First-tier automotive supplier has, since 1998, installed 21 UK-built lathes for hard- and soft-turning of transmission components and a further three machines are ready.
Almost every day there are gloomy reports of a declining manufacturing base in Britain, but there is still some good news, even in large volume production which is supposedly being lost to low-wage countries. For example, first-tier automotive supplier, GKN Driveline, Birmingham, has since 1998 installed 21 UK-built lathes from the MHP division of Geo Kingsbury Machine Tools for hard- and soft-turning of transmission components. A further three machines are ready for pass-off at Geo Kingsbury's Gosport factory.

In addition, a robotically loaded MHP50 CNC lathe is currently in build, due for installation at GKN Driveline in October 2005, for hard turning critical features on the constant velocity joint, or bell, that forms part of front-wheel and four-wheel driveshafts.

There are already five robot-fed MHP machines on the Birmingham site being used for similar work, each teamed with other machinery including hardening, spline rolling, washing plant to form automated manufacturing cells for outer race constant velocity bells.

Production rate is 1,400 components per cell per shift with five operators.

Each automated MHP lathe is fitted with its ABB robot at Geo Kingsbury's Gosport factory and is supplied, after pass-off, to GKN Driveline as a turnkey package, complete with programs.

The other MHP lathes are in manually loaded cells for soft turning operations on bells and tulips, the latter forming part of the plunging joint in a driveshaft nearer to the gearbox.

Mike Poyner, the engineer responsible for project managing the new production cells at the Birmingham factory, said, 'It is our policy to replace as many grinders as possible with hard turning'.

'Each time a lathe is installed it replaces pairs of external, angle-approach grinders'.

'By doing this, there is a six-fold saving in capital investment, amounting to several hundred thousand pounds''.

''Additionally, it takes two hours to change over an external grinder for a new batch compared to 10 minutes for a lathe, so production downtime is less by a factor of 12.' Driving the original change from grinding to hard turning were difficulties with grinding the hub support diameter of the bell and more particularly a shoulder called the back location face, both of which are pre-hardened to 58-62HRC.

The main problem used to be cracking of the location face during grinding, caused by overheating owing to difficulty in projecting sufficient coolant between the grinding wheel and the vertical face.

The earlier grinding operation and the dry hard-turning sequence that has replaced it includes in-cycle machining of a third OD in an unhardened state of 45-48HRC, namely a seating diameter for an ABS pulse ring.

As all turned features need to be concentric with six internal ball tracks, drawing tolerances are tight: +/-0.013mm for the hub support diameter and +/-0.015mm for the ABS diameter, surface finish for both being 1.6 micron.

As regards the back face, 0.15mm of material is machined away to leave a 0.8 micron surface finish.

The Ra figures achieved in practice are significantly lower than these.

Process capability achieved is Cpk 3.66 for the hub support diameter and Cpk 2.65 for the ABS diameter - significantly better than the required Cpk of 1.67 (5 Sigma).

More recently, GKN Driveline has been working in conjunction with Geo Kingsbury to identify inserts for soft turning that would last longer and reduce cycle times.

When machining a bell in its soft state, the incumbent supplier's insert used to result in a 65s turning cycle and it lasted for 70 components.

After research and subsequent trials, a Kennametal insert reduced the cycle to 55s and was found to machine nearly three times as many parts before it needed replacing.

Using a massive cast iron 45 deg slant bed with optimal chip clearance ensures that a CNC lathe, with choice of main spindle drives, produces a high level of swarf removal capability.
A massive high grade SG iron casting creates a 5.2 tonne 45 deg slant bed with optimal chip clearance defines the high level of swarf removal capability of the latest Dugard Eagle 300 CNC lathe which now incorporates the ability to select the most appropriate spindle and drive system package to suit the intended production use. Available from C. Dugard of Hove, Sussex, this competitively priced machine, with swing over the bed of 600mm and a maximum cutting diameter of 450mm by 700mm cutting length, provides the choice of three drives.

