Claimed to far outperform any traditional single spindle cam machines in both flexibility and profitability, a linear motor drive CNC automatic makes simultaneous use of several tools.
Claimed to far outperform any traditional single spindle cam machines in both flexibility and profitability, a linear motor drive CNC automatic makes simultaneous use of several tools. For those who were unable to attend the last EMO, DMG is staging a British re-run, complete with several machines never before demonstrated publicly in the UK. In total, eleven machines will feature showing a wide range of machining solutions and four of those are brand new.

The star performer for turning is undoubtedly the new Sprint 32 linear, aptly named as it far outperforms any traditional single spindle cam machines in both flexibility and profitability.

One of the key features of this new CNC automatic turning machine is its motor spindle and the linear arrangement of the tool holders, which allow the simultaneous use of several tools.

These features, combined with the unique configuration of up to 8 axes, make it possible to process turned parts, inexpensively and at reduced cycle times.

The next universal turning newcomer is the CTX410, one of the latest additions to the CTX 10-Series whose hallmark is low capital cost; a CTX210 model with Fanuc control will also feature on the stand.

Competitive price is achieved through efficient production and assembly methods.

In addition to the standard configuration, the design may be specified with fixed or driven tools.

The use of high-tech components such as the integrated spindle motor and fast servo-turret ensure up to 25% idle time reduction resulting in greater productivity and cost efficiency.

With the introduction of the new GMX 200 linear, DMG extends it turn-mill capabilities up to 560mm diameter, making this product line the most comprehensive for complete 6-sided machining with linear technology.

A linear drive, compound slides with a Y- and B-axis and the highly dynamic turning and milling spindle with 100Nm and a maximum 12,000 rpm are just some of the features that make this machine both a high-end lathe and a high-tech machining centre.

Speed and angle-synchronous workpiece transfers as well as integrated spindle motors provide the shortest cycle times, both for the counter spindle and the tail stock versions.

Thanks to linear drive technology, the CTX 320 linear universal lathe has been rewarding several UK companies with significant productivity increases and at MACH its abilities will be demonstrated on 65mm bar.

DMG's twin spindle range is to be represented by the Twin 65.

The large frame size of this lathe has created space for a CNC-controlled B-axis in the area of the upper turret.

In combination with the Y-axis and driven tools, it is therefore able to machine slanted bores, planes and even complicated milling contours.

Among 10 machining centres, CNC lathes and a VTL to be shown at MACH 2004, will be a large spindle bore CNC lathe, turning centres and a CNC VTL with a 17kW driven tool facility.
With a total of 10 machines being displayed - including three new models from Kia (the 1 m plus capacity VX500 vertical machining centre), Toshulin (the cost-competitive SKL12 vertical boring and turning machine) and Soraluce (the high-performance SP-8000 travelling column, fixed-bed mill, which is also likely to be the biggest machine at the show), Ward CNC's 500m2 display in Hall 4, the largest stand at MACH, will certainly emphasise that both 'big and small machines are beautiful'. With a variety of the machines either under power or cutting metal, the Ward CNC display will also include representatives of the company's Union (boring and milling) and Hankook (turning) ranges, so clearly the Sheffield-based machine tool specialist will be presenting something for everyone at the NEC. Included in the 11 machine tools on show, and being demonstrated, are the following CNC lathes and vertical turning lathe (VTL): * Toshulin SKL12 VTL.

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Three Kia turning centres - SKT21LMSB with driven tools and sub-spindle, SKT15LM universal with driven tools, and the SKT300 heavy-duty with geared head and solid slideways.

* Hankook 9NC large spindle bore CNC lathe with front and rear chucks and 4000mm between centres.

Visitors to the stand will be spoilt for turning centre choice, with three models on view.

Complete with a C axis, live tooling, sub-spindle and a 65mm spindle bore, the Super Kia Turn 21LMSB is a machine that Ward CNC managing director Simon Whitworth describes as 'world beating' for maximising value-for-money productivity on bar work up to 65mm.

The main 15/11kW spindle motor produces 25 to 4,000 revs/min, while the 3.7/2.2kW sub-spindle reaches 30 to 6,000 revs/min.

