The revolutionary Hardinge / EMAG joint venture produced VL machines provide a guaranteed load / unload time of 4 - 6 seconds - chip to chip - which is critical for cycles of 30 sec and less.

Hand loading CNC lathes with billets, castings or forgings is a costly variable in the production process. The short cycle time of many CNC turning operations exacerbates the situation, relying on the machine operator to react instantaneously to the machine finishing its cycle to load the next part. Fully Flexible Integrated Automation is the key to minimising the overall machining cycle time, including loading and unloading the part from the machine spindle.

The revolutionary Hardinge / EMAG joint venture produced VL machines provide a guaranteed load / unload time of 4 - 6 seconds chip to chip which is critical for part operations involving a machining cycle time of 30 seconds or less.

Over the course of a day, it is unlikely that an operator can do better than load / unload a part in a horizontal spindle machine in better than 20 seconds and frequently significantly longer.

For machining cycles where the spindle is turning for as little as 10 seconds, the load / unload time can therefore be twice as long as the machining time.

Changing to the VL method with its fast low cost integrated automation system can double the production output achieved under this scenario.

The VL pick up spindle design features, many of which are patented and exclusive to the VL range, position the parts within 200 - 300 mm of the machine's working area and uses the same workholding to pick up the part as is used for machining.

VL Customers are reporting 50 - 150% more production output from their VL machines than was being previously achieved on hand loaded horizontal spindle CNC lathes.

These outstanding performances are achieved by a combination of the power and speed built into the VL machines but primarily by the radical design philosophy which makes competitive machines look pedestrian in comparison.

Hardinge EMAG VL3 specifications include a part size of minimum diameter 10 mm, maximum diameter 125 mm, minimum length 10 mm and maximum length 100 mm The VL3 spindle has a speed range up to 7,500 rpm maximum.

Power is 16 kW and torque 200 Nm at a 40% duty cycle.

VL5 part size capacity is for a minimum diameter 20 mm, maximum diameter 220 mm, minimum length 10 mm and maximum length 110 mm.

VL5 Spindle Speed is 4,500 rpm maximum (5,500 high speed option) Power is 27 kW Torque 303 Nm at a 40% duty cycle High performance features are common to VL3 and VL5:- X-Axis rapid rate is 60 m/min Z-Axis rapid rate is 30 m/min Part to part load / unload time is 4 - 6 seconds Patented centreline support for high acceleration / deceleration wraparound motor pick up spindle.

Patented cardanic plate pick up station for automatically seating parts correctly in workholding system.

Standard no change-over time universal loading prisms for round parts.

Massive fixed centreline position 12 station VDI-40 quick -change turret.

High power 12 kW, 6,000 rpm, 37 Nm at a 10% duty cycle driven tooling option (all stations) with C-Axis.

Standard linear scale position feedback.

Standard 8 bar coolant system with integrated chip conveyor and mist extractor included in the basic price.

Other productivity enhancing features of the VL design include gravity assistance for chip evacuation from workpiece and a synthetic granite reinforcement of machine base for extended tool life and enhanced surface finishes.

Quick change / no change-over VL features mean that automation can now be applied to small batch quantities economically for the first time, to achieve radical productivity benefits.

The Citizen M20 is able to carry up to 80 tools on its 10, all-driven position turret, five turning tools and three rotary tools on a gang tool post and a further three rotary tools on a third slide.

The Citizen M20 is able to carry up to 80 tools on its 10, all-driven position turret, five turning tools and three rotary tools on a gang tool post and a further three rotary tools on its third tooling slide. This high level of tool carrying capability, to support the main 3.7 kW and 1.5 kW back spindle, not only makes one of the most flexible of tool setting arrangements, it allows 'permanent' tool settings to be held on the machine to give ultra-fast changeover between different jobs. Now available from NC Engineering of Watford, the Citizen M20's all-electric turret design has a 0.3 secs chip-to-chip time which is a key element in its high productivity capability.

