACH.' * Principal exhibits new at MACH - NEF 600 Fanuc entry-level lathe - the latest NEF universal lathes from DMG provide top performance from a wealth of high-tech features at an unbeatable price.

Successive generations of the NEF brand have brought users excellent value for money and with the new 400 and 600 range, whose prices start at just £31,000, this tradition continues.

No other entry-level lathe in this price bracket can match these new models for their quality, reliability and profit potential.

This price includes Fanuc 210i CNC control with Manual Guide, manual 3-jaw chuck (200mm), eight station turret and tailstock with life centre.

* CTV 400 linear, vertical turning technology at an exceptional price - exceptional performance and flexibility have already earned the CTV linear Series a high reputation in the automotive industry and similar high productivity sectors.

With specific tooling these high-speed vertical turning machines from DMG can also perform auxiliary operations such as milling, drilling and tapping.

This versatility has already enabled manufacturers to reduce unit cost significantly making them much more competitive.

With the addition of the new CTV400 linear to the range DMG has opened up this potential to larger diameters.

With a chuck capacity of up to 400mm this top-of-the-range machine has dual-track loading and unloading that can reduce handling time by up to 40%.

The high performance of the machine is complemented by a wear-free linear drive on the 1620mm X-axis that accelerates at 1G for rapid traverses up to 100m/min.

* DMC 635V - vertical machining centre - the latest generation of DMC V vertical machining centres from DMG has a terrific pedigree.

Its forerunners, the DMC 63 and 103V, were worldwide best sellers and now with a bundle of high-tech features three new models are set to uphold the trend.

With bigger tables and smaller footprints, these new verticals - the DMC 635/835/1035V - have been designed to provide a rapid return on investment.

The machines are characterised by long axis travel, a compact design, excellent performance and highly attractive starting price of GBP 39,950 (UK price) for the DMC635V machine.

They shave 20% off the production time of a typical job providing excellent value for money especially as an alternative for flexible single part machining and small to medium batch production.

The models only differ in the size of their working area; the largest machine in the range allows a work piece up to 1,000kg to be accommodated.

* DMU 50eVolution linear universal machining centre - with 5 NC axes, the newly upgraded DMU 50eV linear is ideal for highly efficient five-sided machining and 5-axis simultaneous contouring.

The NC swivel rotary table pivots the work piece around its centre of gravity and allows undercuts of up to 18 deg.

This new model now has linear drive in the X-axis for more power and precision.

* Other exhibits - Sprint 42 linear CNC auto - this machine allows complete machining of short workpieces with diameters up to 42mm in small to medium batches (65mm for the SPRINT 65).

This machine series replace conventional single spindle cam machines with higher flexibility and greater efficiency.

Integrated spindle drives and linear tool mounts allow simultaneous machining with several tools in up to 10 axes.

Shown for the first time among CNC lathes at MACH 2006 was a heavy duty 2-axis slant bed 50HP lathe has turning length of 1800mm and diameter of 700mm, and is for large shaft work.
Ward Hi-Tech used MACH 2006 to confirm their position as one of the leading privately owned CNC machine tool distributors in the UK. With more than 60 models available from a portfolio of principal partners that include Doosan Mecatec of Korea, Dah Lih of Taiwan and CME of Spain the company showed a total of 10 CNC machines - including three new models. The Doosan S700 heavy duty 2-axis slant bed lathe from South Korea has a turning length of 1800mm and is ideal for large shaft work.

The S700 accommodates chuck sizes up to 762mm diameter with a turning diameter of 700mm whilst its 50HP main motor and three step gear box delivers full power from 63 rev/min - making it ideally suited for heavy duty machining.

The lathe is equipped with rigid 12 station turret accommodating 32mm2 tooling and up to 60mm diameter boring bars.

The control is the powerful Fanuc 18iT system, which can drive the option of a driven tool turret and spindle C axis control.

The S700L will be demonstrated machining a typical large shaft component from the aerospace industry.

Also shown for the first time in the UK was a Doosan S400 slant bed 2-axis lathe.

Specification includes maximum turning diameter of 400mm, turning length of 716mm, chuck size of 12in (optional 15in dia.) with a bar capacity of 76.5mm (optional 99mm diameter).

The S400 has a 12 station drum type turret, accommodating a standard tool size of 25mm2 and boring bar of 50mm diameter.

it is equipped with a 'P' type 30HP wide power main motor and has spindle speeds of 35-3500 rev/min.

A standard feature of the S400 is the unique Doosan machine management (DMM) software built into the CNC system.

This provides the operator with a comprehensive 'on screen' menu of production information including machining time, production sort, tool life sister tool management, operational status report and machine maintenance guidance information.

* High power turning - the Doosan S550 LG is built with a 50HP main drive incorporating twin range ZF gear box ensuring full power is generated at 158 rev/min.

With chuck size of 15in or 18in diameter, turning length of 1130mm, 12 station turret and heavy duty tailstock, the S550 was shown machining a typical oil industry component from Nimonics demonstrating the suitability of this particular machine of tackling the most arduous of materials.

* Low cost, 2-axis turning - completing the line up of Doosan 2 axis turning machines at MACH was the ever popular S280N.

This best selling small CNC lathe is suited to a wide variety of applications across every industry sector and every size of user! The S280N specification features a maximum turning diameter of 280mm and turning length of 330mm, chuck size of 8in with bar capacity of 51mm dia.