These provide the option of 35 to 3,500 revs/min from a 20kW AC motor, 2,500 rev/min through a 18.5kW motor and high torque two-speed gearbox, or 25 to 3,500 rev/min from a 22kW drive.

The hydraulic 10 station turret with 0.3s index time is mounted on linear guideways to enable rapid traverse rates of 20m/min in X and 24m/min in Y to be achieved.

Positioning accuracy is two microns and repeatability +0.0013 mm in X and 4 microns for positioning and +0.0025mm repeatability in Z.

A hydraulic tailstock with 85mm quill diameter and 120mm programmable quill travel is standard with programmable auto-positioning an option.

Barfeed is optional for stock size up to 77mm diameter with parts-catcher and choice of manual or automatic tool setting probes.

As a further option a 315mm power chuck with eight station turret can be specified in preference to the standard 252mm hydraulic chuck with through bore.

A massive high grade SG iron casting and optimal chip clearance provides the basis for high level of swarf removal on the latest CNC lathe with a cutting diameter of 450mm.
A massive high grade SG iron casting creating a 5.2 tonne, 45 deg slant bed with optimal chip clearance provides the basis for high level of swarf removal on the latest Dugard Eagle 300 CNC lathe. As part of the specification the machine can be customised to carry the most appropriate spindle and drive system package to suit the intended production use. Available from C Dugard of Hove, Sussex, UK, this competitively priced machine, with swing over the bed of 600mm and a maximum cutting diameter of 450mm by 700mm cutting length, provides the choice of three drives.

These provide the option of 35 to 3,500 rev/min from a 20kW AC motor, 2,500 rev/min through a 18.5kW motor and high torque two-speed gearbox, or 25 to 3,500 rev/min from a 22kW drive.

The hydraulic 10 station turret with 0.3s index time is mounted on linear guideways to enable rapid traverse rates of 20m/min in X and 24m/min in Y to be achieved.

Positioning accuracy is two microns and repeatability +0.0013mm in X and four microns for positioning and +0.0025mm repeatability in Z.

A hydraulic tailstock with 85mm quill diameter and 120mm programmable quill travel is standard with programmable auto-positioning an option.

Barfeed is optional for stock size up to 77mm diameter with parts-catcher and choice of manual or automatic tool setting probes.

As a further option, a 315mm power chuck with eight station turret can be specified in preference to the standard 252mm hydraulic chuck with through bore.

There are further options of CNC control systems through C

Price-competitive, two-axis slant bed CNC lathes feature a special one-piece, thermally balanced bed that promotes powerful and stable operation.
The Taiwan Takisawa EX Series of two-axis slant bed CNC lathes now available from Ward CNC of Sheffield, UK, boast a level of high-performance that is unrivalled for machines in this class. Coupled with the use of a special one-piece, thermally balanced bed that promotes powerful and stable operation, the machines' four-track super rigid precision linear guideways and high-speed servo turret all combine with the Fanuc 21iT CNC to provide users with an exceptional 'Japanese quality at Taiwanese prices' package. With swings over the bed of 350mm and 400mm, the EX-106 and EX-108 models have crosslide travels of 280mm and 320mm, respectively, and between centres distances of 455mm and 645mm.

Standard turning diameters are 190mm and 216mm, respectively, and with 152mm and 203mm chucks the machines have respective maximum turning diameters and lengths of 240mm and 320mm, and 350mm and 530mm.

Bar capacities are 43mm for the EX-106 and 52mm for the EX-108, and spindle speeds range from 50-5,000 rev/min (5.5/7.5kW motor) and 60-4,000 rev/min (7.5/11kW) for the two models which both have 12-tool turrets.

Auto tool setting arm, parts catcher, swarf conveyor and programmable quill tailstock are standard; collet chucks and bar feed systems can be provided as options to further widen the machines' cost-effective production capabilities.

To bring efficient and precise turning to the 'entry-level' user, CNC lathe control system offers visual user-interface and 3D-realtime simulation.
Both the NEF 600 - an EMO 2005 world premiere - and the established NEF 400, make efficient and precise turning possible for the entry-level user, with the highest technology and the latest high-tech components. The user can take advantage of a high level of flexibility, maximum precision and dynamics in the production process. Numerous options allow customised configurations of the machine, to reach maximum productivity in manufacturing.