Each of the 10 turret stations can be half indexed under CNC control which doubles the number of basic 20 tool positions and, through special tool holders, up to four tools can be held at each position to create a total turret capacity of 80 tools.

In addition, special tooling such as cross-angle rotary head drives or thread whirling tools for internal threading can be utilised in conjunction with a Y-axis turret movement providing an off-centre machining and interpolation capability.

Both main and back spindles are fitted with C-axes.

With this level of flexibility, the M20 becomes almost a hybrid lathe/machining centre for small turned parts up to 20 mm diameter and 600 mm long.

And, with the addition of certain options, long periods of unmanned running can be achieved.

These include an integrated parts handling device which retrieves the finished component from the back spindle for storage in a parts stocker or carried outside of the machine, to prevent damage.

An automatic component gauging device can also be installed on a turret station to measure outside and inside diameters and tool wear detection can be included to measure and compensate the CNC control automatic tool wear adjustment.

The machine base is compact, extremely rigid and built around a 45o slant design for good swarf control and easy setting access.

The main spindle motor is fully integrated giving exceptional levels of noise control and a high precision surface machining capability.

Spindle speed is fully programmable between 200 and 8,100 revs/min.

The back spindle too is a built-in design with 150 to 7,200 revs/min and rapid traverse rates are 18 m/min.

The elimination of hydraulics and pneumatics, in favour of an all-intelligent servo-driven machine design, means maintenance and running costs are reduced while ultimate synchronisation of the, up to three tools simultaneous cutting capability, can be easily performed at the control.

Cycle times, compared against the previous generation of M20 and using the same program, should be about 20 per cent quicker.

This opens up a large sales opportunity for NC Engineering to upgrade existing users of one of the most popular citizen machines in the UK based on a higher productivity justification.

A 10-station tool post and live tool C-axis milling capability feature CNC lathes with heavy-duty construction offering maximum flexibility at minimal cost.

The Kia range of CNC lathes handled exclusively in the UK by Ward CNC of Sheffield (www.wardcnc.com) has been extended with the addition of the Super Kia Turn 28LM turning centre with 10-station tool post and live tool C-axis milling capability. Of heavy-duty construction featuring rigid servo turret indexing and precision roller guides, the 28LM also boasts a thermally symmetrical headstock and double-anchored X-axis ballscrew for the high-precision multi-axis turning and milling of parts from 65mm bar. The 22/18.5kW spindle drive produces 25 to 3,000 revs/min, while the 5.2/3.7kW C-axis motor is capable of 4,000 revs/min.

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

Fanuc 0iT-A CNC is standard.

Designed for maximum flexibility at minimal cost, the Super Kia Turn 28LM has a swing over the bed of 590mm, and maximum turning diameter and length capacities of 410mm and 1070mm, respectively.

A new gantry loader carrying a full 6-axis articulated-arm robot allows large and/or complex shaped parts to be loaded quickly into CNC lathes.

Takamaz CNC lathes from Yuasa Warwick Machinery may be fitted with a new gantry loader carrying a full 6-axis articulated-arm robot. The additional degrees of freedom allow large and/or complex shaped parts to be loaded quickly. The Japanese manufacturer says that, for example, a part that would take 10 seconds to load using a conventional 3-axis gantry arm may be loaded in 8 seconds using the robot.

As with any gantry loader / unloader, a line of lathes may be served.

The machine pictured is a 2-axis Takamaz X-18 lathe with 8 inch chuck, the possibility of C-axis and six 2.2/1.5kW stations in the 12-station drum-type turret.

Spindle options are 7.5/5.5kW - 3,500 rpm, 11/7.5kW- 3,500 rpm, and 11/7.5kW - 5,000 rpm.

Despite its power, the lathe has a footprint of just 2.5 square metres.

Maximum turning diameter and length are 320mm and 270mm respectively.