Built with rigid box ways, 10 station turret and 15HP main drive motor, the S280N will be demonstrating its ability to 'hard turn' an aerospace component to a 'super precision' finish.

* vertical turning lathe - Doosan are one of the world's major manufacturers of vertical turning lathes (VTLs) producing VTLs for many well known automotive and aerospace companies in particular.

The Doosan V740 is one of the most popular size models in the VTL range and was displayed in single spindle format.

The machine has a maximum turning diameter of 740mm, cutting length of 760mm, 50HP main drive with twin range ZF gear box and 12 station turret and can accept chucks up to 24' diameter.

* Multi-axis CNC turning - wo examples from Doosan's multi axis turning range were featured during MACH.

The six axis sub-spindle S310SMLY includes Y-axis turret arrangement together with C-axis control of main and secondary spindle.

Other features include 12 station VDI style driven tool turret, maximum turning diameter of 311mm and machining length of 750mm, 10in chuck with 65mm bar capacity.

The machine will be shown producing a replica 'U' drill from bar utilising all six axes of control.

* Twin turret, multi-axis turning - the Doosan Z290SMY is an eight axis, twin turret, twin spindle turning centre.

Both main and sub spindles are fully synchronised and can be fitted with a combination of chuck or collect chuck.

Twin 12 station turrets can accommodate up to six driven tools in any combination whilst main and sub spindles both have full C-axis capability.

Maximum turning diameter is 290mm and machining length is 580mm with bar capacity of either 66mm or 77mm diameter.

For the MACH presentation the machine was coupled with a magazine bar loader and shown machining from bar a replica collet chuck that can be taken away and used as a desk paperweight.

'Super Precision' CNC turning machines - are all designed to provide significant performances - (better part accuracy, more cost-efficient manufacture) when hard turning parts.
There is no 'mystery' about hard turning 'Super Precision' CNC turning machines - are all designed to provide significant performances - (better part accuracy, more cost-efficient manufacture) when hard turning parts. For years the debate has raged on about the relative merits of hard turning components in favour of more 'traditional' grinding methods. Adding its considerable weight in favour of hard turning is market-leading machine tool specialist and hard turning authority Hardinge, which has introduced a number of Super Precision (SP) CNC turning machines onto the market - all designed to provide customers with significant performance benefits - (better part accuracy, more cost-efficient manufacture, increased productivity, etc) when hard turning parts.

However, to do justice to the whole issue of turning vs.

grinding 'hard' materials - engineers at Hardinge point out that to achieve optimum hard turning results is not simply a matter of plugging-in and playing one of their newly-launched machines.

Instead they suggest that customers can only optimise their performance by understanding the complexities, and subtleties, of hard turning technology - and the interrelationship between machine tool, cutting tools, coolant and the specific application in question.

* What is Hard Turning?

- Essentially hard turning refers to machining parts from materials with Rockwell C hardness greater than 45 Rc).

Although amongst some hard turning aficionados - 60 Rc and above is now considered a more accurate description of 'hard' materials.

Specific materials that fall within this 'hard' materials definition include: case-hardened steels, Inconel, Hastelloy, Stellite and other exotics, etc Parts that are usually manufactured using hard turning operations are diverse but typically include - transmission gears, punches and dies, injector nozzles, shafts and bearings, etc * Performance benefits over grinding - cylindrical grinding of hard materials presents customers with a number of manufacturing and commercial headaches that are eliminated (or certainly reduced) if hard turning is adopted as an alternative method of production.

The benefits of hard turning over grinding are as follows.

* Reduced job set-ups.

* Faster cycle times.

* Higher removal rates.

* Reduced number of machining operations and less fixturing requirements.

* Less expensive process.

What is more these significant benefits and advantages can also be achieved alongside some outstanding performance results, e g, 5 micron size repeatability, 0.5 micron roundness and 0.1 micron Ra surface finish on Hardinge (SP) turning centres.

* Requirements for hard turning - achieving such impressive results requires advanced CNC machine tool technology and a good appreciation of the hard turning process.

Happily at Hardinge both of these can be achieved and accessed.

1 - Machine tool build - to deliver the cutting performance required (accuracy, finish, extended tool life etc) turning centres need to be of a rigid construction and design.

A polymer composite base combined with wide-spaced, heavy-duty linear guides; super-finished tracks and centrally-located, short-pitch ball screws help reduce vibration and minimise stick/slip movement.

Hardinge turning centres are also perfectly balanced exhibiting no overhang - and they are equipped with direct-seated, colletted spindles (spindle bearing closer to workpiece) and hydrostatic ways (optional) for extra accuracy.

2 - Part rigidity - there is little point attempting to hard turn a part that does not have sufficient inherent rigidity to withstand the cutting forces generated by the process.

To understand whether parts are literally up to the job - Hardinge recommends that customers consider the length (L): diameter (D) ratio of the part.

As a rule of thumb a L:D ratio of 4:1 for unsupported components and 8:1 for supported ones - produce optimum results.

If the ratio is exceeded (for longer parts supported with a tailstock), it is likely that chatter will result.

3 - Cutting tools/inserts - CBN tools are widely used for both continuous and interrupted hard turning applications as they deliver exceptional cutting performance with low wear.

However, because of CBN's high cost - alternative cutting tools or inserts can be used - i e, Cermet and Ceramic.