The 12-station bi-directional turret has a driven tool speed range of 20 to 4,000 revs/min generated by a 3.7/2.2kW motor.

With an X axis (cross) travel of 220mm and a Z axis (longitudinal) travel of 550mm, the machine has a maximum swing over the bed of 550mm and a distance between centres of 530mm.

Rapid traverse rates are 36m/min.

The Super Kia Turn SKT300 has a maximum turning diameter of 560mm, a maximum turning length of 720mm and a 90mm diameter bar capacity/305mm diameter chuck.

Travels in X and Z axes are 355mm and 750mm and the spindle provides 3,000 revs/min.

Feed rates 20m/min and 24m/min in X and Z, respectively.

With a 12-tool turret and two-stepped geared headstock designed for high-torque, heavy cutting, and programmable tailstock, the Fanuc-controlled SKT300 is designed to minimise non-cutting times while consistently producing parts to 3.5 micron accuracies (in brass, for example).

Completing the Kia display will be the Super Turn 15LM universal three-axis turning centre with driven tools and C axis, having a maximum swing of 550mm and turning diameter of 255mm.

Distance between centres on this 43mm bar capacity machine is 530mm.

Spindle speeds reach 6,000 revs/min, and rapid traverse rate in both the 220mm X and 550mm Z axes is 36m/min.

New from Toshulin is the SKL12 VTL, which can turn and face workpiece diameters up to 1700mm, and has a Z axis capacity of 1200mm and a ram stroke of 1000mm.

With a 1250mm diameter table having a speed range up to 500 revs/min, and an up to 10 revs/min C axis, the 17kW machine's driven tool spindle has an infinitely variable speed range up to 3,000 revs/min, complemented by working travels and rapid traverse rates of 1-4000mm/min and 3000mm/min, respectively.

Typifying the high quality of build and cost-and-performance specification available from Hankook, the Protec 9NC lathe is based on a double-walled and ribbed one-piece meehanite cast iron bed with induction hardened and ground precision slideways for maximum stability and accuracy.

The large spindle bore (up to 440mm) 9NC has a 950mm swing over the bed, 630mm over the carriage and 4000mm between centres.

With Fanuc CNC, the machine boasts spindle speeds of 2 to 1,000/3 to 440 revs/min.

Marposs Mida Laser 105 laser toolsetting and an E86 radio transmission spindle probe will also be evident on the Ward CNC stand.

A wealth of 'high-tech' features in universal CNC lathes include top-of-the-range Fanuc or Siemens control with graphical user interface and 3D real-time simulation.
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 GBP 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), 8 station turret and tailstock with life centre.

Examples of the features that are atypical in this class of machine include the pivoting DMG SlimLinePanel with 15in TFT screen feature a top-of-the-range Fanuc or Siemens control with graphical user interface and 3D real-time simulation.

Rotational speeds are up to 4,000 rev/min with up to 24kW of drive power and 720Nm torque.

Not to be found on any other entry-level lathe is the 30 deg inclined four-track bed designed for optimal chip clearance and excellent accessibility.

High flexibility and productivity are assured thanks to a large working area and features such as a traversable steady rest and high-speed, 8-station turret.

As a result chucking components up to 55mm and shaft sections up to 1200mm in length can be machined in the shortest time.

The digital drive on the main spindle and dynamically stable linear guideways make a significant contribution to the high precision and excellent surface quality achievable on the new NEF universal lathes.

Manufacturing flexibility is assured by a traversable tailstock with hydraulic quill.

Other notable features are integrated safety systems and a low space requirement.

Following the investment in a CNC slant bed chucking lathe a leading producer of extrusion dies for plastics and rubber insulation has cut extrusion die machining up to 70 per cent.
Following the investment in a Colchester Tornado 220 slant bed chucking lathe Aspin Engineering, a leading producer of extrusion dies for plastics and rubber insulation used on a wide range of cable and wire products, has cut extrusion die machining up to 70 per cent. The company has also adopted hard turning of materials up to 45 HRC and reduced grinding requirements by a third. Aspin Engineering has since expanded its business into general sub contract machining.