The lathe programme run by the GILDEMEISTER group has now become so extensive that there really is no machining job any more that these machines cannot do.

The lathe programme run by the GILDEMEISTER group has now become so extensive that there really is no machining job any more that these machines cannot do. This has been the case at the latest since the buyback of 86% of the shares in Gildemeister Italiana S.p.A. - the seven clearly structured and closely interrelated product lines as well as a large number of new developments have now created the conditions necessary to provide the really optimal solution for every case and without compromise.

The new developments also include the SPRINT 42, a CNC bar automatic which focuses particularly on the segment of highly complex short parts (so closing one of the last holes in the portfolio).

Short parts in this sense are workpieces with a length about three times their diameter turned, often found in particular in the fields of hydraulic systems and automotive engineering.

To date these parts were manufactured on conventional lathes with a movable spindle nose and were characterised by short cycle times, the greatest part of machining operations taking place on the work spindle, and a comparably high number of drilling operations.

It is exactly these basic conditions that the 4-axis CNC automatic lathe SPRINT 42 perfectly masters.

On the one hand, simultaneous machining with at least two tools gives rise to an enormous increase in productivity, and on top the CNC system (compared with cam controlled machines) ensures maximum flexibility with respect to tooling times - of decisive importance in times of decreasing batch sizes.

The SPRINT 42 has a work spindle fitted with a universal turret holding 12 tools (VDI 25 tool holding fixture).

Machining can take place on either the work spindle or the holding spindle, both of which can be used with powered standard tools.

An interesting option is a Y axis for the turret, which facilitates milling operations on both the work and holding spindles.

Installed opposite the work spindle is a saddle fitted with two axes.

This saddle supports in turn a turret with seven tool holders and is used for facing operations that can run parallel to the operations with the universal turret.

This second turret is also fitted with an integrated counter-spindle that transports the workpiece after the cut-off to a third turret fixed to the machine bed.

This third turret is also provided with seven tools, of which four are powered.

Finally, an ejector deposits the finished workpiece on a discharge belt.

This discharge process, by the way, also runs parallel to the production time, i.e when the next machining operations are underway on the work spindle.

The only thing left to mention here is that all axes of the SPRINT 42 are fitted with servo motors controlled by absolute encoders.

In addition, the relatively large working area of this new CNC bar automatic ensures not only good accessibility, but also a good chip clearance.

Besides the SPRINT 42, also the SPRINT 20, SPRINT 32, and Sprint 65, likewise new machines, round off this model series.

The SPRINT 20 and Sprint 32 offer up to 6 axes for the highest production capacity and target a segment that to date is dominated by conventional single-spindle cam-controlled automatic lathes.

The essential features of these machines are the motor spindle and the arrangement of the tool holders that allow simultaneous multi-tool machining as well as configurations with up to six axes - all in all, features that facilitate the manufacture of turned parts with minimised cycle times and operating costs.

The Gildemeister 32/42, a new 2-spindle lathe centre for bar and chuck work, has a distance between centres of 210mm, acceleration of 1G, rapid feeds of 30m/min in all axes.

No compromises made over quality and productivity The Gildemeister Twin 32/42, a new 2-spindle lathe centre for bar and chuck work has a distance between centres of 210mm, acceleration 1G, rapid feeds of 30m/min in all axes, turret indexing times of only 0,1 seconds and an acceleration time of the spindle motors to reach 8000 rev/min in 1 second. These are the most important characteristics of the Twin 32 which will particularly impress suppliers to the automotive industry and users from the hydraulics, fittings or electrical/electronic industry. The Gildemeister engineers' propensity for innovation can be seen in the machine base alone, which is made of a Meehanite cast and provides for a high rigidity due to FEM optimisation.

In addition, the 60deg machine base ensures optimum chip clearance.

The machine top stands in an oil tray and, as a result, any coolant dropping off automatically reaches the chip conveyor.