For decades, the NEF brand has represented lathe-technology at the highest level, ease-of-use and an excellent cost/performance ratio.

With such a successful history, expectations were high when Gildemeister developed the fourth generation of this entry-level machine, which is a high-tech and affordable alternative to low-cost Asian suppliers.

The result is as impressive as it is convincing: both the NEF 400 and the larger NEF 600, which will be presented for the first time at the EMO in Hannover, offer a large number or high-tech components and an overall performance that is unprecedented in the sector of universal turning, making it especially unique.

The impressive innovations of this machine are apparent in the pivoting DMG SlimLinePanel with a stainless steel design, a 15in TFT-screen, high-tech CNCs from Fanuc or Siemens, both with visual user-interface and 3D-realtime simulation, as well as rotational speeds of 4,000 rev/min.

with a drive power of up to 24kW and 720Nm torque.

Another feature unique in this class is the 30 deg slanted bed with four-track design for optimal chip disposal and excellent accessibility.

In addition, the NEF machines feature a large work area combined with a traversable steady-rest and a fast 8x-turret, for high productivity and flexibility.

Chuck workpieces with diameters up to 350mm.

(NEF 400) or 600mm.

(NEF 600), and shaft workpieces with lengths up to 650 or 1200mm can be machined in the shortest possible time.

All this is achieved with the highest level of precision and with excellent surface quality, ensured by digital drive technology for the main spindle and sturdy linear guide-ways.

Additional features of this pioneering machine series are the tailstock with hydraulic quill, low space requirements of the fully enclosed machine in Space Green design (Metallic optional), advanced state-of-the-art central lubrication and integrated safety technology (Safety Integrated/Dual Check Safety).

Innovations - NEF 400 and NEF 600: * Pivoting DMG SlimLinePanel with 15in TFT-screen and state-of-the-art 3D software.

* Excellent shaft machining capabilities due to 4-track bed and traversable steady rest.

* 8x disk turret.

* Traversable tailstock with hydraulic quill.

* Dynamic linear guide-ways.

* Improved ergonomics and chip disposal through 30 deg slanted bed.

* Digital drive on the main spindle for best surface qualities and highest precision, plus high rotational speeds up to 4,000 rev/min as well as drive performance up to 15/24kW and 400/720Nm torque.

Full production models of the Harrison Alpha X Series, which includes the all-new 3-axis Alpha 1550XM model - with full C-axis and milling capability
Harrison Lathes' eye-catching new Alpha X Series, which attracted worldwide interest from the media, industry analysts and global customers alike at EMO 2005 in September, has now had its official launch in the domestic market. Full production models of the Alpha X Series, which includes the all-new 3-axis Alpha 1550XM model - the first Alpha lathe ever produced with full C-axis and milling capability - were unveiled in the Midlands courtesy of Harrison principal distributor, Datamach of Coventry. The late 2005 event attracted unprecedented interest in the new lathes from many of the distributor's large existing customer-base, and potential customers, who started arriving early in the day to view the new Alpha line-up and other advanced-technology Harrison lathes.

These included independent engineering companies, representatives from the manufacturing sector and other engineering specialists.

Datamach's sales director, Lorraine Lloyd, said: 'It was easily our best-ever customer event.

We had representatives from approximately 30 companies throughout the central region, including Lincoln, Oxford, Northampton also the Birmingham and Leicester areas.

There is huge interest in the new machines and customers we had invited were arriving from 8.30am until after 8pm.' She said that a string of important orders had been placed for Harrison Alpha machines at the Datamach launch event, including a V390 centre lathe, an Alpha 1550XS and an Alpha 1800S (3m 120mm spindle bore lathe); the latter being from Summit Precision Engineering , of Solihull, West Midlands.

The company had earlier in the month become the first in the UK to take delivery of a massive 4m Alpha 1800S (170mm spindle bore) lathe, following a major contract win for Scottish offshore oil industry equipment.