It is worth noting that Hardinge engineers advocate the use of CBN - but also advise customers to work in partnership with their cutting tool supplier to ensure that the optimum cutting tools are selected in conjunction with the most appropriate coolant.

To get the best results from hard turning requires an understanding of the process and access to advanced machine tool turning technology.

Customers working closely with Hardinge now have a genuine alternative to grinding and are taking advantage of all the tremendous business benefits that hard turning provides.

A long bed lathe - designed specifically to handle long parts, from oil field components to drive shafts to machinery rollers - comes equipped with a fully programmable hydraulic tailstock.
Long shafts and tubing pose unique challenges for turning centres, especially when deep-hole drilling and boring are involved. To meet those challenges Haas Automation introduces the new SL-40L Long-Bed lathe - a machine designed specifically to handle long parts, from oil field components to drive shafts to machinery rollers. The Haas SL-40L Long-Bed is an extended version of the company's shop-proven SL-40 turning centre that provides a maximum cutting length of 2032mm (nearly twice that of the standard SL-40) and a maximum cutting diameter of 647mm.

It also comes equipped with a fully programmable hydraulic tailstock.

In standard form, the machine features a 381mm chuck and an A2-8 spindle nose that provides a bar capacity of 101mm.

A 40HP (peak) vector dual-drive system combines with a high-torque gearbox to yield 1898Nm of spindle torque for heavy cutting, and provides speeds to 2,400 rev/min for finish work and high surface feedrates.

'On-the-fly' Y-delta switching provides the high torque and wide constant-horsepower band necessary for constant surface speed cuts.

To accommodate large-diameter tubing, a 'Big Bore' version of the SL-40L is also available.

This option upgrades the machine to an A2-11 spindle nose and features a 171mm through-bore (chuck, draw tube and hydraulic coupling are not included).

To support extra-long parts through the bore, a rear chuck provision is available that allows an air chuck to be mounted to the rear of the spindle.

An optional steady rest platform is also available to provide increased support for turning and boring long shafts.

Hydraulic power for the steady rest is provided by the lathe, and the gripper (not supplied) is activated automatically via M code.

Other options for the SL-40L Long-Bed lathe include live tooling, full C-axis, high-pressure coolant, a chip auger and a tool-presetter system.

A number of control options are also available, including expanded program memory, Ethernet interface, user-definable macros and Haas' conversational Visual Quick Code programming system.

Like all Haas machines, the SL-40L features the powerful and user-friendly Haas control.

Designed and built in-house, it is optimized specifically for Haas machines.

The Haas CNC accepts ISO standard G code and is compatible with all major CAM systems.

MACH 2006 witnessed several brand new machines from Haas Automation, the largest CNC machine tool manufacturer in the world.

Haasl demonstrated machines and metal cutting technology for aerospace, automotive, medical, mould and die and general machining industries.

More than 25 CNC technology products were on show demonstrating vertical and horizontal machining and turning applications.

CNC lathe takes up only 2m x 1.5m of floor space, yet provides a generous 255mm turning diameter, 355mm turning length and a 415mm swing over the front apron.
Turning small parts on a large lathe usually is not the most efficient use of a company's assets, and actually may have an adverse effect on the bottom line. The SL-10 CNC lathe from Haas Automation provides an economical solution for small parts turning in a compact package that is loaded with full-size features. The SL-10 takes up only 2m x 1.5m of floor space, yet provides a generous 255mm turning diameter, 355mm turning length and a 415mm swing over the front apron.

This compact machine is a valuable addition to any shop needing a 'second-op' machine, or wanting to add a lathe where space is at a premium.

It is also the perfect lathe for start-up shops, or as a first step into CNC turning.

The SL-10 comes standard with a 160mm hydraulic chuck and a 10-position bolt-on tool turret.

A 5.6kW vector drive spindle provides speeds to 6,000 rev/min for high surface feedrates, and an A2-5 spindle nose accepts bar stock up to 45mm.

A host of high-productivity options, such as a tool presetter, parts catcher, automatic chip auger and tailstock, are available for the SL-10 to further boost productivity, and the Haas Servo Bar 300 intelligent bar feeder may be added for unattended operation.

MACH 2006 witnessed several brand new machines from Haas Automation, the largest CNC machine tool manufacturer in the world.

Haas demonstrated machines and metal cutting technology for aerospace, automotive, medical, mould and die and general machining industries.

More than 25 CNC technology products were on show demonstrating vertical and horizontal machining and turning applications.

A low cost, 'entry level' 15kW main spindle turning machine has been designed on the basis of machining a wide range of components within the smallest possible amount of space.
The new low cost, entry level, XYZ Mini Turn 190 turning centre has been designed on the basis of machining a wide range of components within the smallest possible amount of space. Although it is the smallest model in XYZ Machine Tools' range of turning centres, the 15kW, 4000 rev/min XYZ Mini Turn 190 is capable of a 200mm maximum turned diameter and has a maximum swing of 400mm. It also features a 56mm spindle bore, with a 42mm drawtube capacity, to accommodate oversize bar.

Axis travels are 155mm (X) and 510mm (Z), with rapid traverse rates of 12 and 14m/min, respectively.

Distance between centres is 500mm and the XYZ Mini Turn 190 is equipped with an 8-station turret that holds 40mm diameter boring bars and turning tools with a 20mm by 20mm shank.

Occupying a space-saving 2700mm (W) by 1670mm (D) by 1800mm (H), the XYZ Mini Turn 190 is equipped as standard with a 200mm three-jaw hydraulic chuck, flood coolant and Siemens 810D conversational Shopturn CNC.