Another focus of the developers' activities was the minimisation of down time, which particularly entails a maximisation of the dynamic force.

The Twin 32 provides an acceleration of 1G (this acceleration due to gravity) due to highly dynamic feed drives, and to the excellent linear guiding systems, high rapid feeds of up to 30m/min are possible.

The other features of the Twin 32 are also pure high-tech.

Both spindles, on the left and right, are provided with a power of 15kW.

The most modern spindle motors in synchronous technology are applied which are responsible for both the compact construction and the high dynamic force.

With a spindle capacity of 32mm, machining can be carried out at rotational speeds of 8.000 rev/min and a torque as high as 100Nm.

The rapid acceleration speed of the spindles of only 1sec to maximum rotational speed is just as impressive.

As regards its flexibility, the Twin 32 also will not leave any wishes open: for example, manufacturing off the bar is possible as well as chuck work.

The two highly dynamic turrets hold a respective number of 12 tools, all of which are driven, with the y-axis in the top turret being responsible for exacting complete machining processes.

The operating time from one station to the next amounts to only 0,1sec which should be hard to beat.

The tool holding fixture complies with DIN 69880, with a shaft diameter of 25mm.

Optionally, it is also possible to insert an additional tool for centre machining on the opposite spindle carriage so that simultaneous manufacturing with three tools can be carried out.

The possibility of clearing the operating area of any completed work pieces through the opposite spindle is also of benefit to flexibility.

Due to the transverse travel of the opposite spindle, collisions are excluded regardless of this highly complex machining process in a very confined space.

As regards work piece handling, the Twin 32 is equipped with a modular handling system which reliably masters all work which comes up, from the handling of simple chuck parts to damage-free (as effected without jerks), SPC-capable placing and palleting of completely machined work pieces.

Material in bar work is supplied through the integrated IRCO bar charger.

But as a result of the standardised interface, users may also operate any other commercially available bar charger.

However, if work is performed in the chuck, material is provided from the pallet through a double gripper.

Of course, the control system of the Twin 32 complies with the 'Intel inside' and 'Windows on site' requirement, which is known to be one of the Trends 2000 at Gildemeister.

The Sinumerik 840 D produced by Siemens is utilised: this CNC control system is equipped with two improved diagnostic functions (extended error texts or on-line machine documentation are only two examples) and fulfils all the requirements for connection with the DMG Netservice.

In technological terms, the bar charger is integrated into the scope of functions of the CNC control system.

Consequently, the charger is automatically adjusted and optimally co-ordinated with the process through data import from the component programme.

The Gildemeister software 'MF Programmer' is also contained in the scope of functions of the control system.

This software makes programming, control and simulation equally simple and thus increases the productivity and process safety of the Twin 32.

In addition, the machine can be equipped with a process monitoring device for collision and tool breakage control as an option.

And if you want to be completely on the safe side, you can also order the automatic tool wear monitoring device.

With its comprehensive range of functions for machining both complex bar parts and equally complicated chuck parts with a diameter of no more than 32mm (or 36mm for bars).

The Twin 32 is another important milestone for Gildemeister Drehmaschinen GmbH on its consistent way to becoming a full-range provider.

A range of easy-to-use toolroom standard flat bed lathes now includes a landmark two-axis CNC/manual lathe design with the production capabilities and flexibility of a CNC machine.

Harrison has extended its 'Alpha'range with the introduction of a landmark two-axis CNC/manual lathe design, the Alpha S1000 series. Extremely easy-to-use, the Alpha S1000 series is a toolroom-standard, flat bed lathe with the production capabilities and flexibility of a CNC machine. Available in four models: 1330S (330mm swing), 1400S (400mm swing), 1460S (460mm swing) and 1550S (550 swing), the Alpha S1000 series incorporates a highly advanced, yet extremely simple-to-use touchscreen control, based on the highly successful and tried and tested GE Fanuc 21i-T.