Says managing director Dr Anton Aspin: 'We decided to buy the Tornado 220 CNC lathe following a visit to the Colchester Sales Technical Centre in Heckmondwike.

Originally selected from a shortlist of three turning machines, it was the performance, accuracy and overall value for money that were the major advantages we determined.' He follows on to outline: 'I was particularly impressed by the construction with its wide slideways and polymer concrete filled base which gives a high level of stability.

In my view, stability is an important prerequisite in a machine for holding the tight tolerances which we regularly have to work to on a wide range of precision extrusion dies and various other turning projects.' Dr Aspin's comments on the construction are confirmed following the Tornado's installation in the company's 4,500 (square feet) factory unit on the Moss Lane Trading Estate in Greater Manchester in April.

Cycle times on H13 and P20 tool steel extrusion tooling have been cut in half and 316 stainless steel mixer part machining times have been slashed by almost 70 per cent.

But there have been even further benefits as Dr Aspin explained: 'We have been able to eliminate around a third of our cylindrical grinding work as the Tornado can turn extrusion points and dies consistently to an almost unbelievable accuracy of + 5 microns.

What's more, we've also been able to comfortably machine a range of toughened materials up to 45 HRC, using standard tooling.' Aspin Engineering has found the GE Fanuc B series 21-i controlled Tornado 220 is quick and simple to program.

In fact, the company reckons that it is also able to produce single parts economically on the lathe as it is so easy to generate part programs.

However, batch sizes of between five and 10 are deemed more realistic.

It is the ability of the machine to effectively handle larger volumes of work that is seen as important for expansion of the Aspin Engineering business and has enabled additional savings to be created by the company.

For example, when Aspin received a large order for extrusion parts late last year, it had to spend around GBP 10,000 over a three month period on subcontracting much of the turning due to capacity problems in achieving the scheduled delivery dates.

As Dr Aspin added: 'This really motivated us to look at being self-sufficient and buy a new CNC chucking lathe.' When Dr Aspin discusses the purchase he maintains the lathe's all-round performance and accuracy is directly attributable to its patented 'Duo-Stable' construction which provides a highly stable, true 60 (Degrees) slant bed turning platform.

The base foundation with its engineered polymer concrete fill, strategic reinforcement and integral cast iron bed, reflects an increase in machine weight of some 50 per cent which is coupled with a corresponding 25 per cent improvement in damping.

'This is where the 'performance and accuracy factors' are created and the machine easily copes with the 22 kW spindle power making the larger 250 mm diameter chuck capacity and tailstock options that we ordered meet our planned requirements.' Other advanced technical features of the machine include: larger headstock and a stiffer, five-bearing spindle design; wider, lower and heavier slideways; and improved thermal characteristics - which collectively provide the stability factor required for really high performance machining.

Set-up in 1984 and employing 14 people, Aspin Engineering's work load is now split 20 per cent between producing wire and cable extrusion dies, 40 per cent on general subcontract work and other products and 40 per cent on added-value small assemblies.

The company has CNC machine tools of which two are vertical machining centres, a Colchester Electronic lathe and two thread grinding machines.

Its production of dies for insulating cables ranges from telecommunications work requirements of 0.5mm diameter right up to 152mm diameter for power cables.

Extrusion points and dies range in size from 20mm to 250mm diameter while stainless steel rotors and stators are also produced in diameters up to 200mm.

The company's own Cavity Transfer Miser (CTM) system product, which significantly improves the mixing/blending performance of an extruder, is produced in sizes from 20 mm to 600 mm diameter.

There's no doubt that the Tornado 220 has made a big impression since its arrival at the company's Whitefield works earlier this year.

As Dr Aspin concluded: 'The Tornado has extended our capacity, widened our scope of operations, eliminated certain grinding operations and, allowed us to look at work we could never have economically handled before.