Rigidity and vibration absorption is guaranteed by the Meehanite cast iron construction, with the machine weighing in at 4200kg, and auto lubricated hardened and ground slideways ensure smooth axes travel, minimum wear and a high quality surface finish for the machined component.

Offering a host of canned cycles, the Siemens 810D Shopturn control makes shopfloor programming fast and simple, involving the minimum of keystrokes and the maximum reassurance to the less experienced operator.

Hotchkiss evaluated the Colchester Combi 6000 from the Colchestersales (UK) Southern Technical Centre at RK International in Erith, Kent, to represent the best return on investment.
The Hotchkiss family has been associated with engineering since at least 1799 when John, a Royal Navy Lieutenant invented a mechanism for lifting heavy weights and ships anchors. Indeed, it was a modification of his development that is said to have helped the British fleet to outgun the opposition at the Battle of Trafalgar because it enabled cannon balls to be transported far quicker and easier to the gundecks. Today, the family owned Hotchkiss Group, located at West Kingsdown, a stones throw from the Brands Hatch race circuit in Kent, is a specialist heavy machine workshop and general engineering business.

The Group is split into two operations.

John Hotchkiss Engineering named after the current managing director Bill Hotchkiss' father, is still well known for developing, producing, re-engineering and refurbishing rolls largely for the paper industry but also applies its diverse skills to the cable making sector, mining, shipping, car breaking and food producers.

The heavy duty operations of the business would not normally be expected in the Kent countryside - perhaps more at home in the Midlands or North East, but the skills in the business are very specialised for the 23 people operation.

A further 40 are also employed 20 miles away in Strood at the Group's contract engineering operation, Westwell Developments, which undertakes refurbishment, rebuilding and resiting of plant and machinery.

These projects range from fragmentisers used in scrap metal reclamation weighting up to 40 tonnes each, to pump transmissions for a wide range of industries.

The nature of the business is obvious when viewing the West Kingsdown machine shop where craneage can manoeuvre rolls and fabrications weighing up to 60 tonnes.

Its largest lathe has 2.6 m swing by 11.2 m between centres, two other lathes have 12 m and 8.5 m between centre dimensions but by clever siting of beds these machines can form a single unit, with a massive 20 m between centres capacity.

A 17 m long roll grinder has a 1.6 m swing by 10 m between centres and a CNC mill a 6 m by 8 m table.

It was, however, the demand for higher precision and productivity on smaller shaft and chucking work for refurbishing and general turning that recently set Bill Hotchkiss's workshop team to look across the market for a CNC lathe to replace an ageing centre lathe.

They eventually evaluated the Colchester Combi 6000 from the Colchestersales (UK) Southern Technical Centre at RK International in Erith, Kent, to represent the best return on investment.

In particular, it was the machines credentials as a combination lathe able to perform one-off tasks, have very easy to use programming assist and its ability to faithfully reproduce further components when required under automatic cycle that scored highly in the evaluation.

Says Bill Hotchkiss: 'We are engineers and are constantly involved with quite complicated mechanisms and structures.

While we tend to 'engineer' solutions on a large scale, we require high levels of flexibility in our machining because we never know what is going to come through the door.

Our equipment has to be real work horses so top of the agenda for any lathe we were going to install was real fitness for purpose.' The Hotchkiss family definitely has engineering in the genes.

In 1872 Benjamin Berkley Hotchkiss, credited by Bill as probably the most famous of them all, invented the revolving-barrel machine gun and a magazine rifle that became widely used in British, French and American Military.

Later he turned his talents to designing engines, particularly the internal combustion engine, founded the company that produced the famous Hotchkiss car in 1903 and is now sought after by enthusiasts around the world.

In 1930 Donald Hotchkiss, a ship's architect invented the coned propeller used by tugboats for manoeuvring ships in harbour and Bill's father John, who started the current company in 1938 with just £75, invented the portable rotary lathe in the 50s.

His invention was a breakthrough because it enabled in-situ machining and repair work to be carried out on bearing journals on large rolls in paper mills for instance, saving the time and expense of major stripdowns.

He also developed an in-situ keyway cutter able to cut keys in shafts up to 75 cm long by 10 cm wide and another invention of his was the HB static-spindle bearing cartridge that totally revolutionised roll installation and maintenance.

His development enabled the bearing to be changed in-situ, without the roll having to be removed from the machine.

Other inventions include a single bearing 12 metre hydraulically driven floor level rotary turntable capable of coiling some 600 tonnes of submarine power and optical fibre cables without twist during manufacture.

Components machined today on the Combi 6000 are to far higher tolerance and surface finish than could be produced before and quite often repair and reclamation demands a lot of turning skill which, operator Dave Plant maintains, the Manual Guidei software on the Combi is extremely useful in support of what he needs to do.

He describes an often and classic case that would take ages to get the component running true and parallel when, say, a journal diameter has to be remachined.

'I set it true in a four-jaw chuck and then quickly program in a slight taper to compensate for parallelism rather than have to mess around jacking the tailstock.

This type of flexibility has allowed us to reduce a job that could take around three days to within a shift or at worst, a day and a half.' Much of the work is shaft based, these can be up to 300 mm diameter by 1,500 mm long and involving multi step diameters and the finish turning of journal diameters.