Possibly the easiest-to-use controller on the market yet, the Fanuc Colour Touchscreen control features a 10.4 inch-wide touch panel, Alphanumeric keypad and system selection key to give operators a wide range of machining permutations ranging from effortlessly easy manual turning through to sophisticated semi-automatic and full CNC machining.

A major new feature of the control is its Manual Guide System, a welcome addition to the comprehensive range of operating modes already available on the Alpha range.

The Manual Guide System is a touchscreen accessible cutting program enabling the full generation of simple cutting profiles and complex automatic programs directly at the machine.

A teach facility is available, allowing hand wheel initiated moves to be recorded as a program and rerun automatically after completion of the first component, while all programs generated can be stored to memory for later use or saved to the supplied AlphaLink software.

Additionally, all programs generated in the comprehensive 'Cycle Cutting' mode may be converted to a full CNC program if required.

The Manual Guide System complements the industry proven AlphaSystem which has gained wide popularity through its flexibility and ease-of-use.

The AlphaSystem provides a semi-automatic machining capability for stops, taper turning and automatic thread cutting; and an offline CAD/CAM machining facility.

One of the heaviest and most powerful lathes in its class, the Alpha S1000 series punches its weight in terms of supreme cutting performance and ultra rigidity, while its highly productive blend of advanced engineering design, precision manufacture and the finest in quality components assure excellent repeatability and long life.

The Alpha_s high precision machine beds are hardened to 450 Brinnel prior to precision grinding while a PTFE-based (moglice) material is used in key areas to ensure low friction and reduced wear on slides.

All Alpha S1000 series lathes use high precision ballscrews, ground and pre-loaded to achieve high accuracy with minimum friction.

The use of such ballscrews in conjunction with Fanuc servo drives ensure low maintenance, extremely high levels of accuracy and long life expectancy.

Equally important, high specification Gamet 'Class 9' rated tapered roller spindle bearings are used in the headstock, offering superior radial run-outs of 1.5 microns or less.

This translates to precise and consistent component quality, rigidity and high metal removal rates.

The Alpha S1000 series completes the comprehensive and extremely popular Alpha ranges, and should find a unique market to complement the already well-established Alpha U and Alpha T lathes.

The Alpha U is a highly advanced, slant-bed CNC/manual lathe designed to carry out manual, sequential or full CNC operation for small-to-medium batch production, while the Alpha T is a sophisticated, yet very affordable flat-bed electronic lathe, ideal for toolroom standard 'one-offs' and small batches.

The machining capacity and capability, as well as the quick delivery of a two-axis semi-CNC lathe enabled Colcrete Eurodrill to meet urgent demand for over 11,000 drilling and casing systems.

The machining capacity and capability, as well as the quick delivery of a Hankook Protec two-axis semi-CNC lathe from Ward CNC has enabled Colcrete Eurodrill to meet an urgent delivery demand for over 11,000 Eurodrill drilling and casing systems used in the geotechnical and exploration industries. With a maximum working diameter of 950mm and a distance between centres of 3000mm, and fitted with 800mm diameter four-jaw independent chuck, the Hankook Protec 9NF was needed by the company quickly to enable it to satisfy the substantial order intake for mini piling systems, and was initially used for threading applications on steel casings of 244mm diameter then in the production of 460mm diameter casings. One of a number of Hankook two-axis horizontal lathes available from Ward CNC's Sheffield site, the Protec 9NF has a swing over the bed of 950mm, a swing over the crosslide of 630mm and a spindle speed of 3 to 400 revs/min.

It has a four-position toolpost.

Based on a double-walled and ribbed one-piece meehanite cast iron bed, the machine boasts induction hardened and ground precision slideways for maximum stability and accuracy.

It combines the accuracy and productivity of user-friendly CNC turning with the simplicity and versatility of a manual machine by offering CNC and dual electronic handwheel control.