Dr Stephen Le Beau, Product Strategy and Marketing director said: 'The introduction of the new Alpha X Series is already making a big impact on the international lathes market, with orders being received from across the globe, most notably in Europe, the USA and Australia.

The launch and availability of the Alpha X range in the UK represents another major step forward for Harrison and the undoubted success of Datamach's launch day, with so many customers coming to see the machines for themselves, clearly demonstrates their enthusiasm for Harrison's lathe technology and quality manufacturing.

It also reflects the importance of the trust and confidence which customers have in Datamach , not only to supply market-leading lathes which deliver maximum engineering performance with lower component production costs, but also to provide a complete programme of after-sales support for total peace of mind following the initial investment.' * About Harrison - Harrison - a member of 600 Group, the UK's largest machine tool company - has successfully combined new, market-leading touchscreen technologies and designs with traditional manufacturing quality in the Alpha X Series.

Harrison design engineers have incorporated no fewer than 85 individual technical enhancements with the result that the new range provides even faster turning speeds and more power plus the very latest G E Fanuc-based control system available.

This highly advanced new 'total system solution' has been specially developed by Harrison and Fanuc for optimum integration of all key systems: servos, spindle, drives, control, operator panel and electrical components.

The full Harrison Alpha X Series, officially launched at EMO 2005, comprises the following lathes: ALPHA XT - Alpha 1350XT, Alpha 1400XT, Alpha 1460XT, Alpha 1550XT, Alpha 1800XT; ALPHA XS - Alpha 1350XS, Alpha 1400XS, Alpha 1460XS, Alpha 1550XS, Alpha 1800XS; ALPHA XM - Alpha 1550XM.

Great Britain can compete successfully on the world stage, according to Phil Round, chief executive of the Herefordshire and Worcestershire Group Training Associations (GTAs).
Great Britain can compete successfully on the world stage, according to Phil Round, chief executive of the Herefordshire and Worcestershire Group Training Associations (GTAs). 'I'm convinced that motivated workforces using the appropriate production equipment and armed with first-class skills can enable UK companies to be global competitors,' he exclaims. With an obvious bias, Phil Round enthusiastically promotes the benefits of continual skills development - in terms of companies' profit margins as well as increased rewards and job satisfaction for their employees - and, unsurprisingly, he vigorously promotes the various training courses available via his organisation, which is a Learning and Skills Council-accredited Centre of Vocational Excellence.

Proudly, he states that the GTA is the largest college provider of apprenticeships in the area.

'The most important thing to remember about us is the fact that we are financed and controlled by local companies - firms of all sizes across various industry and business sectors - and we therefore work in partnership with these companies to develop training courses that are designed to produce maximum benefit for the companies, their employees [the trainees] and the local communities.

'I have no doubt that UK companies, if armed with the correct skills and equipment, can retain their world status - and GTA members like Special Metals Wiggin, Bulmers and Sun Valley Foods consistently prove that!' Much of Phil Round's talk of creating 'world class' employees is based around the provision of an extensive number of courses that are tailor-made to the trainee/partner company, and they include the delivery of NVQ qualifications in engineering manufacture, design, engineering maintenance and engineering production.

In addition to focused courses that cover fluid power (pneumatics and hydraulics) draughting, computer-aided design, welding and fabrication (MIG and TIG welding, plasma cutting) and industrial electrical courses (motor power control and diagnostics, for example), the engineering training centres at both Hereford and Worcester are characterised by impressive 'shopfloors'.

These serve as home to the 200 or so apprentices that all undertake substantial periods of training on turning, milling and CNC machining courses.

The key to success, he continues, is not only dependent on bright and enthusiastic trainees, but it also relies on the use of the correct calibre of equipment.

'And in the case of machine tools, this means utilising machines that are industry-standard and fit for purpose.