Tolerances tend to be 0.012 mm for bearing diameters and surface finish straight from the machine are often required to be within 0.8 and 1.6 um RA.

Says Dave Plant: 'Most of our shaft work is on pretty tough material such as EN24T and EN42 and due to the type of work a lot of threads are machined.

Here I find the screw cutting macros on the Combi are really helpful as we have to machine both metric and imperial and these can be between 50 mm and 300 mm diameter by 100 mm long.

We also have to produce the occasional taper thread.' He also makes use of the simulation on difficult parts and has found the rigidity of the Combi ideal for roughing out with 3 mm depth of cut on the shaft work.

'It will easily cut faster but you need to take into account insert life.

We are not a production shop,' he says, 'most parts are just single items but we do use the CNC for repeat cycles when we can have batches of up to six parts.' As Bill Hotchkiss maintains: 'We needed a machine that would give us a good quality turn.

It was the guys in the workshop that made the decision and they are the ones who make the installation a success.

When we look at the overall package from Colchestersales and the price that was paid, we feel we are getting a very good return on our investment.'

Latest CNC lathes feature Fanuc OiTC conversational programming based control which includes enhanced 3D graphics simulation and are an ideal platform for novice operators to program.
Loaded with the latest revolutionary Fanuc Manual Guide i software in the Fanuc OiTC conversational programming based control which includes enhanced 3D graphics simulation, the Colchester MultiTurn 2000 provides the ideal platform for novice operators to program and have full confidence in machining cycles created prior to cutting metal. The previous generation Colchester MultiTurn 2000 has already proven to be a top-seller being equally useable for single part manual cycles using computer macro and tool path assist or full CNC repeat operations over a small batch of parts direct from memory and with the latest changes, it is predicted wider use of the machine in training type applications will be created. The very competitively priced latest version of the mid-range MultiTurn 2000 enables parts up to 400mm diameter by 1250mm long to be swung over the bed.

However, by utilising the gap bed, a swing of 585mm by 165mm is available.

It is the Fanuc OiTc CNC contouring control with the powerful but simple and quick to use Fanuc Manual Guide i conversational programming that sets this machine apart.

It enables the operator to manually turn a part using its electronic handwheels with the control screen functioning as a digital readout for tool positioning.

To this, a series of canned cycles can be added to reduce the input required and the operator also has the facility to cut and paste or call-up his own prepared macros to create the toolpath.

Further help is at hand in building a program through an extensive tool library able to store up to 64 tools with the added supporting bonus of virtual tool and solid modelling programs plus on-screen CAD/CAM using icon-based commands.

For the advanced user, conventional CNC programming can be performed using G-codes.

And, in the same fashion as a normal CNC lathe, programs can be downloaded by DNC or input from a 'flash card' taken from a PC.

The MultiTurn CNC lathe is very competitively priced and provides high levels of functionality that takes full advantage of the 7.5kW spindle drive.

The spindle is carried on a cast iron flat bed with an eight-station 360mm diameter, bi-directional, electrically indexing disc turret capable of holding 20mm by 20mm tool section size and 32mm diameter boring bars.

Quick-change toolposts from Parat, Multifix or Dickson are available on request.

A three-jaw 250mm scroll chuck and No5 MT revolving centre is standard with options of four-jaw independent and three-jaw powered chucks.

A complete range of travelling and fixed steadies can also be supplied by Colchestersales (UK).

The ergonomically positioned Fanuc OiTC control has a large 10.4in colour screen and can be moved totally independently of the fully interlocked enclosure which has twin, slide-aside guard doors providing excellent access to the working area.

A portal milling machine with linear drive achieves extremely high chip volumes/time of up to 4500cm3/min in aluminiumusing feedrates of up to 60m/min and spindle speeds up to 35,000 rev/min.
With the new FZ 38, Zimmermann-Boko is presenting a CNC portal milling machine with linear drive. The impressive dynamism of this machine bears witness to the highest level of compe-tency in the field of demanding drive technology. The aim Zimmermann is to offer optimum drive concepts for the specific requirements of their customers.

Towards this end, Zimmermann is making use of decades of experience at the peak of technological developments.

Current drive tech-nologies, such as linear motors, rack and pinion drive and ball screws are assessed objectively and customers profit from this: the result is comprehensive machine concepts with optimum drive for precisely defined employment pur-poses - an example of this is the FZ 38 with pure linear drive technology.

This is further proof that Zimmerman assimilate the individual requirements of each customer and focus their solutions accordingly - customer orientation of the highest quality.

F.

Zimmermann - the innovative company from Denkendorf near Stuttgart, Germany - offers state-of-the-art constructions for large-scale CNC portal milling machines and CNC plano-milling machines with high-speed technologies.

This year, the experts from Zimmerman will once again impress their target group at the trade show.

With the FZ 38, Zimmermann is pre-senting a CNC portal milling machine driven by linear motors that points the way to the future with its special qualities.

* Dynamism dimension 1 - exceptional efficiency - the most important aim when using linear drives is the increase in productivity.

The FZ 38 achieves extremely high time / chip volumes of up to 4500cm3/min (aluminium).

Feed rates on linear axes of up to 60m/min and spindle speeds of up to 35,000 rev/min make genuine HSC processing possible.

Just as im-pressive are the torque motors on rotational axes with feed rates of up to 150 deg/s.

The accuracy and surface quality realised in this way are decisive for this outstanding performance data.

And it is precisely in this point that the FZ 38 sets standards.