Machining programs can be created using simple menu keys and easy-to-follow displays.

Control system options include Fagor-8055TC, Siemens 810D CNC or Fanuc.

Standard features also include servo motors on both axes, four-jaw independent chuck, square tool post with curvic coupling, cooling equipment, machine lighting, two-speed tailstock quill adjustment and infinitely variable feed rates.

Options include various chucks (hydraulic and three-jaw scroll-type), automatic tool post and live centre.

At its Clay Cross site in Derbyshire, Colcrete Eurodrill produces rotary duplex/mini piling systems in a standard range with outside diameters from 114mm to 660mm and in lengths of 500mm to 6m.

Specials up to 915mm diameter can be manufactured to order.

The casings accommodate either drill rods or augers.

Setting new operating standards in CNC universal lathes are linear motor powered axis, Siemens 810 D powerline with ShopTurn user interface with 3D-simulation and fast turrets and tailstocks.

The new CTX 320/420 linear universal lathes set new standards due to linear drives, Siemens 810 D powerline with ShopTurn user interface including 3D-simulation, rapidly indexing 12-position turret, fast tail stock, and absolute measuring systems. The new universal lathes CTX 320 and CTX 420 linear offer perfection in process and performance, as well as an output increase of at least 10%. The foundation for this increase lies in the dynamic linear drive in the X-carriages, the high-speed Siemens 840D powerline control with ShopTurn, a Windows based, shop floor programming system including extensive 3D functionalities, integrated spindle drives in synchronous technology, the fastest turret on the market, a fast tailstock, as well as direct measuring systems in all linear axes.

The fascination with linear drive technology springs no doubt from the unique dynamics that can be achieved because of the reduced quantities moved, while simultaneously high rapid traverse speeds lead to previously inconceivable productivity increases.

And all this at an even higher rate of precision, because of the zero slack drive system.

Furthermore, the contact-free power transfer makes a wear-free construction of the drive train possible, which benefits availability of the machine during tough, multi-shift operation.

High process safety because of 3D simulationAlready in the standard configuration, the new CTX linear generation is controlled by the new Siemens 840 D powerline with ShopTurn.

The 'powerline' designation stands for a performance increase of more than 100% in the CNC- and PLC sector.

This performance increase is due to no small degree to the integrated ShopTurn user interface and the comprehensive 3D functionalities.

Even complex work pieces with face- and shell surface requirements can now be generated very quickly with a high performance technology cycle package, with interactive, context sensitive operator guidance, and integrated 3D simulation, which can be operated without DIN/ISO knowledge.

In addition, ShopTurn makes machine setup easier through intuitive tool administration for the turret, and practice oriented support for workpiece introduction and - measurement.

The Siemens 840D powerline with ShopTurn is included in the machine price, as well as a Windows based PC version, which turns every computer into a high performance tool for external program generation and archiving purposes.

ShopTurn thus stands for highest productivity, maximum operating comfort, and impressive process safety during programming, installation, and machining.

The performance of the integrated spindle drive with impressive acceleration and deceleration capabilities is no less impressive.

Thus, it now takes only 1 second to go from zero to the maximum speed of 5,000 rpm, and it takes no longer to bring the speed back down to zero.

The torque in this case, for the CTX 420 linear, for example, lies at 270Nm (at 100% DC), which is a remarkable 12.5% higher than in the previous model.

The CTX 320/320 linear machines are offered in a number of production oriented expansion configurations: these start at a configuration with a 12-station turret for fixed tools and tailstock, they include a package with 12 driven tools in the turret, a version with driven tools in the Y-axis, and finally include machines with counter-spindle, driven tools and an (optional) Y-axis.

The swing diameter of both machines measures 400 mm for the smaller CTX 320 linear, and 680mm for the CTX 420 linear, with a longitudinal path of 450mm and 635mm respectively.