'We haveve invested approximately GBP 1 million during the past three years on re-equipping our Hereford and Worcester centres to make them among the best such facilities in the country, and we certainly wouldn't have spent such a sum if we thought that Great Britain was in terminal decline.' Much of that capital expenditure has been invested in machines supplied by Gate Machinery International, the Watford-based specialist supplier that, says Phil Round, 'has played a key role in upgrading our facilities with a superb portfolio of predominantly two- and three-axis turning and milling machines'.

All the machines are of quality build and have high-class specifications, and they include the user-friendly functionality of Anilam DRO/CNC systems - multi-axis control technology that suits all possible skill levels and needs.

'Around 75% of the investment has been made at the Worcester Training Centre, where in the 10,000ft2 of refurbished training workshops and lecture rooms we've replicated our successful Hereford training area,' says Phil Round.

'The new Worcester centre, operated in partnership with Worcester College of Technology, commenced training in March 2005, and could not have come at a better time, since a recent Strategic Area Review confirms manufacturing and engineering as a priority for Herefordshire and Worcestershire, and forecasts that nearly 11,000 new employees will be required locally in suitable disciplines by the year 2012.' With a pot of money and an extensive shopping list, it was vital that Phil Round and his team spent every penny in the most effective way.

'It soon became clear that our budget would go furthest and provide all the machines we required - with no detriment to machine specification and quality - with Gate Machinery International,' he confirms.

'In addition, based on the highly professional way in which the Gate team fulfilled their obligations when we re-equipped the Hereford centre - the machine installation programme was carried out with military precision - coupled with such a high level of back-up and after-sales service, it really wasn't a difficult decision to choose Gate again.' Of highly rigid construction, the Gate Eclipse ECM-1 CNC turret mill exemplifies what Phil Round describes as 'affordable quality' with a high-class specification.

The machine's Anilam 5300 CNC allows both conversational and G-code programming which enables the instructors to fully follow the CNC curriculum.

With a table of 1,067 mm by 230 mm, the machine can accommodate loads of 125 kgs, which is more than adequate for the workpieces processed - predominantly one-offs for the toolmaking and maintenance machinist environments, though batchwork is also progressed.

The machine has X, Y and Z (quill) axes travels of 660mm by 305mm by 100mm complemented by a powered knee travel in Z of 406mm (optional).

Variable spindle speeds as standard are from 60 to 4,200 revs/min and rigid tapping is optional.

Anilam off-line programming software enables the control to be replicated in a classroom environment, allowing programs to be created off-line and sent to the machine via DNC link or floppy drive.

In the event, Gate Machinery International has supplied a total of 31 machines to the Hereford and Worcester centres, including turret and CNC milling, heavy duty and centre lathe capacity, and variable speed and CNC turning machines.

With this armoury of production equipment complementing such a comprehensive training syllabus, Phil Round is justifiably proud of what is being achieved in Hereford and Worcester.

'The area may be regarded by some as a rural backwater,' he concludes.

'But we are leading the way when it comes to utilising world-class equipment and training courses that produce world-class engineers.'

A recent convert to CNC machining specialises in the manufacture from high-grade stainless steels of bespoke parts such as nozzles, nozzle holders, fittings and lances for waterjetting applications.
A recent convert to CNC machining with the installation of a XYZ ProTURN VL 355 lathe, Hydrojet Precision Engineering specialises in the manufacture from high-grade stainless steels of bespoke parts such as nozzles, nozzle holders, fittings and lances for waterjetting applications. The many and varied uses of high-pressure waterjetting demand a multitude of specialist delivery systems, and that is where Hydrojet comes into the picture. Formed in 1996 by brothers Michael and Graham Wilkes, this Bromsgrove, Worcestershire company is a leading manufacturer and supplier of high and ultra-high pressure (up to 36,000 lb/in2) waterjetting accessories and consumables.

But why opt for a CNC machine tool when manual machining of one-offs and small batches, often dispatched on the day of order, has been sufficient to establish an industry-wide reputation for quality, reliability and speed of response?

'Buying the ProTURN has undoubtedly made life easier for us,' says Graham Wilkes.

'We were working on an extremely awkward job, knowing that one mistake could scrap the component, when we had a visit from XYZ.