A 'lights-out' mill-turn package giving an unmanned running capability secured a GBP 40,000/year contract that would not have been quoted for before the installation.
Committing to purchase his fifth Colchester Tornado in five years at MACH 2004 but this time a 'lights-out' package giving an unmanned running capability, managing director Roger Metcalfe of Cleveland Components, Skelton in Cleveland maintains for his progressive business build-up and for the type of parts he has to produce, he has not been able to find a better investment in turning machines. And, as a result of the exhibition purchase which for Cleveland Components proved to be very timely, Roger Metcalfe almost immediately secured a GBP 40,000 a year contract that he would not have been able to even quote for before the installation. With four Tornados already installed since the company was set up in March 1999 alongside four very different makes of vertical machining centre, Metcalfe admits to having deep concerns over 'comfort' buying.

'I went to MACH at the NEC in Birmingham with a completely open mind and carefully weighed up features and specifications of different lathes against the type of work we produce and the type of components we want to make in the future.

Always in mind, of course, is the installed price,' he insists but has to admit: 'No other machine tool supplier came close!' Adding to his concerns over the 'comfort' factor was that he strongly believed a lathe was for turning and a machining centre was for milling.

This gave his company the best flexibility for production and allowed most to be achieved from producing parts individually on each machine type.

However, Colchester Sales convinced him that he should think wider than two-axis turning and that for his type of parts he would never look back even though the Tornado 120M, in a 'Lights-out' unmanned mill/turn centre package, was more expensive than the two-axis machine he felt he was in the market for.

To which he now adds: 'We cannot believe the benefits of three-axis' and expresses his feelings by waving the GBP 40,000 contract purely won as a result of the Tornado 120M, that he would never have been competitive to bid for - let alone win.

Cleveland Components has grown from just two people to 13 in five years and had sales in 2003 of over GBP 700,000.

With the new Tornado 120M Metcalfe is now moving the business to create a machining cell giving unmanned running between shifts and at night.

To achieve this he can program the machine using ColCAM, the Colchester developed off-line programming software, set up the tooling, tool monitoring limits and production scheduling software, program the Renishaw probing routines, load the bar, press the button and let it go.

The company is very active and has developed a very loyal and 'live' customer list of over 100 companies.

At the day of the visit, 25 different customers had orders on the job list from automotive and motorsport, telecoms, aerospace, chemical and medical sectors in batches that varied between 10 and 5,000.

Originally business was generated locally and in the North East but as the company expanded customers are now based all over the UK and materials processed vary from steel and stainless steel, copper, brass and aluminium as well as the occasional exotic steel.

It was this background of customers, diverse parts and materials that helped Metcalfe follow his repeat purchases of Colchester machines.

He maintains: 'I identified the type of machine to give accuracy and repeatability but I had to be very aware of commercial pressures and with the Tornado the rate per hour I can charge is very competitive.' His progression of purchase started with a Tornado A50 and bar feed package in 1999.

After moving to the current premises when they were first built and within six months of setting up Cleveland Components, he added a second Tornado, this time a 100 chucker, followed by a Tornado A90 again with a bar feed package.

At that point in the expansion of the business he found enquiries and orders were beginning to be won from blue chip companies.

A larger capacity Tornado 200 was then installed which led to the Tornado 120 three-axis mill/turn 'lights-out' package machine decision at MACH 2004.

Metcalfe readily admits to it being a speculative purchase but has turned out to be one of the most rewarding made because of the opportunities it has opened up.

'It's my busiest machine and most importantly, a point I never considered when placing the order, is that it has completely changed the workload on the machining centres enabling us to take on further work for them.' Lead times have been dramatically reduced which has been helped by the ColCAM off-line programming package bought with the machine.

He now maintains: 'You would not believe how differently we work.

It is all down to the ability to mill and turn in the same cycle and being able to set and run parts without having to be involved except to oversee and prepare the next batch run.' The Tornado 120M 'Lights-out' package has a 52mm bar capacity and 12 driven tool positions and incorporates the Colchester patented Duo-stable polymer concrete base configuration that gives some 25 per cent improvement in damping.

This also enables the machine to reach running temperature faster and provides a much more stable cutting platform especially when mill/turning.