This options are rounded off with a new hydraulically traversable tailstock with 0,5m/min (an NC-tailstock with 20 m/min ipm rapid traverse is available as an option), as well as a fast indexing turret, which brings the next tool into position in only 0.15 seconds.

The bottom line: the machines of the CTX linear series excel with an idle time improvement up to 40%.

And with regard to idle times: because of the direct measuring systems the exasperating reference point method during start up will no longer required in the future.

Due to the availability of a long term finance package, a sub-contract machining company has moved up to supply higher value aerospace, pharmaceutical, motor sport and marine industries.

Due to the availability of a long term competitively priced finance package available through 600 Finance, Colchester Sales of Heckmondwike, has given Paragon Engineering and Logistics of Wolverhampton the immediate capability to step change its business to service higher value aerospace, pharmaceutical, motor sport and marine industries. Said John Harper, Co-director: 'The long term 600 Finance rental is ideal as it gives us the opportunity to have the two Colchester Tornado 120M and 220M bar fed, driven tool machines now. Then at any time in the future we can convert from rental to hire purchase with the rental paid deducted from the value of the machines.' Paragon Engineering was set up in March 2000 by two Lucas Aerospace engineers John Harper and Steve Price who had both held senior management positions.

Within six months of establishing the business, they gained the necessary ISO certification and moved into mainly aerospace machining.

The company then built-up a highly skilled workforce of 30 people working manual and some CNC machines producing mainly low volume spares, repairs and development work.

Explains Steve Price: 'We have grown steadily and decided we are now ready to move into new areas where we can utilise our skills in machining specialist materials and difficult stainless steels with the benefit of the latest CNC technology in turned part machining.

Both directors looked at the market of three-axis lathes so they could combine secondary operations into single mill/turn cycles, reduce lead times and offer competitive pricing with high levels of quality built into the machining cycle.

They decided the driven tool Colchester Tornado 120M and 220M were ideal because they were UK built, had a good specification and provided good value for money.

Says John Harper: 'The two year full warranty meant Colchester obviously had faith in their machines and Colchester Sales technical centre is just up the road.

Colchester could also deliver within four weeks.' The driven tool M-Series has rejuvenated the Tornado range and by purchasing both the 120M and 220M, Paragon has the advantage of different capacities to accommodate existing and new component machining.

The more compact 120M has a 54mm bar capacity from the Colchester developed MBF 1000 bar feed and the 220M will accept material up to 65mm diameter.

The 15kW spindle 120M has a 12 position all-driven 3.7kW 5,000 revs/min turret and the larger machine a 22kW main spindle with a six driven, six fixed position turret having 4,000 revs/min drive.

Both machines have disc brakes to hold position in the C-axis and are built using Colchester's patented Duo-stable base foundation which gives some 25 per cent improvement in damping.

A series of turnkey solution robot-loaded packages for 'one-hit' chucking type machining applications is being developed for CNC production lathes and extended 'lights out' unmanned operation.

Colchester Lathe has extended its 'Lights-out' unmanned running portfolio for its Tornado two and three-axis driven tool lathes by developing, in conjunction with Fanuc Robotics, a series of turnkey solution robot-loaded packages for 'one-hit' chucking type machining applications. The addition of higher productivity achieving automation and cell technology, to create an extended or totally unmanned running capability, follows the success of the Lights-out Tornado bar machining package where users, such as, door furniture maker Paraid of Birmingham which now relies on Colchester's tool monitoring to maintain a limited operator attention scenario when turning batches of up to 1,000 parts. A further subcontract company Vire Engineering of Totnes, Devon uses a Lights-out Tornado to maintain unmanned production of batches of up to 2,000 motor sport pipe fittings with automatic sister tool replenishment and in process gauging.

The new Lights-out chucking package brings together a picking list of standard options for tailoring the machining cell to customer requirements.

However, it can also form the basis of the complete turnkey engineering of a cell or machining system involving robot loading on a number of Tornado machines or compatible products such as vertical machining centres or co-ordinate measuring machines.