It was pointed out to us that this particular job could be programmed quickly and easily on a manual/CNC lathe and the program checked before machining began, thereby avoiding a costly mistake with a one-off and providing a program that could be retrieved at any time for a repeat order.

We have actually had that same job since installing the new lathe,' adds Michael Wilkes, 'And it was perfect.

Initially we were apprehensive about moving to CNC but with a day's training it proved to be totally painless.

The manual/CNC option is great, as we can, for instance, intervene to change the feedrate while the program is actually running.

This ensures we achieve the optimum chip breaking conditions when machining difficult materials.' The 5.75kW, 360mm swing over bed XYZ ProTURN VL 355 provides Hydrojet with a choice of manual machining or, courtesy of the ProtoTRAK VL control, partial or full CNC.

This degree of flexibility is ideal for a business that has made its name with the speedy production of one-offs and small batches, and it is the 'traking' feature of the ProtoTRAK VL control that makes it possible.

In CNC mode the electronic handwheels on the machine allow the operator to 'trak' through a program while controlling the speed at which the machine moves.

Slow or stop winding the handles and the machine also slows or stops, a unique feature that eliminates any possibility of collision.

'Our business has grown mainly as a result of word of mouth recommendations,' says Michael Wilkes, 'Although we still regard ourselves as skilled machinists rather than businessmen.

We concentrate our resources mainly on turning and to a lesser extent milling, but the demand for our products is such that we needed to find ways to meet that demand without taking on people, moving to larger premises or working longer hours.'

New from Colchester Lathe is the fully integrated 7-axis turning cell development of the Tornado T6MS that features a fully programmable, APL5000 automatic loading and unloading system.

Extending its highly competitive and cost-effective 'Lights-out' machine package strategy for the top-selling Tornado range of CNC turning centres, new from Colchester Lathe is the fully integrated 7-axis turning cell development of the Tornado T6MS that features a fully programmable, APL5000 automatic loading and unloading system. Available from Colchestersales of Heckmondwike, the Tornado T6MS is a true integrated mill/turning cell devised for maximum utilisation involving unmanned operation. Now with loading and unloading of components performed by purpose developed automation, that operates within the confines of the machine without additional guarding or fencing, it sets a new standard for economic production at, in true Colchester Lathe tradition, an affordable price.

The automation is fully programmable via teach pendant and operates through the Fanuc 18i-TB control with Manual Guide i software on the machine as standard while being integrated with Colchester Lathe developed automation programs.

As a result, loading sequences are combined with first and second chucking operations with automatic part transfer between main and subspindle for parts up to 80 mm diameter by 100 mm long and weighing up to 5 kg.

The machine concept involves a loading beam mounted above and onto the headstock and running parallel to the centre line or Z-axis to link component storage at the headstock side of the machine to the cutting zone.

Powered via ballscrew and servo drives a novel rotating arm mechanism carrying two hydraulic chucks handshakes with the user specified material handling systems of either part stockers, carousel, palletising or conveyor systems.

The different types of material and work handling systems are able to manipulate raw material supply to the main spindle and accept the off-load of completed parts from the main or subspindle enabling the production cycle to continue independent of the loading system.

The loading system therefore is able to carry on to complete the handling sequence with the part storage elements and is able to be parked clear of the machine working area to enable normal machine operation.

The Tornado T6MS has a 440 m swing over bed and 220 mm maximum turned diameter by 450 mm long with a 54 mm bar capacity and 130 mm chuck size.

The 15 kW, 6,000 revs/min main and 5.5 kW, 6,000 revs/min subspindle are serviced by a 12 station all-driven tool turret with 3.7 kW, 5,000 revs/min drive.

Rapid traverse rates are 30 m/min in Z and 25 m/min in X.

Maximum stiffness of the machine is achieved via Colchester Lathe's well-proven 'Duo-Stable' construction that uses an encapsulated polymer concrete base fill with a compact cast iron bed to minimise vibration and thermal effects and provide new levels of mill/turning operational consistency.