The linear drives achieve a very high level of standard control with a large Kv factor which also makes a low trailing distance and high po-sitioning accuracy possible even at high feed rates.

* Dynamism dimension 2 - well-established technical know-how - a prerequisite for the performance and accuracy values achieved with the FZ 38 lies primarily in a machine designed especially for using linear drives.

Zimmerman customers can profit here from exceptional empirical val-ues in the development of structurally stiff machines.

The solution lies in the combination of optimized lateral stands and torsion-free portal on the one hand and intelligent arrangement of the interfaces, i e, the drives on the other hand.

* Dynamism dimension 3 - high degree of economic efficiency - the overall economic efficiency of the FZ 38 is a result of the interplay of different aspects.

The high accuracy of the machine reduces manual work on finishing surfaces as far as possible or even avoids them entirely.

Due to the high feed rates, the ancillary times, e g, for reposi-tioning, tool orientation or tool change can be reduced.

The FZ 38 achieves very high levels of availability.

This is not least due to the contact-free, play- and wear-free and there-fore low-maintenance direct drives.

* Some technical details - construction method - as with all high-quality CNC portal milling machines from Zimmerman, with the FZ 38 we are dealing with a modularly constructed machine concept which allows different work areas, milling spindles and con-trol systems to be combined.

The machine has permanent lateral walls, a clamping table perma-nently connected to the foundation and an upper portal which moves in X-direction and is driven on both sides.

The workpiece is not moved.

The constantly moved masses (portal slide, cross slide and z-slide, milling head) ensure consistently dynamic behaviour - a prerequisite for optimum surface quality and the use of linear drives.

* Machine frame and guides - the machine bed is constructed from grey cast steel; lateral walls, portal and Z-slides are welded steel constructions.

The lateral walls are filled with a special compound material for dampening vibrations and stabilizing temperature.

The guides, drive and measuring systems on the X-, Y- and Z-axes are extensively protected against contamination or penetration by chips.

* Axis drive - irrespective of the make of the control system, all linear axes are equipped with the latest generation of Siemens digital linear motors.

At standstill, the machine is held in position by brake shoes on tes X- and Y-axes.

* Safety concept - if electricity fails, the Z-slide is effectively secured by powerful clamping heads and all axes are braked by the backfeed of the poten-tial energy through the effect of the generator.

* Cooling - the linear drives are uncoupled effectively from the machine by precision coolers with separate cooling cycles for magnet and motor ele-ments.

* Accuracy - the dynamism of the machine and the extreme inherent stiffness enable high levels of accuracy, in particular when finishing with high speeds and feed rates.

* The new VH 6 milling head with MuST technology - the new VH 6 milling head is especially designed for the HSC technology.

The drive of both rotation axes is carried out by backlash free torque motors.

With the high driving power the rotation axes can be used for simultaneous operations or they can be electronically fixed in position.

In addition, the two axes can be clamped hydraulically.

Both axes drives are designed following the Thermosandwichprinzip, and are equipped with a power and a supplementary precision cooling unit.

This drive technology enables a combination of precision, high driving power and increased dynamics.

In general two different spindles with various specifications are available for all application areas such as roughing, finishing and fine finishing.

* Universal spindle for all kinds of machining of aluminium, composites and light machining of cast iron and steel.

* Finishing spindle - high frequency spindle designed for finishing, for milling of fine contours and for fine finishing with highest surface quality.

Concerning flexibility Zimmermann came up with even more ideas.

Due to its modular design, the MuST system enables different configurations.

1 - One spindle is fixed in the milling head - however this can be changed manually as well.

2 - Semi-automatic spindle change system.

3 - Full automatic spindle change system - enables unmanned shifting * Areas of application - thanks to high stability and stiffness, constantly moved masses and highly dynamic linear drives as well as the spindle changing concept MuST, the FZ 38 is suitable for HSC work on all common materials in making tools, moulds and models as well as in the aircraft industry.

* Aluminium chipping with extreme feed rates.

* Compound materials.

* Overall processing of heavyweight materials such as steel, cast products and even titanium.

Conclusion - Zimmermann's strength is to offer efficient combinations of different machine concepts, drives, milling heads and spindle types.

Zimmermann is consistently enlarging its machine program and with its latest innovation, the FZ 38, it is now enriched by the ultimate high speed type dynamics and speed directly turn into benefit for our cus-tomers.

Rolf Roehm, Zimmermann sales and marketing director resumed: 'The perfect combination of machine design, tools, tool and work piece clamping devices, material technology parameters, the applica-tion know-how as well as the so called C-techniques has highest pri-ority when consulting our customers'.

'The development of the FZ 38 contributes a further option to the drive technique which is of great advantage to our customers.' * F Zimmermann will be exhibiting at IMTS 2006, Chicago, USA, September 6-13, Booth A-8568.

CNC bridge mills offer an economical alternative to routers and large milling machines for producing large components under optional thermal control conditions.
Ideally suited to light and medium duty metal cutting applications, XYZ Machine Tools' new BRM CNC bridge mills offer an economical alternative to routers and large milling machines. Control is by way of the easy-to-use XYZ VMX-7 CNC, with Siemens' Shopmill conversational or G Code programming systems available as an option. Each of the six models in the BRM range is equipped as standard with a 24 hp high-torque, vector drive, spindle with a BT40 taper.

This provides speeds of 50-8000 rev/min as standard, with options of 12,000 rev/min, 15,000 rev/min or 24,000 rev/min.