The package also includes interlocked guarding.

For the standard option list Colchester is able to specify from the range of Fanuc stand-alone or gantry robots according to component size and operations required.

A choice is available from single or double grippers, a programming package and a series of static pallet stands, conveyors or component magazines.

In addition, in-process or post-process gauging with feed-back correction, tool life management and sister tool replenishment based on axis torque loadings can be selected.

The Lights-out package is configured around the Tornado two-axis A50 which has a 125mm or 170mm chuck size, the Tornado A90 with 170mm chuck size and the latest high performance 220 which has optional chucking sizes of 210mm or 254mm.

For three-axis driven tool applications, the Tornado 120M is available with powered tooling to each of its 12, VDI 30 turret positions and chuck sizes of 170mm or 210mm or the larger 220M, with six VDI 40 driven and six standard turret positions and 210mm or 254mm chuck sizes.

The first UK 'taker' for a linear motor axis powered CNC lathe reports some cycle times cut by up to 35% on complex aerospace hydraulics components, and considers buying another.

The first UK customer for DMG's groundbreaking CTX 420 linear lathe is aerospace specialist Metric Precision Engineering. This investment has allowed the Birmingham-based company to cut some of its cycle times by up to 35%. The CTX 420 linear, and the smaller CTX 320, offer dramatically increased production through the use of dynamic linear drives in the X-axis.

The result is instant response, with acceleration/deceleration up to 1.5G and rapid traverse speeds of up to 60m/min.

Both CTX lathes utilise the high-speed, Pentium-powered Siemens 840D Powerline CNC with 3D ShopTurn software - a Windows-based interface that gives fast and simple interactive programming and integrated 3D real-time simulation.

The machines also feature extremely fast turrets and tailstocks as well as direct measuring systems in all axes.

The result is minimum idle time and maximum productivity.

Metric Precision supplies four of the biggest aerospace companies in the country with complex turned parts, including components for hydraulics, linkages, gearboxes, drives and control valves.

As Joint Acting MD Darren Causer explains: 'Our parts are made to the highest standards and we are quality assured suppliers to all of our customers.

We work to very close tolerances on a daily basis, often with exotic materials, and specialise in making the components other companies find almost impossible.

Nothing we make is simple - they are all complex parts.

'To achieve our goals we needed a machine to help us maintain our competitive edge.

I started looking at what was available, and what would complement the range of machinery that we already had in place.

The CTX 420 linear turn and mill machine from DMG, with a magazine bar feed and twelve driven tools, was the machine I was looking for.

'The linear drive gives a big advantage over a ballscrew as there is no delay in the response time - it moves instantly when the CNC tells it to.

It is also totally consistent with no play or variation in diameter due to changes in temperature.

And it really is fast.' As well as the linear drive, he was also impressed by the Siemens control with real-time simulation and the 5000-rpm main spindle.

The integrated spindle drive gives exceptional acceleration and braking - from 0 to maximum revs in just 1 second, from full speed to zero in the same time and a continuous duty torque of 270Nm.

Typical operations on a component might include turning, back-turning, drilling, reaming, thread cutting, chamfering and boring.

According to Mr Causer: 'With the CTX 420 linear we can get the component off the machine complete with no need for second operations on a milling machine.' The CTX 420 linear will be used on some of Metric Precision's longer running components to make the most of its superior capabilities.

It is currently running 10 hours a day turning and milling on bar up to 65mm in diameter.

'The linear motor's speed and versatility mean we have cut some of our cycle times by up to 35%.

Installation and training went very smoothly with no disruption to our other manufacturing.

The back-up service seems to be very good too.

We are probably looking at buying another one in 18 month's time,' says Mr Causer.

'Nothing can touch this machine - and we've got some nice machines.

We not only have the first CTX linear lathe in the UK, we also have the edge on the competition.'