High stability is important with the all-driven turret being powered by a 3.7kW motor giving 5,000 rev/min and with the disc brake on the spindle to hold position.

This enables Roger Metcalfe's setter to take effective cuts without problems of vibration, chatter and movement when milling.

The 'lights-out' package with Fanuc 21i-Ta control includes the Colchester developed MBF bar feed system programmable at the control, a parts-catcher and integral swarf conveyor, axis torque monitoring, on-board production control software, the ColCAM on-machine graphics-based programming software and Renishaw's component probing system.

A typical part produced by Cleveland Components is a complex valve housing out of 25mm aluminium bar in batches of 250.

The part requires six driven tools, three applied axially and three radially.

The part has a 9 mm off-centre profiled boss of 7mm diameter which has a drilled and tapped M5 x 0.8 hole 7mm deep and a blended profile with a 6mm radius to the main component centre line.

A cross drilled hole of 2mm diameter also breaks into two centre bores which are 8mm and 5mm diameter which also have a further cross hole breaking through of 5mm diameter.

There are also grooves, radii and chamfers.

The part is turned and milled complete in under three minutes but as Roger Metcalfe admits, although he can machine 90 per cent of the part in one cycle, he still has to perform a second operation to finish the part- off face and drill and tap another hole in the end.

'I need a subspindle machine now and the new Tornado T6MS is going on the shopping list,' he insists.

'It's no longer lathes for turning, machining centres for milling - I want a part in one cycle.

A CNC lathe, costing 30% less than its predecessor, is turning the internal form of diamond wheel dresser moulds to within a +/-2 micron tolerance to meet growing deamnd.
Lower cost lathe machines mould IDs within +/-2 micron A CNC lathe, costing 30% less than its predecessor, is turning the internal form of diamond wheel dresser moulds to within +/-2 micron tolerance. A Daewoo lathe from Mills Manufacturing Technology has been installed at Tyrolit, Crawley, to turn the internal form of bespoke diamond roller dresser moulds to within +/-2 micron tolerance. Over 80 per cent of the dressers are for sharpening the profile of Viper and conventional creep-feed grinding wheels used for machining the tip and root features on aero engine hot-end turbine blades, which are produced from nickel and other exotic alloys.

Other applications include high precision roller dressers for grinding wheels used in the manufacture of land-based turbine blades, bearings including double-track types, saw blades and automotive components such as gear trains.

Around a third of production is exported, Israel and China being particularly buoyant markets at present.

Commented Norman Crown, Tyrolits Technical Manager - Roller Dresser Unit, 'We are expecting a 70 per cent increase in throughput at Crawley within the next 12 months as our parent company in Austria transfers its dresser production to the UK to make way for manufacture of a new product over there.

So we needed to increase our mould turning capacity by installing a second lathe.

The decision was made to buy a Daewoo Puma 240LC, as the cost was 30 per cent less than a new version of the Japanese turning machine we have used for the same job since we set up operations on this site in September 2003 - yet trials showed that the Korean-built machine was just as accurate'.

Accuracy is the watchword in turbine blade production.

Engine manufacturers stipulate a very tight tolerance on the critical fir tree root form, often extending this tolerance to all dimensions on the root and tip.

The form on the grinding wheel, and consequently that of the dresser, needs to be within the same tolerance.

This applies not only to the internal profile of the dresser mould but also to the concentricity of internal features with the outside diameter, which can be up to 250mm.

Profile accuracy is verified using a contour measuring machine, on which every turned mould is checked.

The measured trace is aligned on computer screen as a best fit within a tolerance band taken as DXF output from the CAD model of the dresser, or of the component that will eventually be ground.

The system shows that Tyrolit routinely holds +/-2 microns on mould profile using the Daewoo lathe, well within tolerance, eliminating the need to diamond lap the resulting dresser, which is time consuming and reduces its service life.

The CAD model is normally used to download programs to the Daewoo lathe via Pathtrace EdgeCam software and a suitable post-processor.

Sometimes if the program is simple, the X,Y co-ordinates generated by the CAD system are entered by the operator into the Fanuc control, reducing the load on the CAD/CAM department.