Table sizes vary from 1220 mm by 2440 mm to 2030 mm by 3810 mm, while x, y and z axes maximum travels are 3810 mm, 2030 mm and 760 mm, respectively.

Rapid traverse rates of 25 m/min and a positioning accuracy of +/-0.025 mm over 300 mm (+/-0.12 mm over full travel) combine with a maximum component weight of 2270 kg to provide extremely cost-effective large machine performance.

Repeatability on all three axes is 0.01 mm, and machine construction features linear ways with axes protected by steel way covers.

Versatility is the hallmark of the BRM range, with options including a 24-station toolchanger, 4th axis, electronic spindle, digitising and thermal compensation.

Extended warranty and collision protection insurance can also be provided and, as with all XYZ machines, operator training is provided free-of-charge.

Able to accommodate a wide variety of 5-sided machining and 5-axes simultaneous contouring applications, a universal miller has dynamic linear axes drives with 1G acceleration.
The first model in the DMU 50V Series was unveiled in 1995 and by 1999, 600 units had been installed worldwide. The popularity of this universal milling machine has never wavered with successive generations and with the introduction of the latest model, DMG is again aiming to meet the needs of a wide manufacturing community. The new DMU 50 eVo linear is a highly productive machine, able to accommodate a wide variety of 5-sided machining and 5-axes simultaneous contouring applications.

Despite a smaller footprint than its predecessor this new machine has longer X and Y axes, 450mm and 400mm respectively.

It also boasts greater stability and rigidity.

As the suffix suggests, the 500mm X-axis is equipped with a dynamic linear drive that accelerates at 1G achieving rapid traverses up to 80m/min.

This represents an increase of 60% on the previous design, promising higher productivity and positioning accuracy.

The NC rotary table with 50 rev/min C-axis and 40 rev/min B-axis allows flexible 5-axis machining.

Its larger swivel range of 108 deg allows undercuts of 18 deg.

The universal design of this machine is complemented by the option to fit a 120-tool magazine as an alternative to the 30- and 60-station magazines whose double gripper reduces chip-to-chip times to less than 5 seconds.

The customer can choose from a range of spindle options - 12,000, 24,000 and the high-speed 42,000 rev/min - and controls, Heidenhain iTNC 530, Siemens 840D powerline or MillPlus IT.

All feature the ergonomic DMG ControlPanel with large 15in TFT screen and 3D software.

Special packages, for machining aluminium or graphite for example, are also available.

Portal milling machine's modular construction enables the specification to be tailored in order to optimise specific machining demands with high orders of geometric accuracy.
he modular construction of the Zimmermann FZ 37 portal milling machine enables the specification to be tailored in order to optimise specific machining demands with high orders of geometric accuracy and surface integrity. It is available in four or five axis configurations to machine a wide range of materials from aluminium to steel or cast iron. Available from Brackley-based StarragHeckert UK, the Zimmermann FZ 37 can be specified with an X-axis from 3000mm to 10m, a Y-axis between 2000 and 3000mm and the vertical Z-axis between 1000 and 2000mm.

A range of spindles with 28kW, 24,000 rev/min; 40kW, 24,000 rev/min and 20kW, 28,000 rev/min are available with a choice of controls supplied by Fidia, Heidenhain or Siemens.

Central to the high credibility machining capability of the FZ 37 is the construction using a floor-mounted, cast iron base with twin fabricated sidewalls and gantry fabrication that separate the workpiece from the moving gantry elements that carry the spindle.

Each axis is driven by Siemens Simodrive digital system with the option of linear motor or rack and pinion.

In each case, Heidenhain glass scales or for axes over three metres, steel scales are fitted with a compressed air barrier for protection against contamination.

Rapid traverse rates up to 50m/min can be achieved using the linear motor axis drive option to minimise lost time during positioning or, for instance, when performing a tool change.

The optional 15 or 30 position pick-up magazine is sited on the table at the end of the X-axis travel axis.

The 28kW and 40kW milling spindles use ceramic bearings which are mounted in a quick-change cartridge and on the four axis (3 + 1) milling head there is an automatic cutter-positioning axis.

Meanwhile, the five-axis version of milling head can be swivelled around the A and C driven axes.

The machine can be used for both wet or dry cutting cycles.

Integrated milling system based on CNC milling centres mounted at either end of a shared table- work on individual components or one large one - including 5-axis scanning.
Now available from 600 Centre of Shepshed in Leicestershire, is the Fidia Y2K Boxer, an integrated milling system based on either the Fidia K411 or K414 milling centres mounted at either end of a shared table. Both milling centres are totally autonomous when machining different work pieces or can work on different pre-defined areas of a single workpiece. Both spindles can also overlap along the Y-axis of the machine if required.

Five-axis digitising and scanning can be performed using both spindles and there is an electronic tracer whereby the Fidia C20 control compensates for any differences between tracer and milling cutter when machining.

Control is via Fidia's C20 unit with 60GB hard disk memory and HIMILL software for 3-D toolpath generation.

The machines have working strokes of 4350mm in X, 2475mm in Y and 1000 mm in Z for the K411 and 1400 mm in Z for the K414.

Axis speeds are 24m/min and the table will take loads up to 30 tonnes.

The spindles are 34 kW units giving 24,000 rev/min and +95 deg to -110 deg A-axis bi-rotary movement taken at up to 2000 deg/min.