The 10-station turret of the Puma 240 LC lathe is large enough to house boring bars for turning the majority of moulds produced at Crawley, so the indexable carbide insert tools are accurately clamped and rarely exchanged.

The bed is extended on this lathe model to allow the long boring bars to gain access to the inside of moulds used to make the wider Tyrolit dressers.

Average diameter of the finished product is around 130 to 150mm, although it can be as low as 50mm for some Viper grinding applications; and width is normally 50 to 60mm.

Tyrolit dressers are made using the industry-standard method of reverse-plating, which results in a nickel-based matrix carrying industrial diamond grit, with natural diamonds set by hand around the periphery of the dresser where there are sharp changes in the contour.

A finished roller dresser can easily cost GBP 1,500, which is why customers normally leave ordering a new one to the last minute.

Tyrolit prides itself on turning round quotes in 24 hours and keeping lead times short six weeks for standard deliveries.

In searching for a robust, high build specification turning centre, a machine shop found a slant bed CNC lathe that has since reduced cycle times on tough, complex parts by 12 per cent.
In searching for a robust, high build specification turning centre, a machine shop found a slant bed CNC lathe that has since reduced cycle times by 12 per cent. When Martin Beer, general manager at Plymouth-based specialist sub-contractor PTG Precision Engineers, wanted to increase capacity and throughput in line with customer improvement projects, his search centred on a robust, high build specification turning centre that could cope with the aggressive machining of cast iron components. After a review of several machines, he opted for a Super Kia Turn SKT300 two-axis slant bed lathe from Ward CNC of Sheffield - and not only is the machine satisfying PTG's demanding production routines, but it has also reduced cycle times by 12 per cent.

PTG has been established since 1977 and has evolved from a small toolmaking company into one of the most valued and progressive sub-contractors in the UK.

PTG is currently introducing lean manufacturing throughout its operation and continues to maintain high quality standards, including ISO 9001:2000.

'We have a fair spread of customers throughout industry including companies that manufacture hydraulic motors and pumps, compressor manufacturers as well as a customer base in the valve industry,' Beer explains.

'Recently we have been keen to enter into partnership agreements with many of our customers and suppliers, so that we can forecast further ahead using Kanban techniques.

To help ensure we had sufficient capacity to introduce such a method we required another CNC turning centre.' However, no ordinary turning centre would suffice.

At PTG, much of the machining is based on medium-to-high complexity cast iron or SG (spheroidal graphite) iron gear casing components.

This required a robust machine with enough 'grunt', as Beer describes it, to cope with the rigours of such tough materials in the aggressive fashion required to match the company's high productivity demands.

'We looked at turning centres from several suppliers,' he says, 'but when we saw the robust build quality of the Kia we knew we had found our solution.

Even more so when the machine's excellent value for money high-specification and support were added to the equation.' This latter is a point that Beer is keen to elaborate.

'Ward CNC has been first class.

The machine was delivered and installed on time, and commissioning and training went without hitch.

I have to say that since then (August 2004) the Kia has been very reliable.' Also significant is the fact that the machine is arranged in a production flowline, supplying parts to machining centres across a six-day, double shift work pattern.

'It means that reliability and speed of manufacture are key - and the power of the machine in combination with high technology insert grade tooling has enabled us to reduce cycle times by around 12 per cent.' With a 22/26kW spindle motor producing 3,000 rev/min, the SKT300 has a swing over the bed of 750mm, a maximum turning length of 720mm and a 90mm diameter bar capacity.

Feed rates are 20m/min and 24m/min in X and Z axes, respectively.

Featuring a 12-tool turret and a two-stepped geared headstock for high torque, heavy cutting - and optional programmable tailstock - the Fanuc-controlled SKT300 is designed to minimise non-cutting time.

Its single-piece cast construction boasts a three-layer solid bed and box ways on all axes.

The machine is fitted with a Q-Setter for quick tool compensation as standard.

'The Kia has been excellent,' concludes Beer.

'We have no complaints, and I wouldn‚t hesitate in recommending the machine.'