C-axis rotation is + 200 deg taken at up to 1,200 deg/min and the A-axis +95 deg to -110 deg.

Latest Soraluce fixed-table travelling column, floor-type and travelling table milling centres now offer high cutting speeds and higher rapid traverses than their predecessors.
All Soraluce fixed-table travelling column, floor-type and travelling table milling centres now available in the UK from Ward CNC offer high cutting speeds and higher rapid traverses than their predecessors - rapids of 25m/min and high-speed electro-spindles rated at 18,000 to 30,000 rev/min - as well as a choice of automatic indexing heads, floor and angle plates, and auxiliary and CNC rotary and tiling tables. Indeed, the modular design of certain ranges allows for extensive customisation and the provision of specific solutions to meet users' applications. The result is an unrivalled choice of large-capacity, ultra-flexible milling machines that will accommodate any multi-axis milling application - and in particular, one-hit machining from heavy-duty cutting through to finish machining.

Importantly, the machines are available with a variety of optional automatic indexing heads (plus automatic head changing facilities), and each head has different levels of capabilities to suit a variety of tasks.

For example: The 30kW automatic indexing head has a torque rating of 1,240Nm and two indexing joints - one vertical to the spindle centreline and another at 45 deg, capable of positioning in both rotating planes at 2.50 increments; The 37kW orthogonal head is rated at 1,410Nm and, again, has two similar indexing joints and can be positioned at 10 in either plane.

Fixed boring heads rated at 30kW and 37kW are also available.

Utilising the optional electro-spindles, Soraluce users are promised faster production cycles, higher quality surface finishes and 'dual' machining capabilities, and by effectively 'doubling up' machine capacity can rough and finish with the same spindle or quickly swap the unit with the standard automatic indexing head arrangement used for heavy metal removal.

The electro-spindles' 'cold' rotor also extends the lifetime of the bearings - equating to a spindle life of at least 7,000h compared with the usual 3,000h available from an asynchronous unit - courtesy of the very low levels of vibration generated by the low-inertia unit, and its ability to achieve balance independent of both speed and power.

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! Outline capacities of the Soraluce range are: * travelling column floor types FP, FS and FR range - X, Y and Z axis travels from 4000mm by 1600mm by 1200mm and to 4000mm by 3600mm by 1500mm, and 28 to 37kW motors producing spindle speeds up to 6,000 rev/min.

* With fixed tables and travelling columns, SL, SP and SM - X, Y and Z axis capacities from 2500mm by 1600mm by 1000mm up to 3500mm by 1600mm by 2400mm, and spindle motors of 28kW to 37kW that produce speeds up to 6,000 rev/min.

* TL, TR and TF travelling table bed-type - 2500mm by 1400mm by 1000mm in X, Y and Z axes (and up to 1200mm in Z), spindle motors of 28kW to 30kW and spindle speeds up to 3000 rev/min.

Heidenhain TNC CNC is offered as standard as well as various toolchanger capacities up to 40 tools.

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

Their characteristic build qualities of stability and rigidity are based on finite element analysis and heavy-duty GG-30 cast iron construction for optimal stiffness, and vibration and stress absorption, complemented by INA linear guideway technology (for effective rapid traversing).

Travelling bridge-type machining centre has an integrated vertical turning capability for completing large, complex components in 'one hit'.
Uniport 7 Travelling Bridge Machining Centre with 3.5m integrated carousel turning station completely machines five-sides of large and complex components, including turning operations, of parts up to 4000mm in diameter. The proven flexibility of this large travelling bridge gantry machine is further increased by integrating a 3500mm rotarytable at one end of the large 12000mm X-axis (X-axis can be specified between 4000 and 18000mm). The 4000mm horizontal and 1900mm vertical clearance of the travelling gantry bridge enables large components to be completely set up for five-sided machining on the standard clamping tables.

Large ring- or cylindrically-shaped components can be completely set up for vertical turning on the rotary table.

* Powerful turning capabilities - the fully integrated rotary table of 3500mm diameter is equipped with an 2500mm diameter axial roller bearing and a 2400mm diameter radial bearing set.

This bearing configuration allows the table to receive components of up to 100 tonnes in weight.

For powerful turning operations, the Carousel Turning Station is equipped with an 80kW drive unit in conjunction with an automatically shifting two-stage gearbox.

The maximum speed of rotation of the 3500mm rotary table is 120 rev/min and the maximum torque is 43000Nm to allow highest metal removal rates.

The work area around the turning station is fully enclosed with the gantry bridge at its designated X-position for turning.

Access to the work area is from the front via large access doors.

The turning tools are loaded into a Turning Tool Adapter that is attached to the spindle nose at the lower end of the ram.

This Turning Tool Adapter is equipped with a Sandvik Capto C8 interface (option HSK-100) for automatic tool change of the turning tools from a pick-up station.

The pick-up station also acts as a separation wall between the turning station and the large stationary clamping table.

For five-sided machining of large and complex components, the flexible Unisign Right angle head can be automatically attached to the vertical main spindle.

The Unisign Right Angle Head offers the same power, torque and spindle speed as the vertical main spindle (i.e 36kW / 4.000 rev/min / 1350Nm).

Located at the front of the travelling bridge are two operator platforms, one on either side of the bridge.

Both platforms are equipped with a guarding section with operator access door to the machine work area.

At the front face of the machine, near the carousel turning station, an additional guarding section is located with large access doors for loading of the turn table.